Non-Interlock Flooring with Flexible Base and Cut Grooves
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Solution Overview
Problem
Existing flooring systems, particularly wood flooring and interlock assembled flooring, are time-consuming and labor-intensive to install, remove, and transport, and they face challenges with uneven floor surfaces and limited thickness of floor tiles.
Innovation Solution
A non-interlock assembled flooring system comprising a base sheet layer and a surface slat layer with wood floor slats cut from a single wood panel, featuring cut grooves as expansion joints and fold lines for easy installation, storage, and transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If interlock assembled flooring with male and female connecting grooves is used, then installation without gluing or nailing is achieved, but manufacturing process becomes time-consuming and thickness of floor tiles is limited
Solution Approach 1:
The flooring system is divided into modular tiles that can be independently manufactured and then assembled together. Each tile is a complete unit with the wood panel, base sheet, and adhesive layer already combined, allowing simple manufacturing of individual tiles and easy assembly on-site without complex grooves or fasteners.
Solution Approach 2:
The patent combines multiple components (wood panel, base sheet, adhesive layer) into a single integrated tile unit before installation. This merging eliminates the need for separate manufacturing steps for connecting grooves and simplifies the installation process to simple laying of complete tiles.
2Strength
If wood planks are glued or nailed to the floor one by one, then secure attachment is achieved, but installation is time-consuming and labor-intensive
Solution Approach 1:
The adhesive layer is pre-applied to the base sheet during manufacturing, and the wood panel is pre-attached to form a complete tile unit. This preliminary action transfers the attachment work from the installation phase to the manufacturing phase, where it can be done more efficiently, allowing rapid installation by simply laying the pre-prepared tiles.
Solution Approach 2:
The patent merges the wood panel, base sheet, and adhesive layer into a single integrated tile unit. This combination ensures secure attachment is built-in during manufacturing, eliminating the need for time-consuming on-site gluing or nailing operations while maintaining strong attachment security.
3Area of stationary object
If conventional flooring systems are used, then floor coverage is achieved, but removal and replacement is difficult
Solution Approach 1:
The flooring system is segmented into discrete, independent tiles that can be easily removed and replaced individually or in groups. Each tile is a self-contained unit with the wood panel, base sheet, and adhesive layer, allowing simple removal without damaging the underlying floor and easy replacement by laying new tiles.
Solution Approach 2:
The patent uses a flexible base sheet that can adapt to floor variations, and the adhesive layer provides sufficient bonding for installation but allows for relatively easy removal and replacement. This parameter optimization balances permanent attachment during installation with ease of removal for repairs or replacements.
4Productivity
If large flooring panels are used to cover floor area, then installation time is reduced, but storage and transportation becomes difficult
Solution Approach 1:
The flooring system is divided into smaller modular tiles that are easier to store and transport. Each tile is a compact unit that can be stacked efficiently, and multiple tiles can be quickly assembled to cover large floor areas, maintaining installation efficiency while solving storage and transportation challenges.
Solution Approach 2:
The patent uses a flexible base sheet that allows the tiles to be bent and conform to floor contours during installation. This flexibility enables efficient storage and transportation in compact forms while still achieving complete floor coverage when installed, effectively utilizing three-dimensional space during logistics.
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 system allows for rapid installation without gluing or nailing, can be bent to fit uneven surfaces, and reduces storage and transportation costs by folding, thus requiring less time and labor compared to conventional systems.
Implementation Method 1
an adhesive layer, having a first surface bonded to the base sheet layer and a second surface bonded to the wood panel
Implementation Method 2
a base sheet layer, made of a flexible sheet
Data Source
AI summary
Disclosed is a non-interlock assembled flooring system, comprising: a base sheet layer and a surface slat layer disposed on the base sheet layer, wherein the surface slat layer includes a plurality of wood floor slats arranged side-by-side in a widthwise direction, the wood floor slats are separated by a plurality of cut grooves serving as expansion joints, and the surface slat layer has a continuous wood-grain surface formed by upper surfaces of the wood floor slats.