Floor Panel Coupling Profile with Integrated Locking
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Solution Overview
Problem
Existing floor panel coupling systems face challenges in achieving strong, easy-to-install connections while maintaining low production costs, with one-piece coupling profiles often resulting in inadequate strength or requiring costly elastic locking strips.
Innovation Solution
The development of floor panels with integrated coupling parts that incorporate both horizontally and vertically active locking systems, made from the same material as the panel, allowing for secure interlocking via a turning or downward movement, and featuring specific design elements such as inclined tangent lines and support points to enhance locking strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate elastic locking strips are used to achieve vertical locking, then the locking strength is improved, but the production cost increases
Solution Approach 1:
The patent combines the vertical locking function with the horizontal locking profile into a single integrated coupling structure. The coupling profile incorporates both vertical locking elements (such as undercut features, snap-fit mechanisms, or interlocking geometries) and horizontal locking features (such as tongue-and-groove or finger joint configurations) as unified components, eliminating the need for separate elastic locking strips while maintaining both locking functions.
2Ease of manufacture
If one-piece coupling profiles are used to reduce cost, then the production cost decreases, but the connection strength becomes insufficient
Solution Approach 1:
The coupling profile is segmented into distinct functional zones within a single piece: vertical locking segments (with features like undercuts, cam-locks, or snap-fit geometries), horizontal locking segments (with interlocking profiles), and transition zones that facilitate the fold-down installation movement. This segmentation allows each zone to be optimized for its specific function while remaining part of a unified one-piece structure.
Solution Approach 2:
The patent employs parameter changes in the coupling profile geometry, such as varying the thickness, curvature, or flexibility parameters of different sections to achieve both strength and ease of manufacture. By carefully controlling geometric parameters like the radius of curvature in transition zones or the depth of locking features, the profile achieves adequate connection strength without requiring additional components.
3Device complexity
If coupling parts are made from the same material as the panel, then the manufacturing complexity is reduced, but the locking mechanism becomes less reliable
Solution Approach 1:
The coupling profile incorporates local quality variations within the same material, such as zones of different density, thickness, or structural configuration. For example, certain sections may be designed with higher material concentration or reinforced geometries to provide enhanced strength where needed, while other sections maintain standard thickness for cost-effectiveness. This local differentiation maintains locking reliability without requiring different materials.
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.