Overmolded Elastomer Support Members for Modular Floor Tiles
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Solution Overview
Problem
Conventional modular injection-molded tiles face challenges in manufacturing tiles with multiple colors, non-slip characteristics, and durability, especially when subjected to heavy loads, and require additional substrates like rubber sheets for stability.
Innovation Solution
The use of a two-polymer compound system where a first polymer compound forms the tile body, and a second polymer compound is overmolded onto the surface to create nonslip pads and support members, with a vent hole system to prevent voids and enhance adhesion, allowing for the creation of tiles with contrasting colors and improved friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional single-color injection-molded tiles are used, then manufacturing is simple and cost-effective, but aesthetic versatility and design options are limited
Solution Approach 1:
The tile is segmented into multiple color zones by dividing the mold cavity into separate injection zones. Each zone receives a different colored polymer compound through dedicated gates, allowing multiple colors to be integrated into a single tile without requiring post-manufacturing assembly or additional substrates.
Solution Approach 2:
The tile incorporates composite construction by combining different polymer compounds with distinct color properties within a single injection-molded structure. This allows aesthetic versatility through color variation while maintaining manufacturing simplicity through a unified molding process that integrates multiple materials in one operation.
2Strength
If conventional modular tiles are used, then assembly is simple with few tools, but the tiles are easily dislodged when wheeled vehicles are driven onto them
Solution Approach 1:
The tile integrates multiple functional elements into a unified structure: the load-bearing body, the connector mechanisms, and the surface features are all merged into a single injection-molded component. This consolidation enhances structural strength and load-bearing capacity while preserving assembly simplicity through the inherent snap-fit connectors that require no additional tools or substrates.
3Reliability
If rubber inserts are physically inserted into receiving holes after molding, then cushioning characteristics are achieved, but manufacturing time and cost increase significantly
Solution Approach 1:
The cushioning features are incorporated into the tile body during the initial injection molding process rather than being added as separate post-manufacturing components. The mold cavity includes provisions for forming cushioning zones directly in the tile structure, eliminating the need for separate rubber insert manufacturing, flash removal, and physical insertion operations.
Solution Approach 2:
The cushioning functionality is merged with the tile body structure by integrating elastomeric material directly into the rigid polymer matrix during co-injection molding. This creates a unified cushioning system that achieves the same performance as separate rubber inserts while dramatically improving manufacturing efficiency through a single integrated process.
4Stability of the object's composition
If conventional injection-molded tiles are used, then manufacturing is cost-effective, but the tiles require additional rubber sheet substrates for stability
Solution Approach 1:
The stabilizing features are merged directly into the tile body through injection molding. The tile incorporates integrated support members, friction surfaces, and interlocking mechanisms as inherent parts of the molded structure, eliminating the need for separate rubber sheet substrates and reducing overall system complexity.
Solution Approach 2:
The tile uses composite polymer construction with different material zones within the single molded body to achieve both stability and functionality. The integrated design combines rigid structural elements with friction-enhancing surfaces and support features in one composite structure, replacing the need for additional substrate layers.
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 solution enables the production of modular tiles that are durable, non-slip, and aesthetically pleasing, with the ability to withstand heavy loads without the need for additional substrates, while maintaining a cost-effective manufacturing process.
Implementation Method 1
The vent hole permits gas or other fluid to be displaced out of the upper feature cavity, thereby obviating or minimizing any void in the as-molded upper feature
Implementation Method 2
a second polymer compound is overmolded onto the surface to create nonslip pads and support members, with a vent hole system to prevent voids and enhance adhesion
Data Source
AI summary
A modular plastic floor tile is formed by molding a body of a first polymer compound and overmolding features onto the body from a second polymer compound. The compounds may be different from each other in hardness and/or color. The overmolded features may include skins on the sides and bottoms of support member cores disposed below the tile lower surface.