Floor Panel Locking Surfaces for Strong Vertical Coupling
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Solution Overview
Problem
Existing floor panels experience weak vertical locking, leading to separation and gap formation due to temperature changes, such as expansion and shrinkage, which can occur even with exposure to sunlight.
Innovation Solution
The floor panels feature locking surfaces with a small angle to the panel plane, extending continuously over a significant portion of the edges, and are made of deformable synthetic material, allowing elastic deformation and tensioning forces for strong vertical locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the locking elements are designed with locking surfaces forming a small angle with the panel plane, then the vertical locking strength is improved, but the installation smoothness may be compromised
Solution Approach 1:
The locking surfaces are designed with a specific angle parameter (smaller than 30 degrees relative to the panel plane) to optimize the balance between vertical locking strength and installation smoothness. This parameter change allows the locking elements to engage firmly while still permitting smooth downward movement during installation.
Solution Approach 2:
The locking mechanism utilizes both vertical locking (perpendicular to the panel plane) and horizontal locking (parallel to the panel plane) dimensions simultaneously. This multi-dimensional locking approach ensures strong vertical connection while the horizontal coupling allows smooth installation movement.
2Strength
If the locking surfaces extend continuously over the major part of the edges, then the vertical locking is strengthened, but the manufacturing complexity increases
Solution Approach 1:
The locking surfaces are segmented into discrete locking elements distributed along the edges, rather than forming a continuous complex structure. This segmentation simplifies manufacturing while still providing continuous locking coverage over the major part of the edges.
Solution Approach 2:
The extent of locking surface coverage is defined as a specific parameter (major part of the edge length) that balances manufacturing simplicity with locking strength. This parameter optimization ensures sufficient locking without requiring complete edge coverage that would complicate manufacturing.
3Adaptability or versatility
If the substrate is made of deformable synthetic material, then the coupling parts can accommodate temperature changes and manufacturing tolerances, but the structural stability may be reduced
Solution Approach 1:
The substrate material properties are optimized to provide appropriate deformability for accommodating temperature changes and manufacturing tolerances, while maintaining sufficient structural stability. The material parameters are selected to ensure the coupling parts can flexibly adapt without compromising overall panel stability.
Solution Approach 2:
The deformable synthetic material substrate provides inherent cushioning capability that anticipates and absorbs the effects of temperature changes and manufacturing variations. This beforehand cushioning prevents stress concentration and maintains structural integrity under varying conditions.
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 design minimizes gap formation and ensures smooth installation by providing a strong, stable connection between panels, accommodating manufacturing tolerances and temperature-induced changes.
Implementation Method 1
allowing elastic deformation and tensioning forces for strong vertical locking
Data Source
Figure 1~3
Figure 4~7
Figure 8
AI summary
Floor panel (1) for forming a floor covering, wherein this floor panel (1) comprises a substrate (2), which substrate (2) preferably is manufactured on the basis of synthetic material; wherein this floor panel (1), on at least one pair of opposite edges (5-6), comprises coupling parts (7-8), which coupling parts (7-8) allow that two such floor panels (1) can be coupled to each other by means of a downward movement (M) of one floor panel (1) in respect to the other floor panel (1).