Modular Surface Covering Panels With Shear-Tolerant Fastening
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Solution Overview
Problem
Existing artificial surface covering panels, such as synthetic turf with padding layers, are heavy, difficult to install and reinstall, and require complex fabrication processes, making them cumbersome and expensive to handle and transport.
Innovation Solution
A panel assembly design featuring a padding layer panel and a sheet member with a fastening element, using materials like EPP and EPE, allows for easy installation and reinstallation by enabling thermal expansion without damaging the panels, and includes a joining padding layer panel with a different material to maintain fastening under shear displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If synthetic turf panels are made in full size rolls of 12' or 15' width, then the coverage area per panel is increased, but the weight and handling difficulty increase requiring fork lift or heavy equipment
Solution Approach 1:
The patent divides the large synthetic turf panel into smaller modular sections with interlocking edges. Each section can be handled individually without heavy equipment, yet when assembled together they cover the same large area as traditional full-size rolls.
2Ease of operation
If synthetic turf panels are made into smaller pieces, then the handling and transportation become easier, but the number of panels required increases leading to longer and more expensive installation processes
Solution Approach 1:
The patent combines multiple small turf sections into a unified assembly through interlocking edges and joining mechanisms. This allows them to be installed as a coordinated unit rather than individually, reducing total installation time while maintaining ease of handling.
3Adaptability or versatility
If panels are made removable for non-permanent installation, then the flexibility and reusability are improved, but the installation and reinstallation process becomes lengthy and expensive
Solution Approach 1:
The patent incorporates pre-designed joining mechanisms and interlocking features during manufacturing. These preliminary preparations enable rapid assembly and disassembly during installation and reinstallation, eliminating the need for complex on-site fabrication or securing processes.
4Device complexity
If larger panels are used to reduce the number of panels, then the number of installation components is reduced, but the burden on installation personnel increases due to heavier panels
Solution Approach 1:
The patent segments large panels into smaller modular units with standardized interlocking interfaces. This maintains a manageable number of components for assembly while ensuring each unit remains light enough for manual handling by installation personnel.
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 design enhances panel flexibility, durability, and reduces installation time and cost by allowing easy manipulation and assembly, even under thermal expansion, while maintaining panel integrity.
Implementation Method 1
the fastening element has a width designed to maintain fastening of the adjacent surface covering panels when the surface covering panels and the joining padding layer panels undergo thermal expansion resulting in shear displacement of the first component and of the second component relative to each other parallel to the sheet member
Data Source
AI summary
A panel assembly is designed to be installed adjacent each other comprising surface covering panels and joining padding layer panels. Surface covering panels comprises padding layer panels made of a first material, a sheet member affixed to the padding layer panel comprising edges extending beyond the padding layer panel; and a first component of a fastening element affixed to the edges. Joining padding layer panels comprise a body made of a second material different to the first material; and a second component of the fastening element affixed to the top surface of the joining padding layer. The components of the fastening element are adapted to interface with each other such as releasably attaching joining padding layer panels to the edges of adjacent surface covering panels, and maintain fastening of the adjacent surface covering panels when undergoing thermal expansion resulting in shear displacement of the components of the fastening element.