Flush Wood Flooring via Segmented Tongue and Groove
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Solution Overview
Problem
Conventional flooring systems often result in visible seams and an uneven upper surface due to the abutment of lateral surfaces of different flooring panels, which can detract from the aesthetic appeal and structural integrity of the floor.
Innovation Solution
A flooring system comprising first and second panels with grooves and tongues, respectively, that interlock to create a flush surface, along with a retention element and protective inserts to secure the panels and maintain the surface's smoothness, utilizing monolithic solid wood elements and geometric patterns for enhanced stability and design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional flooring panels are abutted together, then the floor can be assembled, but visible seams and uneven upper surfaces are created
Solution Approach 1:
The flooring panel is segmented into multiple layers including an upper layer, lower layer, and intermediate layer, with grooves and tongues created through partial cutting of these layers. This segmentation allows the panel to interlock with adjacent panels while maintaining a flush upper surface, resolving the contradiction between surface flatness and assembly simplicity.
Solution Approach 2:
The groove and tongue structures are nested within the panel layers themselves, with the tongue of one panel fitting into the groove of an adjacent panel. This nesting approach eliminates visible seams and creates an uneven surface-free floor without requiring additional external fastening components.
2Shape
If grooves and tongues are added to panels to create flush surfaces, then surface flatness is improved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process segments the panel into distinct layers (upper, intermediate, lower) and creates grooves and tongues by selectively cutting through specific layers. This layered approach simplifies manufacturing by allowing standard cutting techniques to be applied to predetermined layer boundaries, making the complex shapes easier to produce.
Solution Approach 2:
The grooves and tongues are pre-formed as integral parts of the panel structure during the panel manufacturing process itself, rather than being added as separate components later. This preliminary action embeds the complexity into the manufacturing stage, simplifying subsequent installation while achieving the desired flush surface.
3Stability of the object's composition
If panels are constructed from multiple wood elements, then structural stability is improved, but visual seams are created
Solution Approach 1:
The panel is constructed by adhesively affixing multiple substantially monolithic solid wood elements together to form distinct layers (upper, intermediate, lower). This segmentation provides structural stability through the layered construction while the adhesive bonding and careful alignment ensure that no visual seams appear on the upper surface.
Solution Approach 2:
Multiple wood elements are merged through adhesive bonding to create a unified panel structure. The upper layer elements are positioned and bonded to intermediate and lower layer elements, combining the structural benefits of multiple pieces while presenting a continuous, seam-free upper surface.
Data Source
AI summary
A flooring system including at least two sets of flooring panels. A first set of flooring panels having a first shape and recessed grooves on the opposite lateral sides. The first set of panels being constructed from a plurality of wood elements adhesively affixed together. A second set of flooring panels having a second shape and an integral tongue protruding from the opposite lateral sides. The second set of panels being constructed at least one wood element. The first set of panels and second set of panels are connected by mating the tongue and groove. The resulting connection between the panels forming a floor with substantially flush upper surface.