Floor panel and floor system for passenger vehicles and method of installation

Abstract

Floor panels and floor systems for passenger vehicles and methods of installation. An example floor panel for a floor system in a passenger vehicle is disclosed that includes a top sheet, a bottom sheet, a body between the top sheet and the bottom sheet, and an interlocking feature extending outward from the body for slidably engaging an adjacent floor panel. An example floor system in a passenger vehicle includes a first set of floor panels including panels rigidly attached to a structure of the passenger vehicle, and a second set of floor panels, and each floor panel of the second set of floor panels has an interlocking feature for slidably engaging an adjacent floor panel and for enabling lateral relative motion to occur and limiting vertical relative motion between the panels of the second set of floor panels and respective adjacent floor panels.

Description

[0001] This application is a divisional application of Chinese Patent Application No. 201910132558.8, filed on February 22, 2019, entitled "Floor paneling and floor system for passenger vehicles and installation method thereof". Technical Field

[0002] This disclosure generally relates to floor panels, and more specifically to interlocking floor panels that enable relative movement between adjacent floor panels. Background Technology

[0003] Cabin floors for commercial and military aircraft typically comprise a structural subfloor with a thin laminate overlay and a top floor cover sealed to the laminate overlay. Moisture-proof strips can also be installed along the joints of the subfloor. In this existing design, double-sided tape is laid over the entire subfloor area, and the rigid laminate portion is laid and sealed to it. A second layer of double-sided tape is then laid over the laminate portion, followed by the panels of the top floor cover. This technique for forming the floor is time-consuming and difficult to replicate in a production environment. Furthermore, because the panels are firmly bonded to each other, replacing or repairing individual floor structural panels is difficult.

[0004] At least some known conventional flooring materials used in buildings, such as hardwood or solid hardwood flooring (e.g., tile or laminate), may not be suitable for use on aircraft because these aircraft floors are configured to withstand certain vertical loads (e.g., approximately three times the force of gravity) that hardwood flooring used in buildings would not experience. Additionally, the subfloor of aircraft or other vehicles is configured to move (i.e., shift and / or bend relative to structural components), which may render conventional hardwood or solid wood flooring impractical. Furthermore, hardwood flooring used in buildings can be relatively heavy, creating unnecessary additional weight on an aircraft. Moreover, cavitation in the adhesive may expand and / or contract over time as altitude changes occur during flight, resulting in an uneven surface when the aircraft is at cruising altitude (e.g., lower pressure). Furthermore, hardwood flooring used in buildings typically does not absorb noise as well as carpet, and spills can create a slippery hazard on hardwood flooring types used in buildings. Summary of the Invention

[0005] In one example, a floor panel for an aircraft floor system is described. The floor panel includes: a top sheet; a bottom sheet opposite to the top sheet; a body comprising a plurality of units, each unit having a cavity, and the body being located between the top sheet and the bottom sheet; and an interlocking feature extending outward from the body for slidably engaging adjacent floor panels. The interlocking feature is formed via an outward extension of the bottom sheet beyond the top sheet, such that the top sheet is raised relative to the interlocking feature to form a seat configured for engaging the adjacent floor panel.

[0006] In another example, a floor system in a passenger vehicle is described. The floor system includes: a first set of floor panels comprising panels rigidly attached to a structure of the passenger vehicle; and a second set of floor panels. Each floor panel in the second set of floor panels has an interlocking feature for slidably engaging an adjacent floor panel, and the interlocking feature is configured to allow lateral relative movement between a panel in the second set of floor panels and its corresponding adjacent floor panel while restricting vertical relative movement therebetween. The second set of floor panels is positioned to define a space between a corresponding floor panel in the second set of floor panels and its corresponding adjacent floor panel to allow lateral relative movement between the panel in the second set of floor panels and its corresponding adjacent floor panel, and each floor panel in the second set of floor panels is positioned to engage at least one adjacent floor panel in the first set of floor panels.

[0007] In another example, a method for installing a floor system in a passenger vehicle is described. The method includes: attaching a first set of floor panels to a structure of the passenger vehicle at a location distributed throughout a region of the passenger vehicle; and positioning a second set of floor panels such that each floor panel in the second set is positioned to engage at least one adjacent floor panel in the first set. Each floor panel in the second set has an interlocking feature for slidably engaging adjacent floor panels, and the interlocking feature is configured to allow lateral relative movement between the panel in the second set and its corresponding adjacent floor panel while restricting vertical relative movement therebetween. The second set of floor panels is positioned to define a space between the respective floor panel in the second set and its corresponding adjacent floor panel to allow lateral relative movement between the panel in the second set and its corresponding adjacent floor panel; and filling the space with a sealant or elastomer insert.

[0008] The various examples of systems and apparatuses described herein may include any components, features, and functions of any other examples of systems and apparatuses described herein in any combination.

[0009] Various examples of the methods described herein may include any components, features, and functions of any other example of the methods described herein in any combination.

[0010] The features, functions, and advantages already discussed can be implemented independently in various examples or combined in other examples, further details of which can be seen in the following description and figures. Attached Figure Description

[0011] The appended claims set forth novel features that are considered illustrative examples. However, the illustrative examples, their preferred modes of use, additional purposes, and descriptions will be best understood by referring to the following detailed description of the illustrative examples of this disclosure when read in conjunction with the accompanying drawings, wherein:

[0012] Figure 1 This is a top view of an exemplary floor panel used in a floor system for an aircraft.

[0013] Figure 2 yes Figure 1 A top view of the floor paneling, showing a partial cross-section.

[0014] Figure 3 yes Figure 1 and Figure 2 The bottom view of the floor paneling shows another partial section.

[0015] Figure 4 yes Figures 1 to 3 A perspective view of a portion of the floor paneling, used to illustrate an example of multiple units.

[0016] Figure 5 yes Figures 1 to 4 Side view of the floor paneling.

[0017] Figure 6 yes Figures 1 to 4 Another side view of the floor paneling, showing a surface on the floor paneling.

[0018] Figure 7 This is a side view of another example of floor paneling.

[0019] Figure 8 This is another top view of another example of floor paneling.

[0020] Figure 9 An exemplary floor system in a passenger vehicle (such as an airplane) is shown.

[0021] Figure 10 It shows Figure 9 An enlarged view of a portion of the flooring system.

[0022] Figure 11 yes Figure 9 A side view of a portion of the flooring system, showing floor panels interlocked with adjacent floor panels.

[0023] Figure 12 yes Figure 9 Another side view of a part of the flooring system, showing floor panels interlocked with adjacent floor panels.

[0024] Figure 13 yes Figure 9 Another side view of a part of the flooring system, showing floor panels interlocked with adjacent floor panels.

[0025] Figure 14 A schematic layout of the floor system is shown in a part of a passenger transport vehicle, such as an airplane.

[0026] Figure 15 A flowchart is shown for an exemplary method of installing a floor system in an aircraft.

[0027] Figure 16 It shows that it can be implemented Figure 15 The flowchart shows the additional functions used during or after the method in the process. Detailed Implementation

[0028] The disclosed examples will now be described more fully below with reference to the accompanying drawings, which illustrate some, but not all, of the disclosed examples. In fact, several different examples may be described and should not be construed as limited to those set forth herein. Rather, these examples are described so that this disclosure will be comprehensive and complete, and will fully convey the scope of this disclosure to those skilled in the art.

[0029] Within the examples described herein, components for the interior cabin of passenger vehicles (such as airplanes, trains, or ships) are described, with particular attention to floor coverings for passenger vehicles. The use of hardwood or solid hardwood floors has long been a requirement in aircraft, especially in some top-tier cabin areas. Therefore, taking into account the above and other factors, the examples described herein can provide the look and feel of hardwood flooring in aircraft. More specifically, the floor structures described herein can reduce installation time, provide increased installation reliability and repeatability, allow for improved aesthetics, increased durability, and / or provide the ability to replace individual panels.

[0030] Now refer to the attached diagram, Figure 1This is a top view of an exemplary floor panel 100 for a floor system in an aircraft, based on an example. Figure 2 This is a top view of floor panel 100, showing a partial cross-section. Floor panel 100 includes a top sheet 102, a bottom sheet 104 opposite to the top sheet 102, and a body 106 located between the top sheet 102 and the bottom sheet 104. Floor panel 100 also includes an interlocking feature 108 extending outward from the body 106 for slidably engaging adjacent floor panels. The interlocking feature 108 is formed via an outward extension 109 of the bottom sheet 104 beyond the top sheet 102, such that the top sheet 102 is raised relative to the interlocking feature 108 to form a seat 110 configured for engaging adjacent floor panels.

[0031] The main body 106 includes a plurality of units 112, each unit 112 having a cavity (such as cavity 114). See below for reference. Figure 4 Further description of subject 106.

[0032] Interlocking feature 108 is configured to allow floor panel 100 to slidably engage adjacent floor panels during installation, as described more fully below. For example, seat 110 is configured to engage adjacent floor panel 124, and seat 110 includes interlocking feature 108 abutting top sheet 102 at an angle of approximately 90°. However, interlocking feature 108 can abut top sheet 102 at any suitable angle that allows floor panel 100 to engage with adjacent floor panel 124.

[0033] In this example, the top sheet 102, bottom sheet 104, body 106, and interlocking feature 108 are monolithic structures. Therefore, the floor panel 100 can be a single piece manufactured using additive manufacturing or 3D printing technology. For example, the top sheet 102, bottom sheet 104, body 106, and interlocking feature 108 can comprise composite materials, resulting in a non-woven floor covering. In yet another example, the floor panel 100 comprises a monolithic monolithic structure consisting of multiple material layers, wherein the material used for the bottom sheet 104 differs from the material used for the top sheet 102. The floor panel 100 can be manufactured with specific patterns embossed thereon to match specific locations in an aircraft (e.g., around a door / kitchen).

[0034] Figure 3 This is a bottom view of the example floor panel 100, which shows another partial section. Figure 3In this diagram, the bottom sheet 104 is not shown, and thus a plurality of units 112 of the body 106 are shown. The plurality of units 112 are all located within the body 106, and corresponding cavities are defined between the top sheet 102, the bottom sheet 104, and the first inner wall 116 and the second inner wall 118 of the body 106. The inner walls 116, 118 are oriented perpendicularly to each other to form an internal honeycomb structure of the body 106. For example, a plurality of inner walls are included to form units arranged in multiple rows and columns. Furthermore, the first inner wall 116 can be in any suitable orientation relative to the second inner wall 118 without being perpendicular.

[0035] Each of the multiple units 112 of the main body 106 has a cavity (e.g., in...). Figure 4 (shown as cavity 114), and compared to floor panels with a solid structure, this allows the floor panel 100 to be lightweight. For example, using a composite material for the floor panel 100 with a honeycomb structure can achieve a high weight-to-stiffness ratio compared to using a solid material.

[0036] Figure 4 This is a perspective view of a portion of floor panel 100, illustrating an example of multiple units 112. As shown, each of the multiple units 112 has a volume defining a cavity (such as cavity 114 of a specific unit). Holes (such as holes 120) are included in each unit 112 based on manufacturing techniques, allowing for further weight reduction. The multiple units 112 can comprise rectangular or square structures arranged in rows and columns, such as... Figure 4 As shown; however, each unit 112 can have any suitable shape that can be configured to enable the body 106 to function as described herein.

[0037] Figure 5 This is a side view of floor panel 100. Seat 110 is located in... Figure 5 More clearly shown is interlocking feature 108 abutting the top sheet 102 at an angle of approximately 90°. However, seat 110 may be configured, for example, at other angles (including angles greater than 90° or less than 90°) to provide alternative interlocking mechanisms. For example, interlocking feature 108 may include a lip extending outward from the body 106 of floor panel 100 to engage adjacent floor panels during installation.

[0038] Figure 6 This is another side view of floor paneling 100. Figure 6In this configuration, surface 122 is positioned on top sheet 102. Surface 122 can be a gripping surface (e.g., a rubber material), a decorative surface (e.g., a pattern similar to wood grain embossed in a substrate, or a wood grain texture printed into a substrate, wherein a rubberized surface is provided on top of the embossed and / or printed substrate for gripping), and / or any other desired aesthetic surface. Surface 122 is the surface on which aircraft passengers walk and therefore requires a non-slip surface.

[0039] Figure 7 This is a side view of another example of floor paneling 124. Figure 7 In this configuration, floor panel 124 is substantially the same as floor panel 100, and includes a top sheet 102, a bottom sheet 104, a body 106, interlocking features 108, and a base 110. Floor panel 124 is configured such that interlocking features 108 fit into corresponding interlocking features 108 of floor panel 100. Floor panel 100 can be considered to be configured in a male or female form, and floor panel 124 is considered to be in the opposite form, such that floor panels 100 and 124 interlock with each other.

[0040] In some examples, such as Figure 1 As shown, the interlocking feature 108 extends along at least a portion of the periphery of the body 106. The periphery includes two opposite sides 111 and 113 of the floor panel 100 and two opposite ends 115 and 117. In one example, the interlocking feature 108 extends along both sides 111 and 113 and both ends 115 and 117 of the floor panel 100. In other examples, the interlocking feature 108 extends along one or both ends 115 and 117 of the sides 111 and 113 of the body 106, but not along the other side 111 / 113 of the body 106.

[0041] Figure 8 This is another top view of an example of floor paneling 100 according to an exemplary embodiment. Figure 8In this configuration, the interlocking feature 108 extends along a full side 113, but only partially along the opposite side 111 of the floor panel 100, and then also only along one end 117 of the floor panel 100. Therefore, the floor panel 100 can be configured in many different ways to accommodate multiple different floor coverage areas on the aircraft 150 or other passenger vehicles, and the interlocking feature 108 can be included, for example, on one or both of the sides 111 and 113 of the body 106, one or both of the ends 115 and 117 of the body 106, or any combination of the sides and ends of the body 106. The floor panel 100 can also be configured in a variety of different sizes with different lengths and widths. In some examples, for floor coverage along aisles in the aircraft 150, the floor panel 100 can be five feet (1.52 meters) long.

[0042] Figure 9 An exemplary floor system 130 in an aircraft 150 according to an exemplary embodiment is shown. The floor system 130 includes a first set 132 of floor panels 100, which includes floor panels 100 attached or rigidly attached to a structure 134 of the aircraft. More specifically, the floor panels 100 in the first set 132 are rigidly attached to the structure 134 by permanent adhesives, screws, bolts, snap-fit ​​engagements, etc. The floor system 130 also includes a second set 136 of floor panels 100, and each floor panel 100 in the second set 136 of floor panels has an interlocking feature 108 for slidably engaging an adjacent floor panel 124. Figure 10 (As further shown below). For example, the interlocking feature 108 is configured to allow lateral relative movement between a panel 100 in the second set 136 floor panels 100 and its corresponding adjacent floor panel 124, while restricting vertical relative movement therebetween (described more fully below). The second set 136 floor panels are positioned to define a space 138 between the floor panel 100 and its corresponding adjacent floor panel 124, allowing lateral relative movement between the panel 100 in the second set 136 floor panels and its corresponding adjacent floor panel 124. Each floor panel 100 in the second set 136 floor panels is positioned to engage at least one adjacent floor panel 124 in the first set 132 floor panels.

[0043] The first set of 132 floor panels is attached to the structure 134 of the aircraft. For example, the first set of 132 floor panels can be directly attached to the structure 134 of the aircraft 150 using screws, bolts, snap-fits and / or any other suitable mechanical fastening device.

[0044] Each panel in the first group of 132 floor panels can be configured Figure 7 The floor panel 124 shown, and each panel in the second group 136 floor panels can be configured as follows: Figure 1 The floor panel 100 is shown. Next, the panels in the second group 136 of floor panels have interlocking features 108 for slidably engaging adjacent floor panels 124, which may be floor panels from the first group 132 of floor panels, such as... Figure 9 As shown (although other installation configurations exist as described below).

[0045] exist Figure 9 In the configuration shown, floor system 130 includes a first group of 132 floor panels and a second group of 136 floor panels arranged in alternating rows. Additional configurations of floor system 130 are possible and are described below (see reference). Figure 14 ).

[0046] Figure 10 An enlarged view of a portion of a floor system 130 according to an exemplary embodiment is shown. Figure 10 As shown, the interlocking feature 108 is configured to allow lateral relative movement between the panels in the second set of 136 floor panels and their respective adjacent floor panels due to space 138. For example, panels 100 and 124 can move toward and away from each other, causing a change in the width of space 138. The interlocking feature 108 is also configured to restrict vertical relative movement between the panels in the second set of 136 floor panels and their respective adjacent floor panels due to the interlocking feature 108 of panel 100 abutting the interlocking feature 108 of panel 124.

[0047] Therefore, in the example described herein, the floor system 130 enables floor panel 100 in the second set 136 of floor panels to float (e.g., move freely relative to a fixed structure) on the aircraft's underlying floor (e.g., aircraft structure 134). Floor panel 100 has an interlocking feature 108 that engages with adjacent floor panel 124, allowing floor panel 100 to float laterally, but preventing floor panel 100 from being lifted off the underlying floor (such as structure 134).

[0048] Because the forces and loads exerted on the floor system 130 by the aircraft 150 in flight mean that the floor system 130 is configured to withstand specific forces (e.g., an upward pulling force on the floor system 130 is approximately three times the weight of the floor system 130, and a forward pulling force on the floor system 130 is approximately nine times the weight of the floor system 130). Therefore, the floor system 130 can be compliant with the mechanisms of dynamic loads experienced in the aircraft 150 (e.g., flight loads at a certain altitude and thermal contraction) while keeping the respective floor panels 100, 124 substantially in place relative to each other and the structure 134 (e.g., movable only within the area of ​​space 138).

[0049] By allowing floor panel 100 to move relative to adjacent floor panel 124, floor system 130 remains substantially in place, but has components that allow lateral floating to reduce stress on floor system 130 caused by aircraft operating mechanisms.

[0050] Figure 11 This is a side view of a portion of the floor system 130, showing a floor panel 100 interlocked with an adjacent floor panel 124. When the two floor panels are interlocked, a space 138 exists. For example, the interlocking feature 108 of each respective floor panel 100, 124 is configured to limit vertical relative movement between the floor panel 100 and the floor panel 124 by preventing movement of the floor panel 100 in a direction perpendicular to the surface of the floor panel 100. Figure 11 As shown, the interlocking feature 108 (i.e., lip) of the floor panel 100 is in adjacent contact with the interlocking feature 108 (i.e., lip) of the adjacent floor panel 124 at surface 140.

[0051] Figure 12 This is another side view of a part of the floor system 130, showing floor panel 100 interlocked with adjacent floor panel 124. Figure 12 In this configuration, sealant 142 is positioned within space 138. Sealant 142 can be compressed, thereby allowing relative lateral movement between floor panel 100 and floor panel 124. Sealant 142 fills all or substantially all of the volume of space 138 to prevent any foreign material or substance from embedding into space 138 and provides a smooth and consistent outer surface to which surface 122 can be positioned.

[0052] Figure 13 This is another side view of a part of the floor system 130, showing floor panel 100 interlocked with adjacent floor panel 124. Figure 13 In this configuration, an elastomeric insert 144 is positioned within space 138. For example, the elastomeric insert 144 may be an extruded rubber element. The elastomeric insert 144 may be configured in a “P-shape” (i.e., a shape having a relatively linear portion and a basic arcuate portion attached to the relatively linear portion) such that a portion of the elastomeric insert 144 (i.e., the relatively linear portion) slides beneath the interlocking feature 108 of the floor panel 124, and another portion of the elastomeric insert 144 (i.e., the basic arcuate portion) fills or substantially fills the volume of space 138. A surface 122 is then positioned over the elastomeric insert 144 onto the floor panels 100 and 124. Thus, in this example, relative movement between the anchor points of the first set 132 floor panels (e.g., the location where floor panel 124 is attached to structure 134) of the floor panel 100 is absorbed by the seams between adjacent panels that may be filled with sealant 142 (e.g., a rubberized sealant) or the elastomeric insert 144.

[0053] Figure 14 A schematic layout of a floor system 130 in a part of an aircraft 150 or other passenger transport vehicle according to an exemplary embodiment is shown. Figure 14 The image shows the various areas of the aircraft 150, including the galley area and the seating area. Figure 14 A specific layout for a particular aircraft design is shown, wherein floor panels 124 are distributed throughout the area in such a manner that all floor panels 100 are in contact with and adjacent to at least one floor panel 124 along at least one side or one end. In this manner, floor panels 100 are rigidly attached abuttingly to at least one floor panel 124 of structure 134 of aircraft 150.

[0054] In some examples, some floor panels 100 in the second group 136 floor panels are positioned to engage both a corresponding floor panel 124 in the first group 132 floor panels and a corresponding floor panel 100 in the second group 136 floor panels. For example, this can be done using... Figure 8 The floor panel 100 shown, or other specially configured panels with related interlocking features 108 in male / female form, may be configured as needed.

[0055] exist Figure 14 In the first group of 132 floor panels, some floor panels 124 are anchored to the structure 134 of the aircraft 150 at a peripheral area 152. Additionally, some floor panels 124 in the first group of 132 floor panels are anchored to the structure 134 of the aircraft 150 at one or more door interfaces. The locations where the floor panels 124 are attached to the structure 134 can be referred to as "anchor points." The specific arrangement and location of the floor panels 124 can depend on the design of the aircraft 150.

[0056] Furthermore, in the example and based on the configuration of floor panel 100, the second set of 136 floor panels can be positioned to define a space 138 between floor panel 100 and a corresponding adjacent floor panel 124 disposed along the periphery of the second set of 136 floor panels, so that relative movement can occur in both the lateral and longitudinal directions. Alternatively, in other arrangements, the second set of 136 floor panels can be positioned to define a space 138 between floor panel 100 and a corresponding adjacent floor panel 124 disposed along one of the two sides 111 and 113 of the second set of 136 floor panels or the two ends 115 and 117 of the second set of 136 floor panels, so that relative movement can occur in both the lateral and longitudinal directions. For example, the interlocking feature 108 of each floor panel 100, 124 is configured to allow relative longitudinal movement between the panel 100 in the second set of 136 floor panels and the corresponding adjacent floor panel 124.

[0057] In the example, space 138 can range from approximately 0.1 inches (2.54 mm) to approximately 0.2 inches (5.08 mm). However, the size of space 138 can differ from the aforementioned range due to the dimensions of the floor panels used. Furthermore, during use, the size of space 138 can change as floor panels 100 and 124 move relative to each other.

[0058] Figure 15 A flowchart is shown of an exemplary method 200 for installing a floor system 130 in an aircraft 150 according to an exemplary embodiment. Figure 15 The method 200 shown illustrates a method that can be used with, for example... Figure 1-8 Floor panel 100 and floor panel 124 shown, and / or Figure 9-14 Examples of methods used with the floor system 130 shown. In some examples, components and / or devices may be configured so that the components are actually configured and constructed to achieve such performance. In other examples, components and / or devices may be arranged to be suitable for, able to, or adapted to perform a function. Method 200 may include one or more operations, functions, or actions, as shown in one or more of blocks 202-210. Although the blocks are shown in a sequential order, these blocks may also be performed in parallel, and / or in an order different from that described herein. Moreover, various blocks may be combined into fewer blocks, divided into additional blocks, and / or removed based on desired implementation methods.

[0059] It should be understood that, for the processes and methods disclosed herein, the flowcharts illustrate the functionality and operation of one possible implementation of this example. Alternative implementations are included within the scope of the examples disclosed herein, wherein, depending on the functionality involved, functions may not be performed in the order shown or discussed, including substantially simultaneously or in reverse order, as understood by those skilled in the art.

[0060] At frame 202, method 200 includes attaching a first set 132 of floor panels to structure 134 of aircraft 150 at locations distributed throughout the entire area of ​​aircraft 150. For example, floor panels 124 in the first set 132 are rigidly attached to structure 134 in a suitable manner by permanent adhesive, screws, bolts, snap-fit, or bonding or adhering to structure 134.

[0061] At frame 204, method 200 includes positioning a second set of 136 floor panels such that each floor panel in the second set of 136 floor panels is positioned to engage at least one adjacent floor panel in the first set of 132 floor panels. Each floor panel in the second set of 136 floor panels has an interlocking feature 108 that slidably engages an adjacent floor panel. As discussed above, the interlocking feature 108 is configured to allow lateral relative movement between a panel in the second set of 136 floor panels and its corresponding adjacent floor panel, and to restrict vertical relative movement therebetween. The second set of 136 floor panels is positioned to define a space 138 between a corresponding floor panel 100 in the second set of 136 floor panels and its corresponding adjacent floor panel 100 / 124, to allow lateral relative movement between a panel in the second set of 136 floor panels and its corresponding adjacent floor panel.

[0062] At frame 206, the method may include engaging floor panel 100 with adjacent floor panel 124 by interlocking the interlocking features 108 of each respective floor panel such that the interlocking features 108 of the respective floor panels are adjacent to each other.

[0063] At frame 208, method 200 includes filling space 138 with sealant 142 or elastomeric insert 144.

[0064] At frame 210, method 200 may include mounting surface 122 onto a first set 132 floor panel and a second set 136 floor panel.

[0065] Figure 16 It shows that it can be implemented Figure 15 The flowchart illustrates the additional functionality used at or after method 200. At box 222, the additional functionality includes removing a corresponding floor panel 100 (or panel subgroup) from the second group 136 floor panels. In some examples, removing a panel subgroup may include removing all panels in the floor system 130 and replacing the removed panels with new floor panels for the new floor system 130 to alter the floor of the passenger vehicle.

[0066] In some other examples, additional functionality may include removing a corresponding floor panel 124 from the first set 132 floor panels by disassembling the corresponding floor panel 124 from the structure 134.

[0067] At frame 224, an additional function includes replacing the corresponding floor panel 100 in the second set of 136 floor panels with a new floor panel. Replacing the corresponding floor panel 100 may include inserting the new floor panel 100 (or panel group) into the opening left by removing the corresponding floor panel 100 (or panel subgroup). The new floor panel 100 can be inserted due to the space 138 between the corresponding panels in the floor system 130, and by engaging the corresponding interlocking feature 108 of the new floor panel 100 with the existing panel in the floor system 130.

[0068] In some other examples, additional functionality may include replacing the corresponding floor panel 124 in the first set of 132 floor panels with a new floor panel by reattaching the new floor panel to the structure 134.

[0069] Figure 15 The exemplary process shown in the flowchart can be performed or executed manually by a system integrator, maintenance / repair / overhaul company, other third parties and / or operators (e.g., airlines or other transportation companies). Because less installation material is required and there is no need to rigidly attach each individual floor panel of the floor system 130 to the structure 134 of the aircraft 150, therefore... Figure 15 The exemplary process shown in the flowchart can reduce the installation time of the floor panels. Instead, only the panels in the first set 132 of floor panels can be attached to the structure 134 of the aircraft 150.

[0070] Figure 15 The example process shown in the flowchart can also improve installation reliability and repeatability, as well as enhance aesthetics and customer satisfaction. Furthermore, Figure 15 The exemplary process shown in the flowchart can improve durability and the ability to replace individual panels because the floor panels are not permanently glued to each other.

[0071] Compared to using generic floor mats, installing a non-woven floor system 130 in commercial aircraft or other vehicles (such as in the galley area of ​​a passenger vehicle) allows for a customized, aesthetically pleasing floor covering. Furthermore, the example described herein avoids the problem of floor covering warping by allowing the floor panels to move relative to each other. Therefore, the floor panels of the floor system 130 described herein will not leak, warp, or bubble because the interlocking feature 108 of the floor panels 100 will allow relative lateral movement between the floor panels while ensuring that the floor panels 100 do not lift when an upward load is applied.

[0072] Furthermore, in this example, if a panel becomes worn, damaged, defective, or undesirable for use, an individual floor panel can be replaced. For instance, because floor panels can be moved relative to each other, a non-permanent, softer, non-adhesive sealant can be used, thereby allowing easy replacement of one or more floor panels.

[0073] Furthermore, when using the floor system 130 described herein, a thin laminate layer is not required on the aircraft's subfloor. Instead, in this example, the floor panels of the floor system 130 can be directly attached to structure 134 of the aircraft 150.

[0074] Unless otherwise indicated, the terms “first,” “second,” etc., are used merely as labels in this document and are not intended to impose any order, position, or hierarchy requirements on the items they refer to. Furthermore, references to items such as “second” do not require or exclude the presence of items such as “first” or lower-numbered items and / or items such as “third” or higher-numbered items.

[0075] The terms “substantially” and / or “about” mean that the listed characteristic, parameter, or value does not need to be achieved precisely, but deviations or variations may occur within a quantity that does not impair the effect that the characteristic is intended to provide, including, for example, tolerances, measurement errors, measurement accuracy limitations, and other factors known to those skilled in the art.

[0076] The various examples of systems, apparatuses, and methods disclosed herein include a wide range of components, features, and functions. It should be understood that the various examples of systems, apparatuses, and methods disclosed herein may include any combination of any components, features, and functions of any other examples of systems, apparatuses, and methods disclosed herein, and all such possibilities are intended to be within the scope of this disclosure.

[0077] Descriptions of different advantageous arrangements have been presented for illustrative and descriptive purposes, and are not intended to be exhaustive or limited to the form of disclosure. Many modifications and variations will be apparent to those skilled in the art. Furthermore, different advantageous examples may describe different advantages compared to other advantageous examples. One or more examples have been selected and described to best explain the principles and practical applications of the examples, and to enable others skilled in the art to understand this disclosure for use with various examples having multiple modifications suitable for the specific purpose covered.

[0078] Furthermore, this disclosure includes examples pursuant to the following terms:

[0079] Clause 1. A floor panel for a floor system in a passenger vehicle, said floor panel comprising:

[0080] Top sheet;

[0081] The bottom sheet is opposite to the top sheet;

[0082] A body comprising multiple units, each unit having a cavity, the body being located between the top sheet and the bottom sheet; and

[0083] An interlocking feature extends outward from the body for slidably engaging adjacent floor panels, wherein the interlocking feature is formed via an outward extension of the bottom sheet beyond the top sheet, such that the top sheet is raised relative to the interlocking feature to form a seat configured for engaging the adjacent floor panels.

[0084] Clause 2. The floor panel according to Clause 1, wherein the plurality of units are all located inside the body, and the respective cavities are defined between the top sheet, the bottom sheet and the inner wall of the body.

[0085] Clause 3. The floor panel as described in Clause 1, wherein the interlocking feature extends along the periphery of the body.

[0086] Clause 4. The floor panel as described in Clause 1, wherein the interlocking feature extends along one of the two sides of the body or the two ends of the body.

[0087] Clause 5. The floor panel as described in Clause 1, wherein the top sheet, the bottom sheet, the body and the interlocking feature are a single piece.

[0088] Clause 6. The floor panel as described in Clause 1, wherein the seat includes an interlocking feature that abuts the top sheet at an angle of approximately 90°.

[0089] Clause 7. The floor paneling described in Clause 1 further includes:

[0090] The gripping surface located on the top sheet.

[0091] Clause 8. The floor paneling described in Clause 1 further includes:

[0092] The decorative surface located on the top sheet.

[0093] Clause 9. A floor system for a passenger vehicle, the floor system comprising:

[0094] The first set of floor panels includes panels rigidly attached to the structure of the passenger vehicle; and

[0095] The second set of floor panels, each of which has an interlocking feature for slidably engaging adjacent floor panels, wherein the interlocking feature is configured to allow lateral relative movement between a panel of the second set of floor panels and its corresponding adjacent floor panel while restricting vertical relative movement therebetween.

[0096] The second set of floor panels is positioned such that a space is defined between a corresponding floor panel in the second set of floor panels and the corresponding adjacent floor panel, allowing for lateral relative movement between the panel in the second set of floor panels and the corresponding adjacent floor panel; and

[0097] Each floor panel in the second group of floor panels is positioned to engage at least one adjacent floor panel in the first group of floor panels.

[0098] Clause 10. The flooring system according to Clause 9, wherein some of the floor panels in the second set of floor panels are positioned to engage both a corresponding panel in the first set of floor panels and a corresponding floor panel in the second set of floor panels.

[0099] Clause 11. The flooring system according to Clause 9, wherein the interlocking feature is configured to restrict vertical relative movement between the panels in the second set of floor panels and the corresponding adjacent floor panels by preventing the panels of the second set of floor panels from moving in a direction perpendicular to the surface of the panels of the second set of floor panels.

[0100] Clause 12. The flooring system according to Clause 9, wherein the interlocking feature is configured to enable relative longitudinal movement between the panel in the second set of floor panels and the corresponding adjacent floor panel.

[0101] Clause 13. The flooring system according to Clause 9, wherein a respective floor panel in the second set of floor panels comprises a top sheet, a bottom sheet opposite to the top sheet, and a body located between the top sheet and the bottom sheet, and wherein the interlocking feature comprises a lip extending outward from the body of the respective floor panel, wherein the lip is formed via an outward extension of the bottom sheet beyond the top sheet, such that the top sheet is raised relative to the lip to form a seat configured to engage an adjacent floor panel in the first set of floor panels.

[0102] Clause 14. The flooring system according to Clause 13, wherein the lip is in adjacent contact with the lip of the adjacent floor panel.

[0103] Clause 15. The floor system according to Clause 9, wherein the panels in the first set of floor panels are anchored to the structure of the passenger vehicle at the periphery of the area of ​​the passenger vehicle.

[0104] Clause 16. The floor system according to Clause 9, wherein the panels in the first set of floor panels are anchored to the structure of the passenger vehicle at one or more door interfaces of the passenger vehicle.

[0105] Clause 17. The flooring system as described in Clause 9 further includes:

[0106] The sealant is positioned in the space.

[0107] Clause 18. The flooring system as described in Clause 9 further includes:

[0108] An elastomeric insert positioned in the space.

[0109] Clause 19. An aircraft comprising a floor system as described in Clause 9.

[0110] Clause 20. A method for installing a floor system in a passenger vehicle, the method comprising:

[0111] The first set of floor panels is attached to the structure of the passenger vehicle at locations distributed throughout the entire area of ​​the passenger vehicle;

[0112] The second set of floor panels is positioned such that each floor panel in the second set is positioned to engage at least one adjacent floor panel in the first set of floor panels, wherein each floor panel in the second set of floor panels has an interlocking feature that slidably engages adjacent floor panels, wherein the interlocking feature is configured to allow lateral relative movement between a panel in the second set of floor panels and its corresponding adjacent floor panel and to restrict vertical relative movement therebetween, wherein the second set of floor panels is positioned to define a space between a corresponding floor panel in the second set of floor panels and its corresponding adjacent floor panel to allow lateral relative movement between a panel in the second set of floor panels and its corresponding adjacent floor panel; and

[0113] The space is filled with a sealant or an elastomer insert.

[0114] Clause 21. The method described pursuant to Clause 20 further includes:

[0115] The surface is mounted onto the first set of floor panels and the second set of floor panels, wherein the surface includes at least one of a gripping surface and a decorative surface.

[0116] Clause 22. The method described pursuant to Clause 20 further includes:

[0117] Each floor panel in the second set of floor panels is joined to at least one adjacent floor panel in the first set of floor panels by interlocking the interlocking features of each floor panel in the second set of floor panels to the interlocking features of at least one adjacent floor panel such that the corresponding interlocking features are adjacent to each other.

[0118] Clause 23. The method described pursuant to Clause 20 further includes:

[0119] Remove the corresponding floor panel from the second group of floor panels.

[0120] Clause 24. The method described pursuant to Clause 23 further includes:

[0121] The new floor panel replaces the corresponding floor panel in the second set of floor panels by inserting it into the opening left by removing the corresponding floor panel in the second set of floor panels.

[0122] Therefore, it should be understood that this disclosure is not limited to the specific examples shown, and that modifications and other examples are intended to be included within the scope of the appended claims. Furthermore, although examples of this disclosure have been described above in the context of certain illustrative combinations of elements and / or functions in the foregoing description and the accompanying drawings, it should be understood that different combinations of elements and / or functions may be provided by alternative embodiments without departing from the scope of the appended claims.

Claims

1. A floor panel for a floor system in a passenger vehicle, the floor panel comprising: Top sheet; The bottom sheet is opposite to the top sheet; A body comprising a plurality of units, each having a cavity, the body being located between a top sheet and a bottom sheet, wherein the plurality of units are all within the body and the respective cavities are defined between the top sheet, the bottom sheet and the inner wall of the body, and wherein each of the plurality of units includes a hole for weight reduction extending from the body through the bottom sheet; as well as An interlocking feature extends outward from the body for slidably engaging adjacent floor panels, wherein the interlocking feature is formed via an outward extension of the bottom sheet beyond the top sheet, such that the top sheet is raised relative to the interlocking feature to form a seat configured for engaging the adjacent floor panels.

2. The floor panel of claim 1, wherein the inner walls are oriented perpendicularly to each other to form an internal honeycomb structure of the plurality of units of the body.

3. The floor panel according to claim 2, wherein the internal honeycomb structure is configured as multiple rows and columns of cells.

4. The floor panel of claim 1, wherein the interlocking feature extends along the periphery of the body.

5. The floor panel of claim 1, wherein the interlocking feature extends along one of the two sides of the body or the two ends of the body.

6. The floor panel of claim 1, wherein the interlocking feature extends along one full side of the body, but only partially along the opposite side of the body.

7. The floor panel according to claim 1, wherein the top sheet, the bottom sheet, the body and the interlocking feature are a single-piece structure.

8. The floor panel of claim 1, wherein the seat includes the interlocking feature that abuts the top sheet at a 90° angle.

9. The floor panel of claim 1, wherein the seat includes the interlocking feature that abuts the top sheet at an angle greater than 90°.

10. The floor panel according to claim 1, further comprising: The gripping surface is positioned on the top sheet.

11. The floor panel according to claim 1, further comprising: The decorative surface positioned on the top sheet.

12. The floor panel of claim 1, wherein the interlocking feature is configured to restrict vertical relative movement with respect to the adjacent floor panel.

13. The floor panel of claim 1, wherein the interlocking feature is configured to allow relative longitudinal movement with respect to the adjacent floor panel.

14. The floor panel of claim 1, wherein the outward extension of the bottom sheet beyond the top sheet further includes a hole.

15. An aircraft comprising a plurality of floor panels as claimed in claim 1.

16. A floor panel for a floor system in a passenger vehicle, the floor panel comprising: Top sheet; The bottom sheet is opposite to the top sheet; A body comprising a plurality of units, each having a cavity, the body being located between a top sheet and a bottom sheet, wherein the plurality of units are all inside the body and the respective cavities are defined between the top sheet, the bottom sheet and the inner wall of the body, and wherein each of the plurality of units includes a hole for weight reduction extending from the body through the bottom sheet; as well as An interlocking feature extends outward from the body for slidably engaging adjacent floor panels, wherein the interlocking feature is formed via an outward extension of the top sheet beyond the bottom sheet such that the bottom sheet is recessed relative to the interlocking feature to form a seat configured for engaging the adjacent floor panel.

17. The floor panel of claim 16, wherein the inner walls are oriented perpendicularly to each other to form an internal honeycomb structure of the plurality of cells of the body.

18. The floor panel of claim 16, wherein the interlocking feature extends along the periphery of the body.

19. The floor panel of claim 16, wherein the interlocking feature extends along one of the two sides of the body or the two ends of the body.

20. The floor panel of claim 16, wherein the outward extension of the top sheet beyond the bottom sheet further includes a hole.

Images