Interlocking Floor Panels With Grouted Joints for Water Sealing
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Solution Overview
Problem
Existing floor and wall coverings made of water-resistant materials can still allow water penetration through panel joints, and there is a need for improved mechanical coupling that enhances strength and durability.
Innovation Solution
The solution involves floor or wall panels with integrated coupling parts, including male and female edges with recesses and grouting material, designed to prevent water penetration and enhance mechanical locking, featuring configurations such as tongue-groove and double hook mechanisms that facilitate secure and durable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If panels are mechanically coupled using traditional methods, then installation is simple, but water can penetrate through the panel joints
Solution Approach 1:
The coupling structure is divided into distinct male and female coupling parts with separate functional zones: a mechanical locking zone for structural connection and a grouting zone for water sealing. This segmentation allows the locking mechanism to provide structural stability while the grouting material fills gaps to prevent water penetration, resolving the contradiction between simple installation and water resistance.
Solution Approach 2:
Grouting material is introduced as an intermediary substance between the male and female coupling parts. This mediator fills the gaps and recesses in the coupling structure, creating a water-tight seal while allowing the mechanical locking means to maintain structural connection. The grouting material bridges the gap between mechanical coupling and water protection functions.
2Strength
If traditional mechanical coupling is used, then installation is easy, but the coupling strength is insufficient
Solution Approach 1:
The invention merges two coupling mechanisms into a single integrated system: mechanical locking means provide immediate structural connection and alignment, while grouting material provides enhanced bonding strength and gap filling. This combination achieves high coupling strength through the synergistic effect of mechanical interlocking and chemical adhesion, while maintaining installation ease through the straightforward sequence of mechanical coupling followed by grouting.
Solution Approach 2:
The mechanical locking means are designed to establish preliminary alignment and connection between panels before the grouting material is applied. This preliminary action ensures proper positioning and initial structural stability, making the subsequent grouting process simpler and more effective, thereby maintaining ease of operation while achieving high coupling strength.
3Reliability
If panels are coupled with tight joints, then water penetration is prevented, but thermal expansion is restricted
Solution Approach 1:
The coupling structure features localized recesses and channels specifically designed to accommodate grouting material at the joint interfaces. These localized features provide water sealing precisely where needed at the panel joints, while the main panel surfaces and bodies remain free to expand and contract thermally. The grouting is confined to specific zones rather than creating continuous tight joints across the entire panel assembly.
Solution Approach 2:
The grouting material serves as an intermediary that provides water tightness at the joints while its flexible properties allow it to accommodate thermal expansion and contraction. Unlike rigid tight joints that would restrict movement, the grouted joints maintain water sealing through the adhesive and sealing properties of the grout while permitting natural thermal movement of the panels.
Data Source
AI summary
A recess is provided at the surface of a floor or wall covering between two panels mechanically coupled to each other by a male coupling part and a female coupling part. The recess may include a first recess cut out or otherwise provided at the female edge through the top layer and extending into the substrate. The recess may have a second recess cut out or otherwise provided at the male edge through the top layer and extending into the substrate. The recess includes a grouting material.