Floor Panel Lower Lip Geometry for Smooth Coupling
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Solution Overview
Problem
Existing floor panel coupling systems with thick panels often result in a rough installation process due to the design of coupling parts, which do not allow for smooth connection.
Innovation Solution
The floor panel design features a lower lip that protrudes beyond the upper lip by a distance of at least 1/3 times the panel thickness, with a minimum thickness of 1/4 times the panel thickness, allowing for a smooth turning movement and improved mechanical locking, especially effective with panels between 9 and 15 millimeters thick.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the lower lip protrudes beyond the upper lip with a portion not longer than one time the thickness of the floor panel (conventional design), then the mechanical locking is good, but the installation process becomes rough with increased resistance for thick panels
Solution Approach 1:
The patent changes the geometric parameters of the lower lip, specifically setting its minimum thickness to maximum 1/4 times the panel thickness and positioning the locking element at least 1/3 times the panel thickness from the underside. This parameter optimization reduces coupling resistance while maintaining locking strength for thick panels (9-15mm).
Solution Approach 2:
The lower lip is designed with non-uniform thickness, being thinnest (maximum 1/4 panel thickness) in the critical coupling region between the free end of the upper lip and the locking element. This local thinning creates a flexible hinge zone that reduces installation resistance, while the overall lip structure maintains sufficient strength for mechanical locking.
2Ease of operation
If the lower lip minimum thickness is reduced to maximum 1/4 times the panel thickness, then the turning movement becomes smoother, but the structural strength of the lower lip decreases
Solution Approach 1:
The patent optimizes the lower lip thickness parameter to maximum 1/4 times the panel thickness in the coupling region. This parameter change creates sufficient flexibility for smooth turning movement while the locking element positioning (at least 1/3 panel thickness from underside) compensates for the reduced lip thickness, maintaining overall structural strength.
Solution Approach 2:
The patent compensates for the reduced lower lip thickness by repositioning the locking element vertically (at least 1/3 times panel thickness from the underside). This dimensional adjustment in the vertical direction compensates for the thickness reduction in the horizontal direction, maintaining locking strength while enabling smooth movement.
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 configuration enables a smoother and more efficient installation process with reduced resistance, ensuring a strong and flexible connection without material wastage, and provides effective vertical and horizontal locking.
Implementation Method 1
The lower lip (9) protrudes beyond the free end of the upper lip (8) and the portion protruding beyond the upper lip (8) is not longer than one time the thickness (T) of the floor panel (1)... the most upward-situated point (P) of the locking element (11) on the lower lip (9) is situated at a distance (D)... of at least 1/3 times the thickness (T) of the floor panel (1) from the underside (28) of the floor panel (1)... the minimum thickness (T1) of the lower lip (9) is maximum 1/4 times the thickness (T) of the floor panel (1)
Data Source
Figure 1~3
Figure 4
AI summary
Floor panel (1) comprising coupling parts in the form of a tongue and groove connection with locking elements (10-11); wherein the groove (7) is bordered by an upper lip (8) and a lower lip (9); and wherein the one locking element (10) is provided on the lower side of the tongue (6) and the other locking element is provided on the upper side of the lower lip (9); characterized in that the most upward-situated point (P) of the locking element (11) on the lower lip (9) is situated at a distance (D) of at least 1/3 times the thickness of the floor panel (T) from the underside (12) of the floor panel (1); and that the minimum thickness (T1) of the lower lip (9) is maximum 1/4 times the thickness (T) of the floor panel.