Split-Tongue Connector for High-Speed Flooring Panel Assembly
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Solution Overview
Problem
Existing connector systems for joining building panels and furniture components are inefficient due to geometric sensitivity to manufacturing tolerances and require specialized cutting tools, limiting high-speed production capabilities, especially in commercial flooring applications.
Innovation Solution
A connector system featuring a base plate with split-tongue elements and flexible arms with nubs, and a mating groove with specific regions (recess, converging entry, minimum width apex, diverging hold, and cap) that allows for high-speed fabrication using circular saw cuts, enabling economical production and easy removal of components without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If steps are formed in the mating groove using rotary router or linear broach cutters, then the connector can be forcibly drawn into the groove, but the production speed is limited due to tool heating and chip removal considerations
Solution Approach 1:
The connector tongue is divided into two separate flexible arms instead of a solid tongue. This segmentation allows the arms to deflect and engage with the groove steps, providing the necessary draw-in force through elastic deformation rather than requiring high-speed specialized cutting tools.
Solution Approach 2:
The groove geometry is modified to include steps that interact with the flexible arms at specific positions. The hold region extension line exits through the groove entrance, allowing standard high-speed circular saws to create the necessary geometric features without specialized tools, thereby increasing production speed while maintaining connector engagement force.
2Strength
If a solid tongue is machined from the substrate, then structural strength is maintained, but saleable decorative surface is lost
Solution Approach 1:
The solid tongue is segmented into two flexible arms that can be positioned at the edges of the substrate rather than removing material from the center. This allows the decorative surface to be preserved while still providing the necessary structural elements for connection.
Solution Approach 2:
The connector uses flexible arms instead of rigid solid tongue material. These flexible arms provide sufficient structural strength for connection while requiring minimal substrate material, thereby preserving the decorative surface area of the flooring panels.
3Manufacturing precision
If the hold region extension line intersects the opposite sidewall of the groove, then specialized cutting tools are required, but this limits high-speed commercial flooring production
Solution Approach 1:
The groove geometry parameters are specifically designed so that the hold region extension line exits through the groove entrance rather than intersecting the opposite sidewall. This geometric modification allows the use of standard high-speed circular saws with diameters appropriate for commercial flooring production, eliminating the need for specialized low-speed cutting tools while maintaining precise connector engagement.
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 system facilitates efficient and cost-effective mechanical joining of construction elements, allowing for high-speed production and easy removal of components, while maintaining structural integrity and aesthetic concealment.
Implementation Method 1
The connector element comprises a base plate with split-tongue elements protruding from said base plate, each split-tongue element designed to mate with one of said mating grooves and having two flexible arms protruding from said base plate. The flexible arms have outward facing protruding nubs at their distal ends. Contact of the nubs with said groove diverging region imposes significant residual arm deflection after the connector element is fully inserted in the mating groove such that a force applied to the diverging hold region by said deflection of the flexible arms results in a force component tending to pull said connector split-tongue elements into said mating groove.
Data Source
Figure 1~3B
Figure 4
Figure 5~6
AI summary
A connector system for mechanically connecting two structural elements to each other, consisting of a connector element and mating grooves in each structural element. The connector element is comprised of a base plate having a split-tongue element at each side or end of said base plate. Each joined element has a mating groove formed into its connector- receiving surface. The mating groove is designed to allow fabrication via four sequential circular saw cuts, without loss of saleable decorative surface, and at a rate consistent with economical commercial production of vinyl, laminate, or hardwood flooring. The connector element is readily extruded in a variety of polymers, including PVC. The connector and mating grooves interact so as to generate a force component acting to forcibly draw the connector into the mating grooves. The connector system operation is relatively insensitive to geometric deviations associated with normal manufacturing methods.