Floor Panel Core Spring Integration for Locking
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Solution Overview
Problem
The existing locking mechanisms for wood-based floor panels, which rely on separate plastic spring elements, are costly due to specialized production requirements, material strength issues, and misalignment of manufacturing tolerances between wood and plastic components, leading to potential locking failures and consumer dissatisfaction.
Innovation Solution
Integrating the spring element directly into the core of the panel using vertical slots, allowing it to be connected at both ends, simplifies production, reduces costs, and ensures complete locking functionality without separate components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate plastic spring element is used for locking, then locking functionality is achieved, but production costs increase and manufacturing complexity increases
Solution Approach 1:
The spring element is integrated directly into the core of the panel as a single piece, eliminating the need for separate plastic locking components. The core material itself forms the spring structure that provides locking functionality, merging what were previously separate components (panel core and spring element) into one unified structure.
Solution Approach 2:
The core material serves multiple functions simultaneously: it provides structural support for the panel and also forms the spring element that enables horizontal locking. This multi-functionality eliminates the need for separate dedicated locking components, reducing overall device complexity while maintaining locking reliability.
2Reliability
If separate plastic spring elements are used, then locking is achieved, but manufacturing tolerance alignment becomes complex and costly
Solution Approach 1:
By integrating the spring element into the core as a single piece, the patent eliminates the interface between different materials (wood and plastic) that caused tolerance misalignment issues. The spring element and panel core are manufactured as one homogeneous component, ensuring consistent dimensional tolerances without the complexity of coordinating separate manufacturing processes.
3Reliability
If separate locking elements are provided, then locking functionality is achieved, but the risk of missing components increases
Solution Approach 1:
The spring element is formed as an integral part of the panel core, eliminating the need for separate locking elements to be provided separately. This integration ensures that the locking functionality is always present and cannot be missing, as the spring element is inherently part of the panel structure itself.
4Reliability
If plastic spring elements are used, then horizontal locking is achieved, but production costs increase due to specialized tools and high-quality material requirements
Solution Approach 1:
The spring element is made from the same core material as the panel body, creating a homogeneous structure. This eliminates the need for specialized plastic injection molding tools and high-quality plastic materials, as the same material used for the panel core is used for the spring element, significantly reducing production costs while maintaining 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
This solution enhances production efficiency, reduces costs, and ensures reliable locking without the risk of missing components, improving the overall quality and usability of the panels.
Implementation Method 1
the spring lip eventually overlaps the undercut formed in the upper lip, snaps back in the vertical direction, and engages in the undercut, causing locking in the horizontal direction
Data Source
Figure 1
Figure 1a
Figure 2~3
AI summary
The panel has a core made of wood material or wood material-synthetic mixture. An upper side (16) and a lower side (17) have a spring at a lateral edge and a groove corresponding to the spring with a lower lip at the opposite lateral edge. The two identically formed panels (1a) are connected and locked with each other by a horizontal joining movement in horizontal direction and vertical direction. The spring element (5a) is formed one piece from the core.