Interlocking Floor Panels with Composite Shock Absorption

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Solution Overview

Problem

Existing flooring base systems are expensive to install and difficult to remove, and they lack the necessary rigidity and shock absorption properties required for recreational surfaces that need to be easily movable and provide fall-height protection.

Innovation Solution

Interlocking panels with a planar top surface and side surfaces featuring interlocking mechanisms, made from materials like polypropylene, structural urethane foams, or rubber, which include a shock absorption material beneath the top surface for structural support and impact protection, allowing for easy assembly and disassembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional base materials (compacted stone, asphalt, plywood, or cement) are used, then structural support is provided, but installation cost increases and removal difficulty increases

Engineering Contradiction:

Improvestructural supportVSAvoidinstallation cost and removal difficulty

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The floor system is divided into multiple interlocking panels that can be independently installed and removed. Each panel contains integrated shock absorption material and support structure, allowing the system to be segmented into manageable units that are easier to install and remove compared to traditional monolithic base materials.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The panels combine rigid plastic material with integrated shock absorption material (foam or rubber) to create a composite structure that provides both structural support and impact protection. This composite approach eliminates the need for separate base layers, reducing installation cost and complexity while maintaining strength.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If foam or rubber panels are used, then shock absorption is improved, but rigidity and structural support deteriorate

Engineering Contradiction:

Improveshock absorptionVSAvoidrigidity

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The panel combines rigid plastic material with integrated shock absorption material (foam or rubber) to create a composite structure that provides both structural support and impact protection. This composite approach eliminates the need for separate base layers, reducing installation cost and complexity while maintaining strength.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The shock absorption material is strategically positioned beneath the rigid top surface in specific zones where impact forces are most likely to occur. This local placement optimizes shock absorption while maintaining overall panel rigidity for structural support.

Inventive Principle:

Principle #3Local quality

3Strength

If plastic panels with internal grid structure are used, then rigidity is improved, but shock absorption properties deteriorate

Engineering Contradiction:

ImproverigidityVSAvoidshock absorption

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The rigid top surface and shock absorption material are merged into a single integrated panel unit. The shock absorption material is bonded to the underside of the rigid surface, combining structural support and impact protection functions in one component rather than requiring separate layers.

Inventive Principle:

Principle #5Merging (Combining)

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 interlocking panels provide a cost-effective, easily movable flooring system that offers both structural support and adequate fall/impact protection, suitable for various recreational surfaces by combining the rigidity of plastic with the shock absorption of foam or rubber.

Implementation Method 1

A bottom support structure made from a shock absorption material is held within the cavity and abuts directly against an underside of the substantially planar top surface, thereby providing support and shock absorption to the substantially planar top surface

Methodology Applied

Scientific EffectShock absorption: Damping

Data Source

PatentUS10738484B2Shock absorbing interlocking floor system

Publication Date: 2020.08.11 CH3 SOLUTIONS LLC

AI summary

Floor panels include a top portion that is molded from a plastic material. The top portion has a substantially planar top surface and side surfaces. The side surfaces depend downward from the substantially planar top surface forming a cavity in an underside of the substantially planar top surface. A bottom support structure fills the cavity, thereby providing support and shock absorption to the substantially planar top surface.