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
1Device complexity
If the coupling parts are designed with simple hook-shaped structures, then the device complexity is reduced, but the locking strength and reliability are insufficient
Solution Approach 1:
The coupling part is segmented into multiple functional elements: an upper hook-shaped part with a downward-directed locking element, a lower hook-shaped part with an upward-directed locking element, a support surface, and guiding surfaces. This segmentation allows each element to perform its specific function while maintaining overall structural integrity and reliability.
Solution Approach 2:
The locking elements are nested within recesses of the opposite hook-shaped part. The upward-directed locking element of the lower hook is received in a recess of the upper hook, and the downward-directed locking element of the upper hook is received in a recess of the lower hook, creating a nested configuration that enhances locking strength.
2Reliability
If the coupling parts are designed with complex locking mechanisms, then the locking strength is improved, but the ease of operation during installation is reduced
Solution Approach 1:
The hook-shaped parts are pre-formed with integrated locking elements and guiding surfaces during manufacturing. The support surface is pre-positioned to automatically bear the load when panels are coupled, eliminating the need for additional assembly steps or complex adjustment mechanisms during installation.
Solution Approach 2:
The coupling mechanism is designed to automatically lock when the panels are pressed together. The locking elements engage with the recesses of the opposite panel automatically, and the support surface automatically bears the load, allowing the system to service itself without requiring complex external mechanisms or extensive manual adjustment.
3Reliability
If the support surface is positioned closer to the distal extremity of the upper hook-shaped part, then the locking strength is improved, but the structural stability is reduced
Solution Approach 1:
Different regions of the hook-shaped part are assigned different functional qualities: the support surface is positioned closer to the distal extremity to provide optimal locking strength, while the proximal region maintains sufficient material thickness and structural continuity to ensure overall stability. The guiding surfaces are positioned to provide stability during the coupling process.
Solution Approach 2:
The upper and lower hook-shaped parts are designed with asymmetric features relative to each other. The upper hook has a downward-directed locking element while the lower hook has an upward-directed locking element, and their respective support surfaces are positioned at different locations optimized for their specific functional roles, creating an asymmetric but balanced structure.
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.