Interlocking Floor Tile Continuous Mechanism
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Solution Overview
Problem
Existing interlocking floor tiles require significant time and effort to install and remove, often necessitating professional installers and adhesives, and they can be prone to uneven surfaces and functional issues due to flashing and discontinuous interlocking structures, which also complicate the removal of excess material.
Innovation Solution
A dual-construction interlocking floor tile made from recycled rubber and virgin materials with a continuous interlocking mechanism that allows for easy installation and removal without adhesives, featuring a seamless connection along all sides and shallow studs for reduced contact with the subfloor, enabling quick and efficient installation and reinstallation, and accommodating various tile sizes for aesthetic patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional molding processes are used to manufacture interlocking floor tiles, then tiles can be produced, but excessive flashing is left behind requiring time-consuming removal
Solution Approach 1:
The patent applies preliminary action by designing the molding process to automatically trim excess material during tile formation. The molding apparatus includes cutting elements that remove flashing at the moment of tile creation, eliminating the need for separate flash removal operations and enabling direct production of ready-to-install tiles
Solution Approach 2:
The invention extracts the harmful element (excessive flashing) from the manufacturing process by integrating trimming mechanisms directly into the molding apparatus. This allows excess material to be removed during manufacturing rather than requiring post-manufacturing removal, thereby reducing installation time and labor
2Ease of manufacture
If discontinuous interlocking structures are used, then manufacturing is simplified, but corner support is insufficient leading to tile depression
Solution Approach 1:
The patent merges the interlocking function with the corner support function into a single integrated structure. The interlocking elements extend continuously to the corners and incorporate support features that prevent tile depression, combining what would otherwise be separate structural requirements into one unified design
3Reliability
If professional installers and adhesives are used for installation, then tiles are securely installed, but installation time and costs increase significantly
Solution Approach 1:
The patent applies self-service by designing an interlocking mechanism that enables installers to secure tiles together without requiring professional expertise or adhesive materials. The tiles feature complementary interlocking elements that automatically engage and lock when tiles are positioned adjacent to each other, making the installation process self-sufficient and eliminating dependency on specialized installers or additional materials
Solution Approach 2:
The invention replaces the chemical bonding system (adhesives) with a mechanical interlocking system. The interlocking elements provide physical connection between tiles through geometric engagement, substituting the need for adhesive chemicals with a purely mechanical attachment method that is equally secure but faster to install
4Manufacturing precision
If flashing removal is performed manually with utility knives, then excess material can be removed, but the process is time-consuming and costly
Solution Approach 1:
The patent replaces manual mechanical removal (utility knives) with automated mechanical trimming integrated into the molding process. The molding apparatus includes automated cutting elements that precisely trim excess material during tile formation, substituting manual labor with automated machinery to achieve both precision and high productivity
Solution Approach 2:
The invention performs the trimming action preliminarily during the molding process itself, rather than as a separate post-processing step. This preliminary trimming ensures precise edge geometry is achieved at the moment of tile creation, eliminating the need for subsequent manual flash removal and maintaining both precision and production speed
Data Source
Figure 1A
Figure 1B
Figure 2A~2C
AI summary
A flexible interlocking floor tile having a dual construction with an interlocking mechanism allows for easy installation of multiple tiles. The dual construction can include recycled material and new material. The tile also includes an adequate support at the corner of the tile when assembling multiple tiles. The tile has a single interlocking structure or groove to keep the entire tile joint tight with other tile joints, instead of interrupted interlocking structure which can lead to functional and aesthetic flaws in the entire floor. The single continuous interlocking structure allows for a one-step easy removal of any excess material or flashing from the tile after the molding process.