Resilient Composite Floor Covering for Adhesive-Free Interlocking
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Solution Overview
Problem
Existing floor coverings face issues with adhesive-based installation processes that are time-consuming, costly, and messy, and mechanical locking systems in laminate flooring are heavy, water-resistant, and prone to joint strength failures due to humidity changes.
Innovation Solution
A resilient composite sheet with interlocking tongue and groove profiles on opposite sides, featuring balanced dimensions and angles, allows for easy installation and enhanced joint strength without adhesives, suitable for vinyl and rubber materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive-based installation is used, then floor covering can be secured to sub-floor, but installation process becomes time-consuming, costly, and messy
Solution Approach 1:
The patent replaces the chemical adhesive system with a mechanical interlocking system. The tongue and groove profiles create a mechanical connection between floor planks and the sub-floor, eliminating the need for adhesives. This mechanical system provides secure attachment while significantly reducing installation time and complexity.
Solution Approach 2:
The floor covering is divided into individual planks with standardized tongue and groove profiles. This segmentation allows for modular installation where planks can be independently positioned and interlocked, streamlining the installation process compared to applying adhesive to entire large sheets.
2Ease of operation
If mechanical locking system is used in laminate flooring, then installation is easier, but joint strength fails due to humidity changes
Solution Approach 1:
The patent modifies the tongue and groove profile parameters, specifically the angles and dimensions, to optimize both installation ease and joint strength. The groove angle is set between 30-60 degrees to balance insertion ease with locking strength, while the tongue thickness and groove depth are calibrated to maintain joint integrity under humidity variations.
Solution Approach 2:
The floor planks are constructed from composite materials that combine dimensional stability with moisture resistance. This composite construction allows the mechanical locking system to maintain its joint strength even when exposed to humidity changes, addressing the failure mode of traditional laminate flooring.
3Strength
If wood-based core is used in laminate flooring, then mechanical locking is achieved, but flooring becomes heavy and water-resistant properties are insufficient
Solution Approach 1:
The patent replaces traditional wood-based cores with composite materials that offer superior strength-to-weight ratio and inherent water resistance. These composite materials maintain the structural integrity needed for mechanical locking while significantly reducing weight and improving moisture performance.
Solution Approach 2:
The patent changes the material composition parameters from wood-based to composite materials, fundamentally altering the density, moisture content, and strength characteristics. This material substitution achieves the same mechanical locking capability with reduced weight and enhanced water resistance.
Data Source
AI summary
Surface coverings, such as floor coverings, with an interlocking design are described. Methods of making the surface coverings are further described. A plank including a resilient composite sheet having four sides, an upper surface, a lower surface, and an overall thickness, and said composite sheet including at least one base layer, wherein said at least one base layer including at least one polymeric material and at least one filler, wherein opposite sides of the composite sheet include a first tongue on a first side and a first groove on the opposite second side, wherein the first tongue and first groove have complementary shape to each other to be interlockingly engageable with a corresponding groove or tongue on an adjacent floor plank.