Vertical Assembly Panel Coupling with Horizontal Locking
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Solution Overview
Problem
Existing floor and wall coverings struggle with resistance to horizontal disassembly, particularly under heavy loads, and current solutions either complicate installation or compromise aesthetic appeal.
Innovation Solution
A polyvinyl chloride panel design featuring parallel grooves and studs with inclined and chamfered features that facilitate vertical assembly and enhance resistance to both horizontal and vertical disassembly forces, while maintaining a visually appealing aesthetic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional male-female coupling means are used with inclined proximal walls, then vertical assembly is facilitated, but resistance to horizontal disassembly is insufficient
Solution Approach 1:
The coupling means are segmented into multiple functional elements: proximal walls for vertical guidance, distal walls with notches for horizontal locking, and separate stopper formation. This segmentation allows each element to specialize in one function, resolving the contradiction between ease of vertical assembly and resistance to horizontal disassembly.
Solution Approach 2:
The invention adds a horizontal locking dimension to the traditionally vertical coupling system. By introducing distal walls with notches that engage horizontally, the system gains resistance to horizontal disassembly without compromising vertical assembly ease, as the horizontal locking occurs after vertical insertion.
2Strength
If dovetail shapes are used to maximize bearing surfaces, then resistance to horizontal disassembly is improved, but manufacturing complexity and aesthetic appearance deteriorate
Solution Approach 1:
Instead of changing the fundamental dovetail geometry, the invention modifies parameters such as the addition of notches and lugs on existing wall surfaces. This allows achieving enhanced horizontal locking through parameter adjustments rather than complex shape changes, simplifying manufacturing while maintaining strength.
Solution Approach 2:
The coupling means use simple groove and stud geometries that can be easily replicated through copying in manufacturing processes, avoiding the need for complex die-cutting operations required for traditional dovetail shapes. The notches and lugs are formed as additional features on these simple base geometries.
3Strength
If external studs are positioned on the inner side of the panel, then horizontal disassembly resistance is improved, but the locking effect weakens and the profile complexity increases
Solution Approach 1:
The coupling means employ asymmetric geometries where the male and female components have complementary but non-identical shapes. The notches and lugs are positioned asymmetrically on the distal walls, creating a reliable locking effect that prevents both horizontal and vertical disassembly while maintaining simple manufacturing profiles.
4Strength
If gluing is used to resist heavy loads, then resistance to horizontal disassembly is improved, but installation time and complexity increase
Solution Approach 1:
The coupling means are self-locking through the engagement of notches and lugs on the distal walls, eliminating the need for external adhesives or additional fastening operations. The mechanical interlocking provides sufficient resistance to heavy loads while maintaining quick, tool-free installation.
Data Source
AI summary
A panel (1) having a blade or slab shape, preferably made of a plastic material for producing a floor or wall covering, said panel (1) comprising two pairs of opposite sides defining four edges, two edges of which comprise male coupling means (2), and two edges comprise complementary female coupling means (3), the kinematics of assembling of two adjacent panels (1) being vertical, characterized in that:the male coupling means (2) comprise two parallel grooves extending along the edge and opening onto a bottom face of the panel (1), so as to define an internal male groove (2a), an external male groove (2b), an internal male stud (2c), and an external male stud (2d);the female coupling means (3) comprise two parallel grooves extending along the edge and opening on an upper face of the panel (1), so as to define a female internal groove (3a), a female external groove (3b), a female internal stud (3c), and a female external stud (3d);the male coupling means (2) comprise two lugs (4) and/or notches (5) and the female coupling means (3) comprise two complementary notches (5) and/or lugs (4) forming, after assembly of two adjacent panels (1), stoppers against a vertical displacement between two assembled adjacent panels (1).