Floor Panel Support Portion Prevents Flexible Locking Deformation
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Solution Overview
Problem
Existing floor panels with flexible coupling parts can deform under load, leading to height differences between panels, which compromises the evenness of decorative surfaces.
Innovation Solution
Incorporating a support portion within the core of the panel to prevent bending of the flexible portion perpendicular to the panel plane, allowing for a snap engagement mechanism with a tongue-shaped locking part, ensuring panels remain co-planar and providing controlled movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the flexible portion is made entirely free at the locking zone to supply flexibility, then the coupling flexibility is improved, but the panel deforms under load causing height differences
Solution Approach 1:
The flexible portion is segmented into different zones: a free locking zone for flexibility and a supported rear zone for stability. This segmentation allows the flexible portion to perform its coupling function while being prevented from excessive deformation that would cause height differences.
Solution Approach 2:
Different portions of the flexible element have different structural properties. The locking zone is completely free to allow maximum flexibility for coupling, while the rear portion receives support from the support portion to maintain panel planarity under load.
2Ease of manufacture
If the flexible portion is made as a lip entirely free at the locking zone, then the snap coupling effect is achieved, but the lip bends perpendicular to panel plane under heavy load
Solution Approach 1:
The flexible portion is divided into a free locking zone for snap coupling and a supported zone for stability control, resolving the conflict between coupling simplicity and height uniformity.
Solution Approach 2:
The support portion acts as an intermediary element that provides localized support to the flexible portion's rear side, preventing excessive bending while maintaining the simplicity of the snap coupling mechanism.
3Ease of operation
If the flexible portion is completely free to enable bending for snap effect, then the coupling operation is simplified, but height differences occur under irregular loads
Solution Approach 1:
The flexible portion is segmented into a free locking zone for easy snap coupling and a supported rear zone for reliability under load, maintaining both installation simplicity and panel levelness.
Solution Approach 2:
The flexible portion has different structural qualities at different locations: completely free at the locking zone for ease of operation, and supported at the rear for reliability under irregular loads.
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
The solution effectively prevents undesired bending and height differences, ensuring panels remain in the same plane under all conditions, with a play-free support function and controlled displacement, maintaining evenness and stability.
Implementation Method 1
a flexible portion (31), made in one piece with said core (10), which portion extends along the respective edge and can be bent at least in the plane of the panel, as a result of joining together two of such panels (1)
Implementation Method 2
said panel (1) comprising a support portion (36), which, with two of such coupled panels (1), when exerting a force in a direction opposed to said downward movement, forms a support against bending of the flexible portion (31) in a direction perpendicularly to the plane of the coupled panels (1)
Implementation Method 3
Each respective locking part (25) is preferably made as a tongue-shaped part which, during connecting two of such panels (1), causes an elastic bending in the lip-shaped portion, such that this tongue-shaped portion can take place behind the lip by means of a snap movement
Data Source
Figure 1~3
Figure 4~6
Figure 7~17
AI summary
Panel, more particularly a floor panel, wherein this panel (1) comprises a core (10) and at least two opposite edges (8-9); wherein coupling parts (13-14) are provided at said two opposite edges (8-9); wherein these coupling parts (13-14) have such a configuration that two of such panels (1) can be coupled to each other by means of a downward movement, such that a locking is obtained in the plane of the panels (1) and perpendicular to said edges (8-9), as well as perpendicular to the plane of the panels (1); wherein the coupling parts (13-14) at said two edges (8-9) comprise locking parts (25-26) ensuring said locking in the direction perpendicular to the plane of the panels (1), wherein at least one of these locking parts (26) forms part of a flexible portion (31) made in one piece with said core (10), said flexible portion being bendable at least in the plane of the panel, characterized in that the panel (1) comprises at least one support portion (36) which forms a support against bending of the flexible portion (31) in a direction transverse to the plane of the coupled panels (1).