Floor Panel Locking Mechanism with Continuous Slot
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Solution Overview
Problem
Existing panel locking mechanisms, particularly in thin panels, face limitations in achieving strong and secure locking in both vertical and horizontal directions due to the limited elasticity of common core materials like MDF or HDF, and the instability of flexible locking elements under heavy loads.
Innovation Solution
Incorporating a continuous slot in the web of the lower connecting element with a width smaller than the second hook element, allowing for increased deflection and further engagement of the locking lug into the undercut, along with strategically placed slots and angled undersides to enhance elasticity and stability, facilitates stronger panel locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If MDF or HDF core materials are used to provide high strength, then the panels can withstand walking stresses, but the locking elements can only be expanded elastically to a limited extent
Solution Approach 1:
The web of the lower locking element is divided into multiple segments by introducing continuous slots, creating a multi-segmented structure that allows each segment to deflect independently while maintaining overall structural integrity. This segmentation enables greater elastic expansion of the locking elements without compromising the strength of the MDF or HDF core material.
Solution Approach 2:
The locking element is designed as a composite structure combining the rigid MDF or HDF core material with strategically placed slot features that introduce controlled flexibility. This composite approach allows the locking element to exhibit both the strength of the core material and the elastic expansion capability needed for strong locking engagement.
2Strength
If the locking elements are expanded elastically as far as possible to achieve strongest locking, then the locking strength increases, but the web material must have relatively high elasticity which MDF and HDF lack
Solution Approach 1:
The locking mechanism transitions from a static rigid structure to a dynamic system where the web can deflect and expand elastically during the locking process. The continuous slots enable the web to dynamically adjust its shape and size, allowing the locking elements to expand as far as needed for strong locking while the material itself remains MDF or HDF.
Solution Approach 2:
The invention changes the geometric parameters of the locking element by introducing slots with specific widths and positions, transforming the rigid web into a flexible structure. This parameter change allows the locking element to exhibit different elastic properties during installation versus service, achieving strong locking without requiring high-elasticity core materials.
3Ease of operation
If spring elements are freed by millings to allow horizontal deflection, then locking can occur, but the connection between spring element and panel core can break under heavy loads
Solution Approach 1:
The continuous slots are pre-formed in the web during manufacturing, creating predetermined deflection paths that guide the locking element during installation. This preliminary action ensures that the web deflects in the intended manner without risking connection failure, as the slots are strategically positioned to maintain structural integrity while enabling necessary movement.
4Ease of operation
If the locking element reaches through a window forming a bending beam, then vertical locking occurs, but the bending beam thickness is limited to approximately one third of panel thickness reducing stability
Solution Approach 1:
The invention transitions from a two-dimensional window opening to a three-dimensional slot system that extends through the web thickness. This dimensional change allows the locking element to achieve vertical locking capability while maintaining greater thickness and stability, as the slots provide structural support in multiple directions rather than creating thin weak points.
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 enables secure and strong locking of panels in both directions, even with thin panels, by allowing greater expansion of the locking elements and maintaining stability through precise slit placement and angled surfaces, thus overcoming the limitations of traditional materials and designs.
Implementation Method 1
Both the lower locking element and the upper locking element are continuously elastically expanded until the locking lug of one panel snaps into the undercut of the second panel
Data Source
Figure 1a~1c
Figure 2~3
Figure 4
AI summary
The panel (1) has a lower locking element (8) and an upper locking element (16) provided at respective side edges (2, 4). The lower and upper locking elements include respective bars (10, 18), which are arranged at respective lower and upper sides (6, 14). Hook elements (12, 20) are arranged at outer ends of the respective bars. One of the hook elements (12) includes an undercut (22) and the other hook element (20) includes a locking catch (24). A continuous slit (26) is provided at one of the bars (10) and includes a breadth, which is smaller than a breadth of one of the hook elements (20). A core of the panel is made of wood composite or wood composite-plastic mixture.