Composite Lap Joint for Trailer Flooring
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Solution Overview
Problem
Conventional shiplap joints in composite wood floorboards for trailers are structurally weak due to unreinforced top lips, prone to cracking under fatigue loads, and lack effective moisture sealing, leading to water ingress and material inefficiency.
Innovation Solution
A composite lap joint design where the composite underlayer of one board extends to form a lip that mates with the recess of an adjacent board, providing enhanced flexibility, improved sealing, and increased strength by eliminating shiplaps and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional shiplap joints are used in composite floorboards, then the joint provides load transfer capability, but the unreinforced top lips are structurally weak and prone to cracking under fatigue loads
Solution Approach 1:
The patent applies composite materials by extending the fiber-reinforced composite underlayer to form a lap joint flange that mates with an adjacent board recess. This composite flange structure provides both strength and flexibility, preventing cracking under fatigue loads while maintaining load transfer capability between floorboards.
Solution Approach 2:
The invention implements local quality by extending the composite underlayer specifically at the edge region where the lap joint is formed, while maintaining the conventional structure elsewhere. This localized reinforcement provides enhanced strength and cracking resistance at the critical joint area without adding unnecessary material throughout the entire board.
2Device complexity
If conventional shiplap joints are used, then the joint structure is simple, but moisture sealing is ineffective leading to water ingress
Solution Approach 1:
The fiber-reinforced composite material used for the lap joint flange provides inherent moisture sealing properties. The composite material forms a continuous barrier that prevents water ingress at the joint, eliminating the need for additional sealing components while maintaining structural function.
3Strength
If conventional shiplap joints with full thickness wood edges are used, then the joint provides structural strength, but material usage is inefficient
Solution Approach 1:
The patent uses the fiber-reinforced composite underlayer to provide the necessary strength and sealing function at the joint, eliminating the need for excessive wood material. The composite flange replaces redundant wood portions, achieving material efficiency while maintaining structural performance.
Solution Approach 2:
The invention extracts the sealing and reinforcement function from the wood material and assigns it to the composite underlayer. This separation of functions allows the wood to be used more efficiently for its primary structural role while the composite handles sealing and joint strength.
Data Source
AI summary
A composite wood floor board assembled adjacent to another composite wood floor board, each the board comprising: a top layer of laminated hardwood comprising: a top side; a bottom side; a first lateral side; and a second lateral side opposite the first lateral side, wherein at least one of the first and second lateral sides is formed without shiplap lips; and a bottom layer comprising a planar fiber-reinforced polymer composite that is bonded to the bottom side of the top layer of the laminated hardwood and reinforces the top layer, wherein the bottom layer of fiber-reinforced polymer composite extends laterally outwardly by a distance up to two inches (2″) from the first lateral side of the top layer, and wherein a part of the bottom layer of the composite wood floor board is bonded to the top layer with a first adhesive and a part of the bottom layer is bonded with a second adhesive or sealant.