Board Edge Lock Profile for Stable Single-Tool Assembly
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Solution Overview
Problem
Existing methods for connecting two boards, such as those described in EP 4 446 054 A1, require different tools for each part of the tongue-and-groove profile, making the manufacturing process complex and inefficient.
Innovation Solution
A connection system for boards using a profile with standard and terminal cutouts and undercuts, allowing the use of a single set of templates and enabling a two-step assembly process without additional tools, ensuring stability and ease of manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a tongue-and-groove profile is used to connect two boards, then the connection stability is improved, but different tools are required for each part of the profile making the manufacturing process complex
Solution Approach 1:
The patent combines multiple profile components (tongue, groove, stop shoulder, recess) into a single integrated profile structure that can be created with one tool. The profile includes a tongue extending from the first board, a groove in the second board, a stop shoulder on the tongue, and a recess in the groove, all formed as a unified connection system requiring only a single manufacturing tool.
Solution Approach 2:
The single profile structure serves multiple functions simultaneously: it provides the tongue-and-groove connection for stability, includes a stop shoulder to prevent over-insertion, and creates a recess for glue application. This multi-functional design eliminates the need for separate tools for each feature while maintaining comprehensive connection capabilities.
2Stability of the object's composition
If a complex profile with multiple components is used, then the connection stability is improved, but the manufacturing process becomes inefficient and costly
Solution Approach 1:
The patent merges multiple profile components into a single structure that can be manufactured in one operation. The profile integrates the tongue, groove, stop shoulder, and recess into a unified design that requires only a single tool and one manufacturing pass, eliminating the need for sequential tooling operations.
Solution Approach 2:
The profile is designed with pre-formed features including the stop shoulder and recess that are created during the single manufacturing operation. The stop shoulder is preliminarily positioned to control insertion depth, and the recess is pre-formed to receive glue, both features being created in advance during profile formation rather than requiring additional steps.
3Ease of operation
If a profile with stop shoulder and recess is used, then the assembly process is simplified, but the manufacturing complexity increases
Solution Approach 1:
The profile structure is designed to be self-guiding during assembly. The stop shoulder automatically limits insertion depth by contacting the second board when the tongue is fully inserted, and the recess automatically positions itself to receive glue. These self-service features guide the assembly process without requiring external tools or complex alignment procedures.
Solution Approach 2:
The profile employs asymmetric features including the stop shoulder positioned at a specific distance from the tongue end, and the recess located at a predetermined position within the groove. This asymmetric design provides clear directional guidance during assembly and ensures proper positioning without requiring complex symmetric mechanisms.
4Loss of substance
If the undercut is placed closer to the edge, then material removal is reduced, but the connection stability decreases
Solution Approach 1:
The patent optimizes the undercut parameters by positioning it at a specific distance range from the board edge (0.3 to 2 times the board thickness). This parameter optimization balances material conservation with connection stability, ensuring the undercut is close enough to minimize material removal but far enough to maintain structural integrity and connection strength.
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The invention concerns a connection of a 1st board and a 2nd board made from wood or reconstituted wood, said 1st and 2nd boards being arranged in a XY-plane, said 1st and 2nd boards each having a 1st and a 2nd surface, a thickness and an edge area with an edge surface (4a) extending over the thickness (T) of the board. To provide a simple and easy to manufacture link between two boards, the connection comprises a profile (5) in each board (1, 2) extending over at least part of the edge area (4), said profile (5) comprising at least one standard cutout (6) and a terminal cutout (6a) extending in the edge area (4) from a surface (3, 14) of a board over part of its thickness (T), each cutout (6, 6a) being less deep in a 1st section (7) adjacent to the edge surface (4a) of the board (1,2) and being deeper in a 2nd section (8) at a distance from the edge surface (4a) of the board (1,2), with an undercut (9) separating the 1st and the 2nd section, said undercut (9) forming a 1st abutment (10) in an X-direction, wherein a 2nd abutment (15) in a Y-direction is formed on the 1st and on the 2nd board, said 1st and 2nd abutment (10,15) being arranged in the X- or Y-direction, respectively, or at an angle thereto, with the profile (5) of the 1st board (1) and the 2nd board (2) complementing each other, wherein a terminal cutout (6a) is shorter in Y-direction than a standard cutout (6). The invention further comprises a method of forming a connection between a 1st and a 2nd board.