Floor Panel Drop-Down Coupling with Rounded Edges

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Solution Overview

Problem

Existing interconnectable floor panels experience breakages due to tension on coupling edges during assembly and use, affecting their reliability and durability.

Innovation Solution

A drop down coupling mechanism with inclined sides forming a closed groove system, including a rounded recess and bulge for additional locking, providing horizontal and vertical locking, and preventing rotational uncoupling, along with a resilient bridge design to manage deformation and stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a traditional drop down coupling mechanism is used to lock panels vertically, then vertical locking is achieved, but breakages occur at coupling edges due to tension during assembly and use

Engineering Contradiction:

Improvevertical locking stabilityVSAvoidcoupling edge durability

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The patent applies curvature by replacing the traditional sharp-edged coupling profile with rounded elements. The downward tongue features a rounded leading edge, and the upward groove has a rounded bottom surface. This curvature distributes stress more evenly during the dropping and locking process, preventing stress concentration that causes breakages at the coupling edges while maintaining effective vertical locking.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent implements beforehand cushioning by designing the upward groove with a rounded bottom surface and the downward tongue with a rounded leading edge before the actual coupling action occurs. This pre-engineered rounding acts as a cushioning element that absorbs and distributes the impact stress during the dropping process, preventing breakages before they can occur at the coupling edges.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Strength

If coupling edges are designed for secure locking, then connection strength is improved, but strain and stress on panels during coupling increases

Engineering Contradiction:

Improveconnection strengthVSAvoidpanel stress during coupling

Core Design Contradiction:

StrengthVSStress or pressure

Solution Approach 1:

The rounded leading edge of the downward tongue and the rounded bottom surface of the upward groove create a progressive contact interface. This curvature allows the panels to make contact gradually during coupling, distributing the locking force over a larger area and longer time period, thereby reducing peak stress and strain on the panel structures while maintaining strong connection.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Ease of operation

If a simple coupling mechanism is used, then ease of assembly is improved, but rotational uncoupling can occur

Engineering Contradiction:

Improveassembly easeVSAvoidrotational stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The patent employs asymmetry in the coupling profile design where the downward tongue has a specific asymmetric shape with a rounded leading edge that fits into the asymmetric upward groove with a rounded bottom. This asymmetric geometry provides inherent rotational guidance and locking, preventing unwanted rotation while maintaining the simplicity and ease of the drop-down assembly process.

Inventive Principle:

Principle #4Asymmetry

Data Source

PatentUS11603669B2Panel and covering

Publication Date: 2023.03.14 I4F LICENSING NV

AI summary

A panel, in particular a floor panel, interconnectable with similar panels for forming a covering, and a covering consisting of mutually connected floor panels.