Floor Panel Coupling Geometry for Low-Force Vertical Locking
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Solution Overview
Problem
Conventional floor panels require significant force for coupling, which can lead to detachment under heat and humidity, causing bulging or excessive gap formation, and risk damage to delicate structures during assembly.
Innovation Solution
The floor panel design incorporates inclined core and outer side flanks with a curved recess and complementary bulge, allowing vertical locking perpendicular to the surface, guided alignment, and resilient coupling parts to minimize damage and ensure secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If significant force is applied to couple floor panels, then the coupling strength between panels is improved, but the risk of damaging delicate structures during assembly increases
Solution Approach 1:
The patent applies curvature to the tongue structure by introducing a curved recess in the upper portion of the tongue and a corresponding curved protrusion. This curved geometry allows the panels to guide each other into proper alignment during assembly, distributing the coupling force more evenly and reducing stress concentration on delicate structures while maintaining strong coupling strength.
2Reliability
If strong coupling forces are used to prevent detachment, then the stability of the floor panel connection is improved, but the force required by the user to assemble the panels increases
Solution Approach 1:
The curved recess and curved protrusion create a self-aligning mechanism that guides the panels into proper position during assembly. This reduces the manual force and effort required by the user while ensuring reliable connection stability, as the curved geometry naturally directs the panels into their final coupled state.
Solution Approach 2:
The curved geometry is pre-formed in the tongue structure, creating a preliminary guiding action that prepares the panels for coupling. This preliminary alignment action reduces the effort needed during the actual coupling process, making assembly easier while maintaining connection stability.
3Ease of manufacture
If conventional coupling structures are used, then the manufacturing simplicity is maintained, but the risk of panel misalignment and bulging under heat and humidity changes increases
Solution Approach 1:
The curved recess and curved protrusion provide a self-aligning mechanism that compensates for dimensional changes caused by heat and humidity. This curved geometry allows for thermal and moisture expansion while maintaining proper panel alignment, preventing bulging and misalignment issues without significantly complicating the manufacturing process.
Data Source
AI summary
A floor panel includes a core provided with an upper and lower surface, and a first and second core flank at a first and second side of the core, respectively. The floor panel includes a first coupling part and a second coupling part provided at the first side and the second side of the core, respectively. Each of the coupling parts includes an inner side flank, an outer side flank, and an upper portion flank connecting the inner side flank to the outer side flank. A portion of the first core flank and an upper portion of the outer side flank of the second coupling part are inclined such that when the floor panel is coupled to an adjacently arranged further floor panel these upper portions lie against each other for the purpose of providing a locking in a vertical direction.