Modular Flooring Tray with Snap-in Grout for Stable Installation
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Solution Overview
Problem
Conventional tile floor installation is complex and requires expertise, and previous modular flooring systems often lack a full supporting structure, leading to instability and shifting of tiles, which results in poor performance.
Innovation Solution
A modular flooring assembly with a tray substrate that securely holds flooring components using interlocking tabs and snap-in grout, allowing for easy installation and disassembly without adhesives, and can be installed over existing subfloors without a concrete backer board, using either snap-in or fill-in grout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional tile floor installation methods are used, then the floor provides stable and secure flooring, but the installation process is complicated and requires expertise
Solution Approach 1:
The flooring system is divided into modular trays with individual flooring components that can be independently installed and replaced. Each tray is a self-contained unit with integrated grout members, eliminating the need for complex continuous installation processes and allowing non-experts to easily assemble the flooring system.
Solution Approach 2:
Grout members serve as intermediary elements that connect adjacent trays and secure flooring components in place. These pre-formed grout members simplify the installation process by providing a mechanical connection system that eliminates the need for complex adhesive applications and drying等待 times.
2Ease of operation
If prior art modular flooring assemblies are used, then installation is simpler, but they lack full supporting structure causing flooring material to break or bend
Solution Approach 1:
The tray structure serves multiple functions simultaneously: it provides the base support for flooring components, incorporates grout members for connection, and creates a rigid framework that prevents flooring material from breaking or bending. This multi-functional design maintains ease of installation while ensuring structural strength.
Solution Approach 2:
Instead of relying on the flooring material itself to provide structural support, the system inverts the support structure by placing a rigid tray framework beneath the flooring components. This inverted approach ensures the flooring material is supported rather than bearing the structural load, preventing breakage and bending.
3Ease of operation
If prior art modular flooring systems are used, then installation may be simplified, but tiles shift or migrate resulting in unacceptable performance
Solution Approach 1:
Grout members act as intermediary locking elements that physically connect adjacent trays and secure flooring components. These grout members prevent tile shifting and migration by creating a mechanical interlock system that maintains tile stability while allowing for simple installation.
Solution Approach 2:
The system replaces traditional adhesive-based mechanical bonding with a mechanical interlock system using grout members. This substitution provides more reliable tile stability through physical connection rather than relying on adhesive strength, preventing tile migration while maintaining ease of installation and replacement.
4Reliability
If conventional tile installation with grout compound is used, then tiles are securely held, but the process requires several hours or days of drying time
Solution Approach 1:
The system replaces chemical adhesive bonding with a mechanical interlock system using grout members. This substitution eliminates the need for drying time while maintaining secure tile holding through physical connection. The mechanical system provides immediate stability without waiting for chemical curing.
Solution Approach 2:
The invention extracts the drying time requirement from the installation process by removing the need for liquid grout compounds that require curing. Instead, pre-formed solid grout members are used that provide immediate mechanical connection, eliminating the time-consuming drying phase while maintaining secure tile holding.
Data Source
AI summary
A modular flooring assembly including a flooring component adhered to a tray substrate is described. The modular flooring assembly may be interconnected with additional modular flooring assemblies 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. One suitable snap-in grout is a right angle grout member.