Breakproof Floor Panel Coupling Elements
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Solution Overview
Problem
Existing floor panels for cladding experience material failure and fracture during assembly due to high material loads, especially with thermoplastic styrene-block copolymer-deferred panels.
Innovation Solution
The panel design features a lower coupling element with a material thickness less than 100% of the upper coupling element, along with a uniform arch-shaped locking element and surface, and a counter surface with a reduced angle to distribute forces evenly and reduce stress concentrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coupling elements are designed with sufficient material thickness to withstand assembly loads, then the strength and reliability of the panel connection is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The coupling element is divided into two distinct parts: an upper coupling element and a lower coupling element. Each part is optimized independently for its specific functional requirements, allowing the upper element to have greater material thickness for withstanding spreading forces while the lower element can be thinner as it rests on the substrate for support.
Solution Approach 2:
Different material thicknesses are applied to different parts of the coupling system based on local stress requirements. The upper coupling element has greater material thickness in regions subjected to high spreading forces, while the lower coupling element has reduced material thickness where the substrate provides support, optimizing both strength and material efficiency.
2Reliability
If the lower coupling element material thickness is reduced to less than 100% of the upper coupling element, then the assembly load distribution is improved and material failure risk is reduced, but the strength of the lower coupling element decreases
Solution Approach 1:
The substrate acts as a counterweight or support structure for the lower coupling element. By resting the lower coupling element on the substrate, the system compensates for the reduced material thickness of the lower element, allowing it to withstand assembly loads without requiring excessive material thickness while maintaining overall structural integrity.
3Strength
If the locking element surface is designed with uniform arch shape, then the force distribution is improved and stress concentrations are reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The locking element surface is designed with a uniform arch shape (curved surface) instead of a flat surface. This curvature distributes contact forces more evenly across the locking interface, reducing stress concentrations at specific points. The arch shape naturally redirects forces along its curve, improving load distribution while the uniformity of the arch simplifies manufacturing compared to complex variable curvature surfaces.
Data Source
Figure 1~2
AI summary
The present invention relates to a panel (10a, 10b) for a paneling, more particularly to a floor panel for a floor covering, comprising: - a panel upper surface (12) and a panel lower surface (14) parallel to the panel upper surface, which are mutually spaced by a total thickness (G); - an upper coupling element (16) and a lower coupling element (18), wherein two panels (10a, 10b) of this type are designed such that said panels can be coupled to each other by means of a downward movement of the upper coupling element (16) of the first panel (10a) relative to the lower coupling element (18) of the second panel (10b); wherein the upper coupling element (16) has a detent element (24) and the lower coupling element (18) has a detent receptacle (26); wherein the upper coupling element (16) has a locking receptacle (28) and the lower coupling element (18) has a locking element (30); and wherein a material thickness (UM) of the lower coupling element (18) between the panel lower surface (14) and the detent receptacle (26) is less than 100 percent of a material thickness (OM) of the upper coupling element (16) between the panel upper surface (12) and the locking receptacle (28).