Floor Panel Coupling Parts With Angled Locking Planes
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Solution Overview
Problem
Existing floor panels require excessive force to couple together during installation, which can be cumbersome and inefficient, while also lacking sufficient coupling strength in the horizontal direction.
Innovation Solution
The floor panel design features a first pair of opposite edges with coupling parts that include locking planes forming convex and concave sections, allowing for easy mechanical coupling through tilting or sliding motions, with specific angle and area configurations that reduce the required force while maintaining strong horizontal coupling. These coupling parts are integrated into the substrate, ensuring secure locking across the panel face and in the plane perpendicular to the edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional coupling parts are used in floor panels, then the coupling strength is sufficient, but excessive force is required to couple the panels together during installation
Solution Approach 1:
The coupling part is divided into multiple locking planes (first locking plane, second locking plane, third locking plane, fourth locking plane) with different orientations and functions. The first and second locking planes form a convex section while the third and fourth locking planes form a concave section, allowing segmented engagement that reduces coupling force while maintaining strength
Solution Approach 2:
The locking planes are arranged asymmetrically with specific angle relationships: the angle between the first locking plane and the floor panel surface is smaller than the angle between the second locking plane and the floor panel surface, and similarly for the third and fourth locking planes. This asymmetric arrangement optimizes the coupling mechanism to reduce force requirements
2Ease of operation
If the coupling force is reduced for easier installation, then the installation process becomes simpler, but the coupling strength in the horizontal direction may be insufficient
Solution Approach 1:
The coupling mechanism operates in multiple dimensions through the arrangement of locking planes at different angles and orientations. The convex and concave sections engage in both vertical and horizontal directions, with the locking planes creating multi-directional constraints that maintain horizontal coupling strength while reducing installation force
Solution Approach 2:
The specific angle parameters of the locking planes are optimized: the enclosed angles between adjacent locking planes are between 90° and 175° (preferably greater than 100°, more preferably greater than 120°, more preferably greater than 140°). These parameter optimizations ensure that the coupling mechanism achieves the right balance between ease of installation and coupling strength
Data Source
AI summary
A floor panel contains opposite edges that contain coupling parts to link two floor panels. These coupling parts contain locking planes: first and second locking planes on the first edge with an enclosed angle between 90° and 175°; and third and fourth locking planes on the second edge with an enclosed angle between 90° and 175°. The first locking plane is closer to the top of the floor panel than the second locking plane. The angle with the surface of the floor panel of the first locking plane is smaller than the second locking plane. The angle with the floor plane surfaces of the third locking plane is smaller than that of the fourth locking plane. The second locking plane is provided for interaction with the fourth locking plane of a coupled panel. The first locking plane is provided for interaction with the third locking plane of a coupled panel.