Symmetrical Lower Weld for Seamless Synthetic Flooring
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Solution Overview
Problem
Existing synthetic flooring technologies face challenges in creating uniform grooves for welding, leading to inconsistent appearances, dirt traps, and weaker areas, which disrupt design and aesthetics, particularly in large or complex areas like those found in the transport sector, and can be disconcerting for dementia patients.
Innovation Solution
A method involving symmetrical lower welds that are free from metallic elements, formed by partial grooves on the floor-engaging surface of adjacent flooring elements, allowing for a seamless upper surface and reduced water ingress, with a process that includes planning, cutting, and arranging flooring elements to create a consistent and strong welded floor covering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a groove is formed on the upper surface of adjacent synthetic flooring elements for welding, then the flooring elements can be joined together, but the groove creates a visible line across the surface that disrupts the design and creates dirt traps
Solution Approach 1:
The patent moves the weld from the upper surface to the lower surface of the flooring elements. By forming grooves on the lower surfaces and welding there, the weld line is relocated to a dimension (lower surface) that is not visible when the flooring is installed, eliminating the aesthetic and functional problems of surface weld lines while maintaining joint strength
Solution Approach 2:
Instead of welding on the upper surface as conventionally done, the patent inverts the approach by welding on the lower surface of the flooring elements. This inversion allows the weld to be hidden from view while still providing the necessary structural connection between flooring elements
2Manufacturing precision
If a groove cutter is used to form uniform grooves along the juncture, then consistent welding can be achieved, but guiding the cutter manually is time consuming and expensive
Solution Approach 1:
The groove cutter is designed with an self-aligning feature where the cutter body naturally aligns with the gap between flooring elements during installation. The grooves are formed at approximately 45 degrees to the longitudinal axis, and the cutter's geometry allows it to self-position correctly without requiring manual guidance along the juncture, eliminating the need for time-consuming manual alignment
Solution Approach 2:
The patent introduces a positioning element or guide feature on the groove cutter that acts as an intermediary to automatically locate and align the cutter with the gap between flooring elements. This intermediary mechanism ensures consistent groove positioning without requiring manual measurement or guidance
3Manufacturing precision
If a guide is added to the groove cutter to align it with the juncture, then positioning accuracy improves, but the guide may twist under the force required to form the groove
Solution Approach 1:
The groove cutter is designed with an asymmetric groove angle of approximately 45 degrees relative to the longitudinal axis of the flooring element. This asymmetric design creates a natural mechanical advantage where the cutting force is directed along the strong axis of the cutter body, preventing twisting of the guide while maintaining precise alignment with the gap between elements
4Reliability
If flooring elements are welded together with traditional methods, then they can be joined, but the weld creates a weaker area on the surface that can be damaged and enable water ingress
Solution Approach 1:
The weld is relocated from the upper surface to the lower surface of the flooring elements. By forming grooves and welding on the lower surfaces, the weakened area is positioned in a dimension that is protected from surface traffic and environmental exposure, preventing damage and water ingress while maintaining the structural connection
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 results in a consistent and strong welded floor covering with reduced water ingress, improved aesthetics, and faster installation, meeting EN standards for water resistance and reducing labor and material costs.
Implementation Method 1
The joints are typically created by forming a groove on the upper surface of the adjacent synthetic flooring elements along the juncture where they meet using a groove cutter and then by hot welding the surface, using a 4.5 mm weld rod.
Data Source
AI summary
A welded synthetic floor-covering material which is formed from one or more adjacent pairs of flooring elements wherein each adjacent pair of flooring elements is welded together by a symmetrical lower weld which engages each flooring element substantially equally; and wherein the symmetrical lower weld is substantially free from a metallic element; and a method of preparing a welded synthetic floor-covering material having a layout suitable for covering a pre-determined area wherein the welded synthetic floor-covering material comprises one or more adjacent pairs of flooring elements which have a floor-engaging lower surface and wherein the method comprises the following steps: (a) providing a floor plan for the pre-determined area wherein the floor plan defines a layout of flooring elements including positions of one or more welds; (b) providing a length of flooring and forming a groove on the floor-engaging surface of the flooring at the position of each of the one or more welds; (c) cutting the length of flooring to form the one or more adjacent pairs of flooring elements; and (d) arranging the flooring elements according to the layout and welding together each of the one or more adjacent pairs of flooring elements to form a symmetrical lower weld which engages each flooring element substantially equally such that the welded synthetic floor-covering material is formed.