Flexible Floor Member with Beveled Edges and Surface Declination
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Solution Overview
Problem
Existing methods for producing non-ceramic tiles with rounded edges require significant force, elevated temperatures, and frequent tool replacement, making them inefficient and costly.
Innovation Solution
A flexible floor member with peripheral surface declinations and beveled edges is formed using a roller assembly and grinding tools, reducing the need for pre-heating and minimizing force requirements, while allowing for efficient production of tiles with rounded and beveled edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional cutting tools are used to form rounded edges, then rounded edges can be produced, but the cutting tool must be replaced frequently when the cutting edge becomes dull
Solution Approach 1:
The patent replaces traditional mechanical cutting tools with a roller assembly that uses abrasion to form rounded edges. The roller assembly includes a roller with abrasive surfaces that gradually wear down the tile edges, eliminating the need for sharp cutting edges and reducing tool replacement frequency.
Solution Approach 2:
The roller assembly is designed to be replaceable and is consumed through controlled abrasion. Rather than replacing expensive cutting tools frequently, the roller wears down gradually and can be replaced when its abrasive surface is exhausted, providing a more economical solution.
2Shape
If traditional cutting and forming operations are used, then rounded edges can be formed, but a relatively large force and elevated temperatures are required
Solution Approach 1:
The patent replaces high-force mechanical cutting and forming operations with a low-force abrasion process. The roller assembly uses controlled friction and gradual wear to shape the edges, eliminating the need for large forces and elevated temperatures required by traditional methods.
Solution Approach 2:
The patent changes the physical parameters of the edge formation process by using abrasion instead of mechanical cutting. This parameter change allows for rounded edge formation with significantly reduced force requirements and without the need for elevated temperatures.
3Shape
If traditional cutting and forming operations are used, then rounded edges can be formed, but elevated temperatures are required
Solution Approach 1:
The patent replaces thermal processes with a mechanical abrasion process. The roller assembly forms rounded edges through controlled friction and wear, eliminating the need for elevated temperatures that are required by traditional cutting and forming operations.
Solution Approach 2:
The roller assembly is designed to be replaced when its abrasive surface is exhausted, providing a cost-effective solution that eliminates the need for expensive thermal processing equipment and energy consumption.
4Ease of manufacture
If traditional cutting tools are used, then edges can be cut, but the cutting edge becomes dull and requires replacement
Solution Approach 1:
The patent replaces cutting tools that rely on sharp edges with a roller assembly that uses abrasion. The abrasive surface of the roller gradually wears down the tile edges, providing a self-sustaining process that extends tool service life and eliminates the need for frequent replacements.
Solution Approach 2:
The roller assembly provides continuous abrasion action as it rotates and contacts the tile edges. This periodic wear action gradually forms the rounded edges throughout the production process, extending the operational life of the tool compared to traditional cutting methods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the production of flexible floor tiles and planks with rounded and beveled edges using less force and without pre-heating, improving efficiency and reducing tool wear, while providing a secure and flexible flooring solution with minimal contact area for easy installation and expansion relief.
Implementation Method 1
forming rounded surface declinations on the tile
Implementation Method 2
reducing the need for pre-heating and minimizing force requirements
Implementation Method 3
peripheral beveled edges... grinding tools
Data Source
AI summary
The floor member, in one embodiment of the invention, is a floor member unit having a surface declination at the periphery of a top surface and extending downwardly to a peripheral beveled edge, and intersecting with the beveled edge between the top surface and a bottom surface. The surface declination can be curved or uncurved. In another embodiment of the invention the floor member unit is laminated in offset relationship to an underlayer of the same size and shape as the floor member unit. In either embodiment, the floor member can be formed as a floor tile or a floor plank.