Modular Sub-Flooring Assembly with Interlocking Cam Lock Mechanism
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Solution Overview
Problem
Conventional sub-flooring designs are labor-intensive to assemble, lack load-bearing capacity, and are not weather-resistant, making them unsuitable for outdoor use and reuse.
Innovation Solution
A modular sub-flooring assembly with interlocking rectangular sections featuring a cam lock mechanism and a keying system that allows for easy assembly, disassembly, and stacking, using materials like HTP structural foam or fiberglass reinforced polypropylene plastic for durability and light weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional stringer sub-floors or metal sub-frame floors are used, then the flooring can provide basic support, but the assembly process is labor-intensive and time-consuming
Solution Approach 1:
The sub-flooring system is divided into multiple modular sections that can be independently manufactured and then quickly assembled together. Each section contains integrated connection features (recesses and protrusions) that enable rapid assembly without requiring complex fastening procedures, thus significantly improving assembly productivity while maintaining ease of operation.
Solution Approach 2:
The connection mechanism is merged into the structural sections themselves through integrated recesses and protrusions, eliminating the need for separate fasteners or complex joining procedures. This integration allows sections to be quickly connected by simply aligning and engaging the built-in features, dramatically reducing assembly time and labor requirements.
2Reliability
If conventional flooring designs with wood components are used, then the flooring can be initially assembled, but they are not weather-resistant and subject to rotting
Solution Approach 1:
The sub-flooring sections are constructed from composite materials that combine the structural integrity of metal framing with weather-resistant paneling materials. This composite construction provides protection against rotting and weather damage while maintaining the load-bearing capacity needed for sub-flooring applications, thereby improving both weather resistance and reusability.
Solution Approach 2:
The material composition parameters are changed from traditional wood-based materials to weather-resistant composite materials. This parameter change fundamentally alters the durability and weather resistance characteristics of the flooring system, enabling it to withstand outdoor conditions and repeated assembly/disassembly cycles without degradation.
3Strength
If web-lock flooring with tongue and groove method is used, then the sections can lock in place, but the load capacity is poor and the structure is not rugged
Solution Approach 1:
The connection system is segmented into distinct recesses and protrusions that are strategically positioned to handle both vertical load-bearing forces and lateral stabilizing forces. This segmentation allows the structure to achieve high load capacity while maintaining a simple, rugged design without requiring complex interlocking mechanisms.
Solution Approach 2:
The protrusions are designed with curved or rounded features that facilitate easy insertion into the recesses while providing substantial mechanical engagement. This curvature allows the sections to be quickly connected by simple vertical lowering motion, maintaining structural simplicity while achieving strong load-bearing capacity through the geometric design of the connection features.
4Ease of manufacture
If conventional flooring sections with protrusions or leg sleeves are used, then the sections can be secured together, but they are difficult to stack and ship
Solution Approach 1:
Instead of adding protruding elements that extend outward from the sections, the connection features are inverted and recessed into the section bodies. This inversion allows sections to stack flat and compact against each other, dramatically improving stackability and shipping efficiency while the recessed protrusion design maintains secure connection capability when assembled.
Data Source
AI summary
The present invention is directed to a sub-flooring assembly. The disclosed assembly includes at least two rectangular sections. Each of the sections have first and second ends and first and second sides. A male component extends outwardly from the first end of each of the sections. The male component has a flange proximate a free end thereof. An opening is disposed on the second end of each of the sections. The opening extends into the section to form a cavity. A pocket is formed in the cavity. The flange of one of the sections is removably received in the pocket of another of the sections for detachably securing the first end of one of the sections to the second end of another of the sections.