Clip Connector Seaming for Modular Floor Covering Without Adhesives
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Solution Overview
Problem
Existing methods for installing modular floor covering units are labor-intensive, costly, and prone to adhesive failure due to weak bonds, moisture susceptibility, and limited compatibility with various backing types, especially under heavy traffic and moisture exposure.
Innovation Solution
A clip connector made from electro-galvanized steel with upwardly angled projections and a releasable silicone tape barrier, allowing for secure joining of modular floor covering units without adhesives, which can be used on various backing types and withstands heavy loads and moisture, with a tacking system to maintain alignment during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If adhesive connectors are used to join modular floor covering units, then the installation process is simplified and labor costs are reduced, but the bond strength is insufficient under heavy traffic and moisture exposure
Solution Approach 1:
The patent replaces the chemical bonding system (adhesive) with a mechanical fastening system (staples, pins, or clips that penetrate the backing). This mechanical approach provides superior bond strength and resistance to heavy traffic while maintaining ease of installation through simple insertion or stapling actions.
Solution Approach 2:
The invention changes the bonding mechanism from chemical adhesion to mechanical penetration and friction. The fasteners physically penetrate the backing material and engage with the floor covering unit, creating a mechanical bond that is insensitive to moisture and capable of withstanding heavy loads.
2Reliability
If traditional adhesives are applied to the entire supporting surface or underside of floor covering units, then complete coverage and bonding is achieved, but the process becomes highly labor-intensive and costly
Solution Approach 1:
The patent extracts the bonding function from a continuous adhesive application and concentrates it at discrete locations where fasteners are inserted. This localized approach achieves sufficient bonding reliability while dramatically reducing the labor and material requirements compared to full-surface adhesive application.
Solution Approach 2:
Instead of applying adhesive to the entire surface (excessive action), the invention uses partial action by concentrating fasteners at key connection points. This partial fastening approach provides adequate bonding reliability while significantly improving installation productivity.
3Object-affected harmful factors
If adhesive connectors with one-sided pressure sensitive adhesive are used, then the connectors are water resistant, but they remain susceptible to moisture from above and adhesive failure
Solution Approach 1:
The patent replaces the adhesive layer with a mechanical fastening system that is inherently immune to moisture degradation. Staples, pins, or metal clips do not deteriorate from moisture exposure and maintain their fastening capability, eliminating the adhesive failure mode entirely.
Solution Approach 2:
The invention uses metal fasteners (steel staples, pins, or clips) as composite elements that combine structural strength with moisture resistance. These metal components work in conjunction with the floor covering unit and backing to create a moisture-resistant assembly that does not rely on adhesive bonds.
4Strength
If spray adhesive is used to supplement adhesive connector systems for extra seam strength, then bond strength is improved, but volatile organic chemicals are introduced requiring ventilation and restricting installation timing
Solution Approach 1:
The patent replaces chemical adhesives (including spray adhesives) with a purely mechanical fastening system. This substitution eliminates VOC emissions entirely while maintaining or improving seam strength through the mechanical action of penetrating fasteners that physically secure the floor covering units together.
Data Source
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AI summary
A clip connector seaming apparatus having upstanding projections arranged in sections to point inwardly on the lateral and longitudinal axes adapted to join a plurality of modular floor covering units comprising a modular floor covering is provided. The clip connector may comprise a releasable silicone backing and a pressure sensitive tape to affix or "tack" the clip connector to a supporting surface. The clip connector does not require any spray adhesives or additional glue to affix floor covering units to a support surface and is resistant to wear, moisture, excessive force. The clip connector may also be reusable to provide for replacing individual floor covering units.