Flexible Tongue Floor Panel Joint for Thin Panel Locking
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Solution Overview
Problem
Existing mechanical locking systems for thin floor panels face challenges in achieving a cost-efficient and compact design suitable for thin floor panels, particularly in forming and inserting flexible tongues that can lock both vertically and horizontally, while maintaining strength and flexibility.
Innovation Solution
A mechanical locking system featuring a flexible tongue with curved sections that can be deformed into a straight rod shape for vertical locking, combined with a method to form and insert the tongue from the core material of the floor panel during production, allowing for a compact and cost-effective solution for thin panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a mechanical locking system with flexible tongue is used in thin floor panels, then the locking strength is improved, but the panel thickness requirement increases
Solution Approach 1:
The locking system is divided into separate functional components: a locking element for horizontal locking and a flexible tongue for vertical locking. This segmentation allows each component to be optimized independently, enabling the flexible tongue to provide strong vertical locking while maintaining compatibility with thin panel structures.
Solution Approach 2:
The locking mechanism transitions from relying solely on vertical engagement to incorporating horizontal locking through a locking element. This dimensional addition allows the system to achieve strong locking performance without increasing panel thickness, as the horizontal component provides additional locking capability.
2Reliability
If a separate flexible tongue component is added for vertical locking, then the locking performance is improved, but the device complexity increases
Solution Approach 1:
The flexible tongue is integrated with the panel core material through forming processes that create the tongue directly from the core. This merging eliminates the need for separate manufacturing and assembly steps for the tongue, reducing overall system complexity while maintaining reliable vertical locking performance.
Solution Approach 2:
The flexible tongue is designed to be formed and inserted during the panel production process itself, rather than being added as a separate post-manufacturing component. This self-service approach embeds the locking functionality directly into the panel manufacturing workflow, simplifying the overall system.
3Ease of manufacture
If the flexible tongue is formed from core material during production, then the manufacturing cost is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The forming process utilizes controlled plastic deformation of the core material to create the flexible tongue geometry. By adjusting forming parameters such as pressure, temperature, and deformation rate, the system achieves the required tongue precision while maintaining cost-effective manufacturing processes suitable for thin panels.
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 the creation of a strong and flexible locking system suitable for thin floor panels, reducing production costs and allowing for the use in panels as thin as 3-5 mm, while maintaining effective locking performance.
Implementation Method 1
The tongue sections are configured to be pressed inwardly during locking by the second edge such that the curved sections are at least partially straightened and deformed
Implementation Method 2
a flexible tongue, which is arranged in a displacement groove at a first edge of a first panel and a tongue groove at a second edge of an adjacent second panel, the flexible tongue being configured to cooperate with the tongue groove for locking
Data Source
Figure 1a~1e
Figure 2a~2f
Figure 3a~3f
AI summary
There is disclosed a set of essentially identical floor panels provided with a mechanical locking system comprising a flexible tongue (10), which is arranged in a displacement groove at a first edge of a first panel (1), and a tongue groove at a second edge of an adjacent second panel (1'). The flexible tongue is configured to cooperate with the tongue groove for locking of the first and the second edges in a vertical direction. The second floor panel comprises a protrusion (21) comprising a sliding edge which is configured to cooperate with a sliding surface of the flexible tongue during locking and to press and bend a flexible tongue section (Ts1, Ts2) into a cavity (22) of the displacement groove. The flexible tongue section is configured to move back outwardly in a final stage of the locking such that the a locking surface of the flexible tongue is inserted into the tongue groove. The flexible tongue is straight, such as being a straight rod shaped component.