Co-extruded Floor Panel Locking Element with Dual-Polymer Zones
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Solution Overview
Problem
Existing 'push lock' systems for floor panels often face issues with reliable coupling due to stiff materials and potential damage during installation, particularly with brittle decorative layers, and may experience height discrepancies between panels under different loads or warping.
Innovation Solution
The use of a co-extruded plastic strip with distinct zones of different polymers for the blocking body and bending zone, where the blocking body is made of ABS and the bending zone is a mixture or entirely of thermoplastic polyurethane, provides a secure and flexible locking mechanism that minimizes the risk of damage and ensures easy coupling without height discrepancies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a stiff material is used for the locking element to ensure strong locking, then the locking strength is improved, but the risk of damage to brittle decorative layers during installation increases
Solution Approach 1:
The patent applies parameter changes by transitioning from a single-material locking element to a multi-material construction. The locking element comprises a first material (e.g., metal or hard plastic) for the locking portion and a second material (e.g., rubber or elastic polymer) for the protective portion. This material parameter differentiation allows the locking portion to maintain high strength while the protective portion provides a softer interface that prevents damage to brittle decorative layers during the pushing operation.
Solution Approach 2:
The patent directly implements composite materials by combining two or more different materials within a single locking element. The first material provides structural strength and locking capability, while the second material provides cushioning and protection. This composite structure resolves the contradiction by allowing each material to perform its specialized function - the hard material for locking strength and the soft material for damage prevention.
2Reliability
If a separate locking element is used to achieve vertical locking, then the reliability of coupling is improved, but the device complexity increases
Solution Approach 1:
The patent applies merging by integrating multiple functions into a single locking element component. The locking element simultaneously provides vertical locking through its engagement with the panel, protective function through its cushioning material, and guiding function during the pushing operation. This consolidation maintains reliability while reducing the number of separate components compared to having distinct locking, protective, and guiding elements.
Solution Approach 2:
The locking element is designed as a multi-functional component that performs multiple roles: it provides vertical locking force, protects the decorative surface during installation, and guides the panel into proper alignment. This universal design approach improves reliability by ensuring all functions are integrated while avoiding the complexity of multiple separate components.
3Ease of manufacture
If a single-material locking element is used, then the manufacturing process is simplified, but the ability to provide both strong locking and damage protection is reduced
Solution Approach 1:
The patent applies segmentation by dividing the locking element into distinct functional zones with different materials. The first material forms the locking portion that engages with the panel, while the second material forms the protective portion that contacts the decorative surface. This segmentation can be achieved through co-extrusion or assembly processes that are relatively simple while providing superior reliability compared to single-material elements.
Solution Approach 2:
The patent uses composite materials to resolve the contradiction between manufacturing simplicity and coupling reliability. By combining materials with different properties in a single element, the design achieves both strong locking (from the hard material) and damage protection (from the soft material) without requiring multiple separate components, thus maintaining manufacturing efficiency while improving reliability.
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
This solution enhances the reliability and ease of coupling between floor panels while preventing damage to brittle surfaces and maintaining uniform height, even under varying loads or warping conditions.
Implementation Method 1
The bending zone (24) consists of an elastic bending zone which forms a connection between the securing section (15) and the blocking body (14)
Implementation Method 2
The locking element (12) consists of a co-extruded plastic strip which, viewed in cross section, consists of several zones made of plastic with different properties
Data Source
Figure 1~4
Figure 3
Figure 5~6
AI summary
Panel comprising a horizontally and a vertically active locking system (6-7), so that two such floor panels (1) can be connected by means of a downward movement (M). The vertically active locking system (7) comprises a locking element (12) formed by an insert, formed by a coextruded strip. This comprises a blocking body (14), a securing section (15) and a bending zone (24). The blocking body (14) is substantially made of a first polymer; the bending zone (24) is substantially made of a second polymer. The blocking body (14) is substantially or entirely made of a mixture of the first polymer and the second polymer, or the bending zone (24) is substantially or entirely made of a mixture of the second polymer and the first polymer.