Composite Floor Plank Interlock for Stronger Adhesive-Free Joints
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Solution Overview
Problem
Existing floor coverings, such as vinyl and laminate flooring, face issues with adhesive installation processes that are time-consuming, costly, and hazardous, and mechanical locking systems often result in weak joint strength, weight, and moisture sensitivity.
Innovation Solution
A resilient composite sheet with interlocking tongue and groove edge profiles, featuring balanced dimensions and angles, allows for easy installation and enhanced joint strength without adhesives, suitable for flexible materials like LVT and VCT.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is used to secure the 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 flooring system entirely, replacing it with a mechanical interlocking system using tongue and groove profiles. This extraction eliminates the hazards and time-consuming preparation associated with adhesive application while maintaining floor covering stability through the interlocking mechanism.
Solution Approach 2:
The patent replaces the chemical bonding system (adhesive) with a mechanical interlocking system (tongue and groove profiles). The mechanical engagement of the tongue fitting into the groove provides the necessary stability and positioning without requiring adhesive application, thereby reducing installation time and eliminating adhesive-related hazards.
2Ease of operation
If mechanical locking system is used to join floor planks, then installation becomes easier without adhesives, but joint strength and moisture resistance are compromised
Solution Approach 1:
The patent employs composite construction within the floor planks themselves (using materials like WPC - wood plastic composite, or SPC - stone plastic composite) that provide inherent strength and moisture resistance. The mechanical interlocking system works in conjunction with these composite materials to achieve both ease of installation and high joint strength, as the composite core provides structural integrity while the tongue and groove profiles enable simple mechanical assembly.
3Ease of operation
If wood-based core material is used in laminate flooring, then the flooring can be joined using mechanical locking system, but the flooring becomes heavy and sensitive to moisture
Solution Approach 1:
The patent fundamentally changes the material composition parameters of the floor plank core, transitioning from traditional wood-based materials (high density fiber board, particle board) to composite materials such as WPC (wood plastic composite) or SPC (stone plastic composite). These composite materials maintain the mechanical interlocking capability while significantly reducing weight and eliminating moisture sensitivity, as the plastic or stone components provide water resistance and lighter density.
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.