Flexible-Core Floorboard Locking for Rotation-Free Assembly
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Solution Overview
Problem
Existing multilayer flooring systems with tongue and groove joints face challenges in assembly, requiring cumbersome rotation and are difficult to disassemble without breaking the tongue, especially for larger floorboards, due to the rigidity of the core layer materials.
Innovation Solution
The use of a less rigid core layer material, such as cork or nonwoven material, which allows the tongue to compress and the groove to expand, enabling a tighter lock and allowing for assembly and disassembly in a single direction without rotation, using materials like wood, WPC, SPC, MDF, and HDF for decorative and backing layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid core layer material is used, then structural stability is improved, but ease of assembly and disassembly deteriorates
Solution Approach 1:
The patent changes the material parameter of the core layer from rigid (traditional wood plastic composite, stone plastic composite, or plywood) to flexible (cork or nonwoven material). This parameter change allows the tongue to compress and the groove to expand during assembly, enabling easy installation without rotation while maintaining structural stability through the flexible core's ability to deform and lock securely.
2Stability of the object's composition
If a rigid core layer material is used, then structural stability is improved, but ease of disassembly deteriorates
Solution Approach 1:
The patent changes the material parameter of the core layer from rigid to flexible, which allows the tongue and groove joint to be easily separated by applying force in a single direction. The flexible core layer can be compressed to release the lock, enabling simple disassembly and replacement of individual boards without damaging the tongue, while still providing structural stability when assembled.
3Strength
If traditional tongue and groove assembly is used, then structural integrity is improved, but device complexity deteriorates
Solution Approach 1:
The patent changes the material parameter of the core layer to flexible, which simplifies the assembly process by eliminating the need for rotation and multiple steps. The tongue can be inserted directly into the groove in a single directional movement, and the flexible core layer automatically compresses to create the lock, reducing assembly complexity while maintaining structural integrity through the secure locking mechanism.
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 design facilitates easier assembly and disassembly of floorboards, provides a tighter lock, and allows for replacement of individual boards without disassembling the entire structure, while maintaining structural integrity and aesthetic appeal.
Implementation Method 1
allows the tongue to compress and the groove to expand
Implementation Method 2
allows the tongue to compress and the groove to expand, enabling a tighter lock
Data Source
AI summary
A multilayer flooring includes floorboards that each have a male edge and a female edge, the male edge including a tongue, the female edge defining a groove. The tongue of one of the floorboards is insertable into the groove of another one of the floorboards to lock the floorboards together. Each of the floorboards includes a decorative layer configured to provide a desired appearance of the multilayer flooring. The decorative layer is made of a first material, and a core layer disposed below the decorative layer and configured to provide at least one of stability, sound deadening, cushioning, and durability. The core layer is made of a second material that is less rigid than the first material, and the core layer makes up at least a portion of at least one of the tongue and the groove.