Reconfigurable floorboard system

A floorboard for a reconfigurable floorboard system may include a substantially trapezoid shaped plate. An interlocking feature may be formed proximate an edge of at least three sides of the plate for interlocking with adjacent floorboards. Each interlocking feature may be formed to interlock with a mating interlocking feature formed at an edge of a side of at least one adjacent floorboard. A notch may be formed on an underside of the plate proximate each corner of the plate to contact a member of a floor grid to prevent movement of the floorboard.

FIELD

The present disclosure relates to aircraft, aerospace vehicles, other vehicles and other structures, and more particularly to dynamic optimized reconfigurable floorboard system for aircraft, other vehicles or other structures.

BACKGROUND

During the fabrication of a vehicle, such as an aircraft or other aerospace vehicle, a floor including a plurality of floorboards may be installed to facility construction of the vehicle or aircraft. Mechanics have to maneuver over a passenger floor grid in the case of a passenger airliner to load the floorboards into the floor grid. The floorboards are then taped together to prevent movement and to prevent foreign object debris (FOD) from falling through any spaces between the floorboards. Taping the boards together requires a significant amount of labor and time. Maintenance is also required to make sure the boards continue to form a barrier to FOD. Additionally, boards often have to be removed to install components of the aircraft, such as galley support hose components and other equipment. This requires removal of the tape from the effected boards and re-taping when the board is reinstalled. The boards may also sit on top of fillers at some locations which may cause the boards to be unstable. The boards can also be cumbersome and difficult to handle requiring multiple mechanics for proper placement and installation. There is need for a reconfigurable floorboard system that can be easily and efficiently installed, protects from FOD and permits floorboards to be easily and efficiently removed and replaced.

SUMMARY

In accordance with an embodiment, a floorboard for a reconfigurable floorboard system may include a substantially trapezoid shaped plate. An interlocking feature may be formed proximate an edge of at least three sides of the plate for interlocking with adjacent floorboards. Each interlocking feature may be formed to interlock with a mating interlocking feature formed at an edge of a side of at least one adjacent floorboard. A notch may be formed on an underside of the plate proximate each corner of the plate to contact a member of a floor grid to prevent movement of the floorboard and to provide stability of the floorboard when it bears weight.

In accordance with an embodiment, a reconfigurable floorboard system may include a floor grid structure. A plurality of floorboards may be disposed on the floor grid structure. Each floorboard may include a substantially trapezoid shaped plate. An interlocking feature may be formed proximate to an edge of at least three sides of the plate for interlocking with adjacent floorboards. Each interlocking feature may be formed to interlock with a mating interlocking feature formed at an edge of a side of at least one adjacent floorboard. A notch may be formed on an underside of the plate proximate each corner of the plate to contact a member of the floor grid structure to prevent lateral movement of the floorboard and to provide stability of the floorboard when it bears weight.

In accordance with another embodiment, a method for installing a reconfigurable floorboard system may include interlocking each of a plurality of floorboards on a floor grid. Interlocking each floorboard may include receiving by an interlocking feature formed at an edge of a side of the floorboard, a mating interlocking feature formed at an edge of a side of at least one adjacent floorboard. The method may also include abutting a notch formed on an underside of the floorboard proximate each corner of the floorboard to a member of the floor grid to prevent lateral movement of the floorboard.

Other aspects and features of the present disclosure, as defined solely by the claims, will become apparent to those ordinarily skilled in the art upon review of the following non-limited detailed description of the disclosure in conjunction with the accompanying figures.

DESCRIPTION

The following detailed description of embodiments refers to the accompanying drawings, which illustrate specific embodiments of the disclosure. Other embodiments having different structures and operations do not depart from the scope of the present disclosure. Like reference numerals may refer to the same element or component in the different drawings.

FIG. 1Ais a top view of an example of a floor grid structure100for a reconfigurable floorboard system102in accordance with an embodiment of the present disclosure. The reconfigurable floorboard system102will be described herein with regard to use in an aircraft104, although the floorboard system102described herein may be adapted for use in any vehicle or other structure. The floor grid structure or floor grid100may be formed or constructed on an interior of a vehicle or other structure. The floor grid100may include a plurality of floor beams106. The floor beams106may extend laterally across the aircraft104between opposite sides of a fuselage108of the aircraft104. The floor grid100may also include a plurality of floor tracks110. The floor tracks110may extend substantially orthogonally to the floor beams106. The floor tracks110may be attached to the floor beams106by suitable fasteners or by another mechanism.

Referring also toFIG. 2,FIG. 2is a detailed cross-section of an example of a floor track200of a floor grid structure202in accordance with an embodiment of the present disclosure. The floor grid202and floor track200may be the same as the floor grid100and floor track110ofFIG. 1with the cross-section taken along lines2-2. The floor track200may be substantially pi (π) shaped including a pair of vertical members204and206at a predetermined spacing “S” from one another and a top member208joining the two vertical members204and206. A lower flange210may extend perpendicular from a lower end of each vertical member204and206. An intermediate flange212may extend perpendicular from each vertical member204and206at an intermediate location between the top member208and each lower flange210. The intermediate flanges212may be disposed on a floor beam214of the floor grid202. The floor track200may be attached to the floor beam214by fastening the intermediate flanges212to the floor beam214.

Referring now toFIG. 1B,FIG. 1Bis a top view of an example of the reconfigurable floorboard system102with a plurality of floorboards112installed on the floor grid structure100(FIG. 1A) in accordance with an embodiment of the present disclosure. As described in more detail herein, each of the floorboards may include a substantially trapezoid shaped plate as illustrated inFIG. 1B. In accordance with an embodiment, particularly for an aircraft104, the plurality of floorboards112may include a plurality of sets of tapered floorboards114. Each tapered floorboard114may have a predetermined tapered form for insertion in the floorboard system102of the aircraft104next to a tapered interior portion116of the fuselage108of the aircraft104. The tapered interior portion116of the fuselage108may also have a selected curvature. An outboard side of each tapered floorboard114may then have a chosen curvature to substantially match the selected curvature of the interior portion116of the fuselage108. Accordingly, the outboard side of each tapered floorboard114may be formed to substantially match or correspond to the interior portion116of the fuselage so that the outboard side of each tapered floorboard114may abut or contact the interior116of the fuselage108to prevent FOD from getting to an area underneath the floorboards112and to provide stability of the floorboards112.

In accordance with an embodiment, each complete set of tapered floorboards114may include three different types of tapered floorboards114a,114band114c. The different types of tapered floorboards114a,114band114cmay respectively each be substantially identical and may have the same dimensions and other structural features in each set of floorboards114so that the respective types of floorboards114a-114cmay be interchangeable with the same type floorboard114a-114cand the floorboards may be dynamically reconfigured, for example, in different aircraft. Along some portions of the fuselage108only one or two tapered floorboards104may be used. For example, a forward section120of the fuselage108in the example ofFIG. 1Bonly uses tapered floorboard types114band114c.

The plurality of floorboards112may also include a set of substantially square shaped floorboards122. In another embodiment, the floorboards122may be another shape, such as rectangular. The set of substantially square shaped floorboards122may be for insertion in the floorboard system102between the sets of tapered floorboards114which are installed next to opposite sides of the fuselage108.

Referring now toFIGS. 3A and 3B,FIG. 3Ais a bottom detailed perspective view of an example of a floorboard300for use in a reconfigurable floorboard system, such as the floorboard system102inFIG. 1Bin accordance with an embodiment of the present disclosure.FIG. 3Bis a top detailed perspective view of the exemplary floorboard300ofFIG. 3Ain accordance with an embodiment of the present disclosure. The floorboard300may be used for floorboards122inFIG. 2B. The tapered floorboards122inFIG. 2Bwould also include similar features to those of floorboard300but may not have an interlocking feature formed on each side of the floorboard. For example, the side of the tapered floorboard114a-114cthat contacts the fuselage108may not include an interlocking feature.

The floorboard300may include a substantially trapezoid shaped plate302. As previously described, the floorboard300or plate302may be tapered to substantially correspond to an interior portion of a vehicle or fuselage of an aircraft. The floorboard300or plate302may also be substantially square or rectangular for insertion into a reconfigurable floor system, such as system102inFIG. 1B.

The floorboard300may also include an interlocking feature304formed proximate an edge of at least three sides of the plate302for interlocking with adjacent floorboards. Each interlocking feature304may be formed to interlock with a mating interlocking feature304formed at an edge of a side of at least one adjacent floorboard.

The floorboard300may also include a notch306formed on an underside308(FIG. 3A) of the plate302proximate each corner of the plate302. As best illustrated inFIG. 4, the notch306is adapted to contact a member400of a floor grid, such as floor grid100inFIG. 1to prevent lateral movement of the floorboard300or114or122inFIG. 1B. The notch306is also located proximate each corner of the plate302or floorboard300to provide stability when the floorboard bears weight to prevent any tipping or movement of the floorboard300.FIG. 4is a side cross-sectional view of a portion of the floorboard system102ofFIG. 1Btaken along lines4-4. The member400of the floor grid may be the floor track110inFIG. 1Adisposed on the floor beam106.

The notch306may include a right-angled portion310formed by a horizontal surface312for contacting a top portion of the floor grid member400and a vertical surface314for contacting a side of the floor grid member400to prevent lateral movement of the floorboard300. A pad307(FIG. 3A) may also be disposed in the right-angled portion310of the notch306to further provide stability of the floorboard.

The interlocking feature304may include a first interlocking feature316on each of two adjacent sides318aand318bof the floorboard300as best shown inFIG. 3A, and a second interlocking feature320on each of two other adjacent sides322aand322bof the floorboard300as best shown inFIG. 3B. Each of the first interlocking features316is adapted to matingly interlock with the second interlocking feature320and vice versa on respective adjacent floorboards.

Each first interlocking feature316may include a lip324integrally extending laterally from an upper surface326of the plate302substantially completely along each side318aand318bof the plate302(FIG. 3A). Referring also toFIG. 4, each first interlocking feature316may also include a projection328extending downward from the lip324at an edge of the lip324. Each first interlocking feature316may also include a groove330formed in an underside332of the lip324by the projection328and a side edge334of the plate302or floorboard300aas best shown inFIG. 4.

Each second interlocking feature320may include a projection336extending upwardly from the edge of an adjacent floorboard300b(FIG. 4). Each second interlocking feature320may also include a groove338formed in an upper surface326of the floorboard300bor plate302. One side of groove338may be formed by the projection336of the second interlocking feature320. The groove338of the second interlocking feature320is adapted to matingly receive the projection328of the first interlocking feature316of the adjacent floorboard300aand the groove330of the first interlocking feature316is adapted to matingly receive the projection336of the second interlocking feature320of the other adjacent floorboard330bto interlock the adjacent floorboards300aand300b. Because the first interlocking feature316and the second interlocking feature320each matingly receive the other as just described, either of the interlocking features316and320may be referred to herein as a mating interlocking feature or similar terminology. As illustrated inFIG. 4, the first and second interlocking features316and320overlap one another and provide a seal when interlocked to prevent any FOD from falling in an area402beneath the floorboards300aand300b. The overlapping structure of the interlocking features316and320provides stability and eliminates the laborious need to tape the joints between the floorboards.

Each floorboard300may also include a handle340integrally formed in the floorboard300. The handle340may include an enclosed interior342except for an opening344in the upper surface326of the floorboard300for insertion of a user's fingers to grip the floorboard300. The interior342of the handle340is enclosed and not open to the area402underneath the floorboard300to prevent any FOD falling into the area402underneath the floorboards300aand300b. Each floorboard300may also include non-slip strips or a similar feature on the upper surface326of the floorboard300to improve footing and minimize slippage by personnel.

Each floorboard300may also include a predetermined reinforcing structure346(FIG. 3A). The reinforcing structure346may be integrally formed on an underside308of the floorboard300. The floorboard300may be made from a suitable plastic, polyvinylchloride (PVC), injection moldable plastic or other material that may be lightweight yet have sufficient strength to withstand any expected loads during use or construction of the vehicle or structure.

FIGS. 5A and 5Bare an example of a moveable cart500for storing multiple floorboards300and efficiently moving the floorboards300from one location to another in accordance with an embodiment of the present disclosure.FIG. 5Ais an illustration of the cart500unloaded or without any floorboards andFIG. 5Bis an illustration of the cart500at least partially filled with floorboards300. The cart500may include a plurality of vertically spaced ledges502or racks adapted to receive the horizontal surface312of the notch306(FIG. 4). Each of the ledges502or racks are at a predetermined spacing from one another to accommodate a second floorboard300being stacked on the first floorboard300on each ledge502with the second floorboard300being placed upside down on the first floorboard300or with the upper surfaces326(FIG. 4) of the two floorboards300facing each other in the cart500.

The cart500may also include a side rack504for storing tapered floorboards, such as tapered floorboards114similar to that illustrated inFIG. 1Bor floorboards with other shapes which may not conveniently fit in the racks or ledges502. Caster wheels506or similar wheels may also be mounted to the cart500for rolling the cart500between locations and for rolling the cart500within an aircraft or structure under construction to facilitate placement of the floorboards500, reconfiguration or removal of the floorboards300.

FIG. 6is a flow chart of an example of a method600for installing a reconfigurable floorboard system in accordance with an embodiment of the present disclosure. The reconfigurable floorboard system may be the same as the system102inFIGS. 1A and 1B. In block602, a floor grid may be formed or constructed on an interior of a vehicle or structure.

In block604, a plurality of floorboards may be interlocked on the floor grid. Each floorboard may be interlocked by receiving by an interlocking feature formed at an edge of a side of the floorboard, a mating interlocking feature formed at an edge of a side of at least one adjacent floorboard. In an embodiment, each floorboard may be interlocked by receiving a projection of at least one adjacent floorboard in a groove of the floorboard. The groove may extend substantially completely along the side of the floorboard at the edge of the floorboard similar to that described herein.

In block606, a plurality of sets of tapered floorboards may be interlocked in the floorboard system, such as for example a floorboard system for an aircraft or similar structure. Each tapered floorboard may include a predetermined tapered form for interlocking in the floorboard system next to a tapered interior portion of a fuselage of the aircraft or other structure.

In block608, a set of substantially square shaped floorboards may be interlocked in the floorboard system between the sets of tapered floorboards. In block610, a notch formed on an underside of the floorboard proximate each corner of the floorboard may abut or contact a member of the floor grid to prevent lateral movement of the floorboard in the floorboard system and to provide stability for bearing weight.