Floor Panel Protrusion-Recess Locking Mechanism

The patent transitions from a single-plane lateral coupling mechanism to a multi-dimensional locking system. The tongue features an undercut geometry that engages with the groove to provide both lateral coupling and vertical locking. The locking element extends downward from the tongue's upper surface, creating a three-dimensional interlocking structure that prevents separation in multiple directions, thereby resolving the contradiction between ease of installation and resistance to separation.

The tongue-and-groove structure employs asymmetric geometry where the tongue has a specific profile with an undercut that does not mirror the groove shape. The locking element is positioned asymmetrically on the tongue, and the bearing surfaces are angled to provide directional locking. This asymmetric design enables the joint to resist separation forces while maintaining ease of assembly through the complementary mismatched profiles.

The locking mechanism is designed to engage automatically during the installation process without requiring additional tools or complex operations. As the tongue is inserted into the groove, the locking element naturally engages with the groove wall, and the bearing surfaces provide self-locking through their angled geometry. The structure serves its own locking function through its inherent geometry, eliminating the need for separate locking operations and maintaining ease of installation while providing robust separation resistance.

The patent combines the coupling function and the locking function into a single integrated tongue-and-groove structure. The locking element is formed as an integral part of the tongue, and the bearing surfaces are incorporated into the same geometric feature. This merging of functions allows the joint to be installed in a single operation while simultaneously providing both lateral coupling and separation resistance, resolving the contradiction between reliability and ease of operation.

The complex locking profile is segmented into distinct functional elements: the tongue body, the undercut geometry, the locking element, and the bearing surfaces. Each element serves a specific function and can be designed and manufactured independently to some extent. The locking element can be formed as a separate feature on the tongue, allowing for modular manufacturing approaches that reduce overall complexity while maintaining the integrated locking functionality.

The patent employs curved and angled surfaces in the locking mechanism, including the bearing surfaces that are oriented at specific angles to the horizontal plane. These curved and angled geometries distribute contact forces more evenly and can be manufactured using standard forming and milling operations. The smooth transitions and curved profiles reduce stress concentrations and simplify the manufacturing process compared to sharp corners and flat surfaces, thereby reducing manufacturing complexity while maintaining reliable locking.