Floorboard Locking Joint With Integrated Core to Cut Material Waste
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing mechanical locking systems for building panels, particularly floorboards, result in significant material waste during manufacturing due to the projection of parts like tongues and strips, leading to increased costs and reduced locking strength.
Innovation Solution
A locking system integrated with the core that guides edges into position during angling, minimizing material waste by using one-piece components and optimized groove formations, allowing for high locking strength and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional mechanical locking systems with protruding tongues and strips are used, then locking function is achieved, but material waste increases significantly
Solution Approach 1:
The locking system transitions from a traditional protruding tongue-and-groove design to a click-lock mechanism where the locking element rotates within the plane of the board. This dimensional change eliminates the need for thick protruding tongues, reducing material waste while maintaining locking functionality through a rotating locking element that engages with a recess in the adjacent board.
Solution Approach 2:
The locking system is divided into separate functional components: a locking element that rotates independently, a guide groove for edge alignment, and a recess for engagement. This segmentation allows each component to be optimized for its specific function, with the locking element being thin and rotating within the board plane rather than requiring a thick protruding tongue.
2Strength
If protruding tongues and strips are used for locking, then mechanical locking is achieved, but locking strength is reduced
Solution Approach 1:
The locking element is designed to rotate dynamically during the locking process. This rotation allows the locking element to engage deeply with the recess in the adjacent board, creating a strong mechanical interlock. The dynamic rotating motion enables the locking element to transition from a retracted position to an engaged position, maximizing locking strength without requiring excessive material.
Solution Approach 2:
The locking system utilizes the composite structure of the board itself, with the locking element formed from the core material and the decorative layer providing the visible surface. This integrated approach ensures the locking element has the necessary strength while minimizing material usage, as the locking function is achieved through the rotation and engagement of this composite structure rather than adding separate protruding components.
3Productivity
If edges are machined to provide mechanical locking system, then locking functionality is achieved, but manufacturing time and cost increase
Solution Approach 1:
The guide groove is formed in advance during the board manufacturing process, prior to the locking operation. This preliminary action ensures that the edges are pre-aligned and guided into the correct position, simplifying the subsequent locking process. The guide groove is integrated into the board structure during manufacturing, eliminating the need for complex post-manufacturing edge machining operations.
Solution Approach 2:
The guide groove and locking mechanism are designed to work together in a self-aligning manner. When two boards are brought together, the guide groove automatically guides the edges into the correct position, and the rotating locking element self-engages with the recess. This self-service mechanism reduces the need for complex external machining equipment and manual alignment procedures, improving manufacturing efficiency.
Data Source
Figure 1a~1e
Figure 2a~2d
Figure 3a~3f
AI summary
There is disclosed building panels (1, 1'), especially floor panels, provided with a locking system configured to lock adjacent edges of the building panels by angling and that comprises a tongue (10) and a strip (6) on the same edge. Horizontal locking surfaces (15) are located below a horizontal strip plane (HPS) intersecting an upper part (6a) of the strip (6) located essentially vertically under an outer part of the tongue (10).