Floor Panel Edge Locking Lip Shortening for Stress Relief
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Solution Overview
Problem
Existing panel connection methods, particularly push-lock panels, often result in damage to the carrier plates due to the rigidity of the materials used, leading to cracks and reduced flexibility, especially when connecting side edges with perpendicular movement, which increases the risk of stress-related damage and requires additional, costly elastic locking elements.
Innovation Solution
The solution involves shortening the locking lip and/or locking lug in sections along the side edges, varying the overhang width, to reduce stress and load on the panels during connection, allowing for a firm and permanent lock without the need for separate elastic elements, by milling the side edges to create varying overhangs that distribute stress more evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the carrier plate is made of rigid wood-based materials like MDF or HDF, then the panel achieves sufficient strength and stability, but the side edges become prone to damage and cracking during connection due to lack of flexibility
Solution Approach 1:
The side edges are segmented into multiple locking elements (locking lips and locking lugs) distributed along the connection length. This segmentation allows localized stress distribution and prevents crack propagation across the entire edge, resolving the contradiction between rigid material strength and connection reliability
Solution Approach 2:
The locking elements are designed with specific local geometries (locking lips with rounded ends, locking lugs with complementary shapes) that concentrate flexibility where needed during connection while maintaining overall carrier plate rigidity. The local quality of these locking features enables reliable connection without compromising the global structural strength
2Reliability
If the locking lip and locking lug are made as separate elastic elements, then the connection reliability improves, but the device complexity and production cost increase
Solution Approach 1:
The locking lip and locking lug are merged into the carrier plate as integral features rather than separate components. This combining maintains the reliability of elastic deformation during connection while eliminating the complexity of separate elastic elements, reducing production steps and assembly operations
Solution Approach 2:
The carrier plate serves multiple functions: it provides structural support, contains the locking mechanisms, and enables the connection process through its own elastic deformation. This multi-functionality eliminates the need for dedicated separate elastic locking elements, reducing device complexity while maintaining connection reliability
3Strength
If the locking lip and locking lug have full length along the side edges, then the connection strength is maximized, but the stress concentration during connection increases causing damage
Solution Approach 1:
The continuous locking profile is segmented into discrete locking lips and locking lugs spaced along the side edges. This segmentation reduces stress concentration at any single point during connection while distributing the loading across multiple elements, maintaining overall connection strength without excessive stress
Solution Approach 2:
The locking elements are designed to engage partially during the connection process, with the locking lip inserting into the locking lug groove and engaging only the necessary portion for secure connection. This partial engagement reduces the excessive stress that would result from full-length continuous contact
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a panel (1, 2, 21, 22, 41, 42, 61, 62) for forming a covering, in particular a floor covering, having additional similar coverings (1, 2, 21, 22, 41, 42, 61, 62), having a first side edge (3, 23, 43, 63) and a second side edge (4, 24, 44, 64) arranged opposite the first side edge (3, 23, 43, 63), wherein the first side edge (3, 23, 43, 63) has a locking lip (7, 27, 47, 67) and the second side edge (4, 24, 44, 64) has a locking nose (12, 32, 52, 72), wherein the first and second side edge (3, 4, 23, 24, 43, 44, 63, 64) are designed such that the locking lip (7, 27, 47, 67) and the locking nose (12, 32, 52, 72) of the side edges (3, 4, 23, 24, 43, 44, 63, 64) connected to one another form a projection (15, 35, 75, 55). In order that damage to the side edges occurs less frequently during connecting of the panels, according to the invention the locking lip (7, 27, 47, 67) and/or the locking nose (12, 32, 52, 72) is shortened in regions so that the width (b) of the projection (15, 35, 55, 75) varies along the side edges (3, 4, 23, 24, 43, 44, 63, 64) that are connected to one another.