Locking Panel Connector with Curved Guide Face
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing interlocking floor panel systems face challenges such as material wastage, increased manufacturing costs, and difficulties in assembling due to the need for specialized tools and equipment, particularly in creating tongues and grooves, and the requirement for separate connectors that can be cumbersome and prone to misalignment.
Innovation Solution
A connector system where each panel has tongues and grooves with specific protrusions and recesses that allow for easy alignment and engagement without the need for additional tools, using a base board and upright portion with locking members and slots that guide the panels into place, enabling secure connection without hammering, and allowing for efficient production with minimal material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tongues and grooves are formed on the panels to enable interlocking connection, then the panels can be connected securely, but a certain width of material must be discarded leading to 10% material waste and increased manufacturing cost
Solution Approach 1:
The invention divides the connection system into two parts: the panel retains its full width without material removal, while a separate connector piece (with tongue and groove structures) is inserted into the panel groove. This segmentation allows the panel to use 100% of its material width while the connector handles the interlocking function, resolving the contradiction between connection security and material waste.
2Ease of manufacture
If a connector with tongue and groove is used to connect panels, then the connection can be achieved, but the notch in the groove is difficult to make at the same time as forming the groove, requiring additional manufacturing steps
Solution Approach 1:
The invention separates the groove formation (in the panel) from the notch formation (in the connector piece). The panel groove can be formed by standard equipment without requiring simultaneous notch creation, while the connector piece is separately manufactured with its tongue and groove features. This segmentation simplifies the manufacturing process for both components.
3Strength
If the connector material has large flexibility to provide sufficient locking force in horizontal direction, then the locking force is adequate, but the assembler has to hammer the panel to force deformation for connection, causing difficulties in assembly and disassembly and potential damage to the groove
Solution Approach 1:
The invention introduces a curved guide face on the connector piece that guides the panel into proper alignment during assembly. This curved surface allows the panel to be guided smoothly into position without requiring hammering or forced deformation, while the connector's flexible material still provides adequate locking force once properly engaged. The curvature resolves the contradiction by enabling gentle, tool-free assembly.
Data Source
AI summary
A flooring system includes multiple panels (10) which are connected to each other by connectors (20). Each panel (10) has a tongue (30) and each connector (20) has an engaging slot (40). The tongue (30) does not extend beyond the side of the panel (10). The panel (10) is moved horizontally to insert the lower protrusion (300) of the tongue (30) into the lower recess (400) of the engaging slot (40) of the connector (20). The inner inclined face (302) of the lower protrusion (300) of the tongue (30) contacts the curved wall (410) of the lower recess (400) of the connector (20). The tongue (30) of the panel (10) is engaged with the engaging slot (40) of the connector (20) by way of pressing the panel in a direction perpendicular to the panel. No hammering to the side of the panel is needed.