Floor Panel Coupling Layout for Low-Stress Multi-Point Locking
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Solution Overview
Problem
Existing interconnectable panels, such as floor panels, experience breakages at coupling edges due to tension during assembly and use, affecting reliability and durability.
Innovation Solution
The panels feature a core with upward and downward coupling parts, each having tongues and flanks with locking elements like bulges and recesses that cooperate to provide horizontal and vertical locking, distributing locking elements for reduced deformation and stress, allowing angling or vertical motion coupling and uncoupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional angling method or drop down coupling is used to join panels at edges, then panels can be mechanically connected, but breakages occur at coupling edges due to tension during assembly and use
Solution Approach 1:
The coupling part is divided into multiple functional elements: an upward tongue with first locking element, an upward flank with fourth locking element, a downward tongue with third locking element, and a downward flank with second locking element. This segmentation distributes the mechanical stress across multiple discrete locking points rather than concentrating it at a single coupling edge, thereby preventing breakages while maintaining connection reliability.
2Reliability
If multiple locking elements are added to coupling parts to prevent breakages, then coupling strength and reliability improve, but device complexity increases
Solution Approach 1:
The patent combines multiple locking elements (first, second, third, and fourth locking elements) into a single integrated coupling mechanism that operates through one angling motion. The upward tongue, upward flank, downward tongue, and downward flank work together as a unified system, allowing all locking elements to engage simultaneously during assembly without requiring separate operations, thus maintaining ease of use while improving reliability.
3Stability of the object's composition
If coupling edges are designed to provide vertical locking effect, then stability of coupled panels improves, but material stress and deformation increase during assembly
Solution Approach 1:
Different parts of the coupling mechanism have specialized functions: the upward tongue and downward groove provide horizontal locking, the downward tongue and upward groove provide vertical locking, and the locking elements on each component provide additional vertical stabilization. This local specialization allows each element to contribute to stability without bearing excessive stress, as the load is distributed across multiple locally-optimized features rather than concentrated in a single structure.
Data Source
AI summary
A panel, in particular a floor panel, including at least one first coupling part and at least one second coupling part connected respectively to opposite edges of the core, which first coupling part includes an upward tongue, at least one upward flank lying at a distance from the upward tongue and an upward groove, which second coupling part includes a downward tongue, at least one downward flank lying at a distance from the downward tongue, and a downward groove, wherein the upward tongue is provided with a first locking element; wherein the downward flank is provided with a second locking element, wherein the downward tongue is provided with a third locking element, and wherein the upward flank is provided with a fourth locking element.