Detachable Protruding Lip for Panel Vertical Locking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing panel systems for wall, ceiling, and floor coverings, especially in herringbone patterns, provide little to no vertical locking, making them unstable and difficult to manufacture with delicate profile elements that are prone to damage during installation.
Innovation Solution
A panel design featuring a detachable protruding lip with a predetermined break-off surface and different joint profiles on each side, allowing for secure horizontal and vertical locking through male and female locking elements, which can be easily aligned and connected without complex machining, reducing the risk of damage during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional coupling elements are used to connect panels, then horizontal connection is achieved, but vertical locking is insufficient or nonexistent
Solution Approach 1:
The coupling element is divided into two separate components: a first coupling element with a locking protrusion on one panel, and a second coupling element with a locking recess on the adjacent panel. This segmentation allows each element to be simple in structure while together they provide reliable vertical locking through the interlocking protrusion-recess mechanism.
2Manufacturing precision
If delicate profile elements are used for locking, then precise fitting is achieved, but they are prone to damage during installation
Solution Approach 1:
The locking protrusion and locking recess are pre-formed as integral parts of the coupling elements during panel manufacturing, rather than being delicate adjustable components. This preliminary formation ensures precise geometry is built-in, and the robust integral construction protects against damage during handling and installation.
Solution Approach 2:
The locking function is extracted as a separate, robust mechanical feature (protrusion and recess) from the overall coupling element design. This allows the locking mechanism to be simple and sturdy rather than relying on delicate profile elements, reducing susceptibility to damage while maintaining precision.
3Reliability
If complex machining is used to create locking profiles, then secure locking is achieved, but manufacturing becomes difficult and expensive
Solution Approach 1:
By segmenting the coupling into separate elements with simple protrusion and recess features, the manufacturing process is simplified. Each component can be produced using basic forming or molding operations rather than complex multi-step machining, reducing cost and difficulty while maintaining secure locking through the interlocking geometry.
Solution Approach 2:
The locking mechanism uses straightforward geometric parameters (protrusion height, recess depth, basic shapes) that are easy to manufacture with standard processes. This avoids complex curvature, undercuts, or precision tolerances that would require sophisticated machining, thereby simplifying manufacturing while ensuring reliable locking.
4Reliability
If multiple separate locking elements are used, then vertical locking is improved, but installation becomes more difficult
Solution Approach 1:
The horizontal connection function and vertical locking function are merged into a single coupling element pair. The first coupling element and second coupling element work together to simultaneously provide both horizontal attachment and vertical locking through their integrated protrusion-recess design, eliminating the need for separate locking components and simplifying installation.
Data Source
AI summary
A panel with a detachable protruding lip for wall, ceiling or floor coverings is provided. Furthermore, methods are provided for manufacturing wall, ceiling or floor coverings comprising or consisting of a plurality of the panels.