Floor Panel Locking System with Slide and Fold Mechanisms
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Solution Overview
Problem
Existing mechanical locking systems for floor panels face challenges in locking strength, material costs, and reliability, particularly in preventing displacement along long edges due to friction changes caused by swelling and shrinking of wood-fiber based materials, and require complex production processes that result in waste and high costs.
Innovation Solution
A locking system with a slide lock mechanism on long edges that allows horizontal locking perpendicular and along the edges, using flexible materials and inclined locking surfaces to prevent displacement, and a fold-down locking system on short edges that locks vertically, eliminating the need for protruding strips and reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional mechanical locking systems are used with protruding strips and locking elements, then locking strength is improved, but material costs increase and production complexity increases
Solution Approach 1:
The patent removes the protruding strip and separate locking element from the edge of the floor panel. Instead, the locking mechanism is integrated directly into the panel body through recesses and corresponding protrusions formed by machining the core material, eliminating unnecessary components and simplifying production.
Solution Approach 2:
The locking mechanism is merged with the floor panel structure itself. The core material is machined to form both the structural body and the locking features (recesses and protrusions), combining what were previously separate components into a single integrated unit.
2Reliability
If friction-based locking is used to prevent displacement along long edges, then locking reliability is improved, but the system becomes sensitive to humidity changes causing swelling and shrinking
Solution Approach 1:
The locking system allows for dynamic adjustment through the fold-down mechanism on short edges, which can adapt to dimensional changes. The locking elements can move relative to each other to accommodate swelling and shrinking while maintaining the locked state, preventing sensitivity to humidity changes.
3Strength
If complex locking mechanisms with multiple locking elements are used, then locking strength is improved, but material waste increases
Solution Approach 1:
The patent eliminates the protruding strip that extends beyond the panel edge, removing the source of material waste. The locking features are formed by machining recesses into the panel body, which uses existing material rather than adding extra components that would be discarded.
4Reliability
If flexible materials are used in the locking system to prevent separation, then locking reliability is improved, but uncontrolled use of flexible materials reduces precision
Solution Approach 1:
The patent uses flexible materials selectively only in specific locations where needed for locking, rather than uncontrolled use throughout. The flexible elements are positioned precisely within the recesses and protrusions to provide necessary flexibility while maintaining overall locking precision.
Data Source
AI summary
Floor panels are shown, which are provided with a vertical folding locking system on short edges that only locks vertically and a mechanical locking system on long edges that prevents displacement along the long edges. A locking system for primarily rectangular floor panels with long and short edges installed in parallel rows, which allows that the short edges may be locked to each other with a vertical movement without a horizontal connection and that such horizontal connection is accomplished by the locking system on the long edges including a first and second horizontal locking perpendicular to the edges and along the edges.