Direct-Attach Non-Wood Decking System for Concrete Surfaces
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Solution Overview
Problem
Concrete floors in home porches and patios are aesthetically unpleasing and hard, making them undesirable for walking or seating, and traditional sleeper systems are difficult to install due to limited vertical clearance and unsuitability for non-dry environments.
Innovation Solution
A flooring system using non-wood decking material with interlocking floating and holding floor members that can be directly secured to a concrete surface with minimal fasteners, allowing for easy installation and aesthetic appeal, suitable for both dry and non-dry environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a sleeper system is used to install flooring atop concrete, then the flooring can be installed, but vertical clearance is required which may not be available
Solution Approach 1:
The patent removes the intermediate sleeper layer from the traditional flooring system, allowing decking material to be installed directly atop the concrete surface. This extraction eliminates the need for vertical clearance that would otherwise be required to accommodate sleepers between the concrete and flooring.
Solution Approach 2:
The patent merges the functions of the sleeper system and decking installation into a single direct attachment system. The decking material is secured directly to the concrete surface using fasteners, combining what were previously separate layers (sleeper + decking) into a more compact configuration.
2Reliability
If traditional fastening methods are used on concrete, then flooring can be secured, but the number of fasteners required is large and installation is difficult
Solution Approach 1:
The patent segments the flooring system into discrete decking boards that can be individually fastened to the concrete surface. Each board is secured with fasteners at specific locations, allowing for manageable installation while maintaining overall system security. The segmentation allows workers to install boards one at a time rather than handling large continuous sections.
Solution Approach 2:
The patent introduces an intermediary mechanism where decking boards with pre-drilled holes or attachment features serve as the medium between the concrete surface and the fasteners. This intermediary structure facilitates easier fastening by providing predetermined attachment points, reducing the skill and effort required for installation while ensuring reliable security.
3Adaptability or versatility
If sleeper systems are used for wooden flooring, then flooring can be installed, but they are not suitable for non-dry environments
Solution Approach 1:
The patent employs composite or treated decking materials that are specifically designed to resist moisture and decay, making them suitable for non-dry environments such as porches and patios. These materials may include pressure-treated wood, composite decking, or naturally rot-resistant species, which maintain their structural integrity and aesthetic properties in humid or wet conditions where traditional sleepers would deteriorate.
Data Source
AI summary
A flooring system that may include one or more floor members, wherein the one or more floor members may be configured together to form a floor covering atop an installation surface, which may be a non-dry environment, and wherein one or more of the one or more floor members are secured directly to the installation surface, and wherein the one or more floor members is made of a non-wood decking material. The one or more floor members may include one or more holding floor members, and one or more floating floor members, wherein the one or more holding floor members engage with one or more of the one or more floating floor members to form the floor covering atop the installation surface, and wherein the holding floor members are configured and arranged to secure the floor covering in place atop the installation surface.