Floor Panel Coupling Geometry for Easy Installation and Strong Locking
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Solution Overview
Problem
Existing floor panels suffer from issues related to ease of installation and strength of coupling, particularly in synthetic materials, due to suboptimal design of coupling parts and locking mechanisms.
Innovation Solution
The floor panels feature specific combinations of hook-shaped parts with defined positional relationships and elastic properties, including support surfaces, recesses, and guiding surfaces, which enhance vertical locking strength and ease of installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional coupling parts are used, then the floor panels can be installed, but the coupling strength and installation ease are insufficient
Solution Approach 1:
The coupling part is divided into functionally distinct segments: an upper hook-shaped part with a downward-directed locking element, a support surface, and an upward-directed recess; and a lower hook-shaped part with an upward-directed locking element. This segmentation allows each component to perform its specific function optimally, resolving the contradiction between coupling strength and installation ease.
Solution Approach 2:
Different regions of the coupling part are given different properties: the locking elements provide rigid mechanical interlocking for strength, while the recesses and support surfaces are positioned to allow controlled elasticity and deformation during installation. This local differentiation of properties enables both strong coupling and easy installation.
2Strength
If the locking elements are positioned closer to the distal extremity, then vertical locking strength is improved, but the elasticity and ease of installation may be reduced
Solution Approach 1:
The solution moves the locking elements to a different dimensional position - the distal extremity region - while compensating in another dimension by strategically positioning the support surface and recesses. This dimensional redistribution allows the locking elements to be distal for strength while maintaining elasticity through the support structure.
Solution Approach 2:
The relative positions of the locking elements, support surface, and recesses are optimized as geometric parameters. The support surface is positioned between the locking element and the proximal extremity, creating specific distance relationships that balance locking strength with elastic deformation capability during installation.
3Strength
If the support surface is positioned closer to the distal extremity, then vertical locking is improved, but the stability and smoothness of installation may be compromised
Solution Approach 1:
The support surface is positioned upstream (closer to the proximal extremity) relative to the locking element, providing preliminary support during the installation process. This preliminary positioning stabilizes the hook-shaped part during deformation and ensures smooth engagement before the locking element engages with the counter-part.
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
These designs provide strong and stable locking surfaces, ensuring smooth installation and improved coupling strength, even with synthetic materials, by optimizing the positioning and elasticity of the hook-shaped parts.
Implementation Method 1
said lip of the upper hook-shaped part is provided with a support surface with which this upper hook-shaped part, in the coupled condition of two of such floor panels, rests on the lip of the lower hook-shaped part
Implementation Method 2
The inventor has found that certain combinations of characteristics of the coupling parts render particularly good results, in particular with synthetic floor panels, however, also with floor panels which are composed of other materials
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Floor panel for forming a floor covering, wherein this floor panel (1) is at least composed of a substrate (2); wherein the floor panel, on at least one pair of opposite edges (3-4), comprises coupling parts (5-6), which coupling parts allow that two of such floor panels can be coupled to each other by means of a downward movement (M) of one floor panel in respect to the other floor panel; wherein these coupling parts, in the coupled condition of two of such floor panels, form a first locking system, which effects a locking in a first direction (V) perpendicular to the plane of the floor panels, as well as form a second locking system, which effects a locking in a second direction (H) perpendicular to the edges and in the plane of the floor panels.