Floor Tile Rim and Interlocking Tongue Groove Alignment
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Solution Overview
Problem
Existing modular flooring systems face challenges in accurately positioning the surface pattern layer on the base layer and layer shrinkage during the moulding and curing process, leading to imperfect fits between the base and surface layers.
Innovation Solution
The solution involves a floor tile design with a rim extending around the perimeter of the substrate to form a nest for the laminate layer, using an adhesive to bond the laminate to the substrate, and interlocking tongues and grooves for precise alignment and connection, along with a method involving injection moulding and roller coater machines for manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If layers are moulded and cured in the prior art system, then the flooring tiles are formed, but layer shrinkage occurs causing imperfect fit between base and surface layers
Solution Approach 1:
The flooring system is divided into separate base layer and surface layer components that are assembled after individual formation, allowing each layer to be optimised independently and eliminating shrinkage-related fitting problems
Solution Approach 2:
The base layer is prepared in advance with pre-formed recesses and positioning features before the surface layer is applied, ensuring accurate alignment and eliminating fit issues that would occur if layers were cured together
2Manufacturing precision
If surface pattern layer is positioned on base layer in prior art, then flooring tiles are assembled, but accurate positioning is difficult resulting in imperfect fit
Solution Approach 1:
The base layer incorporates self-aligning features such as recesses and positioning protrusions that automatically guide the surface layer into correct position during assembly, eliminating the need for complex external positioning mechanisms
Solution Approach 2:
The positioning recesses and alignment features are designed with visual indicators that show when the surface layer is correctly positioned on the base layer, providing immediate feedback for accurate assembly
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
This approach ensures accurate positioning and secure interlocking of tiles, eliminating the need for adhesive during installation and providing a consistent, square fit, thus enhancing the modular flooring system's performance and installation efficiency.
Implementation Method 1
the laminate layer is bonded to the substrate layer using an adhesive
Implementation Method 2
operating an injection moulding machine to form the base substrate
Implementation Method 3
removing the base substrate from the injection moulding machine and allowing the base substrate to cool
Implementation Method 4
operating a roller coater machine to apply adhesive to the laminate layer
Implementation Method 5
applying pressure to the laminate layer on the substrate comprises operating a nip-roller machine
Data Source
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AI summary
The present invention provides a tile and method of forming a tile, in which the tile comprises a base substrate and a laminate layer, whereby the substrate has upstanding edges on a top surface thereof, such that the edges define a rim at a perimeter of the substrate for aligning the laminate layer on the top surface of the substrate. The substrate comprises connecting means for engaging with connecting means of a substrate of a further tile to form an interconnected floor system. Engaging the connecting means of a tile with a further tile aligns and positions a side edge of the tile with the side edge of the further tile in a side by side arrangement to provide a grout effect for the tiles when connected.