One-Piece Floor Panel Coupling for Stable Fold-Down Locking
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Solution Overview
Problem
Existing floor panels with one-piece coupling parts often suffer from unstable connections, either being too taut or offering insufficient resistance against unlocking, and separate elastic locking strips are expensive.
Innovation Solution
The use of one-piece coupling parts with horizontally and vertically active locking systems, integrated into the panel material, allowing for secure coupling through turning or downward movements, with specific structural features and material characteristics to enhance stability and ease of installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate elastic locking strips are used, then vertical locking quality is improved, but production cost increases
Solution Approach 1:
The locking elements and locking surfaces are integrated directly into the coupling profile as a single piece, eliminating the need for separate elastic locking strips. The coupling profile includes laterally extending locking elements with locking surfaces that engage with complementary surfaces on adjacent floor panels, achieving both structural integrity and cost-effectiveness in a unified design.
2Ease of manufacture
If one-piece coupling parts are used, then production cost is reduced, but connection stability deteriorates
Solution Approach 1:
The coupling profile is designed with strategically positioned locking elements and locking surfaces at critical locations along the edge of the floor panel. The locking elements extend laterally from the coupling profile and include specifically shaped locking surfaces that engage with complementary surfaces, concentrating the necessary structural functionality in precise locations to achieve stable connections while maintaining one-piece construction.
3Strength
If coupling parts are made too taut, then connection strength is improved, but ease of installation deteriorates
Solution Approach 1:
The coupling profile incorporates laterally extending locking elements with locking surfaces that engage through a dynamic folding movement. The floor panel edges are folded downward and the locking elements are designed to flex and engage smoothly during installation, allowing the connection to tighten gradually rather than requiring forceful insertion. This dynamic engagement mechanism provides strong connections while maintaining ease of installation.
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 a sturdy and user-friendly coupling mechanism that maintains stability while simplifying installation, suitable for various materials including synthetic panels that expand significantly with temperature changes.
Implementation Method 1
the lip is resilient and can be bent in a downward direction
Data Source
AI summary
A floor panel for forming a floor covering, wherein the floor covering consists of floor panels, which, on at least one pair of edges, are provided with coupling parts. The coupling parts substantially are manufactured from the material of the floor panel, and the coupling parts are configured such that two such floor panels, at the 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.