Portable Floor Panels with Composite Core for Warping Resistance
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Solution Overview
Problem
Portable floor panels used in temporary settings often warp due to temperature and humidity differences, especially when exposed to outdoor conditions, and existing solutions fail to adequately prevent moisture absorption and warping while maintaining a strong, lightweight construction.
Innovation Solution
The floor panels are constructed with a planar core assembly of multiple horizontal, water-resistant layers including a structural reinforced foam core, nonferrous sheets, and a decorative layer, with an unsymmetrical configuration to prevent moisture absorption, and utilize extruded aluminum or weather-resistant plastic edging for secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a wood core is used in floor panels, then the panels provide structural strength and rigidity, but the panels are prone to warping due to temperature and humidity differences
Solution Approach 1:
The patent replaces the traditional wood core with a composite core structure consisting of a foam core (polymer material) combined with a waffle iron or mesh reinforcement layer. This composite construction provides the necessary structural strength and rigidity while eliminating the warping issues associated with wood cores, as the foam and metal components do not expand or contract with temperature and humidity changes.
Solution Approach 2:
The patent changes the material parameters of the core from natural wood (which has high sensitivity to temperature and humidity) to synthetic foam combined with metal reinforcement. This parameter change fundamentally alters the thermal and hygroscopic properties, transforming the core from a material that warps under environmental stress to one that maintains dimensional stability.
2Stability of the object's composition
If floor panels are made without a wood core to prevent warping, then the panels resist warping better, but the panels become lighter and potentially less structurally sound
Solution Approach 1:
The patent employs a composite core structure that combines foam material with a waffle iron or mesh reinforcement layer. This composite design achieves the desired light weight while maintaining structural integrity through the synergistic combination of materials - the foam provides lightweight cushioning and basic structure, while the metal reinforcement grid provides rigidity and strength.
Solution Approach 2:
The patent applies local reinforcement by incorporating a waffle iron or mesh layer specifically at strategic locations within the core structure where additional strength is needed. This localized reinforcement approach allows the panel to maintain overall light weight while providing targeted structural support at critical points.
3Object-affected harmful factors
If decorative layers are applied to both top and bottom surfaces, then the panels have aesthetic appeal and protective properties, but the layers may trap moisture and cause warping
Solution Approach 1:
The patent removes the bottom decorative laminate layer from the panel construction, retaining only the top decorative layer for aesthetic purposes. This extraction of the problematic bottom layer eliminates the moisture trapping issue that previously caused warping, while the panel still provides aesthetic appeal through the top decorative surface and protective properties through the foam core.
4Ease of operation
If floor panels are designed for easy assembly and disassembly, then the panels are more versatile and easier to install, but the connection strength may be reduced
Solution Approach 1:
The patent divides the edge of each panel into separate functional components: a protruding tongue element and a corresponding recessed groove element. This segmentation allows for simple interlocking assembly where panels are easily connected by inserting tongues into grooves, while the modular design maintains strong connection strength through the precision-fitted mechanical joint.
Solution Approach 2:
The patent incorporates a latch mechanism that transitions from a static connection to a dynamic locking system. The latch can be manually actuated to secure the connection between panels, providing easy assembly through simple latching motion while ensuring strong, reliable connection strength when engaged.
Data Source
AI summary
A portable floor includes floor panels connected in an edge to edge relationship to form an extended temporary floor surface. Each of the panels includes a foam layer having a top face and a bottom face with a first aluminum sheet placed on the top face and a second aluminum sheet placed on the bottom face. The aluminum sheet placed on the bottom face is coated with a paint over the bottom surface while a laminate is applied over the upper aluminum sheet. Extruded edge pieces attach along the sides of the floor panels and include complementary tongues along two edges and grooves along the other two edges. The panels also include latches for securing the edges together.