Interlocking Polymeric Floor Panels with Mechanical Locking
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Solution Overview
Problem
Existing flooring solutions, such as plywood and cement, are expensive and difficult to remove, making them unsuitable for temporary or multi-purpose recreational surfaces that need to be frequently relocated or reconfigured.
Innovation Solution
The development of multi-sectional interlocking polymeric panels with a mechanical locking feature that can be easily assembled and disassembled without tools, featuring upward and downward facing steps with convex and concave projections for secure alignment and planar retention, allowing for easy relocation and reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional base materials like plywood or cement are used, then structural support and surface stability are improved, but installation cost and complexity increase, and removal difficulty increases
Solution Approach 1:
The flooring system is divided into multiple modular panels that can be independently manufactured, transported, and installed. Each panel is a self-contained unit with integrated locking features, eliminating the need for expensive traditional base materials like plywood or cement while maintaining surface stability through the interlocking panel structure.
Solution Approach 2:
The panels incorporate self-aligning and self-locking features that enable tool-free assembly. The mechanical locking features automatically engage when panels are placed adjacent to each other, providing stable connections without requiring professional installation tools or expertise, thereby reducing installation cost and complexity.
2Stability of the object's composition
If traditional base materials like plywood or cement are used, then structural support is improved, but removal ease deteriorates
Solution Approach 1:
The flooring system is divided into multiple modular panels that can be independently removed and relocated. Each panel maintains structural integrity as a standalone unit, allowing for easy removal and reuse at different locations, unlike traditional monolithic base materials that are difficult and expensive to remove.
Solution Approach 2:
The flooring system transitions from static, permanent installations to dynamic, movable configurations. The mechanical locking features allow panels to be easily assembled and disassembled, enabling the flooring to adapt to changing needs and be relocated to different positions or completely removed without significant effort or cost.
3Ease of operation
If panels are designed for easy assembly and disassembly, then installation ease is improved, but locking strength and alignment precision may deteriorate
Solution Approach 1:
The mechanical locking features utilize curved or rounded geometric elements that enable smooth engagement and disengagement. The rounded profiles of the locking features allow panels to be easily assembled by simple pressing motions while maintaining strong locking strength through the curved geometry that distributes forces evenly across the locking surfaces.
Solution Approach 2:
The locking features are designed to automatically align and engage panels without requiring tools or complex assembly procedures. The self-aligning geometry ensures that panels naturally find their correct position during assembly, while the self-locking mechanism provides reliable connections through the inherent design of the mechanical features.
4Adaptability or versatility
If panels are designed for easy disassembly and relocation, then mobility is improved, but structural integrity and alignment precision may deteriorate
Solution Approach 1:
The mechanical locking features utilize curved or rounded geometric elements that enable smooth engagement and disengagement. The rounded profiles allow panels to be easily assembled and disassembled while maintaining alignment precision through the curved geometry that guides panels into correct positioning during the locking process.
Solution Approach 2:
The locking features are designed to automatically align and engage panels without requiring tools or complex assembly procedures. The self-aligning geometry ensures that panels naturally find their correct position during assembly, maintaining alignment precision while enabling easy disassembly and relocation.
Data Source
AI summary
Multiple polymeric panels molded as a rigid integral body having a planar top surface and a bottom grid structure are interlocked together mechanically along side edges. Each side edge has alternating upwardly and downwardly facing steps with concave dimples on one and mating convex projections on the other for securely interlocking adjacent panels to each other. The steps of adjacent panels interlock with each other to form a complete floor system. The multiple polymeric panels can be molded to simulate flooring materials such as brick or overlaid with sections of linoleum, carpet, synthetic grass, tile or wood flooring. Alternately, the assembled panels can be covered with a sheet of decorative material.