Floor Panel Coupling Profiles for Stable Fold-Down Locking
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Solution Overview
Problem
Existing floor panels with one-piece coupling profiles offer unstable connections that are either too taut or require damage for installation, and they are costly due to the use of separate elastic locking strips.
Innovation Solution
The floor panels feature coupling parts with horizontally and vertically active locking systems integrated into the panel material, allowing for easy installation and uninstallation through a fold-down technique, using hook-shaped parts for vertical locking and undercut/protrusion configurations for enhanced stability and ease of coupling/uncoupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate elastic locking strips are used for vertical locking, then the locking stability is improved, but the production cost increases
Solution Approach 1:
The patent merges the separate elastic locking strip into the coupling profile itself, creating an integrated structure where the locking element is formed as part of the same piece as the coupling profile. This eliminates the need for separate locking strips while maintaining the vertical locking function, thereby reducing production cost while preserving locking stability.
2Ease of manufacture
If one-piece coupling profiles are used to eliminate separate locking strips, then production cost is reduced, but connection stability deteriorates
Solution Approach 1:
The patent segments the one-piece coupling profile into functional zones: a coupling zone for horizontal connection and a locking zone with an elastically deformable locking element for vertical connection. This segmentation allows the single piece to perform multiple functions while maintaining connection stability through the specialized locking element design.
Solution Approach 2:
The patent changes the physical parameters of the locking element by making it elastically deformable with specific geometry (hook-shaped or spring-like structure). This allows the element to flex during installation and then maintain a stable locked position, providing connection stability while being part of a one-piece profile.
3Strength
If one-piece coupling profiles with tight connections are used, then connection strength is improved, but installation difficulty increases
Solution Approach 1:
The patent introduces dynamic characteristics to the locking element by making it elastically deformable. During installation, the locking element can flex and deform to accommodate the joining motion, and after joining, it returns to its original shape to provide strong connection. This dynamic behavior enables both strong connections and easy installation.
4Device complexity
If one-piece coupling profiles are used, then production complexity is reduced, but uncoupling difficulty increases
Solution Approach 1:
The patent designs the locking element with a preliminary release mechanism that allows for easy uncoupling. The elastic locking element is configured so that applying a specific force in a specific direction (upward or lateral) automatically overcomes the locking action, enabling simple removal without requiring tools or complex procedures, while maintaining a simple one-piece production structure.
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 provides stable, cost-effective connections that require less force for installation and can be easily uninstalled, reducing production costs and installation complexity while maintaining panel integrity.
Implementation Method 1
The coupling parts comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels, effects a locking in the plane of the floor panels and perpendicular to the respective edges; the coupling parts also comprise a vertically active locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
Floor panels for forming a floor covering, which floor panels (1), on at least one pair of edges (4, 5), are provided with coupling parts (8, 9) comprising horizontally and vertically active locking systems, that these coupling parts substantially are manufactured from the material of the floor panel, and that these coupling parts are configured such that two such floor panels, at said pair of edges, can be installed and locked to each other by means of a downward movement and/or by means of the fold-down principle.