Interlocking Floor Panel Profiles That Resist Edge Separation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Resilient core floor panels are prone to separation and curling at locking edges due to their material properties, leading to reduced longevity and increased installation difficulty, especially for DIY homeowners.
Innovation Solution
The design incorporates a resilient base layer and a wear layer with a higher degree of stiffness, featuring specific locking profiles with horizontal and vertical features that interlock to prevent separation, where the wear layer forms at least 5% of the channel bed thickness, facilitating easier and more secure installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If resilient core material is used to make floor panels desirable, then the floor panels become more susceptible to separation, pulling apart, and curling at the locking edges
Solution Approach 1:
The patent employs a composite structure consisting of a resilient base layer and a wear layer with different stiffness properties. The wear layer has a higher degree of stiffness than the resilient base layer, creating a composite material system that combines the desirable resilience of the base layer with the dimensional stability and locking performance of the stiffer wear layer.
Solution Approach 2:
The invention applies local quality by giving different parts of the floor panel different mechanical properties. Specifically, the wear layer that forms the locking edges has higher stiffness to prevent separation and curling, while the base layer maintains resilience for comfort and durability. This localized differentiation of material properties solves the contradiction between overall desirability and locking edge reliability.
2Reliability
If the shape of locking features is altered to gain better locking coupling, then the floor panels need to be bent and rolled into locking engagement, adding time and difficulty to installation
Solution Approach 1:
The patent modifies the geometric parameters of the locking features to achieve both strong locking coupling and easy installation. The locking features are designed with specific dimensional relationships that allow them to engage directly without requiring the panel to be bent or rolled. This parameter optimization resolves the contradiction between locking reliability and installation productivity.
3Reliability
If the wear layer forms at least 5% of the channel bed thickness, then the locking profile achieves better performance, but the manufacturing complexity increases
Solution Approach 1:
The patent specifies a quantitative parameter threshold (wear layer forming at least 5% of channel bed thickness) to achieve optimal locking performance. This clear parameter definition allows for standardized manufacturing processes and quality control, reducing the practical complexity despite the multi-layer structure. The specific threshold provides a straightforward manufacturing target.
Data Source
AI summary
A floating floor system includes a plurality of floor panels, each including: a resilient base layer; a wear layer forming an uppermost surface of the floor panel atop the resilient base layer and having a higher degree of stiffness than the resilient base layer; a first locking edge portion having a first locking profile that includes a first horizontal locking feature, a first vertical locking feature, and a channel having a channel floor, being formed by the wear layer and the resilient base layer, and including a channel bed thickness measured between the uppermost surface and the channel floor, the wear layer forming at least 5% of the channel bed thickness; and a second locking edge portion having a second locking profile that includes a second horizontal locking feature, a second vertical locking feature, and a second vertical ridge and being located opposite the first locking edge portion.