Floor Panel Separate Locking Element for Coupling Strength
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Solution Overview
Problem
Existing floor panels made of supple synthetic materials face challenges with coupling strength due to material elasticity and dimensional stability issues, particularly under temperature variations, leading to gaps and disconnection in floating floor coverings.
Innovation Solution
Incorporating a separate locking element, which can be made of synthetic or metal materials, to provide additional locking strength and stability, allowing for a stronger coupling mechanism in both vertical and horizontal directions, especially for thin and flexible panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If push-lock coupling parts are used on synthetic material floor panels, then installation simplicity is improved, but coupling strength deteriorates due to material elasticity
Solution Approach 1:
The coupling system is divided into two independent functional parts: a fold-down coupling part for installation simplicity and a separate locking element for coupling strength. The locking element is inserted into a recess in the fold-down coupling part and can be inserted at an angle to provide additional mechanical interlocking, preventing the coupling parts from being pushed out during expansion.
2Ease of operation
If fold-down coupling system is used, then installation simplicity is improved, but reliability deteriorates under temperature variations causing gaps and disconnection
Solution Approach 1:
The coupling system is segmented into a fold-down coupling part and a separate locking element. The locking element provides additional mechanical interlocking that prevents disconnection during thermal expansion and contraction, maintaining reliable coupling under temperature variations while preserving the installation simplicity of the fold-down system.
Solution Approach 2:
The coupling system combines two different coupling mechanisms (fold-down and separate locking element) into a composite structure, leveraging the advantages of both systems to achieve both ease of installation and reliability under temperature variations.
3Device complexity
If integrated coupling parts are used, then device complexity is reduced, but coupling strength deteriorates due to material limitations
Solution Approach 1:
The coupling system is divided into integrated fold-down coupling parts and a separate locking element. This segmentation allows the locking element to be made of different materials with superior mechanical properties, providing enhanced coupling strength without significantly increasing overall system complexity.
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
The separate locking element enhances the coupling strength and stability of floor panels, maintaining a secure connection across a range of temperature variations, even in thin and flexible materials, thereby improving the overall performance of floating floor coverings.
Implementation Method 1
The separate locking element, in the coupled condition of two of such floor panels, provides for at least a locking at the respective edges in said first direction and/or allows or enables a snapping on of the respective coupling parts of two of such panels by means of a downward coupling movement
Data Source
AI summary
A floor panel is arranged for forming a floor covering, and substantially consists of synthetic material and has a decorative upper side. The floor panel, on at least one pair of opposite edges, comprises coupling parts which allow coupling two of such floor panels to each other. The coupling parts effect a locking in a first direction perpendicular to the plane of the floor panels as well as in a second direction perpendicular to the respective edge and in the plane of the floor panels. The at least one of the coupling parts comprises a separate locking element, which, in coupled condition, provides for at least a locking in the first direction.