Floor Covering Panels with Segmented Profiles for Smooth, Strong Locking
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Solution Overview
Problem
Existing panels with drop-down coupling profiles require a forceful vertical insertion, which can damage the profiles and are cumbersome, while small inclination angles compromise interlocking strength.
Innovation Solution
The panels feature interlocking surface areas with different inclination angles and creases, allowing smooth vertical insertion and strong locking through upward and downward tongues with complementary sections and creases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the interlocking surface areas have large inclination angles, then the vertical interlocking strength is improved, but the required insertion force increases and profile damage risk increases
Solution Approach 1:
The interlocking surface area is segmented into multiple sections with different inclination angles. The first section has a smaller inclination angle (1-5 degrees) for easier insertion, while the second section has a larger inclination angle (10-30 degrees) for stronger interlocking. This segmentation allows the coupling process to occur in stages: initial insertion through the gentler first section, then locking through the steeper second section.
Solution Approach 2:
Different sections of the interlocking surface area have different local qualities in terms of inclination angle. The first section is optimized for low friction and easy insertion with a shallow angle, while the second section is optimized for high interlocking strength with a steeper angle. Each local region serves its specific function in the coupling process.
2Force
If the interlocking surface areas have small inclination angles, then the insertion force is reduced, but the vertical interlocking strength is compromised
Solution Approach 1:
The interlocking surface area is divided into multiple sections with different inclination angles. The first section uses a small inclination angle (1-5 degrees) to reduce insertion force and allow smooth coupling, while the second section uses a larger inclination angle (10-30 degrees) to provide sufficient vertical interlocking strength. This segmented approach resolves the contradiction by distributing different functional requirements to different sections.
Solution Approach 2:
The inclination angle parameter is changed across different sections of the interlocking surface area. Rather than using a uniform angle, the parameter varies from a small angle in the first section to a larger angle in the second section, allowing optimization of both insertion ease and interlocking strength within the same structure.
3Strength
If additional interlocking features are added to both profiles, then the interlocking strength is improved, but the design complexity and production costs increase
Solution Approach 1:
The additional interlocking feature (such as a downward protrusion or upward recess) is extracted from one profile only, rather than adding features to both profiles. This asymmetric approach provides the necessary additional interlocking strength while keeping the overall design simpler and reducing production complexity compared to adding matching features to both profiles.
4Ease of operation
If the interlocking surface areas are made smooth and continuous, then the insertion process is simplified, but the vertical locking capability is reduced
Solution Approach 1:
The interlocking surface area is segmented into multiple sections with different inclination angles rather than being smooth and continuous. The first section provides smooth insertion with a gentle slope, while the second section provides strong vertical locking with a steeper slope. The crease between sections acts as a locking point that enhances vertical retention.
Solution Approach 2:
The crease between the first and second sections creates a localized curvature or angular feature that serves as a locking point. This subtle geometric feature provides enhanced vertical locking capability without significantly complicating the overall smooth profile design, allowing easy insertion followed by secure locking.
Data Source
AI summary
Provided is a panel suitable as a floor, ceiling or wall panel, which panel is of a planar design having an upper side, a bottom side and side edges which include a first side edge provided with a first profile and a second side edge provided with a second profile. The first profile and the second profile are interacting profiles that can be coupled to each other, so that a first panel can be coupled in one common plane to a second, identical panel by the interacting profiles. The first profile and the second profile in coupled condition establish an interlocking with each other both in a horizontal direction and in a vertical direction. The first profile and the second profile are configured to allow for a coupling of the interacting profiles of the first panel with the second panel by a vertical insertion of the interacting profile of the first panel into the interacting profile of the second panel.