Floating Floor Panel Coupling for Gap-Free Expansion

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Solution Overview

Problem

Existing floating floor coverings suffer from expansion gaps that disrupt the visual continuity of the floor surface and are prone to panel unlocking or lifting due to environmental changes and heavy loads, which hamper the free expansion and contraction of panels.

Innovation Solution

The panels feature male and female coupling parts with a tongue-and-groove joint and overlapping contours, allowing for a pretensioned coupling that compensates for expansion and contraction by relative movement between panels, maintaining a visually seamless surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If expansion gaps are left between floor panels to allow free expansion and contraction, then the floor covering can accommodate environmental changes, but the visual continuity of the floor surface is disrupted and finishing profiles are required

Engineering Contradiction:

Improveexpansion and contraction capabilityVSAvoidvisual continuity of floor surface

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

The coupling parts are designed with movable elements that allow dynamic adjustment between panels. The male coupling part can move relative to the female coupling part along the coupling direction, enabling the joint to adapt to expansion and contraction while maintaining a seamless appearance without requiring finishing profiles

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The coupling mechanism allows change in the distance between adjacent panels along the coupling direction. By permitting movement of the male coupling part relative to the female coupling part, the system can accommodate dimensional changes due to environmental conditions while keeping the floor surface visually continuous

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If mechanical coupling parts are designed with tight locking to prevent panel separation, then panel stability is improved, but the ability to accommodate expansion and contraction is reduced

Engineering Contradiction:

Improvepanel locking stabilityVSAvoidexpansion and contraction freedom

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The coupling parts incorporate movable elements that allow dynamic movement along the coupling direction while maintaining lateral locking. The male coupling part can move relative to the female coupling part to accommodate expansion and contraction, yet the interlocking geometry maintains panel stability and prevents separation when needed

Inventive Principle:

Principle #15Dynamics

3Strength

If heavy loads are placed on the floor surface to test structural integrity, then load-bearing capacity is demonstrated, but the free expansion and contraction of the floor is hampered causing panel unlocking or lifting

Engineering Contradiction:

Improveload-bearing capacityVSAvoidfree expansion and contraction

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The movable coupling parts allow the floor covering to dynamically respond to loads by permitting controlled movement along the coupling direction. This enables the system to maintain both load-bearing capacity and the ability to expand/contract freely, preventing panel unlocking or lifting even under heavy loads

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12595666B2Panel

Publication Date: 2026.04.07 UNILIN BV

AI summary

The panel includes a first pair of opposite edges; these comprise male and female coupling parts—in the form of a tongue and groove and locking elements—in order to couple two such panels to each other on their first pair of opposite edges. The panel and coupling parts thereof are configured so that in a covering formed with these panels, the expansion and contraction of the panels in the coupling zone on the first pair of opposite edges is compensated in this coupling zone itself.