Floor Panel Spring Element Milling for Integrated Locking
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Solution Overview
Problem
The existing methods for producing floor panels with integrated locking mechanisms are costly due to the need for specialized tools and high-strength plastics, and the separate production of locking elements complicates manufacturing and alignment of different materials, leading to potential errors in assembly and reduced locking effectiveness.
Innovation Solution
The method involves integrating the spring element directly into the core of the panel by milling horizontal and vertical slots, allowing for adjustable spring elasticity and secure locking without separate components, facilitating easier production and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the spring element is made as a separate plastic component, then the locking mechanism can be provided, but production costs increase due to specialized tools and high-strength plastic requirements
Solution Approach 1:
The spring element is merged with the core material to form an integrated one-piece structure. The core is milled to create the spring element directly from the wood or wood-based material, eliminating the need for separate plastic components and specialized injection molding tools. This integration resolves the contradiction by maintaining locking reliability while significantly reducing manufacturing complexity and cost.
Solution Approach 2:
The spring element is made from the same core material as the panel itself, creating a homogeneous structure. This eliminates the need for different materials (wood core and plastic spring) and their associated alignment and manufacturing tolerance issues. The homogeneous material composition simplifies production while ensuring sufficient strength for the locking function.
2Reliability
If the locking element is produced separately from the panel, then the locking function can be achieved, but manufacturing complexity increases due to alignment of manufacturing tolerances between different materials
Solution Approach 1:
The spring element and core are merged into a single integrated component produced in one manufacturing process. The core is milled to create the spring element geometry directly, eliminating the need for separate production of locking elements and their subsequent assembly. This integration resolves the tolerance alignment problem between different materials and processes.
Solution Approach 2:
Using the same core material throughout eliminates the complexity of coordinating manufacturing processes for different materials (wood and plastic). The homogeneous material allows for a unified manufacturing approach with consistent tolerances, reducing device complexity while maintaining locking reliability.
3Ease of manufacture
If the spring element is made from low-strength plastic, then production costs decrease, but the spring element dimensions must increase to generate sufficient locking forces
Solution Approach 1:
The material parameter is changed from plastic to wood-based core material, which has different mechanical properties. The core material provides sufficient strength in smaller dimensions compared to low-strength plastic, eliminating the need for oversized spring elements while maintaining locking force capability. This parameter change resolves the contradiction between cost and dimensions.
4Ease of manufacture
If the spring element is integrated into the core, then production is simplified and costs reduced, but the spring element must be securely connected to prevent falling out during manufacturing and transport
Solution Approach 1:
The spring element is merged with the core through direct milling of the core material, creating an integrated one-piece structure. The connection is inherent in the milling process itself, eliminating the need for separate retention mechanisms. This integration simultaneously achieves production simplification and ensures spring element retention.
Solution Approach 2:
The spring element geometry is created during the core milling process itself, before any assembly or transport occurs. The milling operations (horizontal and vertical slotting) preliminarily form the spring element with its connection to the core, ensuring it cannot fall out during subsequent manufacturing or transport steps.
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 approach simplifies production, reduces costs, ensures complete panels with no missing components, and provides a secure and effective locking mechanism capable of handling normal loads without the need for additional components or complex alignment.
Implementation Method 1
at least one spring element which can be moved in the horizontal direction and is formed in one piece from the core on the second side edge
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A panel (1,2) has a core of a wood material or wood-plastic mixture (17), an upper face (18), and a lower face (19), which has on at least two opposite-facing edges a corresponding profile so that two identically-shaped panels (1,2) can be connected together through a vertical joint movement in a horizontal and vertical direction and locked, in which the locking in a vertical direction is effected by at least one movable spring element (3) which, during the movement of the joint, snaps in behind a locking edge (4). The spring element is formed as a single-piece from the core (17).