Modular Flooring Plank Simulated Grout Lines Spacer-Free Installation
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Solution Overview
Problem
The installation of modular flooring planks is complicated by the need for spacers to maintain uniform spacing, which increases installation time and complexity, and can lead to misalignment if incorrect spacers are used, especially when simulating ceramic tile patterns.
Innovation Solution
A rigid polymeric modular flooring plank system that eliminates the need for spacers by featuring a continuous piece with simulated grout lines of varying widths, allowing for uniform spacing and aesthetic grout application without visible seams, achieved through a polymeric base layer, decorative layer, and wear layer configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spacers are used to maintain uniform spacing between flooring planks, then spacing consistency is improved, but installation time and complexity increase
Solution Approach 1:
The flooring plank incorporates pre-formed guide features (such as raised edges or recesses) during manufacturing that automatically guide the placement of adjacent planks at the correct spacing. This preliminary preparation eliminates the need for spacers during installation, maintaining spacing consistency while reducing installation time and complexity
Solution Approach 2:
The guide features on the flooring planks act as intermediaries that facilitate proper spacing between adjacent planks. These built-in features replace the traditional spacer tools, providing the mediating function needed to maintain uniform spacing without adding external components that complicate the installation process
2Manufacturing precision
If spacers are used to maintain uniform spacing between flooring planks, then spacing consistency is improved, but device complexity increases
Solution Approach 1:
The invention extracts the spacing function from separate spacer tools and integrates it directly into the flooring plank structure itself. By incorporating guide features (raised edges, recesses, or other geometric elements) into the plank design, the spacing capability is built-in, eliminating the need for external spacer components and reducing overall system complexity
Solution Approach 2:
The flooring plank merges multiple functions into a single component: the structural flooring function and the spacing guidance function are combined in one element. The guide features are integrated into the plank body, so that the same object that provides the flooring surface also provides the spacing control, reducing the number of separate components needed
3Shape
If smaller tiles are used to simulate ceramic tile patterns, then aesthetic appearance is improved, but the number of spacers and grout needed increases
Solution Approach 1:
The invention transitions from a two-dimensional array of many small tiles to a single large plank that incorporates tile-pattern graphics. By moving the tile pattern representation from physical separate tiles to a graphical depiction on a larger surface, the need for numerous spacers is eliminated while maintaining the aesthetic tile appearance
Solution Approach 2:
The flooring plank uses printed or embossed graphics to copy the appearance of multiple small ceramic tiles on a single larger plank surface. This visual replication allows the aesthetic tile pattern to be achieved without using actual multiple small tiles, thereby eliminating the need for corresponding spacers between each tile
Data Source
AI summary
A rigid polymeric modular flooring plank can be one continuous piece having a top surface, a bottom surface and multiple sides defining the edges of said rigid polymeric modular flooring plank. The rigid polymeric modular flooring plank can include the appearance of multiple tiles or one tile as part of the top surface, with each of the multiple tiles having multiple simulated sides and a decorative surface, and each tile is completely surrounded by simulated grout lines that have a depth and either have a full width W or a half width ½W. Any simulated grout line that is located at any of said multiple sides has the half width and all other simulated grout lines have the full width. The rigid polymeric modular flooring plank has at least a polymeric base layer, a decorative layer, and a wear layer located above the decorative layer.