Floor Panel Coupling Profiles for Strong Strip-Free Locking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing floor panels with one-piece coupling parts face issues of weak connections, either requiring damage for interconnection or insufficient resistance against unlocking, and are costly due to the use of separate elastic locking strips.
Innovation Solution
The floor panels incorporate one-piece coupling profiles with horizontally and vertically active locking systems, utilizing hook-shaped parts and inclined tangent lines for secure interlocking, and support points to facilitate easy installation without separate locking strips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate elastic locking strips are used to achieve vertical locking, then the connection strength is improved, but the production cost increases
Solution Approach 1:
The patent integrates the vertical locking function directly into the one-piece coupling profile by forming locking protrusions and locking grooves as integral parts of the profile structure. This merging of functions eliminates the need for separate elastic locking strips while maintaining connection strength, thereby reducing production cost and simplifying manufacturing.
Solution Approach 2:
The one-piece coupling profile serves multiple functions simultaneously: it provides horizontal locking through interlocking teeth, vertical locking through integrated protrusions and grooves, and structural support. This multi-functionality replaces what would traditionally require multiple separate components, reducing both cost and complexity.
2Ease of manufacture
If one-piece coupling profiles are used to reduce cost, then the production cost is reduced, but the connection strength becomes insufficient
Solution Approach 1:
The coupling profile is segmented into distinct functional zones: horizontal locking teeth for lateral stability, vertical locking protrusions and grooves for vertical retention, and support points for load distribution. This segmentation within a one-piece structure allows each zone to be optimized for its specific function, achieving strong connections without requiring separate components.
Solution Approach 2:
The coupling profile utilizes composite construction with a rigid base material providing structural strength and integrated locking features. The profile combines different structural elements (teeth, protrusions, grooves, support points) within a single piece, creating a composite structure that achieves both cost-effectiveness and connection strength.
3Strength
If the coupling is made taut to increase connection strength, then the resistance against unlocking is improved, but the floor panels cannot be interconnected
Solution Approach 1:
The coupling system incorporates dynamic elements including resilient locking protrusions that can flex during installation and spring-loaded locking mechanisms that engage after connection. This dynamic behavior allows the panels to be interconnected easily during installation, then maintains strong resistance against unlocking during use through the engaged locking features.
Data Source
AI summary
A floor panel arranged to be installed according to the fold-down principle, with a first pair and a second pair of edges. The second pair of edges coupling parts are arranged to be coupled to each other by a downward movement with two contact zones at opposite sides of a male part which fits into a female part. The ratio between the horizontal distance between the middle of the first contact zone and the middle of the second contact zone, and the vertical distance between the middle of the first contact zone and the middle of the second contact zone is more than 5, and/or wherein well-defined support points are applied.