Floor Panel Locking Elements in Wood Core
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Solution Overview
Problem
Existing floor panels with hook profiles suffer from damage to the decorative layer and warping due to the high density of the wood-based material core near the surface, causing compression and internal cracks when locking elements exert pressure.
Innovation Solution
The locking elements are positioned at a greater depth within the wood-based material core, away from the surface, where the density is lower, and the latching elements are designed to engage in a way that avoids direct pressure on the decorative layer, with additional features like snap-in humps and elastic deformation to enhance holding power and prevent separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If locking elements are positioned near the upper side of the floor panel to enable effective locking, then the locking mechanism achieves sufficient holding force, but the decorative layer becomes damaged and the floor panel warps due to compression of the high-density wood-based material
Solution Approach 1:
The patent applies local quality by differentiating the density characteristics of the wood-based material at different depths. The high-density regions near the surfaces provide structural strength, while the lower-density core region allows locking elements to exert pressure without causing damage or warping. This spatial variation in material properties enables the locking mechanism to function effectively without harming the decorative layer.
Solution Approach 2:
The patent transitions from a two-dimensional surface-level locking approach to a three-dimensional solution by positioning locking elements at specific depths within the panel thickness. By utilizing the depth dimension and placing locking elements in the lower-density core region, the solution avoids the harmful effects of surface-level locking while maintaining adequate holding force.
2Object-affected harmful factors
If locking elements are positioned deep within the wood-based material core to avoid damaging the decorative layer, then the decorative layer remains intact, but the holding force of the locking mechanism is reduced
Solution Approach 1:
The patent exploits the local quality variation in wood-based material density, where the core region has lower density than the surface regions. By positioning locking elements in this lower-density core zone, the material can be compressed more easily without causing damage to the decorative layer, while still providing sufficient friction and mechanical interlocking for adequate holding force.
Solution Approach 2:
The patent changes the physical parameter of material density by selecting different depths within the wood-based panel. The lower density of the core region compared to the high-density surface regions allows for effective locking without the harmful compression effects that would occur in denser materials, thus resolving the contradiction between holding force and decorative layer integrity.
3Strength
If the wood-based material core has high density near the surface to provide structural strength, then the floor panel achieves adequate mechanical strength, but compression during locking causes internal cracks and layer separation
Solution Approach 1:
The patent utilizes the natural gradient in material density within the wood-based panel, where high density near surfaces provides structural strength and low density in the core provides compressibility. This spatial differentiation of material properties allows the panel to maintain overall structural integrity while allowing localized compression during locking without causing internal cracks or layer separation.
Solution Approach 2:
The patent resolves the contradiction by transitioning from surface-level locking to depth-based locking. By moving the locking action into the third dimension (depth) and positioning locking elements in the lower-density core region, the solution preserves the high-density surface layers for structural strength while allowing compression in the more compliant core region, thus preventing internal damage.
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
This design prevents damage to the decorative layer, maintains the integrity of the floor panels, and ensures a secure locking mechanism without warping, by distributing pressure through softer material areas and utilizing elastic deformation for secure engagement.
Implementation Method 1
utilizing elastic deformation for secure engagement
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The rectangular floor panel (1) comprises a core (2) made of a derived timber material, a decorative layer (4) positioned on the top side (3) of the panel (1) and in pairs opposite side edges (5, 6, 7, 8), wherein at least one pair of the side edges (7, 8) is provided with complementary form-fitting hooked profiles, namely a receiving hook (9) facing the lower side of the floor panel (1) and a retaining hook (10) located on the opposite side edge (8) and facing the top side (3) of the floor panel (1), the receiving (9) and retaining(10) hooks are provided with a distal side surface (11, 17) having at least one projecting interlocking element (13, 14) which is associated with a receiving pocket (21, 22) arranged in the complementary receiving hook (9), the retaining hook (10) is lockable with the receiving hook (9) by a vertical locking movement with respect to the floor panel (1) plane, the interlocking element (13, 14) of the retaining hook (10) and the top side (3) of the floor panel (1) are separated by at least one gap corresponding to one third the total thickness of the floor panel.