Floor Panel Locking System Using Segmented Clips
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Solution Overview
Problem
Existing mechanical locking systems for thin and flexible floor panels, such as LVT and laminate flooring, face challenges in providing strong and cost-efficient locking solutions due to minimum thickness requirements, especially when the core material is soft or flexible, leading to issues with locking strength and material usage.
Innovation Solution
A locking system comprising a tongue and groove for vertical connection, combined with separate clips attached to the panel edges, where the clips have a locking protrusion that extends upwardly and is positioned in a recess of the tongue groove, providing enhanced horizontal and vertical locking strength without compromising the panel's thickness or material integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a mechanical locking system is integrated into thin floor panels (2-3 mm thickness), then material savings and weight reduction are achieved, but the locking strength becomes insufficient due to the thin panel structure
Solution Approach 1:
The locking system is divided into separate components: a locking element with locking protrusions that engages with corresponding recesses in the panel edge. This segmentation allows the locking mechanism to be optimized independently from the panel thickness, enabling strong locking in thin panels without requiring the entire panel to be thick.
Solution Approach 2:
The locking mechanism utilizes vertical engagement (locking protrusions extending upwardly into recesses) rather than relying solely on horizontal panel thickness. This dimensional transition allows the locking strength to be derived from the vertical locking engagement rather than the panel's horizontal thickness.
2Ease of manufacture
If the panel thickness is reduced to 2-3 mm for material savings, then cost efficiency improves, but it becomes impossible to form a strong and cost-efficient locking system
Solution Approach 1:
By separating the locking element from the panel body, the design allows thin panels (2-3 mm) to be used while maintaining reliable locking through the dedicated locking mechanism. This segmentation enables cost-efficient thin panels without compromising locking reliability.
Solution Approach 2:
The locking element acts as an intermediary component that provides the necessary locking function without requiring the panel itself to be thick. This mediator enables thin panel construction while maintaining locking reliability.
3Quantity of substance
If a locking system is formed in thin panels with flexible cores, then material usage is reduced, but the locking strength becomes insufficient due to the soft core material
Solution Approach 1:
The locking system is segmented into a separate locking element that provides structural strength independent of the flexible panel core. This allows minimal material usage in the panel while maintaining locking strength through the dedicated locking component.
Solution Approach 2:
The locking system combines the flexible panel material with a separate locking element that provides the necessary mechanical strength. This composite approach allows the panel to remain thin and flexible while the locking mechanism provides the required strength.
Data Source
AI summary
Building panels, especially floor panels are shown, which are provided with a locking system comprising several clips connected to a panel edge comprising a recess formed in a lower lip or in the tongue. Each clip may include an upwardly extending locking element, which is configured to cooperate with a locking groove for locking the two edges in a horizontal direction.