Flooring system for use in a sloped floor
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Solution Overview
Problem
Constructing and installing a tiled floor with a slope towards a drain is challenging due to difficulties in achieving the proper slope and avoiding water collection, especially when dealing with existing drains that need adjustment or replacement.
Innovation Solution
A modular flooring system with a gridwork configuration that includes adjustable grid extension and slope panels with leveling holes, allowing for customizable slope creation and attachment to the underlying base, facilitating easier installation and water drainage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional mortar bed or floor base is used to create the slope, then the slope can be formed to direct water towards the drain, but the installation becomes difficult and time-consuming requiring precise manual shaping to avoid low spots and water collection
Solution Approach 1:
The flooring system divides the slope creation into discrete modular components - specifically, pre-formed slope panels with built-in gradient features that segment the continuous slope formation process into manageable, pre-engineered units. Each panel is designed with specific slope characteristics, allowing installers to assemble the overall drainage gradient by combining these standardized segments rather than manually shaping a continuous mortar bed.
Solution Approach 2:
The slope panels are pre-formed with the desired gradient and slope characteristics before installation. The drainage gradient is predetermined in the panel design, including features like progressive height reduction and integrated drainage channels, so that the slope geometry is already optimized for water drainage before the panels are installed on-site.
2Reliability
If existing drains need to be replaced or height-adjusted to match a new tile surface, then proper drainage can be achieved, but the complexity and difficulty of installation increases significantly
Solution Approach 1:
The slope panels incorporate adjustable height mechanisms that allow the panels to be dynamically positioned at different elevations during installation. This adjustability enables the system to adapt to varying drain heights and existing substrate conditions, allowing installers to compensate for drain replacements or height adjustments by simply repositioning the modular panels rather than performing complex remedial work on the drainage infrastructure.
Solution Approach 2:
The system allows for parameter changes in panel height and position to accommodate different drain configurations. The slope panels can be installed at varying heights and angles to match the specific requirements of existing or replacement drains, enabling the drainage system to adapt to different structural conditions without increasing overall installation complexity.
3Manufacturing precision
If manual methods like shims are used to adjust for uneven substrates, then the slope can be corrected, but the installation becomes labor-intensive and time-consuming
Solution Approach 1:
The system extracts the substrate leveling function from the installation process by incorporating self-leveling features directly into the slope panel design. Instead of requiring separate shim components or manual leveling operations, the panels themselves contain integrated mechanisms that automatically compensate for uneven substrates, eliminating the need for additional leveling materials and procedures.
Solution Approach 2:
The slope panels are designed with self-leveling capabilities that allow them to automatically adjust and equalize their own position on uneven substrates. The panels incorporate features such as adjustable support legs, self-aligning mechanisms, or flexible base elements that enable the installation to self-correct substrate irregularities without requiring external leveling tools or materials like shims.
Data Source
AI summary
A flooring system includes a gridwork having a modular configuration that defines a grid with cells for receiving a filler material which forms a bed or floor base sloping toward a drain fixture. The gridwork includes different groupings of leveling holes located at selected junctions between adjacent cells that are arranged to selectively move or tilt the gridwork relative to an underlying base in conjunction with the formation of the bed or floor base.