Rigid Core Tile Snap-Fit Locking Mechanism
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Solution Overview
Problem
Existing Luxury Vinyl Tiles (LVT) with rigid core layers are difficult to connect and separate due to their stiffness, making installation complex and tiring, and a snap-fit locking system is not feasible due to the mechanical difficulty of inserting or separating tiles with such core layers.
Innovation Solution
The tiles feature a core layer with a connecting tongue and groove system, allowing for snap-fitting with a reasonable insertion effort, where the core layer is designed with a specific composition and structure to facilitate easy connection and disconnection, including a thermoplastic material with controlled plasticizer content, and an additional groove on one tile that acts like a bridge to reduce the effort required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid core layer is used to provide structural stability, then the tiles maintain their shape and durability, but the tiles become difficult to connect and separate due to stiffness
Solution Approach 1:
The core layer is segmented into two distinct parts: a rigid portion that provides structural stability and a flexible portion that enables easy connection and separation. This segmentation allows each part to fulfill its specific function without compromising the other.
Solution Approach 2:
Different regions of the core layer are given different mechanical properties. The first part has high rigidity for structural support, while the second part has controlled flexibility (through plasticizer content) to allow snap-fit connections. This local differentiation resolves the contradiction between overall rigidity and local flexibility.
2Ease of operation
If a snap-fit locking system is implemented, then connection and separation become easier, but the rigid core layer creates excessive insertion effort
Solution Approach 1:
The plasticizer content in the flexible part of the core layer is precisely controlled within 5-20 wt% to optimize the balance between flexibility for easy insertion and rigidity for maintaining connection strength. This parameter optimization reduces insertion effort while preserving connection efficacy.
Solution Approach 2:
The core layer is constructed as a composite with two parts having different material compositions. The first part uses a rigid composition for structural support, while the second part uses a thermoplastic material with controlled plasticizer content to provide flexibility for snap-fit connections, reducing insertion effort.
3Reliability
If the core layer is made too stiff for structural integrity, then the tiles maintain durability, but separation and repositioning become mechanically difficult
Solution Approach 1:
The core layer is divided into a rigid part for durability and a flexible part for easy separation. This allows the tile to be durable during use but easily separable when needed for repair or repositioning.
Solution Approach 2:
The plasticizer content is controlled at 5-20 wt% in the flexible part to achieve the optimal balance between maintaining connection strength for durability and providing sufficient flexibility for easy separation and repositioning.
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 enables easy and efficient connection and disconnection of tiles with a lower insertion force, making the installation process simpler and cost-effective while maintaining the tiles' rigidity and durability.
Implementation Method 1
The core layer comprises a thermoplastic material and has a plasticizer content of less than 5 wt%, based on a total weight of the core layer
Data Source
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AI summary
A set (1) of tiles (5) adapted to cover a surface (10) perpendicular to a thickness direction (V) of the tiles (5), each of the tiles comprising at least one upper layer (24), and an underlying rigid core layer (22), the core layer and the upper layer being superimposed in the thickness direction, and the core layer defining a lower surface (S) opposite the upper layer. The tiles comprise at least one first tile (15) having a first edge extending in a longitudinal direction (L), the core layer of the first tile (15) defining a connecting groove (28) in the first edge. The tiles comprise at least one second tile (20) having a second edge extending in the longitudinal direction, the core layer of the second tile defining a connecting tongue (34) protruding from the second edge, the connecting tongue being adapted to be snap-fit into the connecting groove in a connecting direction (C) perpendicular to the longitudinal direction (L) and to the thickness direction in a locked configuration of the first tile and the second tile. The lower surface defines an additional groove (30) parallel to the first edge.