Soft PVC Floor Panel Coupling for Tolerance Control
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Solution Overview
Problem
Existing decorative floor panels made of soft PVC face challenges in coupling due to expansion issues and tolerance deviations, leading to difficulties in fitting and locking mechanisms.
Innovation Solution
The development of panels with coupling parts made partially or entirely from soft PVC, featuring milled profiles and hook-shaped locking systems that allow for precise tolerances and controllable elastic properties, enabling smooth and strong coupling through downward or turning movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If panels are made from soft PVC material, then flexibility and ease of installation are improved, but tolerance deviations and expansion issues occur leading to fitting difficulties
Solution Approach 1:
The patent applies parameter changes by modifying the physical state of the PVC material through plasticization, transforming rigid PVC into soft, flexible PVC that can be easily installed while maintaining dimensional stability. The plasticizers modify the material parameters to achieve both flexibility and tolerance control.
Solution Approach 2:
The patent uses composite materials by combining PVC with plasticizers and stabilizers to create a material that exhibits both flexibility for easy installation and dimensional stability to minimize tolerance deviations and expansion during installation.
2Ease of operation
If coupling parts are made from soft PVC, then smooth coupling and elastic properties are improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the coupling parts with the panel body by integrating them as integral components rather than separate attachments. This reduces overall device complexity while maintaining the smooth coupling functionality through the soft PVC material's elastic properties.
Solution Approach 2:
The patent applies dynamics by designing coupling parts that utilize the elastic deformation of soft PVC during the coupling process. The material dynamically adapts during installation to enable smooth engagement, then maintains a stable locked position afterward.
3Adaptability or versatility
If panels are expanded due to heat or sun radiation, then thermal adaptation is improved, but coupling stability deteriorates
Solution Approach 1:
The patent explicitly accounts for thermal expansion by designing the coupling system to accommodate dimensional changes. The soft PVC material and coupling geometry are configured to allow controlled expansion while maintaining coupling stability through elastic recovery and interlocking mechanisms.
Solution Approach 2:
The patent applies beforehand cushioning by incorporating expansion gaps and flexible coupling elements that anticipate and accommodate thermal expansion before it causes stability issues. The soft PVC material acts as a cushion that absorbs expansion stresses.
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 ensures precise and smooth coupling of panels with improved strength, reducing installation difficulties and maintaining a secure connection despite potential expansions from heat or sun radiation.
Implementation Method 1
at least partially in the form of a milled profiled part of this soft PVC. By milling the coupling parts at least partially from soft PVC, very precise tolerances can be maintained. In combination with the use of PVC then very controllable elastic properties may be imparted to the coupling parts
Data Source
AI summary
A panel for forming a covering, more particularly a floor panel for forming a floor covering, which at least at two opposite edges, comprises coupling parts arranged to couple two of such panels to each other by means of a downward movement of one panel in respect to the other. The coupling parts form a first locking system arranged to lock in the plane of the panels and perpendicularly to the edges, as well as form a second locking system, which effects a locking perpendicularly to the plane of the panels. At least one of the coupling parts is formed at least partially in soft PVC (polyvinyl chloride), as well as at least partially formed from a milled profiled part of this soft PVC.