CN101680230B - Mechanical locking of floor panels by vertical folding - Google Patents

Abstract

The invention relates to floor panels (1, 1', 1") having a mechanical locking system on long and short edges (5a, 5b, 4a, 4b) so that they can be installed by vertical folding, wherein the long edge (5a, 5b) locking system prevents the short edges (4a, 4b) from separating during the folding operation.

Description

Mechanical locking of floor panels by vertical folding

technical field

The present invention mainly relates to the field of floor panels with a mechanical locking system with a flexible displaceable tongue that facilitates installation. The present invention provides a new and improved locking system and method of installation.

Background technique

In particular but not limitatively, the present invention relates to a mechanical locking system for rectangular floor panels having long and short edges. It should be emphasized that the long and short edges are only used to simplify the description. The floor panels can also be square. In general, however, the invention is equally applicable to architectural panels. More particularly, the present invention relates to a mechanical locking system capable of locking all four edges of a panel to other panels with a single angling operation, such mechanical locking system preferably comprising a flexible or partially flexible tenon Tongues and/or displaceable tongues and/or flexible locking strips to facilitate installation of architectural panels.

Such floor panels are described in WO 2006/043893, which discloses floor panels with a locking system comprising a locking element cooperating with a locking groove for horizontal locking, and a tongue groove for Flexible tongue that locks in the vertical direction. During the connection of the floor panels, the flexible tongue is bent in a horizontal plane, so that the panels can be installed by vertical folding or only by vertical movement. "Vertical folding" refers to this connection of three panels: where the first and second panels are connected, and a single angling operation of the new Two vertical edges of the panels are connected to both the first and second panels. This connection takes place, for example, when a long edge of a first panel in the first row has been connected to a long edge of a second panel in the second row. The newly folded panel is then joined by angling to the long edge of the first panel in the first row. This particular type of angling operation, which also connects the short edges of the newly folded panel and the second panel, is called a "vertical fold". As the panels are angled towards the subfloor, the short edges are gradually folded together like scissors and locked from one edge section to the other. It is also possible to lower the entire panel by only a vertical movement relative to the other panel in order to connect two panels. This particular type of locking is known as "vertical locking". The first row in a flooring system that is designed to be locked by vertical folding is often connected by vertical locking, in which one short edge is pressed vertically down towards the other short edge. Other rows are connected by vertical folds. It is also possible to install entire floors by joining a row with vertical locks. The entire row is then connected to the previously installed row by angling.

Similar floor panels are further described in WO2003/016654 which discloses a locking system comprising a tongue with flexible tabs. The tongue extends and bends substantially in the vertical direction, the end of the tab cooperating with the tongue groove for vertical locking.

This vertical locking and vertical folding creates a separating pressure on the short edges when the flexible tongue or the flexible part of the tongue is displaced horizontally during angling of the long edges. The inventors of the present application have analyzed several floor panels and found that during installation there is a serious risk of the short edges being pushed away from each other and creating gaps between the edge portions of the short edges. Such gaps may prevent further installation and the floor panels will not be able to join. Serious damage to the locking system at the short edges is also possible. Pushing the floorboards sideways towards the short edges during installation prevents gaps. However, this method of installation is complex and difficult to use because three operations must be combined and used in conjunction with the downward deflection of the long edges as described below.

a) the edge of the new floor panel must be in contact with the first floor panel laid on the floor and the long edge of the new panel must be pressed forwards towards the first panel in an angled position;

b) The new panel must be displaced laterally where it is squeezed and deflected upwards and pressed laterally against the short edge of the second panel laid on the floor to counteract the back pressure of the tongue ;

c) The new panels must eventually be deflected downwards towards the floor, and forward and sideways pressure must be maintained during the angling operation.

The inventors have found that this often occurs when the panels are of small thickness and have a small compact locking system on the long edges, or when the panel core consists of a material with a smooth surface such as high density fibreboard (HDF). Separation and mounting issues. This problem can also occur when the panels are short, or with the installation of the first or last panel in each row, as this type of installation usually uses panels that are cut to smaller lengths to allow the floor to fit into the wall position paneling to achieve. The problem of separation in any type of panel using a locking system with a strong flexible tongue is of course extremely difficult to deal with, which generates a substantially horizontal separation pressure during vertical folding. Such a strong tongue is very important in many applications where a high quality vertical connection is required and it is very difficult to install panels with such a flexible tongue by known installation methods.

Contents of the invention

The present invention aims to solve the problem of separation in floors to be installed by vertical folding or vertical locking.

Definition of some terms

Hereinafter, the visible surface of the installed floor panel is referred to as the "front side", and the opposite side of the floor panel facing the sub-floor is referred to as the "rear side". The edge between the front and back is called the "joint edge". By "horizontal plane" is meant a plane extending parallel to the outer portion of the surface layer. The closely juxtaposed upper portions of two adjacent joint edges of two joined floor panels together define a "vertical plane" perpendicular to this horizontal plane.

"Joints" or "locking systems" refer to co-acting connection means, which connect floor panels vertically and/or horizontally. "Mechanical locking system" means that the joint can be achieved without the use of adhesives. Mechanical locking systems can also be combined with gluing in many cases. "Integral" means integrally formed with the panel or attached to the panel at the factory.

By "flexible tongue" is meant a separate tongue which has a length direction along the joint edge, forms part of a vertical locking system, and is at least partially displaceable horizontally during locking. The whole tongue is for example bendable, or it may have a flexible and resilient part which can bend into a locked position or which can bend and bounce back to the original position.

"Angling" refers to a connection that occurs through rotation during which an angular change occurs between two parts being connected or disconnected. When the angling involves the connection of two floor panels, the angular movement takes place such that the upper parts of the joint edges are at least partially in contact with each other during at least part of the angular movement.

"Angling locking system" means a mechanical locking system that can be connected vertically and horizontally by angling, the system comprising a tongue and groove that locks two adjacent edges in a vertical a locking strip in one edge of a panel that is "strip paneling" with a locking element that cooperates with a locking groove on the other edge of a panel known as "groove paneling", and Locks edges horizontally. The locking element and locking groove have a substantially rounded guide surface that guides the locking element into the locking groove, and a locking surface that performs locking and prevents horizontal separation between the edges.

"Installation angle" means when one of two panels in the initial stage of angling installation is in an upwardly deflected position and is pressed by its upper edge against the other panel laying flat on the subfloor The angle usually used between the two panels when on the upper edge of the panel. The installation angle is typically about 25 degrees, and in this position there are only two points of contact between the locking strip panel and the groove panel. In very special cases where there may be more than two points of contact between connectors, the mounting angle is higher than 25 degrees.

"Three-point contact angle" refers to the angle between two floor panels when there are at least three points of contact between parts of the locking system during angling.

"Contact angle" refers to the angle at which the panels are folded when the short edge of one panel makes initial contact with the part of the flexible tongue that will displace horizontally and act in the vertical locking at the short edge.

"Guide angle" refers to the angle between the guide surfaces of the locking element and/or locking groove on the locking bar when they contact each other, or the upper portion of the locking element or the lower portion of the locking groove, respectively, during deflection adjustment. angle between the two floor panels. The guide surfaces are usually rounded or chamfered portions which press the upper edges of the panels towards each other during angling and facilitate insertion of the locking elements into the locking grooves. Most locking systems on the market have a lead angle of about 5 degrees.

By "locking angle" is meant the angle between two floor panels at the final stage of the angling operation when the locking elements and the active locking surfaces on the locking grooves are in initial mutual contact. Most locking systems have a locking angle of about 3 degrees or less.

"Friction angle" refers to when, due to the fact that more than two points of contact act in the yaw lock system, the friction force along the long edge increases significantly during yaw adjustment from the mounting angle and hinders the movement along the long edge. The angle at which the edge is displaced.

"Tongue pressure" refers to the pressure in N when the tongue is in a predetermined position. "Maximum tongue pressure" refers to the pressure of the tongue when it is in the inner position during vertical folding, and "tongue pretension" refers to the pressure at which the tongue is pressed against a part of the tongue groove. The pressure of the tongue locks the position.

Summary of the invention

The present invention relates to a set of floor panels or a floating floor with a mechanical locking system which will improve the installation of floor panels installed by vertical folding and which will hinder or prevent short edge separation during installation.

The invention is based on a first basic understanding that this separation problem is mainly related to the locking system located on the long edges. All known locking systems for locking panels by angling are very easily displaced along the joint when the floor panels are in an initial angled position relative to each other. Friction increases significantly at small angles when the floor panels are almost in locked position. This means that when the angle is high and when part of the flexible tongue has to be squeezed horizontally in order to allow vertical folding, the friction between the long edges is not sufficient to prevent displacement of the short edges during the initial stages of vertical folding. In most locking systems the friction between the long edges increases at small angles, but this is a flaw because the short edges may have separated and the locking system on the short edges cannot overcome the friction at small angles And pull the short edges together. This separation further complicates installation, as the panels have to be angled and squeezed sideways during installation, and there is a serious risk of the locking system on the short edges being damaged.

The main purpose of the present invention is, contrary to the prior art, to solve the problem of separation between the short edges by increasing the friction between the long edges when they are in the angled position and before their final locked position. The increased friction between the long edges can hinder or even prevent displacement of the joint along the long edges when the flexible tongue presses the floor panels away from each other during vertical folding, and it can hinder or even prevent completely This separation of short edges during installation.

The invention is based on the second understanding that the combined action of the long-edge locking system and the short-edge locking system is necessary in floors designed to be installed by vertical folding. The long edge locking system and the short edge locking system should be adapted to each other in order to provide a simple, easy and reliable installation.

According to different aspects offering corresponding advantages, the invention provides new embodiments of the locking system at the long and short edges. Fields of use of the invention are floor panels of any shape and material such as laminate; especially panels with surface materials comprising thermosetting resins, wood, HDF, veneer or stone.

According to a first principle, the invention consists of floor panels having long edges with a locking system which, when the panels are connected by vertical folding, hinders displacement along the joint at angles greater than those used by the currently known technology .

According to one embodiment of the first principle, the present invention provides a set of substantially identical floor panels, each of said floor panels comprising a long edge and a short edge, and having first and Second connector. The connectors are configured to connect adjacent edges. The first connector includes a locking bar with an upwardly directed locking element at an edge of one floor panel, and a downwardly opening locking groove at an adjacent edge of the other floor panel for vertical Connecting adjacent edges horizontally in the direction of the adjacent edges, the second connector comprises a tongue at the edge of one floor panel extending horizontally perpendicular to the edge, and at the adjacent edge of the other floor panel A tongue and groove with a horizontal opening in the center for joining adjacent edges in the vertical direction. The connectors on the long edges are configured to be locked by angling and the connectors on the short edges are configured to be locked by vertical folding. The long edges of the new panels in the second row are configured to be connected by angling to the long edges of the first panels in the first row. The short edge of the new panel in the second row and the short edge of the second panel are configured to be joined by the same angular movement. The connector of the long edge has at least three separate parts between adjacent parts of the connector when the new panel is pressed by the upper edge against the upper edge of the first panel at an angle of at least 10 degrees relative to the main plane Contact point or contact surface.

Since the floor panels according to the first principle of the invention have long edges with three points of contact at a deflection angle of 10 degrees, there will be a high friction between the long edges, And this friction force will hinder or prevent the displacement of the short edge due to the tongue pressure during vertical folding. The advantage is that a flexible tongue can be formed and positioned on the short edge with the initial point of contact close to the long edge, for example at a distance of about 15 mm from the long edge, which enables vertical locking over a large length of the short edge.

If the three-point contact angle is greater than 10 degrees, preferably 15 degrees or higher, improved mounting functionality may be obtained in some embodiments. In other embodiments, greater than 18 degrees or even greater than 20 degrees are required for easy installation.

According to a second principle of the invention, the preferred position and shape of the flexible tongue at the short edges and the locking system on the long edges is such that when the panel is deflected down from the installation angle to the contact angle, the flexible tongue Friction along the long edge during initial contact with the adjacent short edge as a result of the vertical folding operation, and when further angling adjustment causes the first flexible edge of the flexible tongue to displace horizontally and creates horizontal separation pressure of the short edge will increase.

According to one embodiment of this second principle, the present invention provides a set of substantially identical floor panels, each said floor panel comprising a long edge and a short edge, and having a first integral with said floor panel. and the second connector. The connectors are configured to connect adjacent edges. The first connector includes a locking bar with an upwardly directed locking element at an edge of one floor panel, and a downwardly opening locking groove at an adjacent edge of the other floor panel for vertical Connecting adjacent edges horizontally in the direction of the adjacent edges, the second connector comprises a tongue at the edge of one floor panel extending horizontally perpendicular to the edge, and at the adjacent edge of the other floor panel A tongue and groove with a horizontal opening in the center for joining adjacent edges in the vertical direction. The connectors on the long edges are configured to be locked by angling and the connectors on the short edges are configured to be locked by vertical folding. The long edges of the new panels in the second row are configured to be connected by angling to the long edges of the first panels in the first row. The short edge of the new panel in the second row and the short edge of the second panel are configured to be joined by the same angular movement. The tongue on the short edge is made of a separate material, is connected to the connecting groove, and has a flexible portion with an edge section closest to the long edge of the first panel. The edge sections are configured to displace horizontally during folding and cooperate with tongue grooves in adjacent short edges to vertically lock the floor panels together. The first and second connectors on the long edge are configured such that when the panels are pressed against each other using the same pressure and with the upper joint edges in contact, the friction force along the long edge is less at the mounting angle than at the The friction force at the contact angle. The installation angle is 25 degrees and the contact angle is the smaller angle corresponding to the initial contact between the edge segment and the adjacent short edge.

The increased friction between the long edges under the contact angle can be obtained in various alternative ways, for example by increasing the pressure between the contact points, and/or by increasing the friction between the first and second connectors. , and/or by increasing the number of contact points from 2 to 3 or from 3 to 4.

According to a third principle of the invention, the locking system on the long edge has friction means so that when there are only two points of contact between the connectors on the long edge, at an angled position, the friction along the long edge will higher.

According to one embodiment of this third principle, the present invention provides a set of substantially identical floor panels, each of said floor panels comprising a long edge and a short edge, and having a first integral with said floor panel. and the second connector. The connectors are configured to connect adjacent edges. The first connector includes a locking bar with an upwardly directed locking element at an edge of one floor panel, and a downwardly opening locking groove at an adjacent edge of the other floor panel for vertical Connecting adjacent edges horizontally in the direction of the adjacent edges, the second connector comprises a tongue at the edge of one floor panel extending horizontally perpendicular to the edge, and at the adjacent edge of the other floor panel A tongue and groove with a horizontal opening in the center for joining adjacent edges in the vertical direction. The connectors on the long edges are configured to be locked by angling and the connectors on the short edges are configured to be locked by vertical folding. The long edges of the new panels in the second row are configured to be connected by angling to the long edges of the first panels in the first row. The short edge of the new panel in the second row and the short edge of the second panel are configured to be joined by the same angular movement. The tongue on the short edge is made of a separate material, connected to the connecting groove, and has a flexible portion configured to displace horizontally during folding and to cooperate with the tongue groove in the adjacent short edge so that Locks floor panels together vertically. The first and second connectors on the long edges include friction means configured to increase friction along the long edges when the panels are at an angle having only two points of contact between the first and second connectors. friction.

When there are three or more contact points in the locking system, the friction device can be active or inactive at small angles

The third principle offers the advantage that the friction along the long edges can be higher even at large angles, for example at installation angles, and this principle can be used in conjunction with such installation methods, where, as shown in Figures 4b and 4c As shown, the edges of the flexible tongue are compressed by the displacement of the long edges during the initial stages of vertical folding. The friction means will prevent or impede displacement along the long edges and separation of the short edges during vertical folding.

Such friction means may comprise mechanically formed parts, such as small protrusions, formed using a rotary cutter or a pressure wheel, on parts of the locking system, for example on the tongue and/or on the locking bar. They may also include chemicals or small particles applied in the locking system to increase friction along the long edges.

According to a fourth principle of the invention there is provided a flooring system with a locking system on the long and short edges, wherein the floor panels can be locked by vertical folding and the position, shape and position of the preferred flexible tongue on the short edges the material properties are combined with a long edge locking system comprising connectors which allow one floor panel cut to a length of 20cm to be connected to another floor panel in the same row by vertical folding, and Friction between the long edges will prevent the short edges from separating.

According to an embodiment of this fourth principle, the present invention provides a set of substantially identical floor panels, each said floor panel comprising a long edge and a short edge, and having a first integral with said floor panel. and the second connector. The connectors are configured to connect adjacent edges. The first connector includes a locking bar with an upwardly directed locking element at an edge of one floor panel, and a downwardly opening locking groove at an adjacent edge of the other floor panel for vertical Connecting adjacent edges horizontally in the direction of the adjacent edges, the second connector comprises a tongue at the edge of one floor panel extending horizontally perpendicular to the edge, and at the adjacent edge of the other floor panel A tongue and groove with a horizontal opening in the center for joining adjacent edges in the vertical direction. The connectors on the long edges are configured to be locked by angling and the connectors on the short edges are configured to be locked by vertical folding. The long edges of the new panels in the second row are configured to be connected by angling to the long edges of the first panels in the first row. The short edge of the new panel in the second row and the short edge of the second panel are configured to be joined by the same angular movement. The tongue on the short edge is made of a separate material, connected to the connecting groove, and has a flexible portion configured to displace horizontally during folding and to cooperate with the tongue groove in the adjacent short edge so that Locks floor panels together vertically. the connectors on the long and short edges are configured such that the second and new panels are not displaced away from the other panel when said panels are in contact position under the installation angle and during vertical folding, One of the panels is cut to a length of approximately 20 cm.

The fourth principle has the advantage that floor panels with such a locking system can be installed with high precision and without Separation of the short edges occurs. A separation of about 0.01 mm is sufficient to cause problems and undesired gaps that are visible in the floor surface or where moisture can seep into the joint.

A second object of the present invention is to provide an installation method for connecting floor panels by vertical folding. The panels have a angling locking system on the long edges and a vertical folding system on the short edges for vertically and horizontally locking the panels, where the first and second panels are at each other on the long edges Tiled on the subfloor in the case of connection, characterized in that the method comprises the steps of:

a) bringing the long edge of the angled new panel into contact with the upper portion of the long edge of the first panel;

b) bringing the short edge of the new panel into contact with the short edge of the second panel, thereby holding the new panel in this position by a locking system on the long and/or short edges;

c) Pressing the short edge sections of the new panels down towards the sub-floor, thereby interconnecting the first, second and third panels by vertical folding.

This mounting method makes it possible to hold the floor panel in an upwardly deflected position, eg by means of the upper part of the locking element and the lower part of the locking groove. This will facilitate installation as the installer can change the hand position from having the panel at the installation corner to a position suitable for pressing the short edge section of the panel down towards the sub-floor. This has the advantage that the combined operations of pressing the upper edges together at an angle, pressing the panels sideways to avoid separation of the short edges, and folding the panels down onto the floor can be avoided and replaced by three separate and independent operation instead.

A third object of the present invention is to provide a new locking system or combination of locking systems that can be used on long and/or short edges and is especially designed to reduce separation problems. These locking systems can of course be used alone to join any type of floorboards or building panels on the short and/or long edges.

According to a first aspect of this third object there is provided a flexible tongue comprising two flexible parts, an inner flexible part in the inner part of the displacement groove and an outer flexible part in the displacement groove. part, which locks in the tongue groove of the adjacent edge of the other panel. The inner part is preferably more flexible than the outer part and is preferably capable of displacement to a greater extent than the more rigid outer part of the vertical locking panel. The invention makes it possible to combine strength with low displacement resistance.

According to a second aspect of this third object, a short edge locking system with a preferably flexible tongue is combined with a compact tongue locking system that can be locked by angling adjustment. This locking system is cost-effective, the geometry is favorable, and it can be used to design a locking system that generates a lot of friction along the long edges during angling. Such a mortice lock is an alternative to the long edge locking system with protruding locking strips in all the principles and methods described above. This embodiment of the invention has a first connector at an edge of one floor panel and a second connector at an adjacent edge of the other floor panel for connecting the adjacent edges horizontally and vertically, The first connector includes a tongue with an upwardly directed locking element at an upper portion of the tongue, and the second connector includes a downwardly extending locking groove in an undercut tongue groove. In this embodiment, the connectors on the long edge are even configured to lock by angling, and the connectors on the short edge are configured to lock by vertical folding. As an example, it may be noted that, according to a first principle, when a new panel is pressed by the upper edge against the upper edge of the first panel at an angle of at least 10 degrees relative to the main plane, the connectors of the long edges are at the opposite sides of the connectors. There are at least three separate contact points or contact surfaces between adjacent parts.

According to a third aspect of this third object, there is provided a short edge locking system with a preferably flexible tongue which hinders or prevents displacement of the long edges during vertical folding. As previously mentioned, the locking system comprises a locking bar with locking elements and a separate flexible tongue in the locking bar panels, and a tongue groove and locking groove in the folding panels. The locking surface of the locking groove is substantially vertical, parallel to the vertical plane VP, and preferably has a height of at least 0.1 times the floor thickness. The locking system is preferably designed such that, when there is no contact between the folded panel and the flexible tongue, the locking element is in contact with the lower part of the locking surface of the locking groove with its upper part of the locking surface at the locking angle. The substantially vertical locking surface will prevent separation when the tongue comes into contact with the folded panel during further angling. In a preferred embodiment, a portion of the locking surface is located on the protrusion and in the cavity.

It is obvious that two or more or even all of the principles described above can be combined and that all embodiments of the locking system described in this application can be used in combination or individually to connect long edges and/or short edges. edge. The figures are only intended to show examples of different embodiments which can be used in different combinations on the long and short edges of the same panel type or of different panel types to be connected to each other. All locking systems on the long and/or short edges of the panels can be integrally formed with the core, or they can consist of a separate material, such as a separate tongue and/or locking strip, which can be integrated with the floor panel Or is connected during installation. Even the locking groove and/or the tongue groove can be made of a separate material. This means that the invention also includes an integral locking system on the short edge, wherein parts of the locking system such as the tongue and/or the locking strip and/or the locking elements are flexible and preferably consist of a wood fiber based material such as HDF, which can be locked by vertical folding, assuming that this locking system generates a separation force during locking. A separate material based on wood fibers can also be fixedly connected to the panel edges, for example by adhesive bonding, and this material can be machined into a locking system in the same way as the integral system described above.

The invention can be used on all types of floors. However, the invention is particularly suitable for short panels of eg 40-120 cm where the friction along the long edges is low, wide panels of more than 20 cm in width where the flexible tongue is long and will generate large tongue pressures, and where in Low friction due to very smooth and low friction surfaces in locking systems eg panels with a core made of HDF, compact laminate or plastic material etc. The invention can also be used for thin panels such as 6-9mm thick, more preferably 8mm and thinner, especially for panels with a compact locking system on the long edges, for example with a length shorter than 6mm locking strips, because this floor panel and this locking system will have small contact surfaces with low friction.

Several advantages may be realized by a flooring system constructed according to one or more of the principles described above. A first advantage is that installation can be achieved in a simple manner, during which no lateral pressure needs to be applied in order to prevent the floorboards from separating at the short edges. A second advantage is that the risk of edge separation which could lead to a rupture of the locking system during folding is significantly reduced. A third advantage is that the locking system can be formed with a more rigid and stronger tongue which locks the panels vertically with higher strength and a great tongue pretension. Such a tongue with a large maximum tongue pressure and pretension will generate high separation forces in the locked position during vertical folding. A fourth advantage is that a flexible tongue can be positioned close to the long edges and a reliable locking function can still be obtained although such a flexible tongue will generate separation pressure at higher contact angles.

The initial contact friction and mounting friction can be measured according to the following principles. The contact angle of the new floorboard and the first floorboard should be measured when the first edge section of the flexible tongue, which plays a role in the vertical locking, comes into contact with the short edge for the first time during the initial phase of the vertical folding operation. The contact friction along the long edge of the 200mm sample shall be measured at this contact angle when the panels are pressed against each other using a normal mounting pressure of 10N. Mounting friction shall be measured according to the same method at a mounting angle of 25 degrees. The contact friction should be at least approximately 50% higher than the mounting pressure.

Friction means including mechanical structures such as protrusions, brushed fibers, scraped edges etc. in the locking system are easy to detect. Chemicals are more difficult to detect.

If it is not clear that mechanical structures, chemicals, impregnations, coatings, separate materials, etc. have been used to increase the friction between floor panels under the installation corner, another method should be used to measure the friction due to the friction device Increased friction. A new locking system having substantially the same design as the original sample shall be produced from the same original floor paneling and core material. Friction should be measured at the same mounting angle and pressure, and friction should be compared between two samples, between original and new samples. Of course, this test method assumes that the entire core contains no friction-increasing material.

A large number of HDF-based floor panels sold on the market have been tested and the results show that samples with a 200mm long edge pressed against the other long edge at an angle of 25 degrees using a pressure of 10N typically have a pressure of about 10N or less. friction. This friction is too low to prevent short edge displacement during vertical folding. The friction device can significantly increase friction.

The contact angle is defined as the angle of the new panel when one edge makes initial contact with a part of the flexible tongue that is about to displace and function in the vertical fold. For example, there may be a protrusion at the edge of the tongue which does not cause any significant horizontal pressure during vertical folding. Such protrusions and similar means should not be considered as part of the flexible tongue.

Unless expressly stated otherwise, all references to "a/an/the [element, structure, component, means, step, etc.]" should be construed openly to mean that said element, structure, component, means, step, etc. At least one instance of .

Description of drawings

Figures 1a-d illustrate prior art locking systems.

Figures 2a-b show a prior art flexible tongue during a locking operation.

Figures 3a-b show floor panels with a prior art mechanical locking system on the short edges.

Figures 4a-d show how to lock the short edges of two floor panels by vertical folding according to the prior art.

Figures 5a-e illustrate an embodiment of a short edge locking system that may be used in conjunction with the present invention.

Figures 6a-c show a displaceable tongue in an embodiment according to the invention.

Figures 7a-d show 3D views of the separation between panels during vertical folding.

Figures 8a-d show the separation pressure of the tongue on the short edge during installation.

Figures 9a-o show a locking system in great use on the market, and the points of contact between surfaces in such a system at various angles during installation by angling.

Figures 10a-c show an embodiment of a long edge locking system according to the invention with a friction angle of 10 degrees.

Figures 11a-c show an embodiment of a long edge locking system according to the invention with a friction angle of 15 degrees.

Figures 12a-c show the long edge and short edge locking systems and the position of the flexible tongue according to an embodiment of the invention.

Figures 13a-d show an embodiment of a panel position at a contact angle.

Figures 14a-d show the position of the flexible tongue in relation to the long edge according to an embodiment of the invention.

Figures 15a-c show an embodiment according to the invention with friction means.

Figures 16a-d illustrate a method of measuring friction at various angles according to an embodiment of the invention.

Figures 17a-c show an alternative embodiment according to the invention with three contact points.

Figures 18a-c show a further alternative embodiment according to the invention with three contact points.

Figures 19a-c show other alternative embodiments according to the invention with two and three contact points generating friction.

Figures 20a-c show an alternative embodiment according to the invention with four contact points at an angle of 20 degrees.

Figures 21a-d show a flexible tongue with two flexible parts.

Figures 22a-c illustrate the installation of panels with a flexible tongue according to the invention.

Figures 23a-b show a tongue locking system.

Figures 24a-e illustrate locking systems that may be used in the present invention.

Figures 25a-c illustrate a method of measuring contact points.

Figures 26a-d illustrate an embodiment of the invention with vertical locking surfaces.

Figures 27a-c show the locking system according to the invention on the long and short edges.

Detailed ways

1-6 and the related description below illustrate the disclosed embodiments and serve to explain the general principles of the invention and to illustrate examples of embodiments that can be used in the invention. The illustrated embodiments are examples only. It should be emphasized that all types of flexible and one-piece tongues that can be used in a locking system capable of vertical folding and/or vertical locking can be used and that applicable parts of this description form part of the invention.

A prior art floor panel 1, 1' with a mechanical locking system and a displaceable tongue is described with reference to Figures 1a-1d.

Figure 1a schematically shows a cross-section of a joint between a short edge joint edge 4a of a panel 1 and an opposite short edge joint edge 4b of a second panel 1'.

The front faces of the panels are positioned substantially in a common horizontal plane HP and the upper parts 21 , 41 of the joint edges 4a, 4b abut each other in a vertical plane VP. The mechanical locking system achieves mutual locking of the floor panels in the vertical direction D1 as well as in the horizontal direction D2.

In order to join the two joint edges in the direction D1 and D2, the edges of the floor panels have locking strips with locking elements 8 on one joint edge, hereinafter referred to as "locking strip panels", in a manner known per se 6, this locking element 8 cooperates with a locking groove 14 in the other joint edge, hereinafter referred to as "folding panel", and provides a horizontal locking.

The prior art mechanical locking system consists of a separate flexible tongue 30 fixed in a displacement groove 40 formed in one of the joint edges. The flexible tongue 30 has a groove portion P1 located in the displacement groove 40 , and a protrusion portion P2 protruding outside the displacement groove 40 . The protrusion P2 of the flexible tongue 30 in one of the joint edges cooperates with the tongue groove 20 formed in the other joint edge.

The flexible tongue 30 has a protrusion P2 with a rounded outer part 31 and a sliding surface 32 which in this embodiment is formed bevel-like. The flexible tongue 30 has an upper tongue displacement surface 33 and a lower tongue displacement surface 35 and an inner part 34 .

The displacement groove 40 has an upper opening 42 and a lower opening 46 which in this embodiment are rounded, a bottom 44 , an upper groove displacement surface 43 and a lower groove displacement surface 45 which are preferably substantially parallel to the horizontal plane HP.

The tongue groove 20 has a tongue locking surface 22 which cooperates with the flexible tongue 30 and locks the joint edge in the vertical direction D1. The folding panel 1' has a vertical locking surface 24 which is closer to the back 62 than the tongue groove 20. The vertical locking surface 24 cooperates with the locking bar 6 and locks the joint edge in the other vertical direction. In this embodiment, the folding panel has a sliding surface 23 which cooperates with the sliding surface 32 of the flexible tongue 30 during locking.

The flexible tongue can be wedge-shaped and can be locked in the tongue groove with a pre-tension force which presses the fold panel 1' against the locking strip panel. Such an embodiment will achieve a very strong high quality joint.

Fig. 3a shows a section A-A of the panel according to Fig. 3b seen from above. The flexible tongue 30 has a length L along the joint edge, a width W parallel to the horizontal plane and perpendicular to the length L, and a thickness T in the vertical direction D1. The sum of the largest groove portion P1 and the largest protrusion portion P2 is the total width TW. In this embodiment, the flexible tongue also has a middle section MS and two edge sections ES adjacent to the middle section. In this embodiment, the dimensions of the protrusion P2 and groove portion P1 vary along the length L and the tongue is spaced apart from the two corner sections 9a and 9b. The flexible tongue 30 has a friction connection 36 on one of the edge sections, which can be formed, for example, as a local small vertical protrusion. This frictional connection keeps the flexible tongue in the displacement groove 40 during installation, or during production, packaging and transport if the flexible tongue is integrated at the factory with the floor panel.

2 a and 2 b show the position of the flexible tongue 30 after a first displacement towards the bottom 44 of the displacement groove 40 . This displacement is mainly caused by bending the flexible tongue 30 parallel to the width W in the length direction L of the flexible tongue 30 . This feature is essential to this prior art. The commercially available embodiment has a maximum tongue pressure of about 20N.

The folded panels can be disconnected by means of a needle-shaped tool which can be inserted into the tongue groove 20 from the corner section 9b and press the flexible tongue back into the displacement groove 40 . The folded panels can then be deflected upwards while the locking strip panels are still on the subfloor. Of course, the panels can also be disconnected by conventional means.

Figure 4a shows an embodiment of vertical folding. The first panel 1" in the first row R1 is connected to the second panel 1 in the second row R2. The new panel 1' faces the first panel by its long edge 5a at a conventional installation angle of about 25-30 degrees. The long edge 5b of the panel 1" moves, presses against the adjacent edge and is connected by its long edge 5a to the long edge 5b of the first panel with angling. This angling operation also connects the short edge 4b of the new panel 1' to the short edge 4a of the second panel 1 . The folding panel 1' is locked on the locking strip panel 1 by a combined vertical and rotational movement along the vertical plane VP. The protrusion P2 has a rounded and/or angled folding portion P2' which cooperates with the sliding surface 23 of the folding panel 1' during folding. The combined action of the folded portion P2' and the sliding surface 32 of the tongue cooperating with the sliding surface 23 of the folded panel 1' during folding facilitates the first displacement of the flexible tongue 30. An essential feature of this embodiment is the position of the protrusion P2 spaced apart from the corner sections 9a and 9b. This spacing is at least 10% of the length of the joint edge, in this case the visible short edge 4a.

Figures 4b-c show an embodiment of a set of floor panels with a displaceable tongue and an optional installation method. In this embodiment the length of the tongue exceeds 90% of the width WS of the front face of the panel, in other preferred embodiments the length of the tongue is preferably from 75% of the width WS of the front face to substantially the same width WS within an equal range. Preferably, the length of the tongue is approximately the total width of the panel minus the width of the locking system of the adjacent edge of the panel. A small bevel may be provided at the end of the outer edge, but the length of the straight part of the tongue at the outer edge is preferably substantially equal to the length of the tongue, or desirably greater than 90% thereof. The new panel 1' is in an angled position with the upper part of the joint edge in contact with the first panel 1" in the first row. The short edges 4a and 4b are spaced apart from each other. As can be seen in Figure 4b, the new panel 1' is then displaced laterally towards the second panel 1 until the short edges 4a and 4b substantially touch and part of the flexible tongue 15 is pressed into the displacement groove 40. The new panel 1' is then displaced towards the second panel 1 is folded downwards. Since the displacement of the new panel 1' only presses the edge section of the flexible tongue 30 into the displacement groove 40, vertical folding is possible with less resistance. This can be achieved by having a straight displaceable tongue on the outer edge. When a panel with the known arcuate tongue 30 (see Figures 2-4) is installed, the entire tongue must be pressed into the displacement groove. When comparing the known Bowed tongues require less force for tongues with the same spring constant (per unit length for the tongue) when compared to tongues according to the invention. Therefore, it is possible to use a tongue with a higher spring constant per unit length and Higher repulsion of the tongue, resulting in a more reliable final positioning of the tongue.With this installation method, chamfered sliding surfaces of the folded panels are not necessary or can be smaller, which is advantageous in thin panels The disadvantage of this method is that the new panels have to be angled and squeezed sideways during vertical folding. Figure 4c shows that all embodiments of the tongue can be located on the folded panels. Of course, some adjustments are required.

It is often advantageous to have the tongue on the locking strip panel, since a rounded or chamfered portion on the fold panel can be used to assist the displacement of the flexible part of the tongue. The embodiment with the tongue on the folded panel as shown in Fig. 4d has the disadvantage that the tongue has to slide against the sharp edge of the panel surface.

The tongue may consist of plastic material and may be produced eg by injection moulding. With this production method, various complex three-dimensional shapes can be produced at low cost, and flexible tongues can be easily connected to each other to form a tongue blank. The tongue can also be made from extruded or machined plastic or metal sections which can be further shaped, eg by stamping, to form a flexible tongue. Apart from the additional production steps, extrusion has the disadvantage that it is difficult to reinforce the tongue, for example by fibers.

Any type of polymeric material can be used, such as PA (Nylon), POM, PC, PP, PET or PE or similar having the properties described above in the different embodiments. When injection molding is used, these plastic materials can be reinforced with eg glass fibres, Kevlar fibres, carbon fibres, or talc or chalk. The preferred material is fiberglass, preferably extra long reinforced PP or POM.

Figures 5a-5e show an embodiment of a flexible tongue 30 according to the invention that can be used to lock short edges. Figure 5a shows a separate tongue 30 on a folded panel with upwardly extending flexible snap tabs. Figure 5b shows a separate tongue 30 on the locking strip panel with downwardly extending flexible snap tabs. FIG. 5 c shows a separate tongue with flexible snap tabs in displacement grooves 40 . According to the same principle shown in Figures 5a and 5b, the snap tabs can extend upwards or downwards and can be located on the locking strip panel or on the folding panel. Fig. 5d shows a flexible tongue comprising the protrusions shown in Fig. 6a, which may be located in the displacement groove 40, or extend into the tongue groove 20 from a vertical plane. Figure 5e shows that the tongue 30 may be integrally formed with the panel and the locking may be achieved due to compression of fibers or parts of the panel material and/or bending of the locking strip 6.

Figures 6a-c show an embodiment of a tongue 30 that can be used according to the invention. These tongues are each configured to be inserted into grooves in the floor panels. FIG. 6 a shows a flexible tongue 30 with a flexible protrusion 16 . FIG. 6b shows an arcuate tongue 30 and FIG. 6c shows a tongue 30 with flexible snap tabs 17 .

A flexible tongue similar to the embodiments shown in Figs. 1-4, 5d, 6a and 6b may for example also be made of wood fiber based material such as HDF, solid wood or plywood with several layers. In particular, very strong and flexible tongues can be made from HDF if the flexibility is achieved by designing the fiber orientation substantially parallel to the HDF fibers.

Figures 7a-d show in four steps the installation with vertical folding and the problems associated with this installation. To simplify the description, one embodiment is shown with a flexible tongue 30 on the locking strip panel. As explained before, the tongue can be located on the folding panel. The new panel 1' is moved towards the long edge of the first panel 1" by its long edge 5a at an installation angle until the upper edges touch. Thereafter, the new panel is displaced laterally until, as shown in Fig. 7a, the short edge 4b is in contact with the short edge of the adjacent second panel in the same row. Then, as shown in Figure 7b, the new panel 1' is deflected downwards to the contact angle, at which point the edge portion 30 of the flexible tongue 30 'First initial contact with the short edge of the new panel 1'. Further angling adjustments - which should be done with contact between the short edges for optimal function - will gradually push the flexible tongue horizontally a larger portion of the tongue, and the flexibility of the tongue will create increased pressure that may push the short edges 4a and 4b away from each other. As shown in Figure 7c, an undesired gap G will be created. In many cases, the locking Element 8 cannot pull back the short edges of the panels because the friction between the long edges is very high when the panels are at a small angle and as shown in Figure 7d a gap G will be maintained during the connection phase. cracking or other damage. Even a very small residual gap of 0.01-0.1mm can cause serious problems because moisture can easily penetrate the joint.

Figures 8a-8d show in detail the separation problem caused by the flexible tongue 30. According to Fig. 8a, the panels 1, 1' are in a contact angle, wherein the sliding surfaces 23, 32 of the folded panel 1' and the flexible tongue are in contact. Figures 8b and 8c show that the flexibility of the tongue will create a separation pressure SP which may separate the panels 1, 1' from each other and create a gap G if the panels are not pressed together by the installer. Figure 8d shows the panels with the permanent gap G in the locked position. In this case, the locking bar 6 is bent and the locking element 8 is only partially located in the locking groove 14 . In the worst case there is a crack in the locking element 8 and the panels will not be locked horizontally at the short edges.

Figures 9a-9o show three angled locking systems widely used in conventional floorboards with locking by angled. Figures 9a-c show floor panels at an installation angle A of 25 degrees. In this position there are only two contact points CP3, CP2 or CP3, CP4 between the first and second connectors. There is always an upper contact point CP3 or contact surface at the upper joint edge and a second lower contact point or somewhere between the inner lower part of the tongue 10 and the locking groove 14 on the lower part of the tongue or Contact surfaces CP4, CP2. Especially in HDF-based floors with smooth surfaces, the displacement friction along the joint edges is very low at this location. Figures 9d-f show further deflection to an angle of 15 degrees and Figures 9g-i show an angle of 10 degrees. At these locations, there are still only two points of contact and friction remains low. Figures 9j-l show the position at an angle of 5 degrees, which in these embodiments is the friction angle. Figures 9j and 9k show the locking system in a locking angle, where the locking surfaces 51, 52 are in partial contact. Figure 91 shows the locking system at a pilot angle, where the pilot surfaces 11, 12 are in contact. Figure 9j shows that this locking system has 4 contact points, including two upper contact points CP3 and CP1 located between the upper joint edge and the upper part of the tongue, and two contact points located between the lower part of the tongue and the locking surface. Lower contact points CP2 and CP4. Figure 9k shows two upper contact points CP1, CP3 and one lower contact point CP4. Figure 9l is similar to Figure 9j, but there is a lower contact point between the guide surfaces 11,12. In particular, if there is a tight fit at the contact points or between the contact surfaces, and/or if the contact surfaces have large dimensions, the displacement friction along the joint edges will increase significantly at these locations. Pre-tensioning can further increase friction, and even in small floor panels, displacements along long edges associated with vertical folding can be hindered and in most cases completely eliminated. However, this locking system is not suitable on the long edges of vertical folding systems with contact angles greater than 5-8 degrees, especially if this locking system is produced to have a normal fit between the connectors, because this Such a locking system will not prevent displacement along the long edges and separation of the short edges.

Figure 10a shows an embodiment of the first object according to the invention. This locking system can preferably be used on the long edges of the vertical folding system with a contact angle A of about 10 degrees and lower. This system can also be used for locking systems with larger contact angles because it will prevent displacement already at 10 degrees when most fold down locking systems generate the highest displacement pressure. Figure 10a shows the position of the panel 1' at an angle of 15 degrees when only two points CP3, CP2 are in contact. The panel 1' is in a frictional angular position of 12 degrees, where there are three contact points CP3, CP2, CP4'. This position is characterized in that there is only one contact point CP2 on the tongue and the guide surfaces 11 , 12 are in contact. This is advantageous because the guide surface presses the tongue into the groove during the further angling adjustment shown in Fig. 10b. The friction force has been further increased and is guided by the vertical contact and cooperation (CP1, CP2) between the tongue 10 and the tongue groove 9, the horizontal contact between the upper edge CP3 and the formation of the second lower contact point CP4 Surfaces 11, 12 lead to. The ideal position is preferably an embodiment having a contact angle equal to or less than the friction and lead angles. Such an embodiment may, for example, have a friction and conduction angle of about 10 degrees, and a contact angle of about 8-9 degrees. Locking is achieved in a very simple manner and only requires downward pressure on the new panel when positioning the panel at the lead angle. Figure 10c shows that the locking system is configured with a high angle between the locking surfaces and that the fibers must be compressed at the top edge CP4 as well as at the locking surfaces CP4 during the final stage of angling adjustment shown in position 1'a , to be able to lock. This configuration achieves several advantages. Friction will increase and be at a high level when the separation force is at its highest level. As shown in Fig. 10b, the floor panel is held in an upwardly deflected position by the locked element and the locking groove independently or in combination with the contact between the short edge of the folded panel and the edge section of the flexible tongue. Friction will prevent the short edge from sliding off the flexible tongue. This will facilitate installation as the installer can change the hand position from having the panel at the installation angle to a vertical squeeze operation at the short edge. Accordingly, the present invention provides a vertical locking system with a long edge angling system that enables one panel to rest in an angled position against another panel with the upper joint edges in contact. There is also provided a locking system in which, at the final stage of angling adjustment, when a part of the locking groove 14 is in contact with the locking element 8, between the upper joint edge and the locking element and/or between the tongue and the recess There is an increased pressure between the slots.

Figures 11a-11c show that the same principle can be used to form a locking system with a higher friction angle A of eg 15 degrees as shown in Figure 11a. The locking element 8 has been made tall and in this preferred embodiment the locking element 8 extends vertically LH from the lowest point of the locking strip 6 by about 0.2 times the thickness T of the floor. The tongue has a lower portion 54 which is substantially parallel to the horizontal plane HP and which extends from the vertical plane VP preferably along a distance TD which is about 0.1 times the thickness T of the floor.

The importance of the contact angle and the combined effect of the long and short edges during vertical folding and vertical locking will be described below with reference to Figures 12d-13d.

Figure 12a shows a long edge locking system 1", 1' and a short edge locking system 1, 1' in an installed floor system to be locked by vertical folding or vertical locking. The long edges have a Locking system.The short edges have a locking system that can be locked by vertical locking or vertical folding.

Figure 12b shows the position of the sliding surface 23 of the new panel 1' seen from the second panel 1 towards the new panel 1' when the new panel 1' is moved vertically downwards. This locking can be used for example to join the first row. The sliding surface 23 lies in a plane in the lower part of the panel 1'.

Figure 12c shows the position of the sliding surface 32, the end 31 of the flexible tongue and the sliding surface 23 when the first panel 1" and the second panel 1 are laid flat on the floor.

Figures 12b and 12c show that the position of the flexible tongue in the length direction of the short edge is not critical in the vertical locking of the entire panel moving vertically downwards.

Fig. 13a shows an embodiment of the same locking system as Fig. 12 during vertical folding. In this embodiment, the edge of the flexible tongue 30 is positioned at a distance FD from the long edge of the first panel 1 ″. Fig. 13b shows the vertical folding of the corner section CS and when the new panel 1 ′ approaches The position of the new panel 1' at the contact angle. Due to the chamfered sliding surfaces 23, 32 there is still no contact between the folded panel 1' and the flexible tongue 30. Fig. 13c shows that in this embodiment A contact angle of 10 degrees. The sliding surfaces 32, 23 overlap each other at the initial point of contact CP5. Further angling adjustments will start to generate a progressively increasing separation pressure between the short edges of the panels 1, 1' because if As shown in Fig. 13d, the larger part TPC of the flexible tongue presses the sliding surface 23 of the folded panel 1' horizontally inwards into the displacement groove.

Figures 14a and 14b show the position of the flexible tongue 30 in two embodiments of the invention. In these embodiments, the flexible tongue 30 is bendable horizontally in the length direction. In Fig. 14a the edge of the flexible tongue is located at a position FD1 close to the long edge 5b, for example approximately 15mm from the long edge. In a laminate floor of conventional thickness, such a locking system will have a contact angle of approximately 10 degrees. The contact angle can be smaller if, as shown in Figure 14b, the edge of the tongue is located a distance FD2 further away from the long edge 5b. In this case, a locking system with a smaller contact angle can be used. Such an embodiment is sufficient in thick and stable floor panels or in narrow floor panels. In thinner floors such as 6-8mm laminate and veneer floors it is advantageous if the flexible tongue is able to lock the short edges close to the long edges and cover a large distance of the short edges. Figures 14c and 14d show the flexible tongue in the basic contact position when the first part of the flexible tongue 30 has been bent horizontally and pressed horizontally inwards into the displacement groove. It is evident that the separation pressure will increase when a larger part of the tongue is bent and horizontally squeezed sideways during the folding operation. These and the previously described embodiments show that the long edge locking system and the short edge locking system are interdependent and must be adapted to each other to ensure a simple and reliable locking function.

Figures 15a-c show friction means 53, 53' which in this embodiment are formed in the upper part of the locking strip 6 on the locking strip panel 1 and in the lower part of the tongue or in the groove panel Small localized bump on 1'. Such protrusions can be formed on other surfaces of the locking system and they will prevent displacement at high angles when there are only two contact points eg as shown in Figure 15a. The friction means may also comprise any type of material or chemical such as small hard particles, rubber, adhesives and similar materials used in locking systems. Preferred materials are those that can be applied on one or more surfaces in the locking system, for example on the tongue and/or tongue groove, on the locking strip, on the locking element and/or in the locking groove, between the guide surfaces Soft waxes such as microcrystalline or paraffin-based waxes on one or both, etc., and they can increase the initial friction especially between HDF surfaces. In the plywood core, different layers and fiber structures can be used to form the tongue 10 and locking strip 6 in order to obtain high friction during angling. The above friction devices can also be combined. Small local elevations, rough surfaces, oriented fiber structures etc. can be combined, for example, with waxes or chemicals.

Figures 16a-d illustrate a method of measuring friction between long edges of floor panels. A sample of a groove panel 1' having a width W2 of approximately 200mm is pressed against a locking strip panel 1" at an angle A using a pressure F1 of 10N against a locking strip panel 1" fixed and having a width exceeding 200mm W1. The pressure F1 is exerted on the groove panel 1' by a wheel rotating with low friction. Displacement friction is defined as: the maximum force F2 required to displace the groove panel 1' along the joint. Curve Fa in Fig. 16b shows the measurement results for a sample of 8 mm laminated panel with a surface formed of printed paper impregnated with thermosetting resin and a core of HDF. Friction should be measured from the mounting angle and progressively lower angles. The displacement friction force of this sample was about 10 N at the installation angle IA, and was almost the same at the contact angle CA of 10 degrees. The friction angle FA is about 5 degrees in this sample. Many HDF-based locking systems on the market have a displacement friction of less than 10N at the installation corner. Friction can be as low as 5N. In this locking system, since the friction angle is smaller than the contact angle, the long edges only contribute to a limited extent in hindering the displacement of the short edges during the initial phase of vertical folding. Curve Fb shows a specific locking system in which, due to the geometry of the locking system, the friction force is higher at the mounting angle than at smaller angles. The invention is based on the principle that the friction at the contact angle should be increased compared to the installation angle or any other angle between the installation angle and the contact angle where the friction is at the lowest level. A preferred embodiment is that the friction force at the contact angle exceeds 15N, more preferably 20N. A preferred embodiment is also a vertical locking system with a flexible tongue that generates a tongue pressure greater than 20N, even greater than 30N.

There are locking systems on the market that exhibit very high friction at high angles. Such a locking system cannot be deflected in a conventional manner from the installation angle down to the contact or lead angle with a pressure F1 of 10N, which corresponds to a pressure of 60N applied to a 120cm floor panel during installation, and Such a locking system is one in which the angling adjustment has to be combined with a very high pressure or a snap-in operation in an angled position. This locking system is not used in vertical folding systems. Such a locking system is not excluded according to the invention, but it is not advantageous in a vertical folding system, since it differs from the conventionally used method of angling the long and short edges, and the short and long edges. Such a locking system only improves installation to a limited extent in some special applications, compared to installations where the edges are snapped, or the long edges are angled and the short edges are snapped.

Figure 16c shows a more advantageous locking system according to the invention, wherein the friction angle FA is about 15 degrees and the contact angle CA is 10 degrees. The friction angle FA is higher than the contact angle CA, and the friction force between the long edges has increased significantly at the contact angle CA compared to the installation angle IA. Fig. 16d shows how two samples 1, 1' with a width W3 of 200mm are installed, according to a fourth principle of the invention, assuming that the panels have a locking system according to the invention, when the folded panels are completely vertical and not This installation shall not cause separation of the short edges with any lateral pressure towards the short edges against the subfloor. The test can also be carried out with a full size panel 1 and a panel 1' cut to a length of about 20 cm. Such a locking system with long edge friction preventing displacement of such small floorboards will enable easy installation not only of ordinary floor panels, but also of all floor panels near walls that are cut to size. installed.

Figures 17a-c show how the locking system in Figure 11 is adjusted to generate friction through the first three contact points CP3, CP1 and CP4. The friction force is mainly obtained by the pressure between the locking element 8 /locking groove 14 and the upper part of the tongue 10 /tongue groove 9 . In this embodiment the tongue has a lower portion 54 which is substantially parallel to the horizontal plane HP and which extends from the vertical plane preferably along a shorter distance TD than in FIG. 11 which is less than 0.1 of the floor thickness T times.

Figures 18a-c show that the locking system in Figure 11 can also be adjusted to generate friction through the first three other contact points CP3, CP1 and CP2. The friction force is mainly obtained by the pressure between the upper part and the lower part of the tongue 10 /tongue groove 9 . In this embodiment the tongue has a lower portion 54 substantially parallel to the horizontal plane HP and extending from the vertical plane preferably along the same distance TD as in FIG. 11 . However, the height LH of the locking element is smaller. The friction means 53 shown are in the form of wax on the lower part of the tongue 10 . The wax should preferably be soft and preferably deformable during angling. This soft wax will prevent initial displacement along the joint. This wax can be applied in all locking systems and prevents displacement especially with respect to surfaces made of HDF.

Figures 17 and 18 show that if the dimensions of the tongue 10, groove 9, locking bar 6, locking element 8 and locking groove 14 are adjusted within the scope of the principle of the invention, a large number of combinations of friction angles and friction points can be obtained.

Figure 19a shows an embodiment with a friction angle of 20 degrees, where the friction force is obtained only through the two contact points CP1 and CP2 between the upper and lower parts of the tongue 10/tongue groove 9. In this embodiment, the tongue also has a lower portion 54 substantially parallel to the horizontal plane HP and extending from the vertical plane along a distance TD greater than 0.2 times the thickness T of the floor. In this embodiment the tongue has a space 55 between the lower part of the tongue and the tongue groove which facilitates the locking and enables the guide surfaces 11 , 12 to move as shown in FIG. degrees of overlap at large angles.

Figures 20a-c show that it is possible to design a locking system with three contact points CP3, CP1 and CP2 at an installation angle of 25 degrees as shown in Figure 20a. The locking elements have been made higher (LH) than in the previous embodiment and the groove panel 1' has a protrusion 56 between the tongue 10 and the tongue groove 9. The upper part of the tongue is at an angle with respect to the horizontal, which facilitates the machining of the tongue groove 9 with a large rotary tool.

A simple vertical lock on the short edge would not work if not combined with a well-working long edge locking system with very good guiding and locking characteristics that enables connection of the long and short edges with a simple angling operation Bring any significant improvement over existing technology. As can be seen, for example, from the embodiments shown in Figures 10b, 11a, 17a, 13c, 18b, 19b and 20b, it is possible to form a locking system that has a combined friction angle and guide angle and has the ability to hold the folded panels in Locking element 8 and locking groove 14 in upwardly deflected position. The only manipulation other than that required to lock the panels is to squeeze the folded panels vertically near the short edges.

Based on this principle, the present invention provides an installation method of three panels, wherein for example the first panel 1" and the second panel 1 shown in Fig. 7a are flatly laid on the subfloor, and their long edges are connected to each other. The method includes the following steps:

a) placing the new panel 1' in an angled position, wherein the long edge 5a is in contact with the upper part of the long edge 5b of the first panel 1";

b) bringing the short edge 4b of the new panel 1' into contact with the short edge 4a of the second panel 1, thereby holding the new panel 1' in this position by means of locking systems located on the long and/or short edges, The new panel 1' can be held in this position by the locking element and the guiding surface of the locking groove as shown in Fig. 10a and/or by the edge of the flexible tongue;

c) Pressing the short edge sections of the new panel down towards the floor, thereby interconnecting the first, second and third panels by vertical folding, preferably without large visible gaps between the short edges.

This installation method makes it possible to keep the floor panels in an upwardly deflected position, for example by means of the guide surfaces 11 , 12 shown in FIG. 10 . This will facilitate installation because the installer can change the position of the hand from a first position where the panels are at an installation angle of 25 degrees, drawn towards the edge of the first panel 1" already installed. Squeeze, and preferably deflect slightly downwards to the friction and guide angle. The installer can then move the hand to a second position suitable for pressing the two short Edge section. The guide surface guides the locking element into the locking groove and the tongue into the tongue groove. The friction between the long edges will prevent displacement. The advantage is that the upper edge is squeezed at an angle The combined operations of pressing the panels together, squeezing the panels sideways to avoid separation of the short edges, and folding the panels down onto the floor can be avoided and replaced by two or three separate and simple independent operations.

Figures 21a-c show a flexible tongue 30 with an inner flexible part 62 and an outer flexible part 61 . The flexible tongue shown in Figures 5a-c suffers from the following drawbacks:

1. They are usually made from cost-effective extruded plastic sections, but the production tolerances are not sufficient to obtain a high-quality lock.

2. Insufficient flexibility due to the use of only one flexible snap tab bent over a very limited vertical distance in thin floorboards. This low flexibility produces high edge separation forces.

3. Especially in the flexible tongue shown in Fig. 5a,b it is difficult to combine flexibility and locking strength. Embodiments according to the present invention reduce or eliminate the above-mentioned problems. The inner flexible part 62, which is not part of the vertical locking, can be made very flexible since its main function is to displace the flexible tongue 30 in the displacement groove. Once the edge of the floor panel is pressed against the outer flexible part 61, the upper part 67 of the inner flexible part will be pressed against the inner part of the displacement groove and will be bent or compressed. Preferably, the outer part 61 is more rigid and stronger than the inner part 62 . The combined flexibility of the inner and outer parts can be designed to achieve a stronger locking with less separation force than known tongues. The flexible tongue 30 can of course have one or more eg W-shaped inner and/or outer parts extending vertically upwards or downwards, which can be used to create greater flexibility and displacement. Such a tongue can also be made with a rigid, non-bendable outer part. The tongue can be connected to the folding panel. In such an embodiment, the outer flexible part 61 would extend vertically upwards and lock against the upper part of the tongue groove.

Figure 21b shows that an extruded tongue, eg made of plastic or metal, can be compensated eg by machining or grinding. This will significantly increase production tolerances to levels similar to injection molding or better. Displacement, locking action and locking strength can be significantly improved. In the illustrated embodiment, the lower contact surface 64 and/or the locking surface 65 have been compensated before insertion into the displacement groove 40 . When the tongue is or has been connected to the edge, a part of the flexible tongue, preferably the outer flexible part 61 , can be compensated. This can be done in a separate production step or in-line when forming the locking system. The flexible tongue may be designed to bend horizontally in length direction during vertical folding. If the tongue section 68 at the edge is removed as shown in Fig. 21d, this bending will be facilitated and the separation force will be reduced. This means that the width W of the tongue 30 will vary along the length L. Such a tongue section can also be removed from the inner elastic part 67 and the tongue will bend lengthwise with less resistance and facilitate vertical folding. This can be done in all types of extruded tongues, especially in tongues with limited flexibility, such as the embodiments shown in Figures 5a, 5b and 6c with only one external resilient or flexible part. The shaping of the part at the cutting edge section. The flexible tongue can also be designed according to the hinge principle with a rigid protrusion and a flexible elbow joint so that it does not bend horizontally during locking. Such an embodiment allows for a firm lock. However, significant separation forces may occur. This can eg be eliminated by an embodiment comprising a plurality of inner or outer individual flexible portions 61a, 61b separated by cutouts 69, eg by stamping or machining. Such separate flexible parts can be snapped separately, and this will enable to reduce production tolerances, especially if the tongue is made from a separate flexible part, which has a length that can vary for example by about 0.1 mm and is designed to Certain predetermined levels are interlocked. This ensures that the individual flexible parts are always in a very well locked position. Each individual part may be combined with a flexible tongue connected in a fixed manner to the panel edge, preferably into a horizontally extending groove.

The invention also comprises a single extruded flexible tongue designed for vertical locking of floors, characterized in that such a tongue has preferably been formed on the upper contact surface 63 and/or the lower contact surface 64 and/or the locking surface 65 is compensated. Such a tongue and the above-mentioned tongue with removed edge sections may also have a shape similar to that shown in Figs. 5a-c, where the flexible tongue only comprises inner or outer flexible snap tabs.

Machining, grinding, and similar production steps will often result in a surface that differs from the original surface from which it was extruded. This can in most cases be detected microscopically. This machining can also be used to increase or decrease the friction between the tongue and the displacement groove.

Figures 22a-c illustrate vertical folding or vertical locking. One panel 1' is preferably moved towards the other panel 1 along a vertical plane VP. When the edge section of the folded panel 1' comes into contact with the outer part of the flexible tongue 30, preferably the outer flexible part 61, the inner flexible part 62 will bend vertically and the flexible tongue will be displaced inwards to the displacement groove 40, in the displacement groove it is preferably connected by a frictional connection. As shown in Figure 22b, gradually even the outer flexible portion 61 will start to bend. Eventually, both the inner part 62 and the outer part 61 will snap back to their original positions and the flexible tongue will be displaced in the displacement groove 40 towards the tongue groove 20 . The locking surface 65 of the flexible tongue 30 will lock against a part of the tongue groove 20 . The connection between the tongue and the displacement groove can have a small play so that the tongue can be easily displaced and some tilting occurs during locking. The outer flexible portion 61 preferably displaces primarily horizontally during locking, with a slight rotation about the upper elbow 70 . The lower contact surface 65 can be made at an angle relative to the horizontal plane, preferably less than 10 degrees, which will increase the locking strength.

Figure 23a shows a tongue lock system that can be locked by angling. The new panel 1' has a first connector comprising a tongue 10 with a locking element 8a in the upper part. The first panel 1" has an undercut tongue groove 9 with an upper flange 6b and a lower flange 6a, and a locking recess formed in the upper flange 6b and extending downwards towards the lower flange 6a Groove 14a. The first and second connectors lock the panels vertically and horizontally. The lower flange 6a preferably extends beyond the vertical plane VP and preferably has a horizontal contact surface with the lower part of the tongue 10 Contact. The locking system can for example be designed with three contact points CP1, CP2, CP3 at an angle of more than 15 degrees, as shown in Figure 23a. A tongue lock can be used as an alternative to the locking bar locking system in all the embodiments described above Solution. A tongue lock on the long edge can be combined with a hooking system on the short edge which preferably only locks horizontally as shown in Figure 24d.

Figure 24a shows a locking system with a double tongue 10, 10' and two corresponding tongue grooves 9, 9', which can be used if the tongue and locking bar are adjusted to allow a vertical snapping operation The system locks the long edges by angling, snap-fitting or even vertical locking. Such a system can have more than four points of contact, and the friction along the joint can be very high.

Figure 24b shows a locking system with a separate locking bar 6' which can be used to lock the long edges in the same way as the embodiment in Figure 24a. Such locking strips may comprise a material or surface having more favorable frictional properties than the core material.

Figure 24c shows a locking system with a separate tongue 10' which can be flexible or rigid and which can be connected to a locking strip panel 1" or a folding panel on the long and/or short edges plate 1' in order to improve the frictional properties or to save material.

Figure 24d shows a hooking system that only locks horizontally.

Figure 24e shows an embodiment of a locking system with a flexible tongue 30 made in one piece with the core. An undercut groove 71 formed behind the flexible tongue 30 increases the flexibility of the tongue. Such grooves may preferably be formed by scraping tools when machining short edges. This scraping or broaching technique can be used to form advanced shapes like extruded plastic sections especially in fiber based materials such as HDF, but even in solid wood and plastic materials. The flexible tongue 30 can also be formed on the folded panel 1' by means of a large rotary cutter and has an outer part extending upwards. The locking system can also have two flexible tongues, ie one tongue on one edge. The wood fibers in the flexible tongue may be impregnated and/or coated eg with adhesive 70 in order to increase strength and flexibility. Impregnation can be done before or after the tongue or edge is formed. The entire edge or part of the locking system, eg the tongue groove 20, the locking element 8 or the locking groove 14 may also be impregnated and/or coated. The undercut grooves can be filled with flexible material for strength and flexibility. Vertical folding is facilitated if the locking strip 6 and/or locking element 8 can flex during vertical folding. Wax in the locking system will help with locking. A substantially vertical groove 73 above the locking bar in the folding panel 1' or a cavity 72 in the locking bar 6 adjacent to the locking element 8 in the locking bar panel 1 will increase the flexibility of the locking system and make some parts More flexible. Portions 78 of the underside of the locking bar and/or the balancing layer may be removed, which may increase the flexibility of the locking bar, making it easier to bend towards the subfloor. The folded panels may have protrusions 74 and preferably also locking surfaces of the type shown in Figure 27c. The flexible tongue may also be formed from a separate material that is fixedly connected to the panel by eg gluing, friction or snap-fitting. Such a separate material may eg be a partial edge portion 77 which may be joined to the edge before final machining. The undercut groove 71 may also be pre-formed before the separate material 77 is attached to the edge of the panel. This connection can be made on the edges of the individual panels, or on the panel boards which will later be cut into the individual floor panels. A separate material 75, 76 may also be attached to the edges of the locking strip panel 1 and/or the folding panel 1' so that it comprises the main part of the locking system. In wooden floors, this separate material is preferably bonded to the upper top and lower balancing layers. Individual materials may include, for example, preferably hard and flexible solid wood such as rubberwood or birch, wood impregnated with an adhesive such as an acrylic adhesive, plastic material, made of wood fiber material and phenol and may also contain glass fibres. Compact laminates of , HDF or HDF reinforced by adhesives, HDF with a substantially vertical fiber orientation, material comprising wood fibers and/or plastic materials and/or glass fibers with multiple layers. These materials may be used alone or in combination. The locking system can of course also be made according to the above principles without undercut grooves 71 , for example according to the embodiment shown in FIG. 5 e , if suitable materials and joint configurations are used in order to be able to obtain the required flexibility.

Parts or the whole of the locking system can be impregnated or coated with various chemicals such as melamine, urea, phenol, thermoplastics such as PP or PUR. These chemicals can be cured, eg, by heat, microwaves, UV, etc., with or without pressure.

The flexible tongue 70 can deflect tens of millimeters in standard HDF material, which is sufficient for vertical locking especially in laminate floors. Dipping and/or coating can significantly increase flexibility.

According to the invention, a preferred embodiment is provided comprising a short edge locking system which can be locked by vertical folding or vertical locking, characterized in that it comprises a locking bar 6, a locking element 8, a flexible tongue 30 The tongue 30 extends downwards and is integrally formed with the panel core or is formed from a separate material which is fixedly connected to the core. The flexible tongue 30 comprises an undercut groove 70 formed behind the tongue.

Figures 25a-c show how the highest three point contact angle is correctly determined in a locking system mainly made of wood fiber based core material. There are hundreds of different locking systems on the market just for joining laminate floors. In most of these locking systems, it is very easy to measure the highest three-point contact angle. This is shown in Figure 25a. A sample having a width W2 and a length of approximately 100 mm is deflected downward from the mounting corner with the top edges in contact until resistance arises from contact between the locking groove and locking element. In this position, at the highest three-point contact angle, the sample should be able to maintain its upwardly deflected position and not drop to the subfloor due to the weight of the sample. This locking system has a design which is characterized in that the three points are the upper edge CP3, the upper part of the tongue and the groove CP1, and the locking element/locking groove CP4. However, the locking system could have a design as shown in Figures 25b, 25c, where the three points of contact are the upper and lower parts of the tongue together with the top edge (CP1, CP2, CP3). However, some such locking systems do not remain in the upwardly deflected position. In such systems, cross-sections of the joints should be analyzed in a microscope. If loose fibers make it difficult to define a three-point contact angle, the friction force should be measured as shown in Figure 16. Increased friction indicates that additional contact points are at work in the locking system.

Figures 26a-d show an embodiment of a locking system on the short edge that impedes or prevents displacement of the long edge during vertical folding. Figure 26a shows a cross-section B-B of the short edge locking system at the edge portion near the start of folding as shown in Figure 4a. As previously described in connection with eg Figures 1-3, 5 and 8, this locking system comprises a locking bar 6 with locking elements 8 and a separate flexible tongue 30 in the locking bar panel 1, and in the folding panel 1' Tongue groove 20 and locking groove 14 in. The locking surfaces are substantially vertical and parallel to the vertical plane VP. Preferably, this locking system can be designed such that when there is no contact between the folding panel 1 ′ and the flexible tongue 30, as shown in FIG. The lower portion of the locking surface 14a is in contact. This can be achieved by the fact that there is no tongue part close to the long edges, or that the tongue is arcuate and has no protrusions in contact with the folded panel 1'. Figure 26b shows a section at C-C in Figure 4a. Assuming that the locking surfaces 8a, 14a are substantially and preferably completely vertical, and that they extend vertically along a large distance so as to prevent displacement at an angle of preferably 10 degrees or more, then when the tongue 30 and the folding inset The locking surfaces 8a, 14a will prevent separation when the plates are in contact, even in embodiments where the flexible tongue 30 is positioned close to the long edges. The locking surface should preferably have a height H which is at least 0.1 times or even more than 0.15 times the thickness T of the floor. The vertical locking surfaces can also be made to have a height H of about 0.2*T or more.

Some variations are possible within the scope of the main principle of the invention. Figure 26d shows that as long as the locking surface 14a of the locking groove 14 meets the above requirements, the functions are equivalent. The function is also the same if the locking groove 14b is for example arcuate towards the outer edge, provided that there are at least two parts positioned vertically along a vertical plane and at a distance of about 0.1*T.

Figure 27a shows an embodiment in which locking grooves 14 and locking elements 8 on the short edges are used to prevent detachment. It is advantageous that the edge 8a of the locking element 8 is close to the long edge 5b of the first panel 1" because this edge will be clamped at a rather high angle in the locking groove of the new panel and the flexible tongue can Positioned to lock close to the long edge. In this embodiment, the flexible tongue 30 is an extruded section with a cut edge section 68 that facilitates horizontal displacement during folding. High on the short edge The flat, vertical locking surfaces are especially suitable for locking systems with flexible tongues comprising extruded plastic sections, especially if such sections have only one outer flexible snap-in tab, which due to limited flexibility resulting in high separation pressure.

Figure 27 shows that if a compact tongue locking system is used on the long edge, the flexible tongue 30 can move further towards the long edge 5b and prevent displacement along the long edge at higher angles because this This locking system does not include a locking bar 6a protruding far beyond the vertical plane VP.

Figure 27c shows such a locking system with a preferably extruded flexible tongue 30, and a substantially perpendicular between the locking element 8 on the locking bar 6 and the locking groove 14 in the folding panel 1' locking surface. The folding panel 1' comprises a protrusion 74 adjacent the locking surface of the locking groove 14, and a preferably substantially horizontal lower contact surface 24 which locks vertically against the adjacent locking bar contact surface 6', the protrusion 74 is received in an adjacent cavity 72 on the locking bar 6 . This configuration is well suited for floors with HDF cores, since the cavities are formed in the lower part of the dense core. This recess reduces the strength of the locking system only to a limited extent. The height H of the vertical locking surfaces is preferably at least 0.1*T. In order to avoid breakage when the floor shrinks and to help secure the individual tongue 30 in the displacement groove 40, the design of the locking system is preferably such that the locking element 8 is located below a horizontal plane H2 comprising the displacement recess The lower part of the groove 40 , and the locking groove 14 is located below a horizontal plane H1 comprising the inner part and the lowermost part of the tongue groove 20 .

Claims (7)

1. A set of substantially identical floor panels (1, 1', 1") each comprising a first and second connector (9, 10, 6, 8, 14, 20, 30 ) long edges (5a, 5b) and short edges (4a, 4b), said connectors are integral with said floor panels and configured to connect adjacent edges, said first connectors are included in a floor panel Locking strips (6) with upwardly directed locking elements (8) at the edge of the panel and downwardly opening locking grooves (14) at the adjacent edge of the other floor panel for vertical connecting adjacent edges horizontally in the direction of the adjacent edges, said second connector comprising a tongue (10, 30) at an edge of one floor panel extending horizontally perpendicular to the edge, and at the other Horizontally open tongue grooves (9, 20) in adjacent edges of one floor panel for connecting adjacent edges in the vertical direction, the connectors at the long edges configured to be adjusted by angling Locking, the connectors at the short edges are configured to be locked by vertical folding, wherein the long edges of the new panels (1') in the second row (R2) are configured to be connected to the first row ( The long edge (5b) of the first panel (1") in R1), the short edge (4b) of the new panel (1') in the second row (R2) and the short edge of the second panel (1) The edges (4a) are configured to achieve connection by the same angular movement, Characterized in that the connection of the long edges when the new panel (1') is pressed by the upper edge against the upper edge of the first panel (1") at an angle of at least about 10 degrees relative to the main plane (HP) The connectors (9, 10, 6, 8, 14) have at least three separate contact points (CP1, CP2, CP3, CP4) or contact surfaces between adjacent parts of the connector; said long edge has at least four contact points (CP1, CP2, CP3, CP4) at intermediate positions; When the new panel is pressed against the upper edge of the first panel by the upper edge, said long edge has a vertical upper contact point (CP1) between adjacent surfaces of the first and second long edges at said intermediate position and lower contact point (CP2), and horizontal inner contact point (CP3) and outer contact point (CP4); The tongue on the short edge consists of a separate material and has a flexible portion configured to displace horizontally during folding and to cooperate with the tongue groove in the adjacent short edge so as to rotate in a direction parallel to the vertical plane (VP). locking the floor panels together vertically (D1); and wherein, in said intermediate position, the new panel (1') is angled such that its short edge (4b) is in initial contact with said flexible portion of the short edge (4a) of the second panel (1), so The flexible portion is expected to be displaced horizontally during vertical folding. 2. A set of floor panels as claimed in claim 1, characterized in that the tongue has an arcuate portion and is flexible in the length direction. 3. A set of floor panels as claimed in claim 1 or 2, characterized in that the tongue has a flexible projection. 4. A set of floor panels according to claim 1, characterized in that a part of the tongue is displaceably arranged in a displacement groove (40) formed at the edge of said one floor panel. 5. The set of floor panels as claimed in claim 1, wherein the flexible portion is a snap tab. 6. A set of floor panels as claimed in claim 5, wherein the flexible part is a snap tab on the locking strip panel, and the snap tab extends downwards. 7. The set of floor panels of claim 1, wherein the angle is at least about 15 degrees.

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