Floor Panel Reinforcement Layers for Locking Tab Stability
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Solution Overview
Problem
Existing floor panels lack an efficient and strong interlocking mechanism that maintains stability over a prolonged life while allowing for easy assembly and flexibility in material choice without compromising the locking tab functionality.
Innovation Solution
The integration of reinforcement layers positioned between 8% and 14% from the lower side and 93% to 96% from the upper side of the floor panel thickness, which supports flexible and strong locking tabs, allowing for optimal adaptation of panel components and enhanced interlocking forces between adjacent panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcement layers are positioned close to the locking tabs, then the locking tabs become sufficiently flexible and strong, but the locking tab functionality may be compromised by excessive stiffness
Solution Approach 1:
The reinforcement layers are positioned at specific locations (8-14% from lower side and 93-96% from upper side) rather than uniformly throughout the panel. This local reinforcement provides strength where needed near the locking tabs while maintaining flexibility in other areas of the panel.
Solution Approach 2:
The invention changes the positional parameters of the reinforcement layers relative to the locking tabs. By positioning them at optimized distances (8-14% and 93-96% of total thickness), the reinforcement provides support without creating excessive stiffness that would compromise locking tab functionality.
2Adaptability or versatility
If different materials are used for various panel components, then optimal adaptation to demands is achieved, but the locking tab strength and flexibility may be compromised
Solution Approach 1:
The floor panel uses composite construction with multiple layers including wear layer, design layer, core layer, and reinforcement layers. Each layer can be made from different materials optimized for its specific function, while the reinforcement layers positioned near the locking tabs provide the necessary strength and flexibility.
Solution Approach 2:
Different materials and reinforcement levels are applied to different parts of the panel. The reinforcement layers are strategically positioned near the locking tabs where strength and flexibility are critical, while other areas of the panel can use different material compositions optimized for their specific requirements.
3Ease of manufacture
If the floor panel uses a simple structure, then manufacturing is easier and cost is reduced, but the interlocking mechanism lacks sufficient stability and strength
Solution Approach 1:
The floor panel employs a composite multi-layer structure with reinforcement layers integrated into the design. This composite construction provides enhanced interlocking stability and strength while maintaining manufacturing efficiency through a systematic layering approach that can be produced using standard flooring manufacturing processes.
Data Source
Figure 1~3
AI summary
Rectangular floor panel is described with mutually parallel, substantially planar upper and lower sides (1,2) and with two pairs of respective mutually opposite side edges (3, 4) connecting the upper and lower sides, wherein the opposite side edges of a pair are provided with complementary profiles for interconnecting adjacent floor panels. Of at least one pair of opposite side edges the profile of a first side edge is provided with a frontal face (5,10) and a counter face (9, 14), whereas the profile of the corresponding second side edge of the respective pair of opposite side edges is provided with a frontal face and counter face, respectively, cooperating therewith. The frontal faces and the counter faces are provided with locking tabs (15, 18) cooperating in the interconnected position of adjacent floor panels. The floor panel further is provided with two reinforcement layers (19, 20) extending substantially in parallel to the upper and lower sides of the floor panel, wherein the locking tabs substantially are positioned at the level of said reinforcement layers.