Interlocking Plastic Base Flooring with Hardwood Surface

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional solid wood flooring systems for athletic applications require significant wood resources and labor for installation, and they face issues with expansion and contraction, leading to maintenance challenges.

Innovation Solution

The development of interlocking elongate molded plastic base components with mating locking hooks and slots, which reduce the need for forestry materials by using recycled plastics, allowing for easier installation and design flexibility, and incorporating a hardwood contact surface secured on top of the base components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional solid wood flooring systems are used, then desirable ball bounce characteristics and aesthetic qualities are achieved, but significant wood resources and labor for installation are required

Engineering Contradiction:

Improveball bounce characteristicsVSAvoidwood resources

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent creates a composite flooring system combining plastic base components with wood veneer or laminate surfaces. This composite structure provides the aesthetic and functional qualities of wood flooring while significantly reducing wood resource consumption by using plastic as the primary structural material.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention changes the fundamental material parameter from solid wood construction to a plastic-based composite structure. By altering the base material from wood to plastic while maintaining wood-like surface characteristics, the system achieves similar performance with reduced wood resource requirements.

Inventive Principle:

Principle #35Parameter changes

2Shape

If conventional solid wood flooring systems are used, then aesthetic qualities are achieved, but significant labor for installation is required

Engineering Contradiction:

Improveaesthetic qualitiesVSAvoidinstallation labor

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

The flooring system is divided into modular interlocking components with standardized connection mechanisms. This segmentation allows for rapid assembly through simple interlocking actions rather than traditional fastening methods, significantly reducing installation labor while maintaining aesthetic quality through consistent modular patterns.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The interlocking base components are designed to self-assemble through inherent mechanical engagement features such as tabs and slots. This self-service mechanism eliminates the need for complex installation tools and procedures, allowing installers to quickly assemble flooring systems with minimal labor while preserving aesthetic appearance.

Inventive Principle:

Principle #25Self-service

3Stability of the object's composition

If conventional hardwood flooring systems are used, then ventilation and expansion/contraction management are provided, but maintenance challenges arise

Engineering Contradiction:

Improveexpansion and contraction managementVSAvoidmaintenance

Core Design Contradiction:

Stability of the object's compositionVSEase of repair

Solution Approach 1:

The invention changes the material parameter from natural wood to plastic, fundamentally altering the expansion and contraction behavior. Plastic materials exhibit different dimensional stability characteristics under environmental conditions, reducing the expansion/contraction issues that plague wood flooring and thereby simplifying maintenance requirements.

Inventive Principle:

Principle #35Parameter changes

4Loss of substance

If recycled plastics are used to create plastic base components, then wood resource consumption is reduced, but manufacturing complexity increases

Engineering Contradiction:

Improvewood resource consumptionVSAvoidmanufacturing process

Core Design Contradiction:

Loss of substanceVSEase of manufacture

Solution Approach 1:

The system recovers and repurposes plastic materials (including recycled plastics) that would otherwise be waste or less useful materials. By incorporating recycled plastics into the base component manufacturing, the system reduces wood resource consumption while the modular design keeps manufacturing complexity manageable through standardized processes.

Inventive Principle:

Principle #34Discarding and recovering

Data Source

PatentUS9382717B2Flooring surface integrated with interlocking plastic base

Publication Date: 2016.07.05 CONNOR SPORTS FLOORING CORP

AI summary

A composite flooring structure and method of constructing a composite flooring structure are disclosed. An elongate plastic base having a top surface and a plurality of side walls forming a perimeter about the top surface is provided. An elongate contact surface material is secured to the elongate plastic base atop the plastic base, wherein the length and width of the elongate contact surface material exceeds the length and width of the elongate plastic base. After securing the elongate contact surface material to the elongate plastic base, the elongate contact surface material is cut such that the length and width of the elongate contact surface material approximates the length and width of the elongate plastic base. The elongate plastic base has a plurality of wings disposed about the sides of plastic base. The alignment wings are removed from the elongate plastic base after securing the elongate contact surface material to the elongate plastic base.