Floor Panel Coupling Mechanism for Gap-Free Installation
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Solution Overview
Problem
Floor panels with mechanical coupling parts experience undesired permanent displacements and shifting apart due to the design of locking parts, particularly at the edges, which can lead to gaps and instability in the floor covering.
Innovation Solution
The floor panels are designed with specific characteristics on the long and short edges, including tongue and groove configurations with elastic forces and tensioning mechanisms, to minimize shifting apart. These features include a turning movement that increases and then decreases elastic force, pre-tensioning forces, and tensionless joining options to ensure secure and gap-free coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If locking parts are positioned at the distal extremity of the lower hook-shaped part to prevent vertical shifting, then vertical locking stability is improved, but horizontal displacement and permanent shifting apart occur due to stress concentration
Solution Approach 1:
The harmful locking part at the distal extremity is removed from the coupling structure. The patent eliminates the locking part that caused stress concentration and horizontal displacement, while retaining the essential vertical locking function through the hook-shaped elements' interlocking mechanism without the problematic distal locking component.
Solution Approach 2:
The coupling structure is modified to have different characteristics at different locations. The groove is designed with specific geometric properties (wider opening, deeper section) to optimize the turning movement and locking action, while the lips are positioned to provide appropriate guidance and locking without creating stress concentration points.
2Strength
If the lower lip extends laterally beyond the upper lip to provide additional locking surface, then horizontal locking is improved, but the complexity of the coupling structure increases
Solution Approach 1:
The locking function is integrated into the existing groove and lip structure rather than adding separate locking components. The groove's geometric configuration and the lips' positioning combine to provide both guidance and locking functions, eliminating the need for additional distinct locking parts.
Solution Approach 2:
The groove and lips serve multiple functions: they guide the turning movement, provide vertical locking through the hook-shaped elements, and offer horizontal locking through their geometric configuration. This multi-functionality reduces the need for separate specialized components.
3Reliability
If the coupling parts are designed to require overcoming elastic force during turning movement, then secure coupling is achieved, but the installation process becomes more difficult
Solution Approach 1:
The coupling system allows dynamic adjustment during installation. The groove's geometric design enables the tongue to be inserted and turned into the groove with controlled resistance, allowing the installer to apply force where needed while maintaining alignment. The elastic force requirement is optimized to provide secure coupling without excessive installation difficulty.
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 solutions effectively reduce the risk of shifting apart and create a stable, gap-free connection between floor panels, ensuring horizontal alignment with minimal play (less than 0.2 mm) and maintaining stability through elastic forces and pre-tensioning, thereby enhancing the overall flooring system's integrity.
Implementation Method 1
during the turning into each other of two of such floor panels an elastic force has to be overcome during the turning movement
Implementation Method 2
locking parts, which, in the coupled condition, prevent the shifting apart of the tongue and groove
Data Source
AI summary
Floor panel, characterized in that it is of the type that can be installed according to the fold down-technique, that it comprises coupling means in one piece on all four edges, and that measures are taken in order to avoid an undesired shifting on the long edges during the turning down of the floor panel.