Floor Panel Locking System with Slit Tongue
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Solution Overview
Problem
Existing mechanical locking systems for floor panels, particularly those with HDF cores, face challenges in achieving strong vertical locking while maintaining cost efficiency and flexibility, as they often require separate flexible tongues that are costly and difficult to produce in one piece with the core.
Innovation Solution
A mechanical locking system featuring a horizontally extending strip with slits that bend inwardly during locking, combining rigid and flexible edge sections to provide strong vertical locking without upward bending, and can be produced in a cost-efficient manner using high-speed equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate flexible tongues are used for vertical locking, then locking strength is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the flexible tongue into the core material itself, forming an integrated locking system where the tongue is a continuous part of the core rather than a separate component. This is achieved by forming the tongue with the core in one piece using high-speed equipment, eliminating the need for separate flexible tongues while maintaining locking strength.
Solution Approach 2:
The patent uses composite material structure where the core material (such as HDF, WPC, or LVT) is combined with a flexible tongue formed from the same or similar material. The tongue is formed as an integral part of the core through material removal or shaping processes, creating a composite structure that provides both rigidity from the core and flexibility from the tongue geometry.
2Strength
If separate flexible tongues are used for vertical locking, then locking strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent combines the tongue formation process with the core manufacturing process, allowing both to be produced simultaneously in one operation using high-speed equipment. This integration eliminates separate manufacturing steps for the tongue, reducing production time and cost while maintaining the strength benefits of a flexible tongue structure.
Solution Approach 2:
The core material itself serves the dual function of providing structural support and forming the flexible tongue, eliminating the need for additional materials or components. The tongue is formed from the core material through controlled removal or shaping, allowing the core to 'self-generate' the locking element without external intervention or separate production.
3Reliability
If upward bending is prevented in the locking system, then locking reliability is improved, but flexibility is reduced
Solution Approach 1:
The patent creates a dynamic locking system where the tongue can bend horizontally during installation to accommodate panel misalignment, but is constrained vertically to prevent upward bending that would compromise locking reliability. The slits in the tongue provide controlled flexibility in the horizontal direction while the overall structure maintains vertical stability through its integration with the rigid core.
Solution Approach 2:
The patent applies different mechanical properties to different parts of the tongue structure. The regions with slits provide local flexibility for horizontal bending, while the regions without slits or near the core interface provide local rigidity to prevent upward bending. This localized variation in mechanical properties allows the tongue to exhibit both flexibility and reliability in appropriate directions.
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 system achieves strong vertical locking with reduced material costs and improved production efficiency, suitable for various core materials, by utilizing a strip with slits that bend inwardly and outwardly during locking, enhancing locking strength and flexibility.
Implementation Method 1
The strip comprises slits located along the first edge and is configured such that a slit wall is bent horizontally inwardly towards an inner part of the first panel during locking
Data Source
Figure 1a~1d
Figure 2a~2e
Figure 3a~3b
AI summary
Floor panels (1, 1') are shown, which are provided with a mechanical locking system that may be locked with a vertical displacement of a first panel against a second panel. The locking system comprises a first rigid (7a) and a second flexible (7b) joint edge section with different locking functions. The first edge section provides a horizontal locking and the second section provides a vertical locking.