Modular Flooring Thermal Expansion and Connector Segmentation
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Solution Overview
Problem
Modular flooring systems face issues with dimensional changes due to high thermal expansion of plastic materials, leading to buckling, shifting, and cracking, as well as damage to underlying surfaces and increased costs due to non-replaceable connectors.
Innovation Solution
A modular flooring system with self-aligning connector loops and receiver pins, optional removable metal cam locks, and a base cover with circular feet for ground protection, featuring an overlap edge and liquid capture channel to prevent leakage and ensure ventilation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If plastic or polymeric materials are used for modular floor tiles, then ease of storage and portability is improved, but dimensional stability deteriorates due to high coefficient of thermal expansion
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical properties of the polymeric material through additive packages that reduce thermal expansion coefficients and control moisture absorption. This allows the floor tiles to maintain dimensional stability while retaining the weight and portability benefits of plastic materials.
Solution Approach 2:
The patent uses composite materials by combining polymeric base materials with specialized additives and fillers that create a composite structure with reduced thermal expansion and improved dimensional stability. The composite formulation maintains the lightweight characteristics while addressing the expansion issues.
2Strength
If fully integrated connectors are used in floor panels, then structural strength is improved, but ease of repair deteriorates as damage to connectors requires replacement of entire panels
Solution Approach 1:
The patent applies segmentation by separating the connector component from the floor panel, allowing connectors to be replaced independently without replacing entire panels. This modular approach maintains structural strength while significantly improving ease of repair and maintenance.
3Ease of operation
If modular flooring is installed on grass or turf surfaces, then temporary walking surface is provided, but damage to underlying surface occurs due to decreased exposure to sunlight and ventilation
Solution Approach 1:
The patent uses porous or permeable floor panel materials that allow sunlight, air, and moisture to pass through to the underlying grass or turf surface. This maintains the ease of installation and removal while preventing damage to the natural surface by preserving sunlight exposure and ventilation.
4Ease of manufacture
If connectors are constructed of the same plastic material as panels, then manufacturing simplicity is improved, but reliability deteriorates when connectors become damaged requiring panel replacement
Solution Approach 1:
The patent applies segmentation by making connectors separate replaceable components rather than integrated parts of the panels. This allows connectors to be manufactured separately and replaced independently, improving reliability while maintaining manufacturing simplicity through standardized components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides stability, prevents tripping hazards, protects underlying surfaces, and allows for easy replacement of damaged components, reducing maintenance and installation time while maintaining surface integrity.
Implementation Method 1
One particular shortcoming of plastic and polymeric materials is the coefficient of thermal expansion, which is relatively high in practice. Changes in temperature of the underlying substrate material, sunlight, as well as the ambient air proximate to the modular floor system cause relatively significant changes in dimensionality of the floor tiles.
Data Source
AI summary
A modular flooring system is disclosed which is designed to support heavy loads while providing stability and ground protection. The invention contemplates a modular tile with fully integrated connector loops, receiver pins and optional metal cam locks located in the corners of the floor tile or along the tile edges. The tiles contain an overlap edge, which engages with an underlay edge on an adjacent tile. This arrangement allows the tiles to overlap at an angle other than 90 degrees, providing greater strength at the point where adjacent tiles meet. The underlay edge contains a liquid capture channel which traps liquids which may seep between the adjacent tiles. The tiles are also provided with longitudinal recesses which extend through the top and bottom surfaces to the surface below, allowing for ventilation that is critical for grass and turf surfaces. The modular flooring system provides increased strength and stability and protection of the subsurface.