Laminated Floor Panel Hook Coupling Against Thermal Decoupling

Solution Overview

Problem

Laminated floor panels experience significant mechanical stress and potential decoupling due to thermal expansion and contraction, especially at the short sides, when coupled using a tongue and groove system, leading to issues like local disengagement from the subflooring and extreme cases of tongues and grooves decoupling.

Innovation Solution

Incorporating a first hook that protrudes from the second upward tongue, parallel to the second side, which hooks into a clearance between the lower upward tongue block and the second upward tongue of an adjacent panel, and a second hook on the fourth downward tongue, allowing for simultaneous locking with a third further panel, thereby strengthening the coupling and reducing thermal expansion and contraction effects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If floor panels are coupled using a tongue and groove system, then the floor panels can be assembled without glue, but significant mechanical stress builds up during thermal expansion and contraction causing decoupling

Engineering Contradiction:

Improveassembly without glueVSAvoidcoupling stability under thermal stress

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The coupling mechanism is divided into multiple independent elements: a first tongue and groove pair for primary coupling, and a second tongue and groove pair for additional stabilization. This segmentation allows each coupling element to independently manage thermal stress, preventing single-point failure and maintaining overall joint integrity during expansion and contraction cycles.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent incorporates clearance spaces between the tongues and grooves of both coupling pairs, creating built-in compression zones that absorb thermal expansion forces before they can cause decoupling. These pre-designed gaps act as cushioning elements that accommodate dimensional changes during temperature fluctuations, protecting the joint from mechanical stress.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Productivity

If floor panels are coupled using a tongue and groove system, then the panels can be installed quickly, but the tongues and grooves may decouple under extreme thermal stress

Engineering Contradiction:

Improveinstallation speedVSAvoidcoupling strength under thermal stress

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The coupling mechanism is divided into multiple independent elements: a first tongue and groove pair for primary coupling, and a second tongue and groove pair for additional stabilization. This segmentation allows each coupling element to independently manage thermal stress, preventing single-point failure and maintaining overall joint integrity during expansion and contraction cycles.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent incorporates clearance spaces between the tongues and grooves of both coupling pairs, creating built-in compression zones that absorb thermal expansion forces before they can cause decoupling. These pre-designed gaps act as cushioning elements that accommodate dimensional changes during temperature fluctuations, protecting the joint from mechanical stress.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Strength

If floor panels are glued to the subflooring, then the connection is strong, but the panels cannot accommodate thermal expansion and contraction

Engineering Contradiction:

Improveconnection strength to subflooringVSAvoidability to accommodate thermal expansion

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The coupling mechanism transitions from a static rigid connection (glue) to a dynamic mechanical system that can move and adjust. The tongues and grooves with clearance spaces create a movable joint that allows panels to expand and contract while maintaining connection, adapting to thermal changes without requiring rigid adhesion.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent incorporates clearance spaces between the tongues and grooves of both coupling pairs, creating built-in compression zones that absorb thermal expansion forces before they can cause decoupling. These pre-designed gaps act as cushioning elements that accommodate dimensional changes during temperature fluctuations, protecting the joint from mechanical stress.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 enhanced coupling mechanism significantly reduces the adverse effects of thermal expansion and contraction, ensuring a stronger and more stable connection between floor panels and the subflooring, minimizing the risk of decoupling.

Implementation Method 1

A well known problem of floor coverings comprising laminated floor panels is related to thermal expansion or contraction, particularly when the floor panels are subjected to moisture in a non-uniform manner.

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentEP3918211B1Floor panel and floor covering

Publication Date: 2022.09.07 I4F LICENSING NV

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AI summary

The present invention relates to a floor panel and to a floor covering comprising a plurality of such floor panels. The present invention particularly relates to a laminated floor panel. The floor panel of the invention comprises a hook that protrudes from an upward tongue of one floor panel to engage a clearance between an upward tongue block and an upward tongue of an adjacent floor panel.