Floor Panel Tongue-and-Groove Coupling With Shared Cutting Tools
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Solution Overview
Problem
Existing methods for manufacturing floor panels with different thicknesses are inefficient and require separate cutting tools, limiting the ease of coupling and production.
Innovation Solution
The floor panels are designed with optimized coupling parts that allow for easy angling movement and use of the same cutting tools to produce panels of varying thicknesses, featuring parallel faces and angled edges for enhanced coupling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If material-removal machining with multiple milling cutters is used to form coupling parts, then floor panels of different thicknesses can be manufactured, but the manufacturing process becomes complex and requires separate cutting tools for each thickness
Solution Approach 1:
The patent applies universality by designing a standardized coupling part geometry that can be used across floor panels of different thicknesses. The coupling part profile is defined with specific geometric parameters (a1, a2, b1, b2, c1, c2, d1, d2, e1, e2, f1, f2) that can be adjusted through parameter changes rather than requiring different tool configurations. This allows the same basic cutting tool setup to manufacture coupling parts for various thicknesses by simply adjusting machining parameters.
Solution Approach 2:
The patent employs parameter changes by defining the coupling part contour through a set of adjustable parameters (a1, a2, b1, b2, c1, c2, d1, d2, e1, e2, f1, f2) rather than fixed geometric shapes. These parameters control the profile characteristics such as the tongue thickness, groove depth, and locking surface angles. By varying these parameters, the same cutting tool can produce coupling parts optimized for different floor panel thicknesses without changing the tool itself.
2Manufacturing precision
If separate cutting tools are used for each floor panel thickness, then manufacturing precision can be maintained, but productivity decreases and manufacturing time increases
Solution Approach 1:
The patent achieves universality by creating a single standardized coupling part design that serves multiple thickness requirements. The coupling part profile is defined with parameters that can be scaled and adjusted to maintain geometric accuracy across different thicknesses, allowing one tool configuration to produce precision results for various panel types without sacrificing manufacturing precision.
Solution Approach 2:
The patent uses parameter changes to maintain manufacturing precision while improving productivity. By defining the coupling part geometry through adjustable parameters (a1-a2, b1-b2, etc.), the system can quickly adapt to different thickness requirements through parameter adjustment rather than tool changes, thereby maintaining precision while significantly reducing setup time and increasing overall manufacturing efficiency.
3Reliability
If the coupling part contour is optimized for specific thicknesses, then locking mechanism performance improves, but the manufacturing process becomes less flexible
Solution Approach 1:
The patent applies parameter changes by defining the coupling part contour through a comprehensive set of adjustable parameters (a1, a2, b1, b2, c1, c2, d1, d2, e1, e2, f1, f2) that control critical locking mechanism features. These parameters can be optimized for specific thicknesses to ensure proper locking surface contact and mechanical interlocking, while simultaneously allowing flexible adjustment for different panel types. The parameterized approach enables the locking mechanism to maintain optimal performance across varying thicknesses without compromising manufacturing flexibility.
Data Source
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AI summary
Floor panels with coupling parts in the form of a tongue and groove with locking surfaces. In coupled state of two such panels, an open space is present, viewed vertically, between the tongue and the lower lip, and viewed horizontally, between the contact zone and the contact between the horizontally active locking surfaces. The underside of the tongue in the open space comprises a first face. The top side of the lower lip in the open space comprises a second face parallel to the first face. In coupled state of two such panels, at least one face is perpendicular to the panel and intersects both the first face of the first coupled panel and the second plane of the panel coupled to the first panel.