Building Panel Locking Device with Displaceable Protrusion
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Solution Overview
Problem
Existing building panel locking configurations do not provide sufficient vertical locking strength while minimizing cupping effects and material usage, particularly when using thermoforming techniques.
Innovation Solution
A set of building panels featuring a locking device with an upwardly extending protrusion integrally formed with one panel, which cooperates with a cavity in an adjacent panel for vertical locking, and includes a locking element and groove for horizontal locking, all made from a polymer-based material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional locking configuration is used, then the panels can be assembled, but the vertical locking strength is insufficient and cupping effects occur
Solution Approach 1:
The protrusion is designed to be displaceable (pivotable and/or bendable) rather than fixed, allowing it to dynamically adapt during assembly and locking. This dynamic capability enables the protrusion to engage effectively with the cavity while reducing stress concentration that causes cupping, thereby improving both vertical locking strength and stability.
Solution Approach 2:
The locking mechanism transitions from conventional single-dimension engagement to multi-dimensional engagement. The protrusion extends at least partially upwards (vertical dimension) and can pivot/bend in multiple directions, creating a three-dimensional locking action that enhances vertical locking strength while distributing forces to reduce cupping effects.
2Quantity of substance
If traditional locking mechanisms are used, then panels can be connected, but material usage is not optimized
Solution Approach 1:
The protrusion is integrally formed with the second edge portion as a single piece, merging the locking function with the panel structure itself. This integration eliminates the need for separate locking components, reducing material usage while maintaining manufacturing simplicity through thermoforming processes.
Solution Approach 2:
The protrusion is designed with specific geometric parameters (extension height, pivot/bend capabilities) that optimize material efficiency. By carefully controlling the protrusion's dimensions and flexibility characteristics, the design achieves effective locking with minimal additional material while remaining suitable for thermoforming production.
3Strength
If the protrusion is made rigid for strong locking, then vertical locking improves, but the ability to pivot and bend is reduced
Solution Approach 1:
The protrusion exhibits different mechanical properties at different locations: the region engaging with the cavity is designed with appropriate flexibility for pivoting and bending, while the overall structure maintains sufficient rigidity for strong vertical locking. This localized differentiation of mechanical properties allows simultaneous achievement of locking strength and adaptability.
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 achieves stronger vertical locking, reduces cupping effects, and allows for more material-efficient production, particularly through thermoforming, while maintaining a robust locking mechanism.
Implementation Method 1
a displaceable, such as pivotable and/or bendable, protrusion arranged in the second edge portion
Implementation Method 2
a displaceable, such as pivotable and/or bendable, protrusion arranged in the second edge portion
Implementation Method 3
The locking element and the locking groove are configured to cooperate for horizontal locking of the first and second edge portions
Implementation Method 4
The protrusion extends at least partially upwards and is integrally formed with the second edge portion
Data Source
AI summary
A set of building panels including a first and second panel and a locking device for locking a first edge portion of the first panel to a second edge portion of the second panel to obtain an assembled state of the panels. A core of the first and second panels includes a polymer-based material. The locking device includes a locking element extending upwards from a lower strip provided in the first edge portion, and a locking groove arranged in the second edge portion, wherein the locking element and the locking groove are configured to cooperate for horizontal locking of the first and second edge portions. The locking device further includes a cavity arranged in the first edge portion and a displaceable protrusion arranged in the second edge portion, wherein the protrusion and the cavity are configured to cooperate for vertical locking of the first and second edge portions.