Modular Synthetic Flooring Panel with Interlocking Base and Vinyl Overlay
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sports flooring technologies face challenges in balancing cushioning and stability, with point elastic floors offering limited sporting properties due to thickness-flexibility compromise, and area elastic floors being costly and prone to humidity-related issues, while suspended synthetic flooring struggles with mold costs and installation time.
Innovation Solution
A modular synthetic flooring system comprising interconnecting elongate molded plastic base components with mating locking hooks and slots, secured with a contact surface material like hardwood, providing design flexibility and reduced forestry material use, and a continuous vinyl sheet secured to these base components for improved resilience and ease of installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If point elastic floors are used with thin synthetic layers, then cost is reduced and durability is improved, but sporting properties deteriorate due to thickness-flexibility compromise
Solution Approach 1:
The flooring system is divided into separate functional layers: a thin durable synthetic wear layer and a separate cushioning layer with greater thickness. This segmentation allows each layer to optimize its specific function without compromising the other, enabling improved sporting properties while maintaining cost-effectiveness.
Solution Approach 2:
The invention transitions from a single-layer point elastic floor to a multi-layer construction with distinct thicknesses for different functions. The cushioning layer provides vertical thickness for shock absorption while the wear layer maintains surface durability, effectively adding a dimensional solution to the thickness-flexibility compromise.
2Reliability
If area elastic floors with wood panels are used, then sporting properties are improved with greater load distribution, but investment cost increases and installation time is extended
Solution Approach 1:
The flooring system separates the cushioning function into a distinct lower layer from the wear surface layer. This segmentation allows the cushioning layer to provide area elastic properties for load distribution while the modular tile construction enables rapid installation without complex multi-tier wood panel assembly.
Solution Approach 2:
The invention changes the material parameters by using synthetic materials for both the wear layer and cushioning layer, eliminating the need for wood panels. This maintains the area elastic sporting properties through the cushioning layer's thickness and flexibility while dramatically reducing installation time and cost through modular construction.
3Reliability
If wood panels are used in area elastic floors, then load distribution is improved, but humidity sensitivity causes deformation and sealing issues
Solution Approach 1:
The invention changes the material composition from wood-based panels to synthetic polymer materials for both the wear layer and cushioning layer. This parameter change eliminates humidity sensitivity entirely while maintaining the load distribution function through the cushioning layer's engineered thickness and elastic properties.
Solution Approach 2:
The flooring system uses composite synthetic material construction with a wear layer and cushioning layer made from different polymer formulations. This composite approach provides both durability and humidity resistance while achieving area elastic load distribution, replacing the problematic wood panel composite structure.
4Ease of operation
If suspended synthetic flooring with area elastic properties is used, then resilience and ease of installation are improved, but mold costs increase and manufacturing flexibility is reduced
Solution Approach 1:
The flooring system is segmented into separate wear layer and cushioning layer components that can be manufactured independently. This segmentation allows each layer to be produced using standard molding processes without requiring expensive custom molds, while maintaining ease of installation through modular construction.
Solution Approach 2:
The modular tile construction serves multiple functions: it provides the structural base, supports the wear layer, enables easy installation through interlocking mechanisms, and allows for design flexibility. This universal approach eliminates the need for specialized expensive molds while maintaining ease of installation.
Data Source
AI summary
A plurality of at least two modular flooring tiles coupled together to form an upper surface defined by an outer perimeter is disclosed. A plurality of side walls extends downward from the outer perimeter and a plurality of coupling members are disposed about the side walls adapted to mate with coupling members of an adjacent flooring panel. A flexible continuous synthetic overlay is disposed about and secured to the upper surface of the at least two modular flooring tiles, wherein the synthetic overlay comprises an outer perimeter substantially similar to the outer perimeter of the at least two modular flooring tiles.