Floor Panel Joint Structure With Dual Locking Recesses
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Solution Overview
Problem
Existing joining systems for floor panels, such as those described in EP 1 338 721 B1, experience high stress on the material due to significant elastic deflection of the lip portion, which can lead to breakages in less dense materials commonly used in flooring, as they are not adequately designed to handle the snap-lock effect without material failure.
Innovation Solution
A joining system featuring dual consecutive locking recesses and lugs with matching curved and inclined horizontal locking surfaces, along with a transitional ridge, which reduces stress on the material by distributing the tension force more evenly and allowing for a stronger mechanical locking function, suitable for less dense materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single locking recess in the lip portion is used to achieve snap-lock engagement, then the locking function is achieved, but high stress concentration occurs in the lip portion material causing breakages in less dense materials
Solution Approach 1:
The single locking recess is divided into two consecutive locking recesses (first locking recess in the groove body, second locking recess in the lip portion). This segmentation distributes the locking function across multiple locations, reducing stress concentration in any single area and preventing material breakage while maintaining reliable locking engagement.
Solution Approach 2:
Different regions of the groove are given different properties: the first locking recess is positioned in the more robust groove body while the second locking recess is in the lip portion. The locking lugs are also differentiated with a first locking lug having a curved locking surface and a second locking lug with an inclined locking surface, optimizing each local region's contribution to the overall locking function while managing stress distribution.
2Reliability
If significant elastic deflection of the lip portion is required for snap-lock effect, then locking engagement is achieved, but the tension force creates high stress on the material
Solution Approach 1:
The locking engagement is segmented into two stages: first locking lug engages with first locking recess to initiate locking, then second locking lug engages with second locking recess to complete the snap-lock effect. This segmentation allows the elastic deflection to be distributed across two engagement points rather than concentrated in one location, reducing peak stress on the lip portion material.
3Ease of manufacture
If less dense materials are used to reduce production costs, then manufacturing cost decreases, but the materials are more prone to breakage under the stress of conventional locking systems
Solution Approach 1:
By dividing the locking mechanism into two consecutive recesses and lugs, the system reduces peak stress concentrations that would cause breakage in less dense, cost-effective materials. This allows manufacturers to use more economical material compositions without sacrificing joint reliability.
Solution Approach 2:
The locking surface geometries are specifically designed with curved and inclined profiles that optimize the distribution of contact forces during engagement. This parameter optimization ensures that less dense materials can withstand the joining process without breakage, enabling cost-effective material selection.
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 proposed system enhances the locking strength and reduces material stress during the joining process, enabling the use of more brittle and less dense materials in large-scale production while maintaining a smooth insertion procedure and improved durability.
Implementation Method 1
The coupling parts exert a tension force towards each other in a mutually engaged position, the tension force being delivered by elastic compression of the material of the coupling parts
Implementation Method 2
The locking means comprises dual consecutive locking recesses arranged in a lower portion of the groove, a first locking recess of which being located in an internally extending portion within the groove and a second locking recess of which being located in a lip portion protruding from an entrance opening of the groove
Data Source
AI summary
A joining system for floor panels includes a groove and a tongue on opposite floor panel sides. The tongue is shaped for vertical locking engagement with the groove of an adjoining floor panel in a direction perpendicular to the sides of the panels and parallel to a horizontal floor plane. Two locking recesses are formed in a lower portion of the groove. A first recess is located in an internal portion and a second is located in a lip portion. Two locking lugs are formed in a lower portion of the tongue for engagement with the recesses. A first lug extends downwardly from a tip portion of the tongue and a second lug extends downwardly from a root portion. The first recess and the first lug have curved surfaces. The second recess and the second lug have inclined surfaces.