Floor Panel Locking System With Pivotable Insert
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Solution Overview
Problem
Existing floor panel coupling systems, particularly 'push-lock' systems, face challenges in maintaining uniform height and stability due to lack of precise vertical locking, especially in thin panels with limited space for locking elements, leading to potential height differences and operational difficulties during installation.
Innovation Solution
The development of a floor panel with a vertically active locking system featuring a pivotable lock-up body and a coextruded synthetic material strip, where the lock-up body forms a stop-forming locking portion and is oriented at an angle less than 60° in the non-coupled condition, allowing for a more gradual locking mechanism and improved stability, even in thin panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate locking element (insert) is used to provide vertical locking, then vertical locking capability is improved, but device complexity increases
Solution Approach 1:
The patent combines the horizontal locking system (male and female coupling parts) and the vertical locking system (locking element with lock-up body) into a single integrated coupling assembly. The locking element is positioned within the female coupling part, creating a unified structure that provides both horizontal and vertical locking functions simultaneously, thereby improving reliability without proportionally increasing complexity.
Solution Approach 2:
The coupling parts are designed to perform multiple functions: the male coupling part provides both the horizontal engagement surface and support for the locking element, while the female coupling part integrates the lock-up body that performs both vertical locking and guides the horizontal insertion. This multi-functionality reduces the need for separate components.
2Ease of operation
If the panel thickness is reduced, then ease of installation and aesthetics are improved, but space for locking elements is limited
Solution Approach 1:
The lock-up body is designed to pivot through a significant angular range (greater than 30 degrees) during the locking operation. This angular movement transforms the limited linear space within the thin panel into an effective locking mechanism by utilizing rotational motion, allowing the locking element to achieve full locking function despite the constrained thickness available for its placement.
3Ease of operation
If a pivotable lock-up body with angular movement is used, then locking smoothness is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies that the lock-up body adopts an angular orientation in the uncoupled state (greater than 30 degrees) and pivots to a different orientation in the coupled state. This parameter change approach allows for tolerance compensation: the angular movement itself absorbs minor manufacturing variations, as the locking action occurs over a range of angles rather than requiring precise alignment at a single angular position.
Data Source
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AI summary
Panel, with a horizontally and vertically active locking system (6-7), which allow that two of such floor panels (1) can be connected to each other at said sides (2-3) by providing one of these floor panels (1), by means of a downward movement (M), in the other panel (1); wherein the vertically active locking element (7) comprises a locking element (12) in the form of an insert; wherein this locking element (12) comprises at least a pivotable lock-up body (14) and an attachment portion; characterized in that said pivotable lock-up body (14) and the attachment portion, in the non-coupled condition, horizontally extend at least for a part underneath each other, however, herein maintain a vertical mutual distance.