Floor panel and methods of use thereof
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Solution Overview
Problem
Existing methods for forming graded wet areas, floors, pathways, and decking are time-consuming, labor-intensive, and require manual formation and waiting for concrete to set, which delays waterproofing and tiling.
Innovation Solution
The use of preformed floor panels with protrusions of varying heights to create a panel gradient, allowing for quick formation of graded surfaces by simply laying or fastening the panels, eliminating the need for manual concrete formation and reducing waiting time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual concrete formation is used to create graded surfaces, then the grading can be customized to specific requirements, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The floor panels are pre-formed with integrated protrusions that create the required gradient before installation. This preliminary formation of the graded structure eliminates the need for manual concrete formation and setting time on-site, directly resolving the contradiction between ease of manufacture and time loss.
Solution Approach 2:
The patent replaces the manual mechanical process of forming concrete grades with pre-manufactured panels having built-in geometric features (protrusions). This substitution transforms a labor-intensive mechanical process into a simple installation process, addressing both ease of manufacture and time efficiency.
2Productivity
If manual concrete formation is used for graded surfaces, then the structure can be formed in-place, but the process requires waiting for concrete to set
Solution Approach 1:
The gradient-forming protrusions are incorporated into the floor panels during manufacturing before installation. This preliminary action eliminates the need for on-site concrete formation and the subsequent waiting period for setting, directly improving productivity while eliminating the duration bottleneck.
Solution Approach 2:
The patent skips the concrete setting phase entirely by using pre-formed panels with integrated gradient features. This allows the process to rush through to the installation stage without the mandatory waiting period, directly addressing both productivity and duration concerns.
3Loss of time
If preformed floor panels with protrusions are used, then installation time is reduced, but the panel design becomes more complex
Solution Approach 1:
The floor panels are segmented with protrusions that create modular gradient sections. This segmentation allows the complex gradient function to be achieved through simple, repeatable geometric features rather than complex continuous forms, reducing manufacturing complexity while maintaining installation efficiency.
Solution Approach 2:
The patent uses variations in protrusion parameters (height, spacing, distribution) to achieve different gradient requirements without changing the fundamental panel design. This allows the same basic panel structure to adapt to various grading needs, reducing design complexity while maintaining installation speed.
Data Source
AI summary
The present invention relates to a floor panel, a flooring system including the panel and methods of use thereof for forming a graded wet area, floor, pathway or decking. In one form, the present invention provides a floor panel for forming a graded wet area. The panel includes a pair of opposed surfaces including an upper surface and an opposed lower surface interconnected by opposed side edges, a first end edge and an opposed second end edge. The panel further includes a plurality of protrusions protruding from one of the opposed surfaces and extending at least partially across the panel between the opposed side edges, said protrusions protruding at differing heights from the one of the opposed surfaces to define a panel gradient extending between the first end edge and the second end edge.