Mechanical Floor Board Coupling for Narrow Grout and Waterproof Edges
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Solution Overview
Problem
Existing floor boards with decorative tiles face installation difficulties due to the thickness of the tiles hindering angling-in coupling, leading to wider grout lines and less attractive solutions, and they lack improved waterproof properties and moisture resistance.
Innovation Solution
A floor board design with mechanical coupling parts featuring a sideward tongue and recessed lower lip, allowing easy angling-down installation and forming narrow grout lines, while using MDF or HDF substrate with water-impermeable treatment and thermal searing for enhanced waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick decorative tiles are used on floor boards, then the aesthetic appearance and durability are improved, but the angling-in coupling process becomes difficult and grout lines become wider
Solution Approach 1:
The coupling mechanism is divided into separate functional elements: a tongue portion extending from one floor board and a groove portion in the adjacent floor board. This segmentation allows the thick decorative tile to remain intact while the coupling function is distributed to dedicated structural elements beneath the surface, enabling easy angling-in installation without compromising tile integrity.
Solution Approach 2:
The coupling mechanism operates in a horizontal dimension parallel to the floor board surface, rather than requiring vertical compression. The tongue and groove engage through lateral movement during installation, allowing thick tiles to be coupled easily without requiring the tile thickness to be reduced, thus maintaining both aesthetic appearance and installation ease.
2Shape
If thick decorative tiles are used on floor boards, then the aesthetic appearance is improved, but the grout line width increases
Solution Approach 1:
The coupling function is extracted from the decorative tile surface and placed in dedicated tongue and groove structures beneath the tile. This allows the tile to maintain its full aesthetic appearance with minimal or no grout lines visible, while the coupling mechanism operates independently in the structural layer, preventing the need to increase grout line width for installation purposes.
3Reliability
If conventional coupling parts are used, then the floor boards can be coupled together, but installation becomes difficult with thick decorative tiles
Solution Approach 1:
The tongue and groove coupling mechanism is designed to self-align and self-lock during the angling-in installation process. The geometric shapes of the tongue and groove automatically guide the floor boards into proper alignment and secure the connection without requiring additional tools or complex manipulation, ensuring both reliable coupling and easy installation even with thick decorative tiles.
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
Facilitates easy installation with narrow grout lines and improves waterproofing and moisture resistance, reducing creaking noises and installation challenges.
Implementation Method 1
at least one side edge of the substrate is treated with at least one water barrier agent, wherein said water barrier agent is preferably water impermeable and/or moisture-repellent
Implementation Method 2
at least a part of at least one edge, preferably at least one side edge, of the substrate is subjected to a thermal searing or ironing step to sear said edge at least partially
Data Source
AI summary
A floor board including a decorative surface layer applied to a substrate, where the substrate is optionally MDF or HDF material at a side edge thereof, and at least one side edge together with a side edge opposite thereto forming a first pair of opposite side edges of said substrate. The first pair of opposite side edges includes mechanical first and second coupling parts, respectively, allowing the floor board to be coupled at the respective side edges with a similar floor board. Also, a floor board covering consisting of a plurality of the floor boards and a method for manufacturing such floor boards.