Modular Floor Tile Latch-Loop Interference Mechanism
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Solution Overview
Problem
Conventional modular injection-molded tiles face challenges in manufacturing tiles with multiple colors, non-slip characteristics, and the ability to withstand heavy loads without requiring a nonslip substrate, while also being cost-effective and easy to assemble.
Innovation Solution
The use of a two-polymer compound system where a second polymer compound is overmolded onto the surface and lower surface of a first polymer compound body, with vent holes to prevent voids and enhance adhesion, and a latch-loop mechanism for easy assembly, allowing for the creation of tiles with nonslip pads and support members that can be colored differently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional single-color injection-molded tiles are used, then manufacturing is simple and cost-effective, but aesthetic appeal and design flexibility are limited
Solution Approach 1:
The tile is divided into multiple color zones or patterns within a single injection molding cycle, allowing different sections of the tile to have different colors or designs while maintaining manufacturing efficiency. This segmentation enables aesthetic variety without requiring multiple separate molding operations.
Solution Approach 2:
Different regions of the tile are given different local qualities through the injection molding process, such as varying colors, textures, or densities in specific areas. This allows the tile to have heterogeneous properties across its surface, enhancing aesthetic appeal while using a single manufacturing process.
2Ease of operation
If conventional modular tiles are used, then assembly is simple with male and female connectors, but the tiles are easily dislodged under heavy loads or wheeled vehicles
Solution Approach 1:
The connector structures are integrated directly into the tile body through injection molding, merging the tile substrate and connection elements into a single unified component. This eliminates weak points at connection interfaces and distributes loads more effectively across the entire tile structure, improving load-bearing capacity while maintaining assembly simplicity.
Solution Approach 2:
The tile uses a composite structure combining rigid connection elements with potentially softer cushioning materials or reinforcement features molded into the same piece. This composite approach enhances the tile's ability to withstand heavy loads and lateral forces while maintaining the snap-together assembly mechanism.
3Reliability
If conventional tiles requiring rubber substrate sheets are used, then non-slip characteristics are achieved, but the overall system complexity and installation time increase
Solution Approach 1:
The non-slip features are merged directly into the tile body through injection molding, integrating the substrate and non-slip surface into a single component. This eliminates the need for separate rubber sheets or additional layers, reducing system complexity while maintaining reliable non-slip characteristics through molded-in surface textures or patterns.
4Reliability
If separate rubber inserts are physically inserted into plastic substrate holes, then cushioning characteristics are achieved, but manufacturing time and cost greatly increase
Solution Approach 1:
The cushioning elements are merged with the plastic substrate through injection molding, creating a single integrated component. This eliminates the separate operations of manufacturing inserts, removing flash, and physically inserting components into holes. The cushioning characteristics are achieved directly during the molding process, greatly improving manufacturing speed and reducing costs.
Data Source
AI summary
Lateral edges of the modular plastic floor tiles are provided with latches which fit into loops with an interference fit. The latch and loop structure may include an undercut behind the lateral edge of the tile. The loops flex in order to impose a compressive force on mating tile edges.