Hook-Shaped Floor Panel Coupling for Stronger Click Locking
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Solution Overview
Problem
Existing floor panels suffer from installation difficulties and insufficient locking strength due to suboptimal design of coupling parts, particularly in synthetic materials like polyvinyl chloride.
Innovation Solution
The floor panels feature hook-shaped coupling parts with specific positional relationships between support surfaces, locking elements, and recesses, enhancing vertical locking strength and ease of installation by allowing for elastic deformation during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional coupling parts are used in synthetic floor panels, then manufacturing is simpler, but installation difficulty increases and locking strength decreases
Solution Approach 1:
The coupling part is divided into functionally distinct segments: a support surface for bearing load, a locking element for securing panels, and a recess for engagement. This segmentation allows each element to be optimized for its specific function, improving installation ease and locking strength independently
Solution Approach 2:
Different regions of the coupling part are given different geometric properties tailored to local requirements: the support surface has a specific orientation for load distribution, the locking element has a protruding geometry for secure engagement, and the recess provides a receiving geometry. This local optimization resolves the contradiction between simple manufacturing and effective installation
2Strength
If coupling parts are made stronger to improve locking strength, then installation becomes more difficult due to reduced flexibility
Solution Approach 1:
The coupling part is designed with dynamic characteristics that allow it to be flexible during installation (enabling easy engagement) and then become rigid in the locked position (providing strong locking). The geometric configuration of the locking element and recess creates this transition from flexible to rigid state
Solution Approach 2:
The physical state of the coupling part changes during installation: initially flexible to allow engagement, then transitioning to a rigid locked state through the interaction of the locking element with the recess. This parameter change resolves the contradiction between strength and ease of installation
3Adaptability or versatility
If material thickness is reduced to enhance flexibility, then locking strength may be compromised
Solution Approach 1:
The coupling part utilizes the inherent properties of synthetic materials (such as polyvinyl chloride) to achieve both flexibility and strength. The material composition and geometric design work together to provide the necessary mechanical properties without requiring increased thickness
Solution Approach 2:
The coupling part incorporates curved and rounded geometric features rather than sharp angles, which distribute stresses more effectively and enhance flexibility. The curved geometry of the locking element and support surface allows the thin material to maintain both flexibility and locking strength
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
The improved locking system ensures strong and stable coupling while facilitating smooth installation, accommodating manufacturing tolerances, and reducing material thickness for enhanced flexibility.
Implementation Method 1
The inventor has found that certain combinations of characteristics of the coupling parts render particularly good results, in particular with synthetic floor panels
Data Source
AI summary
A floor panel for forming a floor covering, wherein this floor panel is at least composed of a substrate; wherein the floor panel, on at least one pair of opposite edges, comprises coupling parts, which coupling parts allow that two of such floor panels can be coupled to each other by means of a downward movement of one floor panel in respect to the other floor panel; wherein these coupling parts, in the coupled condition of two of such floor panels, form a first locking system, which effects a locking in a first direction perpendicular to the plane of the floor panels, and form a second locking system, which effects a locking in a second direction perpendicular to the edges and in the plane of the floor panels.