Extraneous Locking Element for Laminate Panel Corner Stability
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Solution Overview
Problem
Existing surface coverings, such as laminate panels, face instability at interconnection zones where three panels meet due to a lack of coupling means at corners, leading to potential bending and inadequate locking, which complicates the laying process and increases the likelihood of defective products.
Innovation Solution
The introduction of an extraneous locking element that is inserted into channels formed by transverse coupling means, allowing it to also lock longitudinal edges, thereby securing corners and providing additional support against pressure, while its design with wave-shaped protrusions and tapered ends reduces friction during assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coupling means are provided only at transverse edges of panels, then panels can be connected at transverse edges by vertical folding, but corners of connected panels remain unsecured and can deflect downwards under pressure
Solution Approach 1:
The extraneous locking element is designed to perform multiple functions: it locks panels at transverse edges through the channel formed by transverse coupling means, simultaneously locks longitudinal edges by engaging with longitudinal grooves, and secures corners by spanning across panel intersections. This multi-functional design resolves the contradiction by adding corner security without requiring separate coupling means at corners.
Solution Approach 2:
The extraneous locking element acts as an intermediary component that bridges the gap between transverse and longitudinal coupling means. It is inserted through the channel formed by transverse coupling means and extends to engage longitudinal grooves, thereby mediating the connection between panels at corners and preventing downward deflection without modifying the original coupling means design.
2Reliability
If extraneous locking elements are inserted into channels formed by transverse coupling means, then additional locking at corners is achieved, but friction during insertion increases assembly difficulty
Solution Approach 1:
The extraneous locking element features a curved or tapered insertion end that matches the geometry of the channel entrance. This curved design reduces friction during insertion by distributing contact forces and guiding the locking element smoothly into the channel, thereby resolving the contradiction between secure locking and easy assembly.
Solution Approach 2:
The friction reduction is achieved by changing the geometric parameters of the extraneous locking element, specifically the insertion end shape and surface characteristics. These parameter changes reduce the coefficient of friction during insertion while maintaining the locking function, thus resolving the contradiction between reliable panel locking and ease of assembly.
3Reliability
If multiple coupling means are provided at each panel edge, then comprehensive locking is achieved, but device complexity increases
Solution Approach 1:
The extraneous locking element is designed as a universal component that works with both transverse coupling means (through the channel) and longitudinal coupling means (through grooves). This multi-functional design achieves comprehensive locking without requiring separate specialized components for different edges, thereby maintaining simplicity while improving reliability.
Solution Approach 2:
The coupling system is segmented into transverse coupling means, longitudinal coupling means, and the extraneous locking element that bridges them. This segmentation allows each component to be optimized for its specific function while the extraneous locking element coordinates them, achieving comprehensive locking without excessive overall complexity.
Data Source
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AI summary
The present invention relates to a surface covering (100) comprising panels (200) and at least one extraneous locking element (300). The panels (200) are provided with respective longitudinal and transverse coupling means (400, 500) which are adapted to connect similar panels (200) at corresponding adjacent edges (211, 211', 213, 213'). The transverse coupling means (500) are adapted to form a channel (501) in coupled condition which is adapted to receive the extraneous locking element (300). When inserted into the channel (501) formed by the transverse coupling means (500) of panels (200) in a first row (206), the extraneous locking element is adapted to extend at least partially into the groove (430) of an adjacent parallel panel in the second row (207), such that a lower surface (305) of the extraneous locking element (300) is in contact with a lower lip contact portion (433), and the upper surface (307) of the extraneous locking element (300) is in contact with an upper lip contact portion (437).