Flooring Panel Locking Mechanism for Moisture Resistance
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Solution Overview
Problem
The manufacturing of laminated floor panels using tongue-and-groove coupling is costly and complex, and the locking mechanism is weak against moisture and temperature variations, leading to potential gaps.
Innovation Solution
A novel locking mechanism featuring first and second locking elements with recesses and protrusions, divided into sub-recesses and sub-portions, providing a triple lock function that is easier to manufacture and enhances coupling strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tongue-and-groove coupling is used for manufacturing laminated floor panels, then the panels can be joined together, but the manufacturing process becomes costly and complex
Solution Approach 1:
The coupling profile is segmented into distinct functional elements: a first flank forming an inner flank of the core, a second flank forming an outer edge, and a third flank connecting them. The locking elements are further segmented into protrusions and recesses that can be manufactured separately and then assembled, simplifying the manufacturing process while maintaining coupling functionality.
Solution Approach 2:
The locking elements (protrusions and recesses) are extracted as separate features from the main coupling profile structure. This allows the locking mechanism to be manufactured independently and then integrated into the coupling profile, reducing overall manufacturing complexity and cost.
2Reliability
If traditional locking elements are used in tongue-and-groove coupling, then panels can be locked together, but the locking mechanism is weak against moisture and temperature variations
Solution Approach 1:
The locking elements are positioned at specific locations on the flanks where they can effectively resist the harmful effects of moisture and temperature. The first locking element is positioned on the second flank while the second locking element is positioned on the third flank, creating localized locking zones that provide enhanced resistance to environmental factors.
Solution Approach 2:
The locking elements are designed in advance with specific geometries (protrusions and recesses) that preemptively counteract the expansion and contraction caused by moisture and temperature variations. This preliminary design ensures that the locking mechanism remains effective under varying environmental conditions.
3Ease of manufacture
If weak locking mechanism is used, then manufacturing is simpler, but gaps appear between panels under moisture and temperature variations
Solution Approach 1:
The locking elements feature asymmetric geometries where the protrusion on one flank has a different shape and orientation than the recess on the opposing flank. This asymmetry creates a interlocking mechanism that prevents gaps from forming under environmental stress while maintaining manufacturing simplicity.
Solution Approach 2:
The locking elements are nested within the coupling profile structure, with protrusions fitting into recesses in a nested arrangement. This nested design provides stable locking that prevents panel gaps while keeping the overall structure compact and easy to manufacture.
Data Source
AI summary
A panel configured to be used for constructing a floor covering that includes a plurality of such panels. A combination of locking elements is used on the flanks of the coupling profiles on the sides of the panel that provides for replacing the well-known tongue and groove coupling.