Interlocking Composite Floor Covering for Water-Resistant Floating Joints
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Solution Overview
Problem
Existing surface coverings, such as vinyl and laminate flooring, face challenges with adhesive installation processes that are time-consuming, costly, and hazardous, and mechanical locking systems often result in weak joint strength, water resistance issues, and weight concerns.
Innovation Solution
The development of resilient composite planks with interlocking tongue and groove edge profiles that are lightweight, water-resistant, and easy to install, featuring elongated tongue lengths and balanced cross-sectional areas for enhanced joint strength and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive installation is used to secure floor covering, then the floor covering can be kept in place and achieve a level surface, but the installation process becomes time-consuming, costly, and hazardous
Solution Approach 1:
The patent removes the adhesive component from the floor installation system entirely. Instead of using adhesive to bond the floor covering to the subfloor, the invention employs a mechanical interlocking system where planks with tongue-and-groove profiles lock together and to the subfloor through physical engagement, eliminating the need for adhesive application and associated hazards.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (adhesive) with a mechanical interlocking system. The tongue-and-groove profiles create physical engagement between planks and the subfloor, using mechanical forces rather than chemical adhesion to achieve secure attachment and level surface alignment.
2Ease of operation
If mechanical locking system is used to join floor planks, then installation becomes easier without adhesives, but joint strength becomes weak
Solution Approach 1:
The patent incorporates a cam-shaped locking surface with a curved profile in the tongue-and-groove mechanism. This curved surface allows for gradual engagement and locking of adjacent planks, providing both ease of installation through simple pressing motion and strong joint strength through the mechanical leverage created by the cam action.
Solution Approach 2:
The patent adds a vertical locking dimension to the horizontal tongue-and-groove connection. The locking protrusion extends upward from the groove bottom to engage with the tongue, creating a three-dimensional interlocking system that prevents separation in multiple directions while maintaining simple installation procedures.
3Ease of manufacture
If wood-based core material is used in laminate flooring, then the flooring can be mechanically joined, but water resistance becomes insufficient and weight increases
Solution Approach 1:
The patent employs a composite construction with a moisture-resistant core material (such as HDF or particle board with water-repellent treatment) combined with a vinyl or resin-based wear layer. This composite structure provides both the mechanical joining capability through the core material's stability and the water resistance through the protective outer layer, eliminating the weakness of traditional wood-based cores.
Data Source
AI summary
Surface coverings, such as floor coverings, with an interlocking design are described. Methods of making the surface coverings are further described. A plank including a resilient composite sheet having four sides, an upper surface, a lower surface, and an overall thickness, and said composite sheet including at least one base layer, wherein said at least one base layer including at least one polymeric material and at least one filler, wherein opposite sides of the composite sheet include a first tongue on a first side and a first groove on the opposite second side, wherein the first tongue and first groove have complementary shape to each other to be interlockingly engageable with a corresponding groove or tongue on an adjacent floor plank.