Split-Tongue Connector System for Flooring
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Solution Overview
Problem
Existing connector systems for joining building panels and furniture are inefficient due to geometric sensitivity to manufacturing tolerances and require specialized cutting tools, limiting high-speed production in commercial flooring applications.
Innovation Solution
A connector system featuring lateral and normal split-tongue connectors with flexible arms and mating grooves designed for high-speed fabrication using circular saw cuts, allowing for economical production and easy removal of damaged boards without damaging the connector or adjacent boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steps are formed in the mating groove using rotary router cutter or linear broach cutter, then the connector can be forcibly drawn into the groove, but the manufacturing speed is limited and cannot meet high-speed commercial flooring production requirements
Solution Approach 1:
The patent changes the geometric parameters of the mating groove by eliminating the traditional steps and instead using a continuous tapered geometry with specific angle ranges (15-45 degrees). This parameter change allows the groove to be formed by high-speed circular saw cutting rather than requiring slow rotary router or linear broach cutting, thus achieving both reliable connector drawing and high manufacturing speed
Solution Approach 2:
The patent replaces the mechanical cutting system (rotary router cutter or linear broach cutter) with a high-speed circular saw cutting system. This substitution enables the groove to be formed much faster while the connector drawing force is achieved through the geometric design of the tapered groove rather than mechanical steps
2Reliability
If the mating groove geometry is designed with steps to interact with catches, then the connector can be forcibly drawn in, but the system becomes more sensitive to geometric deviations from manufacturing tolerances
Solution Approach 1:
The patent changes the geometry from a stepped configuration with sharp transitions to a continuous tapered configuration with gradual transitions. This parameter change reduces sensitivity to manufacturing tolerances because the gradual taper provides a larger tolerance window for the connector catches to engage, whereas the stepped geometry requires precise alignment to function properly
3Strength
If a solid tongue is machined from the substrate material, then the connector provides structural strength, but saleable decorative surface is lost
Solution Approach 1:
The patent segments the tongue structure into two separate components: a base plate that remains on the substrate and a connector element that attaches to it. This segmentation allows the decorative surface to be preserved on the substrate while the connector element provides the necessary structural strength for joining
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
Enables efficient, cost-effective mechanical joining of construction elements with improved manufacturing speed and ease of board replacement, suitable for both flooring and furniture applications.
Implementation Method 1
a connector system featuring lateral and normal split-tongue connectors with flexible arms and mating grooves
Data Source
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.