KR20140053168A - Mechanical locking system for floor panels - Google Patents

Abstract

A floor panel is disclosed having a vertical locking system on a short edge having a displaceable tongue that is displaced in one direction into a tongue groove during vertical displacement of two panels.

Description

{MECHANICAL LOCKING SYSTEM FOR FLOOR PANELS}

The present invention relates generally to the field of mechanical locking systems for floor panels and building panels. The present invention discloses a floorboard, a locking system, a mounting method and a manufacturing method.

The present invention relates to a floor panel comprising a bottom panel integrally formed with a floor panel and mechanically coupled to a factory mounted locking system and comprising one or more upper layers of veneers, a decorative laminate powder-based surface or a decorative plastic material, Is particularly suitable for use in a floating floor consisting of a fiber based material or intermediate core of plastic material and preferably a lower balancing layer on the back side of the core.

Accordingly, the following description of known techniques, problems of known systems, and features of the present invention is intended, by way of non-limiting example, to be particularly preferred in this application, especially in elongated and short edges intended to be mechanically coupled to each other on long and short edges A panel formed as a rectangular floor panel having an edge and a short edge.

The long and short edges are mainly used to simplify the description of the present invention. The panel may be square. The present invention is preferably used on short edges. The present invention may be used in any floor panel or in combination with any type of known locking system formed on an elongated edge wherein the floor panel has panels connected horizontally and vertically on at least two adjacent sides It should be emphasized that they are intended to be combined using a mechanical locking system.

The invention also relates to a parquet floor having, for example, a rigid wooden floor, a core of wood or wood-fiber based material and a surface of wood or wood veneer, etc., printed and preferably also varnished surfaces It may also be applied to floors with a surface layer of plastic, cork, linoleum, rubber, or the like. It also includes a floor with a hard surface such as stone, tiles and similar materials, and a flooring with a soft abrasive layer, for example a glued needle felt on the board. The present invention may also be used to incorporate architectural panels that preferably include board material such as, for example, wall panels, ceilings, furniture components, and the like.

The laminate flooring generally comprises a core of 6 to 12 mm fiberboard, an upper decorative surface layer of a laminate of 0.2 to 0.8 mm thickness, and a lower balancing layer of a material of laminate, plastic, paper or the like with a thickness of 0.1 to 0.6 mm. The laminate surface consists of melamine-impregnated paper. The most common core material is a fiber board with high density and good stability, commonly referred to as HDF-high density fiberboard. Sometimes also MDF - medium density fiberboard - is used as the core.

Traditional laminate floor panels of this type have been combined by glue-bonded tongue-and-groove joints. In addition to these traditional floors, floor panels have been developed that are mechanically coupled by a so-called mechanical locking system instead of requiring the use of glue. These systems include locking means for locking the panel horizontally and vertically. A mechanical locking system is typically formed by machining the core of the panel. Alternatively, portions of the locking system may be formed of discrete materials such as aluminum or HDF that are integrated with the floor panel, i.e., associated with the floor panel in connection with its manufacture.

The main advantage of float floors with mechanical locking systems is that they are easy to install. These floating floors can also be used once again at different locations, with easy re-tearing.

Definition of some terms

In the following text, the visible surface of the installed floor panel is referred to as the " front "while the opposite side of the floor panel facing the sub floor is referred to as the" rear surface ". The edge between the front and back surfaces is referred to as "joint edge ". By "horizontal plane" is meant a plane extending parallel to the outer portion of the surface layer. The directly juxtaposed upper portion of two adjacent joint edges of two joined floor panels defines a "vertical plane" perpendicular to the horizontal plane. "Vertical locking" means locking parallel to the vertical plane in the D1 direction. "Horizontal locking" means locking parallel to the horizontal plane in the D2 direction.

The term " upward "means facing the front," downward "means facing the rear," inward "means facing the inside and the center of the panel horizontally, Quot; horizontal " from < / RTI >

"Locking system" means a synergistic connection element that connects the floor panels vertically and / or horizontally.

For mechanical coupling of long edges as well as short edges in the first horizontal and vertical directions perpendicular to the edges, a number of methods may be used. One of the most used methods is the angle-snap method. The long edge is installed by angling. The panel is then displaced in the locked position along the long side. Short edges are locked by a horizontal snap connection. The vertical connections are generally tongues and grooves. During horizontal displacement, the strip with the locking element is bent, and when the edges are contacted, the strip resiliently restores and the locking element enters the locking groove to lock the panels horizontally. This snap connection is complicated because the hammer and the tapping block may need to be used to overcome the friction between the elongated edges and bend the strip during the snap connection action.

Similar locking systems may also be fabricated with rigid strips, which are connected by an angling-angling method in which both short and long edges are angled to the locking position.

Recently, new and highly efficient locking systems have introduced individual flexible or displaceable integral tongues on short edges that allow installation only by angling action, generally referred to as "vertical folding ". Such a system is described in WO 2006/043893 (Vaelinge Innovation AB).

Many versions have been used in the market as shown in Figs. 1A-1F. Figures 1a and 1b show a flexible tongue 30 with a flexible snap tab extending from an edge. Figures 1C and 1D illustrate displaceable tongues having an internal flexible portion which can be flexed horizontally at the cross-section of the tongue or along the joint. These systems are referred to as vertical snap systems, and these systems provide automatic locking during the folding action.

The locking system may also be locked by a side pressing action so that the displaceable tongue 30 is urged from the long side edge to the locked position when the adjacent short side edge is folded to the bottom. This side pressing action may be difficult to combine with a simple angle ring, and the friction may be too strong for a wide panel.

Figure IE shows a folding system with a flexible tongue 30 made in one piece with the core. 1F shows an elongated edge locking system of a folding system in connection with an angle ring.

These systems are very efficient, but there is still room for improvement. The vertical snap system is designed to have a tongue on the strip panel. This is because a sloping sliding surface can be formed only on the folded panel when the upper edge is manufactured without a ramp, which is a common case. It is difficult to insert the individual tongue 30 during manufacture in the groove 40 on the strip 6 including the locking element 8. The locking force depends on the snap connection resistance. The high locking force can only be achieved by a high snap connection resistance when the tongue is pressed inwardly and again snap-connected into the tongue groove (40). This creates a separating force that tends to press away the panels during folding. The locking may lose its strength if the tongue's flexibility and pressing force decreases with time. Flexibility should be taken into account, and the flexible tongue should be allowed to displace about 1-2 mm in two directions. The materials used to make these tongues are somewhat expensive, and glass fibers are generally used to reinforce the flexible tongue.

There will be major advantages if individual tongues can be secured to the folded panel and the snap connection can be eliminated in a system that locks automatically during folding.

The overall purpose of an embodiment of the present invention is to provide a device and a method for forming a substantially rectangular floor having a long edge and a short edge provided in parallel rows that allow short edges to be locked together automatically without a snap action, Panel locking system. A particular object is to provide a locking system which can be locked without any contact with the sharp top edge of the strip panel and which has a tongue that is individually displaceable on a folding panel in which the tongue is displaced essentially in one direction and outwardly only from the inner portion of the groove .

The above objects of embodiments of the present invention are wholly or partially accomplished by a locking system and a floor panel according to the independent claims. Embodiments of the invention are apparent from the dependent claims and from the description and drawings.

A first aspect of the present invention is a building panel having a locking system for vertical locking of first and second building panels by vertical displacement of the panels relative to each other. A laterally open tongue groove is provided at the edge of the first building panel. The strip protrudes underneath the tongue groove and outwardly past the upper portion of the edge of the first panel. A displaceable tongue is provided in the displacement groove which is open laterally at the edge of the second building panel. The displaceable tongue is located in the main body extending along the edge of the second panel and preferably in the upper and outer portions of the displaceable tongue and cooperating with the groove locking surfaces of the tongue grooves for vertical locking of the first and second building panels Lt; RTI ID = 0.0 > a < / RTI > The displaceable tongue includes an inner portion spaced inwardly apart from the upper portion of the edge of the second panel and the inner portion includes a tongue pressing surface configured to cooperate with the strip pressing surface on the strip. The displaceable tongue is configured to be displaced into the tongue groove when the tongue pressing surface and the strip pressing surface are displaced perpendicular to each other to obtain vertical locking.

The displaceable tongue is preferably an injection molded tongue.

The displaceable tongue may be asymmetrical and include a projection, and the second panel may include a cavity for receiving the projection.

The projection may include a flexible portion.

The strip may have a locking element cooperating with a downwardly open locking groove formed on the second panel for locking of the first and second building panels in the horizontal direction.

The tongue pressing surface is preferably located on the projection and the strip pressing surface is preferably located on the locking element.

The strip pressing surface is most preferably located on an inclined surface of the locking element that is directed toward the edge of the first building panel.

The locking system may include a cavity extending from the displacement groove to the locking groove.

The strip pressing surface and the tongue pressing surface may be inclined with respect to the horizontal plane at an angle of about 25 to 75 degrees.

The displacement groove may be inclined and may include an internal portion extending downwardly.

The architectural panels may each be vertically locked by two pairs of cooperating surfaces, including the groove locking surface and the tongue locking surface, and the lower portion of the edge of the upper portion of the strip and the edge of the second panel.

The groove locking surface and the tongue locking surface may be inclined with respect to the horizontal plane.

The groove locking surface and tongue locking surface may be inclined at an angle of about 10 to about 60 degrees with respect to the horizontal plane.

The displaceable tongue may comprise a flexible friction element.

The displaceable tongue may include at least two protrusions extending from the main tongue body, each protrusion may include the tongue-depressed surface located at the outer portion of the protrusion contacting the locking element provided on the strip during locking have.

The building panel may be a floor panel and the outer portion of the displaceable tongue is preferably in the unlocking position located within the displacement groove.

The displaceable groove may extend vertically above the locking groove.

The locking groove may be positioned vertically below the upper portion of the displacement groove.

The upper portion of the locking element may be positioned vertically below the tongue locking surface of the displaceable tongue.

The upper portion of the locking groove may be positioned vertically below the tongue locking surface of the displaceable tongue.

The innermost portion of the displaceable tongue may be under the outermost portion of such a tongue.

The tongue pressing surface may be positioned vertically below the tongue locking surface.

The upper portion of the locking element may be located in the lower half of the intermediate core of the first building panel.

The strip may be flexible to flex downwardly during locking.

The cavity may be larger than the projection so that a space S of at least about 1 to 3 mm is present.

The displaceable tongue may be gradually inserted into the tongue groove into another tongue adjacent to the long edge free from the tongue adjacent to the installed long edge.

BRIEF DESCRIPTION OF THE DRAWINGS The invention will be described in more detail below with reference to exemplary embodiments with reference to the accompanying exemplary drawings.

1A-1F illustrate a locking system according to the known art,
Figures 2A-2D illustrate a short edge locking system according to an embodiment of the present invention,
Figures 3A-3D illustrate a short edge locking system according to a preferred embodiment of the present invention,
Figures 4A-4E illustrate a preferred embodiment of a short edge locking system,
Figures 5A-5E illustrate vertical folding of three panels according to an embodiment of the present invention,
Figures 6A-6E illustrate a preferred embodiment of a flexible and displaceable tongue of a locking system during locking,
Figures 7a-7c illustrate a tongue blank according to an embodiment of the present invention including a plurality of displaceable tongues.

To facilitate understanding, a number of locking systems in the figures are shown schematically. It should be emphasized that improved or different functionality may be achieved using a combination of preferred embodiments.

All embodiments may be used individually or in combination. Angles, dimensions, rounded portions, spaces between surfaces, etc. are exemplary only and may be adjusted within the principles of the present invention.

Figures 2a-2d illustrate a short edge locking system with a flexible and displaceable tongue 30 within the edge of a second panel 1 ' inserted into a displaceable groove 40 and extending along the edge of the second panel FIG. 2 illustrates a first preferred embodiment of the present invention. The displaceable tongue 30 has a tongue-locking surface 22 located at the upper and outer portions cooperating with the groove-locking surface 21 located in the interior and upper portions of the tongue groove 20 formed in the adjacent edge of the first panel 1, (31). The locking surface locks the panels in a first vertical direction. The locking surfaces are inclined to have an angle (A2) which is preferably between about 10 and 60 degrees. The displacement groove is preferably also inclined and the outer portion is closer to the panel surface than the inner portion.

The first panel 1 comprises a protruding strip 6 extending outwardly beyond the vertical plane VP. The strip comprises a locking element (8). The second panel 1 'includes a locking groove 14 cooperating with the locking element 8 and locking the panel in the horizontal direction. The strip 6 has an upper portion 6 'that contacts the lower portion 37 of the adjacent edge and locks the panel in the second vertical direction.

The displaceable tongue 30 includes a protrusion 34 extending from the main tongue body 36. The first panel 1 'includes at least one cavity 35 for receiving the protrusions. The cavity extends from the displacement groove to the locking groove 14. The cavity may be formed by a screw cutter or by a displaceable saw blade. The protrusion includes a tongue pressing surface 32 cooperating with a strip pressing surface 33 on the locking element. The strip pressing surface 33 and the tongue pressing surface 32 are inclined at an angle A1 which is preferably 25 to 75 degrees with respect to the horizontal plane HP.

The displaceable tongue is displaced in essentially one direction toward the tongue groove 20 as the tilted pressing surface slides relative to one another during vertical displacement of the adjacent edge. The tongue may be locked with a strong pressure against the groove locking surface 21 and the locking element 8 prevents the tongue from sliding again into the displacement groove.

One major problem associated with the "pressure lock system" as described above is the risk that the panel may be split by the crack 50 between the displacement groove 40 and the locking groove 14, as shown in Figure 2D . The upper part of the locking groove 14a and the locking element 8a are thus preferably arranged on the center line C dividing the bottom panel into two identical parts, one upper part UP and one lower part LP. ), It is preferable to be manufactured in the lower part of the floor panel. It is also preferred that the tongue-pressing surface 32 is vertically positioned below the tongue-locking surface 31. The tongue pressing surface and the tongue locking surface are preferably vertically offset and preferably located on different horizontal planes (H2, H1). It is also preferred that the upper portion of the locking element 8a and / or the upper portion of the locking groove 14a are vertically positioned below the tongue-locking surface 31. [ The innermost portion of the displaceable tongue 30 is preferably located below the outermost portion of such a tongue.

The cavity 35 is preferably formed by a rotating saw blade and preferably includes an upper rounded portion having an outer portion 35b located above the inner portion 35a, as shown in Figure 2D. The cavity is preferably formed to intersect the inner portion 14b of the locking groove 14.

Figs. 3A to 3D show a locking function during vertical displacement of the second panel 1 'relative to the first panel 1. Fig. The displaceable tongues 30 are progressively pressed into the tongue grooves 20 by the cooperating pressure surfaces 32 and 33 and the panels are pressed against the two pairs of cooperating locking surfaces, Is vertically locked by the lower portion 21 of the strip 1 and the upper portion 6 'of the strip 6 and the lower portion 37 of the adjacent edge 1'.

Figures 4A-4E illustrate different embodiments. 4A shows a displaceable tongue 30 with a protrusion 34 located below the main tongue body. The locking groove 14 is vertically positioned below the upper portion of the displacement groove 40. 4B shows a tongue pressing surface 32 that locks against a strip pressing surface that is not activated during horizontal locking. Figure 4c shows that the same locking surface 33 on the locking element 8 may be used as a locking surface for horizontal locking and as a pressing surface. 4 (d) shows that the strip pressing surface may be formed on the individual pressing rod 42. Figure 4e shows a locking element comprising a projection 34 comprising a curved section and an upper portion 44 formed as a local projection over the interior portion of the locking groove 14 and into the cavity 35. [

5A-5E show that the elongated edges 2, 2 'are connected by an angle ring and the short edges 1, 1' are connected by three-panel connections of the angular ring and the vertical displacement, Vertical folding. FIG. 5B shows progressive insertion into tongue groove 20 from one portion of the edge adjacent the elongate edge 2 provided with a displaceable tongue to another free long edge. Figure 5c shows a tongue in cross section AA, and Figures 5d and 5e show tongue positions in cross section BB and CC. The strip 6 and the locking element 8 are designed in this embodiment to bend backward during locking, which facilitates locking since the required flexibility may be provided partially or completely by such strip bending. The locking groove is positioned vertically below the lower portion of the displacement groove 40.

Figure 6a illustrates that a locking system may be formed such that the plurality of portions, e.g., the projections 34, the locking strips 6, and the locking elements 8 are flexible. This flexibility may be used to reduce or eliminate manufacturing tolerances and to facilitate easy and strong locking. Figure 6a shows that the strip 6 may be bent downward and the locking element 8 may be bent downward and outward. Such strip bending may facilitate locking, which may be accomplished by a displaceable tongue that includes limited flexibility, such as a tongue, which essentially comprises a wood fiber material. The locking may be accomplished by the flexibility in which the portion of the displaceable tongue 30 is slightly flexed or compressed, for example, only about 0.1 to 1.0 mm in the horizontal direction.

Figures 6b and 6c illustrate an embodiment of a tongue. The displaceable tongue 30 may be secured within the displaceable groove by the frictional connection 38. The protrusion 34 may include a flexible portion 39 that creates a pre-tension against the tongue groove 20. The cavity 35 may be considerably larger than the projection, and there is a space S, which may be preferably about 1 to 3 mm.

Figure 6d shows a locking system with sliding surface 45 projecting beyond the vertical plane VP. The tongue groove 20 is preferably formed on the sloping edge surface 46. This embodiment provides the advantage that the displaceable tongue 30 may be urged inward and may be combined with unidirectional pushing movement, which normal double directional snap connection action may be used to generate the final locking.

Figure 6E shows a second panel 1 (Figure 1) that includes an upwardly extending snap tab 47 cooperating with a downwardly extending sliding surface 45 located on the first panel 1 and projecting past an upper edge and a vertical plane VP. 1 ').≪ / RTI > The second panel 1 'preferably includes a sloping edge surface 46' located above and / or below the tongue 30. An easy snap connection may also be obtained by a panel having straight and sharp top adjacent edges. The snap tab may be replaced by a displaceable tongue including a flexible snap connection protrusion along its length. The locking system shown in FIG. 1D may also be adjusted to include inclined edge surfaces, and such a design may be used to increase the strength of the joint.

The locking system according to the invention may also be formed without locking grooves 14 and locking elements 8 to only lock the edges in the vertical direction. The locking element 8 may be replaced by a local projection extending upwardly from the strip 6 and in a locked position located in the cavity. The short edge may be locked horizontally by friction between the elongated edges.

All locking systems can be designed such that they can be unlocked by angling and / or sliding along the edge.

Figs. 7A and 7B illustrate a tongue blank 43 including a plurality of displaceable tongues, which are preferably asymmetric along the tongue length. Figure 7a shows an injection molded tongue 30 and Figure 7b shows a displaceable tongue 30 made of wood based material which is preferably machined and punched.

The cavity 35, which is preferably formed by a rotating saw blade, includes a rounded upper portion and may include an inner portion located below the outer portion. The locking system may be partially or fully formed by a carving tool.

Claims (28)

1. A building panel provided with a locking system for vertical locking of a first building panel (1) and a second building panel (1 ') by vertical displacement of the panels (1, 1'
A lateral opening tongue groove 20 is provided on the edge of the first building panel 1 and a strip 6 is provided below the tongue groove 20 and on the edge of the first building panel 1. [ Protruding outward beyond the upper portion,
A displaceable tongue (30) is provided in a displacement groove (40) open laterally at the edge of the second building panel, the displaceable tongue (30) comprising a main body extending along an edge of the second panel And a tongue locking surface (31) located at the top and outer portions of the tongue, the tongue locking surface being configured to cooperate with a groove locking surface (21) of the tongue groove (20) As a result,
The displaceable tongue includes an inner portion (34) spaced inwardly from the upper portion of the edge of the second panel (1 '),
Wherein the interior portion includes a tongue pressing surface (32) configured to cooperate with a strip pressing surface (33) on the strip (6), the displaceable tongue (30) comprising first and second building panels Is displaced into the tongue groove when the tongue pressing surface (32) and the strip pressing surface (33) are displaced perpendicular to each other to obtain a locking of the tongue pressing surface (1, 1 ').
Building panels.
The method according to claim 1,
Characterized in that said displaceable tongue (30) is asymmetrical and comprises a projection (34), said second panel (1 ') comprising a cavity (35)
Building panels.
3. The method of claim 2,
The projection 34 includes a flexible portion 38,
Building panels.
The method according to claim 2 or 3,
The cavity 35 is larger than the projection 34 so that a space S of at least about 1 to 3 mm is present,
Building panels.
5. The method according to any one of claims 2 to 4,
Characterized in that the strip (6) is arranged to cooperate with a downwardly open locking groove (14) formed on the second panel for locking of the first and second building panels (1, 1 ' (8)
Building panels.
6. The method of claim 5,
Wherein said tongue pressing surface (32) is provided on said projection (34), said strip pressing surface (33) being provided on said locking element (8)
Building panels.
The method according to claim 6,
The strip pressing surface 33 is provided on an inclined surface of the locking element 8 which is directed toward the first edge,
Building panels.
6. The method of claim 5,
The strip pressing surface (33) is provided on the upper part of the locking element (8)
Building panels.
9. The method according to any one of claims 5 to 8,
The cavity (35) extends from the displacement groove (40) to the locking groove (14)
Building panels.
10. The method according to any one of claims 5 to 9,
The displacement groove (40) extends vertically above the locking groove (14)
Building panels.
11. The method according to any one of claims 5 to 10,
The upper portion 8a of the locking element 8 is positioned vertically below the tongue locking surface 31 of the displaceable tongue 30,
Building panels.
12. The method according to any one of claims 5 to 11,
The upper portion 14a of the locking groove 14 is positioned vertically below the tongue-locking surface 31 of the displaceable tongue 30,
Building panels.
13. The method according to any one of claims 5 to 12,
Wherein an uppermost portion of the locking element is located in a lower half of an intermediate core of the first building panel,
Building panels.
14. The method according to any one of claims 1 to 13,
The tongue pressing surface 32 and the strip pressing surface 33 are inclined with respect to the horizontal plane HP at an angle A1 of about 25 to 75 degrees,
Building panels.
15. The method according to any one of claims 1 to 14,
The displacement groove (40) has an inclined and downwardly extending inner portion,
Building panels.
16. The method according to any one of claims 1 to 15,
The first and second building panels (1, 1 ') are vertically locked by the first and second pairs of cooperating surfaces, and the first pair comprises a tongue locking surface (31) and a groove locking surface (21) , Said second pair comprising an upper portion of strip (6 ') and a lower portion of edge (37) of said second panel (1').
Building panels.
17. The method according to any one of claims 1 to 16,
The groove locking surface 21 and the tongue locking surface 31 are inclined with respect to the horizontal plane,
Building panels.
18. The method according to any one of claims 1 to 17,
The groove locking surface (21) and tongue locking surface are inclined at an angle (A2) of about 10 to about 60 degrees,
Building panels.
19. The method according to any one of claims 1 to 18,
The displaceable tongue (30) comprises a flexible friction element (38)
Building panels.
20. The method according to any one of claims 1 to 19,
The displaceable tongue 30 includes at least two protrusions 34 extending from the main body 36 and each protrusion including the tongue pressing surface 32 at an outer portion of the protrusion, Wherein the tongue-depressing surface is configured to contact a locking element provided on the strip during locking,
Building panels.
21. The method according to any one of claims 1 to 20,
The building panel (1, 1 ') is a floor panel,
Building panels.
22. The method according to any one of claims 1 to 21,
Wherein the upper and outer portions of the displaceable tongue in the unlocking position are located within the displaceable groove (40)
Building panels.
23. The method according to any one of claims 1 to 22,
Wherein the innermost portion of the displaceable tongue (30) is located below the outermost portion of the displaceable tongue,
Building panels.
24. The method according to any one of claims 1 to 23,
The tongue pressing surface (32) is positioned vertically below the tongue locking surface (31)
Building panels.
25. The method according to any one of claims 1 to 24,
Said strip being flexible to flex downwardly during locking,
Building panels.
26. The method according to any one of claims 1 to 25,
The displaceable tongue 30 is progressively inserted into the tongue groove 20 into another tongue adjacent to an elongated edge free from a tongue portion adjacent the installed elongate edge 2,
Building panels.
The method according to claim 1,
The strip 6 is configured to cooperate with a downwardly open locking groove 14 formed on the second panel for locking of the first and second building panels 1, 1 'in the horizontal direction, (8)
Building panels.
28. The method according to any one of claims 1 to 27,
The displaceable tongue may be an injection molded tongue,
Building panels.

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