Drop-Down Panel Locking Profile With Low Insertion Force
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Solution Overview
Problem
Existing panels with drop-down coupling profiles require a forceful vertical insertion, which can damage the profiles and are cumbersome, and applying small inclination angles compromises interlocking strength.
Innovation Solution
The panels feature interlocking surface areas with upper and lower sections inclined at different angles and creases, allowing smooth vertical insertion and strong locking without additional features, produced easily by milling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the interlocking surface areas have large inclination angles, then the vertical interlocking strength is improved, but the required insertion force becomes excessively high and may damage the profiles
Solution Approach 1:
The interlocking surface area is segmented into multiple sections with different inclination angles. The first section has a smaller inclination angle to facilitate easy insertion, while the second section has a larger inclination angle to provide strong vertical interlocking. This segmentation allows the profile to achieve both easy installation and strong locking without requiring excessive insertion force throughout the entire surface.
Solution Approach 2:
Different sections of the interlocking surface area have different local properties (inclination angles) optimized for different functions. The first section is designed with a smaller angle for smooth insertion, while the second section is designed with a larger angle for strong interlocking. This local differentiation allows each part of the surface to perform its specific function optimally.
2Force
If the interlocking surface areas have small inclination angles, then the insertion force is reduced, but the vertical interlocking strength becomes inadequate
Solution Approach 1:
The interlocking surface area is divided into multiple sections where the first section has a small inclination angle for easy insertion and the second section has a larger inclination angle for strong vertical interlocking. This segmentation ensures that neither extreme (too small or too large angle) compromises the overall performance.
Solution Approach 2:
The solution moves from a single-angle design to a multi-sectional design with varying angles along the vertical dimension. By introducing this dimensional variation, the profile achieves both low insertion force (at the entry section) and high interlocking strength (at the locking section) within the same interlocking surface area.
3Strength
If additional interlocking features are added to the profiles, then the interlocking strength is improved, but the design complexity and production costs increase
Solution Approach 1:
Instead of adding separate interlocking features, the invention optimizes the local quality of the existing interlocking surface area by creating sections with different inclination angles. This approach achieves enhanced interlocking strength through geometric variation rather than adding more features, thereby maintaining design simplicity and reducing production costs.
Solution Approach 2:
The invention changes the geometric parameters (inclination angles) of the interlocking surface area sections rather than adding new features. By varying the angle parameter across different sections, the profile achieves stronger interlocking while maintaining a simple, manufacturable design that can be produced by conventional milling processes.
Data Source
AI summary
Provided is a panel suitable as a floor, ceiling or wall panel, which panel is of a planar design having an upper side, a bottom side and side edges which include a first side edge provided with a first profile and a second side edge provided with a second profile. The first profile and the second profile are interacting profiles that can be coupled to each other, so that a first panel can be coupled in one common plane to a second, identical panel by the interacting profiles. The first profile and the second profile in coupled condition establish an interlocking with each other both in a horizontal direction and in a vertical direction. The first profile and the second profile are configured to allow for a coupling of the interacting profiles of the first panel with the second panel by a downward insertion of the interacting profile of the second panel into the interacting profile of the first panel.