Modular Flooring Assembly Interlocking Tray Substrates
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Solution Overview
Problem
Existing tray substrate systems are not adapted for use with non-standard sized and/or shaped flooring components, such as large rectangular or plank flooring, as they lack the necessary strength and interlocking mechanism to secure these components effectively while maintaining small gaps between tiles.
Innovation Solution
A modular flooring assembly comprising two tray substrates with upward and downward tabs and holes that interlock to form an assembled tray substrate, allowing for the secure attachment of non-standard flooring components with a convex surface and a valley, and a concave surface with a lip, which provides strength and small gaps between tiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tray substrates use standard interlocking mechanisms that completely extend from the side, then the interlocking strength is sufficient, but the gap between trays becomes large
Solution Approach 1:
The patent transitions the interlocking mechanism from a two-dimensional edge-to-edge connection to a three-dimensional configuration where tabs extend partially underneath the tray surface. This vertical dimensionality change allows the interlock to maintain strength while reducing the horizontal gap between adjacent trays.
Solution Approach 2:
The downward tabs are recessed under the tray surface and nest within the space between adjacent trays, while upward tabs extend to engage with corresponding recesses in neighboring trays. This nested configuration provides interlocking strength without requiring large gaps between tray edges.
2Adaptability or versatility
If tray substrates are designed for standard sized flooring components, then the interlocking mechanism is simple, but the system cannot accommodate non-standard sizes and shapes
Solution Approach 1:
The tray substrate design incorporates multiple upward tabs and downward tabs positioned at different locations and orientations, creating a universal interlocking system that can accommodate various flooring component sizes, shapes, and configurations while maintaining a relatively simple overall structure.
Solution Approach 2:
The interlocking mechanism is segmented into multiple discrete tabs (upward tabs and downward tabs) rather than a single continuous edge connection. This segmentation allows flexible adaptation to different flooring component geometries while keeping each individual tab simple in design.
3Length of moving object
If downward tabs are recessed under the tray surface, then the gap between trays is reduced, but the interlocking strength may be compromised
Solution Approach 1:
The patent combines both upward tabs and downward tabs in a complementary configuration where upward tabs extend from the top surface to engage with recesses in adjacent trays, while downward tabs recessed from the bottom provide additional interlocking. This merging of above-surface and below-surface elements ensures adequate interlocking strength while maintaining small gaps.
Data Source
AI summary
Disclosed herein is a modular flooring assembly including a flooring component adhered to a first tray substrate and a second tray substrate which are interconnected to form an assembled tray substrate. The assembled tray substrate may be interconnected with additional assembled tray substrates to form a modular floor suitable for most flooring applications. The flooring component may be tile or wood or other materials commonly used in flooring applications. Convention fill-in grout or a snap-in grout may be used with the modular flooring assemblies.