Substrate-Free Surface Covering With Interlocking Coupling Means
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Solution Overview
Problem
Existing substrate-free surface coverings face challenges with adhesion and durability, particularly in the limited assembly time and aging of adhesives, and lack effective interlocking solutions for resilient applications.
Innovation Solution
A resilient substrate-free surface covering element made from agglomerated plastic particles with interlocking means, such as hooks and loops, that connect without a substrate, ensuring uniform composition and mechanical resistance, and can be embossed and coated for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive or glue is used to install surface covering elements, then adhesion to the surface and between elements is improved, but assembly time is limited and adhesive strength decreases over time due to aging
Solution Approach 1:
The patent removes the adhesive substance from the installation system entirely, replacing it with a mechanical interlocking mechanism. The coupling means consisting of protrusions and recesses enable direct mechanical connection between elements and to the substrate without any chemical adhesive, thereby eliminating both the limited assembly time window and the aging problem of adhesives.
Solution Approach 2:
The patent replaces the chemical bonding system (adhesive) with a mechanical bonding system (interlocking coupling means). The protrusions and recesses create a mechanical lock that provides both installation flexibility and long-term durability without the time constraints or degradation issues associated with adhesive chemistry.
2Reliability
If adhesive or glue is used to install surface covering elements, then adhesion to the surface and between elements is improved, but adhesive strength decreases over time due to aging
Solution Approach 1:
The patent extracts the adhesive component from the system entirely, replacing it with a mechanical interlocking mechanism. The coupling means with protrusions and recesses provide permanent mechanical connection that does not degrade over time, eliminating the aging problem inherent in adhesive-based systems.
Solution Approach 2:
The patent substitutes the chemical bonding mechanism (adhesive) with a mechanical bonding mechanism (interlocking protrusions and recesses). This mechanical system provides durable, long-lasting connection that is not subject to the chemical degradation and aging that limits adhesive lifetime.
3Stability of the object's composition
If substrate-free surface coverings are used, then uniform composition and aesthetic consistency are improved, but interlocking capability is insufficient for resilient applications
Solution Approach 1:
The patent applies local quality by concentrating the interlocking function at specific locations (edges of elements) rather than distributing it throughout the entire element. The coupling means with protrusions and recesses are localized at the boundaries, allowing the bulk material to maintain uniform composition while providing targeted mechanical interlocking where needed.
Solution Approach 2:
The patent creates a composite structure by integrating the coupling means (protrusions and recesses) into the substrate-free material itself. The interlocking components are formed as integral parts of the homogeneous material, combining the benefits of uniform composition with enhanced interlocking capability through the geometric composite structure of the coupling elements.
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 provides a durable, aesthetically consistent, and easy-to-install substrate-free surface covering with improved mechanical resistance, comfort, and insulation, meeting ISO 10581 standards without the need for adhesives and minimizing curl issues.
Implementation Method 1
The interlocking means form a hook and loop engagement
Data Source
AI summary
The present invention relates to a resilient substrate-free surface covering element comprising interlocking means to connect said resilient substrate-free surface covering element to another resilient substrate-free surface covering element.