Wood Panel Locking Edge Width Variation
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Solution Overview
Problem
Existing floor panels with separate plastic locking elements are costly, complex to produce, and prone to errors during self-installation, leading to inadequate locking and potential separation over time, especially with thinner panels.
Innovation Solution
A panel design featuring spring elements integrated into the core of the panel, with angled chamfers and varying locking edge widths, allowing for improved vertical force transmission and simplified production, enabling effective locking and stability even with thin panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate plastic locking elements are used, then locking function is achieved, but production cost increases and manufacturing complexity increases
Solution Approach 1:
The locking element is integrated directly into the panel profile as a one-piece construction, merging the locking function with the panel structure itself. This eliminates separate locking components and simplifies production by removing the need for separate manufacturing and assembly processes for locking elements.
Solution Approach 2:
The panel profile serves multiple functions simultaneously: it provides structural support, contains the locking mechanism, and enables both horizontal and vertical locking. The integrated design makes the panel itself multi-functional, eliminating the need for separate dedicated locking components.
2Reliability
If separate plastic locking elements are used, then locking function is achieved, but manufacturing precision requirements increase due to matching tolerances from two separate production processes
Solution Approach 1:
By integrating the locking element into the panel profile as a one-piece construction, the invention eliminates the need to match tolerances between separate components produced in different processes. The locking feature is manufactured in the same process as the panel profile itself, ensuring consistent tolerances.
3Reliability
If locking element is secured to prevent falling out, then locking reliability is maintained, but production complexity and cost increase
Solution Approach 1:
The locking element is formed as an integral part of the panel profile through one-piece extrusion, eliminating the need for separate securing mechanisms. The locking feature is inherently secured within the profile structure during manufacturing, removing the need for additional retention systems.
4Force
If tongue element dimensions are increased to compensate for insufficient plastic strength, then locking force is adequate, but material cost and device complexity increase
Solution Approach 1:
The panel profile uses composite wood material or wood-plastic mixture that provides superior strength-to-weight ratio compared to pure plastic. This allows the locking element to achieve adequate locking force with smaller, more efficient dimensions while utilizing the inherent strength properties of the composite material.
5Ease of manufacture
If locking surfaces are dimensioned very small to enable joining, then connection is possible, but vertically aligned forces that can be absorbed are limited
Solution Approach 1:
The locking mechanism incorporates features that extend in multiple dimensions, including vertical engagement surfaces and horizontal locking surfaces working together. This multi-dimensional locking approach allows small contact surfaces to effectively transmit both joining forces and vertical loads through the combined action of different dimensional features.
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 cost-effective, stable, and reliable locking mechanism suitable for thin panels, reducing the risk of misinstallation and enhancing durability under normal stress conditions.
Implementation Method 1
at least one spring element (6) which is connected to the core (3) on at least one of its two ends (6a, 6b) in the direction of its side edge (II) and can be moved in the horizontal direction by a joining movement and snaps in behind a locking edge (25, 25a) extending essentially in the horizontal direction
Data Source
AI summary
A panel has a core of wood material or a wood material/plastic mixture, a top and an underside, and two opposite side edges, which have profiles that correspond to each other such that two identically configured panels can be connected and locked to one another in the horizontal (H) and vertical (V) directions by an essentially vertical joining movement. The locking in the horizontal direction (H) can be brought about by a hook connection with an upper locking section having a hook element and a lower locking section having a hook element. The locking in the vertical direction (V) can be brought about by at least one tongue element that is formed from the core in one piece and can be moved in the horizontal direction (H). The at least one tongue element provided on the lower locking section is free with respect to the core in the direction of the opposite side edge by means of an essentially vertical slot and during the joining movement snaps in behind a locking edge extending essentially in the horizontal direction (H), which locking edge is embodied on a locking projection. The tongue element is connected to the core on at least one of its two ends in the direction of its side edge (II), and the width (B1, B2) of the locking edge is different in size over the length (L) of the opposite side edge (I).