Surface-Covering Plank Connections with Low-Overlap Snap-Fit Tongues
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing plank connections require significant vertical pressure to overcome large overlaps, making installation difficult and risking damage to the planks.
Innovation Solution
Incorporating a guiding recess above the proximal lip and optimizing protrusion and lip angles to reduce the overlap to less than 0.15 mm, allowing for a smoother installation process while maintaining connection strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large overlap is used to ensure strong connection, then the connection strength is improved, but the installation difficulty increases due to high vertical pressure required
Solution Approach 1:
The connection process is divided into two distinct phases: a preliminary overlapping phase where planks are aligned with minimal overlap (reducing installation force), and a final locking phase where the connecting tongue engages the connecting groove. This segmentation allows the installation process to proceed with lower force while still achieving strong connection.
Solution Approach 2:
The groove is pre-formed in the second plank before connection, and the tongue is pre-formed in the first plank. This preliminary preparation eliminates the need for large overlaps during installation, as the geometric features are already in place to guide and secure the connection with minimal force.
2Strength
If high vertical pressure is applied to overcome overlap resistance, then the connection strength is improved, but the risk of plank damage increases
Solution Approach 1:
The invention changes the geometric parameters of the connection features, specifically reducing the overlap dimension to less than 0.15 mm. This parameter change directly reduces the resistance force that must be overcome during installation, thereby reducing the risk of plank damage while maintaining connection strength through the tongue-groove engagement.
3Ease of operation
If a small overlap is used to reduce installation pressure, then the ease of installation is improved, but the connection strength may be compromised
Solution Approach 1:
The connecting tongue acts as an intermediary element that transfers and distributes the connection forces. Instead of relying on large overlap areas, the tongue engages with the groove to provide the necessary connection strength, allowing minimal overlap while maintaining structural integrity.
Solution Approach 2:
The connection mechanism transitions from relying primarily on transverse overlap to utilizing vertical engagement through the tongue-groove interface. This dimensional shift allows the connection to achieve strength through depth (vertical engagement) rather than width (overlap area).
Data Source
AI summary
A set of planks (10) for covering a surface (12), comprising a first plank (16) having a first edge (24) defining a connecting tongue (26), and a second plank (18) having a second edge (28) defining a connecting groove (30), the first plank being movable between a disconnected position and a connected position, in which the connecting tongue is snap-fit in the connecting groove, the connecting tongue comprising a distal protrusion (40A) and a proximal protrusion (40B) adapted to abut upwards in the connected position against a proximal lip (42A) and a distal lip (42B) of the connecting groove. The second edge defines a guiding recess (38) at least partly located above the proximal lip (42A) for receiving the distal protrusion in an intermediate position of the first plank, in which the proximal protrusion abuts downwards against the distal lip.