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Número de publicaciónUS20130232905 A2
Tipo de publicaciónSolicitud
Número de solicitudUS 13/544,281
Fecha de publicación12 Sep 2013
Fecha de presentación9 Jul 2012
Fecha de prioridad11 Jul 2011
También publicado comoUS9725912, US20130014463
Número de publicación13544281, 544281, US 2013/0232905 A2, US 2013/232905 A2, US 20130232905 A2, US 20130232905A2, US 2013232905 A2, US 2013232905A2, US-A2-20130232905, US-A2-2013232905, US2013/0232905A2, US2013/232905A2, US20130232905 A2, US20130232905A2, US2013232905 A2, US2013232905A2
InventoresDarko Pervan
Cesionario originalValinge Flooring Technology Ab
Exportar citaBiBTeX, EndNote, RefMan
Enlaces externos: USPTO, Cesión de USPTO, Espacenet
Mechanical locking system for floor panels
US 20130232905 A2
Resumen
Floor panels are shown, which are provided with a vertical folding locking system on short edges that only locks vertically and a mechanical locking system on long edges that prevents displacement along the long edges.
Imágenes(10)
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Reclamaciones(23)
1. A flooring system comprising a plurality of rectangular floor panels with short edges and long edges, the panels are adapted to be installed on a sub floor and connected to each other with a long edge mechanical locking system for locking the panels vertically and horizontally, said locking system comprising a tongue and a tongue groove for mechanically locking together adjacent edges vertical to the horizontal plane, forming a vertical mechanical connection between the panels, and a locking element at a first long edge and a locking groove at an opposite second long edge thereby forming a first horizontal mechanical connection between adjacent long edges locking the panels to each other in a direction parallel to the horizontal plane and at right angles to said adjacent long edges,
wherein the panels are provided with a short edge locking connection comprising a separate tongue, for locking adjacent short edges in a first vertical direction, inserted in a fixation groove at a short edge of a panel, wherein the separate tongue is at least partly flexible and/or displaceable, and a locking strip and a locking cavity for locking adjacent short edges in a second vertical direction,
wherein the short edge locking connection is configured to lock the adjacent edges in the vertical directions only,
wherein the long edges are provided with a second horizontal mechanical connection locking the panels to each other along said adjacent long edges, in a direction parallel to the horizontal plane and parallel to said adjacent long edges, when the panel are laying flat on the sub floor.
2. The flooring system as claimed in claim 1, wherein said second horizontal mechanical connection at the long edges comprises a locking element and locking groove with two sets of cooperating locking surfaces wherein a first set is located closer to a vertical plane and the upper joint edges than a second set.
3. The flooring system as claimed in claim 2, wherein the two sets of locking surfaces are inclined such that a lower part of the locking element is larger than an upper part.
4. The flooring system as claimed in claim 2, wherein the vertical extension of the second set of locking surfaces is essentially the same or larger than the vertical extension of the first set of locking surfaces.
5. The flooring system as claimed in claim 2, wherein the long edge locking system further comprises a third set of cooperating locking surfaces located at the outer and lower part of the strip.
6. The flooring system as claimed in claim 2, wherein there is a space between the upper part of the locking element and the locking groove.
7. The flooring system as claimed in claim 1, wherein that said second horizontal mechanical connection comprises a flexible material which is applied in an essentially vertical groove.
8. The flooring system as claimed in claim 7, wherein said flexible material is compressed horizontally in two opposite directions.
9. The flooring system as claimed in claim 7, wherein said essentially vertical groove is complementary with a wedge shaped locking element.
10. The flooring system as claimed in claim 1, wherein said second horizontal mechanical connection comprises a friction element located on the upper part of the locking element that cooperates with a friction groove.
11. The flooring system as claimed in claim 10, wherein the friction groove comprises a flexible material.
12. The flooring system as claimed in claim 1, wherein said second horizontal mechanical connection comprises friction cavities located on the locking element.
13. The flooring system as claimed in claim 1, wherein said second horizontal mechanical connection comprises compressible material that is applied in the locking system at surfaces that do not comprise cooperative active locking surfaces which lock the panels vertically to the horizontal plane and horizontally in a direction parallel to the horizontal plane and at right angles to said adjacent long edges.
14. The flooring system as claimed in claim 1, wherein the short edge locking connection is locked with a vertical snap action where the separate tongue is displaced in the fixation groove during vertical displacement.
15. The flooring system as claimed in claim 1, wherein the short edge locking connection is locked when the separate tongue is displaced in the fixation groove along the short edge.
16. A flooring system comprising a plurality of rectangular floor panels with short edges and long edges, the panels are adapted to be installed on a sub floor and connected to each other with a long edge mechanical locking system for locking the panels vertically and horizontally, said locking system comprising a tongue and a tongue groove for mechanically locking together adjacent edges vertical to the horizontal plane, forming a vertical mechanical connection between the panels, and a locking element at a first long edge and a locking groove at an opposite second long edge thereby forming a first horizontal mechanical connection between adjacent long edges locking the panels to each other in a direction parallel to the horizontal plane and at right angles to said adjacent long edges,
wherein the panels are provided with a short edge locking connection comprising a separate tongue, for locking adjacent short edges in a first vertical direction, inserted in a fixation groove at a short edge of a panel, wherein the separate tongue is at least partly flexible and/or displaceable, and a locking strip and a locking cavity for locking adjacent short edges in a second vertical direction,
wherein the long edges are provided with a second horizontal mechanical connection locking the panels to each other along said adjacent long edges, in a direction parallel to the horizontal plane and parallel to said adjacent long edges, when the panel are laying flat on the sub floor,
wherein said second horizontal mechanical connection at the long edges comprises a locking element and locking groove with two sets of cooperating locking surfaces wherein a first set is located closer to a vertical plane and the upper joint edges than a second set,
wherein the two sets of locking surfaces are inclined such that a lower part of the locking element is larger than an upper part.
17. The flooring system as claimed in claim 16, wherein the vertical extension of the second set of locking surfaces is essentially the same or larger than the vertical extension of the first set of locking surfaces.
18. A flooring system comprising a plurality of rectangular floor panels with short edges and long edges, the panels are adapted to be installed on a sub floor and connected to each other with a long edge mechanical locking system for locking the panels vertically and horizontally, said locking system comprising a tongue and a tongue groove for mechanically locking together adjacent edges vertical to the horizontal plane, forming a vertical mechanical connection between the panels, and a locking element at a first long edge and a locking groove at an opposite second long edge thereby forming a first horizontal mechanical connection between adjacent long edges locking the panels to each other in a direction parallel to the horizontal plane and at right angles to said adjacent long edges,
wherein the panels are provided with a short edge locking connection comprising a separate tongue, for locking adjacent short edges in a first vertical direction, inserted in a fixation groove at a short edge of a panel, wherein the separate tongue is at least partly flexible and/or displaceable, and a locking strip and a locking cavity for locking adjacent short edges in a second vertical direction,
wherein the long edges are provided with a second horizontal mechanical connection locking the panels to each other along said adjacent long edges, in a direction parallel to the horizontal plane and parallel to said adjacent long edges, when the panel are laying flat on the sub floor,
wherein said second horizontal mechanical connection at the long edges comprises a locking element and locking groove with two sets of cooperating locking surfaces wherein a first set is located closer to a vertical plane and the upper joint edges than a second set,
wherein the long edge locking system further comprises a third set of cooperating locking surfaces located at the outer and lower part of the strip.
19. A flooring system comprising a plurality of rectangular floor panels with short edges and long edges, the panels are adapted to be installed on a sub floor and connected to each other with a long edge mechanical locking system for locking the panels vertically and horizontally, said locking system comprising a tongue and a tongue groove for mechanically locking together adjacent edges vertical to the horizontal plane, forming a vertical mechanical connection between the panels, and a locking element at a first long edge and a locking groove at an opposite second long edge thereby forming a first horizontal mechanical connection between adjacent long edges locking the panels to each other in a direction parallel to the horizontal plane and at right angles to said adjacent long edges,
wherein the panels are provided with a short edge locking connection comprising a separate tongue, for locking adjacent short edges in a first vertical direction, inserted in a fixation groove at a short edge of a panel, wherein the separate tongue is at least partly flexible and/or displaceable, and a locking strip and a locking cavity for locking adjacent short edges in a second vertical direction,
wherein the long edges are provided with a second horizontal mechanical connection locking the panels to each other along said adjacent long edges, in a direction parallel to the horizontal plane and parallel to said adjacent long edges, when the panel are laying flat on the sub floor,
wherein said second horizontal mechanical connection comprises a flexible material which is applied in an essentially vertical groove that is complementary with a wedge shaped locking element,
wherein said flexible material is compressed horizontally in two opposite directions.
20. A flooring system comprising a plurality of rectangular floor panels with short edges and long edges, the panels are adapted to be installed on a sub floor and connected to each other with a long edge mechanical locking system for locking the panels vertically and horizontally, said locking system comprising a tongue and a tongue groove for mechanically locking together adjacent edges vertical to the horizontal plane, forming a vertical mechanical connection between the panels, and a locking element at a first long edge and a locking groove at an opposite second long edge thereby forming a first horizontal mechanical connection between adjacent long edges locking the panels to each other in a direction parallel to the horizontal plane and at right angles to said adjacent long edges,
wherein the panels are provided with a short edge locking connection comprising a separate tongue, for locking adjacent short edges in a first vertical direction, inserted in a fixation groove at a short edge of a panel, wherein the separate tongue is at least partly flexible and/or displaceable, and a locking strip and a locking cavity for locking adjacent short edges in a second vertical direction,
wherein the long edges are provided with a second horizontal mechanical connection locking the panels to each other along said adjacent long edges, in a direction parallel to the horizontal plane and parallel to said adjacent long edges, when the panel are laying flat on the sub floor,
wherein said second horizontal mechanical connection comprises a friction element located on the upper part of the locking element that cooperates with a friction groove.
21. The flooring system as claimed in claim 20, wherein the friction groove comprises a flexible material.
22. A flooring system comprising a plurality of rectangular floor panels with short edges and long edges, the panels are adapted to be installed on a sub floor and connected to each other with a long edge mechanical locking system for locking the panels vertically and horizontally, said locking system comprising a tongue and a tongue groove for mechanically locking together adjacent edges vertical to the horizontal plane, forming a vertical mechanical connection between the panels, and a locking element at a first long edge and a locking groove at an opposite second long edge thereby forming a first horizontal mechanical connection between adjacent long edges locking the panels to each other in a direction parallel to the horizontal plane and at right angles to said adjacent long edges,
wherein the panels are provided with a short edge locking connection comprising a separate tongue, for locking adjacent short edges in a first vertical direction, inserted in a fixation groove at a short edge of a panel, wherein the separate tongue is at least partly flexible and/or displaceable, and a locking strip and a locking cavity for locking adjacent short edges in a second vertical direction,
wherein the long edges are provided with a second horizontal mechanical connection locking the panels to each other along said adjacent long edges, in a direction parallel to the horizontal plane and parallel to said adjacent long edges, when the panel are laying flat on the sub floor,
wherein said second horizontal mechanical connection comprises friction cavities located on the locking element.
23. A flooring system comprising a plurality of rectangular floor panels with short edges and long edges, the panels are adapted to be installed on a sub floor and connected to each other with a long edge mechanical locking system for locking the panels vertically and horizontally, said locking system comprising a tongue and a tongue groove for mechanically locking together adjacent edges vertical to the horizontal plane, forming a vertical mechanical connection between the panels, and a locking element at a first long edge and a locking groove at an opposite second long edge thereby forming a first horizontal mechanical connection between adjacent long edges locking the panels to each other in a direction parallel to the horizontal plane and at right angles to said adjacent long edges,
wherein the panels are provided with a short edge locking connection comprising a separate tongue, for locking adjacent short edges in a first vertical direction, inserted in a fixation groove at a short edge of a panel, wherein the separate tongue is at least partly flexible and/or displaceable, and a locking strip and a locking cavity for locking adjacent short edges in a second vertical direction,
wherein the long edges are provided with a second horizontal mechanical connection locking the panels to each other along said adjacent long edges, in a direction parallel to the horizontal plane and parallel to said adjacent long edges, when the panel are laying flat on the sub floor,
wherein said second horizontal mechanical connection comprises compressible material that is applied in the locking system at surfaces that do not comprise cooperative active locking surfaces which lock the panels vertically to the horizontal plane and horizontally in a direction parallel to the horizontal plane and at right angles to said adjacent long edges.
Descripción
    CROSS REFERENCE TO RELATED APPLICATIONS
  • [0001]
    This application claims benefit of Provisional Application No. 61/506,282, filed Jul. 11, 2011.
  • TECHNICAL FIELD
  • [0002]
    The disclosure generally relates to the field of mechanical locking systems for floor panels and building panels. Furthermore, floorboards, locking systems, installation methods and production methods are shown.
  • FIELD OF APPLICATION OF THE INVENTION
  • [0003]
    The present invention is particularly suitable for use in floating floors, which are formed of floor panels which are joined mechanically with a locking system integrated with the floor panel, i.e. mounted at the factory, are made up of one or more upper layers of veneer, decorative laminate or decorative plastic material, an intermediate core of wood-fibre-based material or plastic material and preferably a lower balancing layer on the rear side of the core. The following description of prior-art technique, problems of known systems and objects and features of the invention will therefore, as a non-restrictive example, be aimed above all at this field of application and in particular at laminate flooring formed as rectangular floor panels with long and shorts edges intended to be mechanically joined to each other on both long and short edges. The long and short edges are mainly used to simplify the description of the invention. The panels may be square. It should be emphasised that the invention may be used in any floor panel and it may be combined with all types of known locking systems, where the floor panels are intended to be joined using a mechanical locking system connecting the panels in the horizontal and vertical directions on at least two adjacent sides. The invention may thus also be applicable to, for instance, powder based floors, solid wooden floors, parquet floors with a core of wood or wood-fibre-based material and a surface of wood or wood veneer and the like, floors with a printed and preferably also varnished surface, floors with a surface layer of plastic or cork, linoleum, rubber. Even floors with hard surfaces such as stone, tile and similar materials are included and floorings with soft wear layer, for instance needle felt glued to a board. The invention may also be used for joining building panels which preferably contain a board material for instance wall panels, ceilings, furniture components and similar.
  • BACKGROUND OF THE INVENTION
  • [0004]
    Laminate flooring usually comprise a core of a 6-12 mm fibre board, a 0.2-0.8 mm thick upper decorative surface layer of laminate and a 0.1-0.6 mm thick lower balancing layer of laminate, plastic, paper or like material. A laminate surface may comprise melamine-impregnated paper. The most common core material is fibreboard with high density and good stability usually called HDF—High Density Fibreboard. Sometimes also MDF—Medium Density Fibreboard—is used as core.
  • [0005]
    Traditional laminate floor panels of this type have been joined by means of glued tongue-and-groove joints.
  • [0006]
    In addition to such traditional floors, floor panels have been developed which do not require the use of glue and instead are joined mechanically by means of so-called mechanical locking systems. These systems comprise locking means, which lock the panels horizontally and vertically. The mechanical locking systems are usually formed by machining of the core of the panel. Alternatively, parts of the locking system may be formed of a separate material, for instance aluminium or HDF, which is integrated with the floor panel, i.e. joined with the floor panel in connection with the manufacture thereof.
  • [0007]
    The main advantages of floating floors with mechanical locking systems are that they are easy to install. They may also be disassembled and used once more at a different location.
  • DEFINITION OF SOME TERMS
  • [0008]
    In the following text, the visible surface of the installed floor panel is called “front side”, while the opposite side of the floor panel, facing the sub floor, is called “rear side”. The edge between the front and rear side is called “joint edge”. By “horizontal plane” is meant a plane, which extends parallel to the outer part of the surface layer. Immediately juxtaposed upper parts of two adjacent joint edges of two joined floor panels together define a “vertical plane” perpendicular to the horizontal plane. By “vertical locking” is meant locking parallel to the vertical plane in D1 direction. By “horizontal locking” is meant locking parallel to the horizontal plane in D2 direction. By “first horizontal locking” is meant a horizontal locking perpendicular to the joint edges in D2 direction. By “second horizontal locking” is meant a horizontal locking in the horizontal direction along the joint which prevents two panels to slide parallel to each other when they are laying in the same plane.
  • [0009]
    By “locking systems” are meant co acting connecting elements, which connect the floor panels vertically and/or horizontally. By “mechanical locking system” is meant that joining may take place without glue. Mechanical locking systems may also be joined by gluing. By “integrated with” means formed in one piece with the panel or factory connected to the panel.
  • RELATED ART AND PROBLEMS THEREOF
  • [0010]
    For mechanical joining of long edges as well as short edges in the vertical and in the first horizontal direction perpendicular to the edges several methods may be used. One of the most used methods is the angle-snap method. The long edges are installed by angling. The panel is then displaced in locked position along the long side. The short edges are locked by horizontal snapping. The vertical connection is generally a tongue and a groove. During the horizontal displacement, a strip with a locking element is bent and when the edges are in contact, the strip springs back and a locking element enters a locking groove and locks the panels horizontally. Such a snap connection is complicated since a hammer and a tapping block may need to be used to overcome the friction between the long edges and to bend the strip during the snapping action.
  • [0011]
    Similar locking systems may also be produced with a rigid strip and they are connected with an angling-angling method where both short and long edges are angled into a locked position.
  • [0012]
    Recently new and very efficient locking systems have been introduced with a separate flexible or displaceable integrated tongue on the short edge that allows installation with only an angling action, generally referred to as “vertical folding”. Such a system is described in WO 2006/043893 (Välinge Innovation AB.
  • [0013]
    Several versions are used on the market as shown in FIGS. 1 a-1 f. 1 a, 1 b shows a flexible tongue 30 with a flexible snap tab extending from the edge. FIG. 1 c, 1 d shows a displaceable tongue with an inner flexible part that is bendable horizontally in a cross section of the tongue or along the joint. Such systems are referred to as vertical snap systems. The locking system may also be locked with a side push action such that a displaceable tongue 30 is pushed into a locked position from the long side edge when adjacent short side edges are folded down to the sub floor. FIG. 1 e shows a fold down system with a flexible tongue 30 that is made in one piece with the core. FIG. 1 f shows a long edge locking system in a fold down system that is connected with angling.
  • [0014]
    All such locking systems comprise a horizontal locking, which is accomplished by cooperating hook element in the form of a strip with a locking element cooperating with a locking groove.
  • [0015]
    Several versions of fold down systems are described in WO2006104436, WO2007015669, WO2008004960, WO2010087752 (Välinge Innovation AB) and they constitute a part of this description.
  • [0016]
    Although such systems are very efficient, there is still a room for improvements. It is difficult to insert the separate tongue 30 during production into a groove 40 over a strip 6 comprising a locking element 8. The locking groove 14 reduces the strength and the edges may crack. The protruding locking strip with the locking element causes a waste when the edges are machined and such waste may be considerable in wide tile-shaped floorboards.
  • [0017]
    It is a major advantage if the strip 6 is more compact and shorter and if the locking element 8 and the locking groove 14 are eliminated.
  • [0018]
    One of the main advantages with the fold down systems is that there is no requirement that the long edges should be displaceable. In fact it is an advantage if the long edges do not slide during angling since a flexible tongue that is used in some systems presses the short edges apart during folding.
  • [0019]
    WO 2006/043893 describes a fold down system with an essentially horizontal protruding strip that does not have a locking element. Such fold down system has no horizontal connection and the short edges may be locked by for example gluing or nailing to the sub floor. It would be an advantage if such floorboards could be installed in a floating manner.
  • [0020]
    Such a floating installation may be accomplished according to this invention with a locking system that comprises long edges that are locked in a first horizontal direction perpendicular to the edge and in a second horizontal direction along the edge. Long edges that are not displaced after locking will also keep the short edges together and prevent separation.
  • [0021]
    It is known that a separation of short edges of floor panels may be prevented with increased friction or with projections and spaces between the long edges that will counteract mutual displacements along the edge and consequently prevent the short edges to slide apart.
  • [0022]
    It is for example known from Wilson U.S. Pat. No. 2,430,200 that several projections and recesses between a tongue and a groove in a mechanical locking system may be used to prevent displacement along the joint. Such projections and recesses are difficult to produce, the panels can only be locked in well-defined positions against adjacent long edges and they cannot be displaced against each other in angled position when top edges are in contact.
  • [0023]
    Terbrack U.S. Pat. No. 4,426,820 describes a locking system with a tight fit in a panel made of plastic material. The tight fit prevents displacement along the joint. A system with tight fit between all surfaces is difficult to produce and does not give a safe and reliable locking over time, especially if the locking system is made of wood fibre based material such as HDF, which swells and shrink when the humidity varies over time.
  • [0024]
    WO1994026999 (Välinge Innovation AB) describes a mechanical locking system that locks vertically and horizontally and where a rubber strip or any other sealing device is applied in the groove or between the flat projection part of the strip and the adjacent panel edge as shown principally in FIG. 1 f. It is obvious that a rubber strip may be used to increase friction along the joint.
  • [0025]
    WO98/22677 (Golvabia) describes a tongue and groove joint where several different types of materials are used to increase friction in order to prevent the edges from sliding apart perpendicularly to the edge. Example of materials inserted or applied in the tongue and groove joint are flock, strip-shaped bands of rubber, plastic, foamed rubber adhesive coated surfaces in which friction-increasing material is fixed such as sand, plastic or rubber particles. Roughened or coarsened surfaces may also be used.
  • [0026]
    WO03025307 and WO03089736 (Välinge Innovation AB) describe that displacement along long edges may be counteracted or prevented by means of high friction, glue, mechanical means etc. and that the short edges may be formed merely with vertical locking means or completely without locking means. WO03012224 (Välinge Innovation AB) describes that flexible elastic sealing compounds based on acrylic plastics, elastomers of synthetic rubber, polyurethane-based hot-melt adhesives etc may be applied between the horizontal locking surfaces in order to compensate moisture movements due to swelling or shrinking. Such elastically material will increase the friction and prevent displacement of long edges along the joint.
  • [0027]
    Wernersson WO2004/083557 discloses floor panels with mechanical locking means wherein predetermined surfaces of the edges are provided with splines. There is no disclosure of the geometry of such mechanical locking means, how such splines are formed and on which surfaces they are applied.
  • [0028]
    WO 2006/123988 (Välinge Innovation AB) describes a panel with a slide locking system comprises a plurality of small local protrusions that prevents displacement along the joint edges when the panels are laying flat on the sub floor. The protrusions may lock against a flexible rubber material at the adjacent panel. The short edges are provided only with a vertical locking comprising a tongue made in one piece with the core. The panels may be locked with vertical folding and the slide lock prevents sliding along the joint after folding. A folding system at the short edges that only locks vertically and which comprise a flexible separate tongue is not described.
  • [0029]
    These known technologies to prevent displacement along the long edges suffer from several disadvantages. Friction created by pressure and small hard materials is not reliable since swelling and shrinking in wood fibre based panels may change the friction forces, thus the panels may as time goes slide and the short edges separate from each other. Friction material that is applied on surfaces that form active horizontal locking surfaces, such as the locking surfaces of the locking element and the locking groove and upper adjacent joint edges may change the locking geometry and prevent an easy installation.
  • SUMMARY
  • [0030]
    A first overall objective of the present invention is to provide a locking system for primarily rectangular floor panels with long and short edges installed in parallel rows, which allows that the short edges may be locked to each other with a vertical movement without a horizontal connection and that such horizontal connection is accomplished by the locking system on the long edges comprising a first and second horizontal locking perpendicular to the edges and along the edges.
  • [0031]
    The invention is based on the understanding that since displacement of the long edges is not needed in a fold down locking system, there is more freedom to design the long edges locking system.
  • [0032]
    The costs and functions should be favourable compared to known technology. An essential part of the overall objective is to improve the function and costs of those parts of the locking system that locks in the second horizontal direction along the joint when panels are installed on a sub floor.
  • [0033]
    More specifically the object is to provide a second horizontal locking system on the long edges, hereafter referred to as “slide lock” where one or several of the following advantages are obtained.
  • [0034]
    The slide lock on the long edges should be activated when a panel is brought in contact with an already installed panel and then angled down to the sub floor.
  • [0035]
    The slide lock function should be reliable over time and the panels should be possible to lock and unlock in any position when two adjacent long edges are brought into contact with each other.
  • [0036]
    The slide lock should be strong and prevent short edges of two locked panels from separating when humidity changes or when people walk on a floor.
  • [0037]
    The slide lock should be possible to lock with high precision and without the use of tools.
  • [0038]
    The locking system and the slide lock should be designed in such a way that the material and production costs are low and that flexible materials may be applied in a safe way without the risk that such separate materials will be included in the active locking surfaces in an uncontrolled way.
  • [0039]
    The invention is based on a general approach that the locking element and the locking groove at the long edges should be used to accomplish a horizontal locking perpendicular to the edge but also along the edge.
  • [0040]
    The above objects of the invention are achieved wholly or partly by locking systems, floor panels, and installation and production methods according to the disclosure herein. Embodiments of the invention are evident from the description and drawings.
  • [0041]
    A first aspect of the invention is a flooring system comprising a plurality of rectangular floor panels with short edges and long edges. The panels are adapted to be installed on a sub floor and connected to each other with a mechanical locking system for locking the panels vertically and horizontally. Said locking system comprising a tongue and a tongue groove for mechanically locking together adjacent edges vertical to the horizontal plane, thereby forming a vertical mechanical connection between the panels. A locking element at a first long edge and a locking groove at an opposite second long edge form a first horizontal mechanical connection between adjacent long edges locking the panels to each other in a direction parallel to the horizontal plane and at right angles to said adjacent long edges. The panels are provided with a short edge locking connection comprising a separate tongue for locking adjacent short edges in a first vertical direction, inserted in a fixation groove at a short edge of a panel. The tongue is preferably at least partly flexible and/or displaceable. The short edge locking connection further comprises a locking strip and a locking cavity for locking adjacent short edges in a second vertical direction. The short edge locking connection is configured to lock the adjacent edges in a vertical direction only. The long edges are provided with a second horizontal mechanical connection locking the panels to each other along said adjacent long edges, in a direction parallel to the horizontal plane and parallel to said adjacent long edges, when the panel are laying flat on the sub floor.
  • [0042]
    Said second horizontal mechanical connection at the long edges may comprises a locking element and locking groove with two sets of cooperating locking surfaces, wherein a first set is located closer to a vertical plane (VP) and the upper joint edges than a second set.
  • [0043]
    The two sets of locking surfaces may be inclined such that a lower part of the locking element is larger than an upper part.
  • [0044]
    The vertical extension of the second set of locking surfaces may be essentially the same or larger than the vertical extension of the first set of locking surfaces.
  • [0045]
    The long edge locking system may comprises a third set of cooperating locking surfaces located at the outer and lower part of the strip.
  • [0046]
    There may be a space between the upper part of the locking element and the locking groove.
  • [0047]
    Said second horizontal mechanical connection may comprise a flexible material which is applied in an essentially vertical groove.
  • [0048]
    Said second horizontal mechanical connection may comprise a flexible material, which is compressed horizontally in two opposite directions
  • [0049]
    Said second horizontal mechanical connection may comprise a flexible material, which is located in an essentially vertical groove that is complementary with a wedge shaped locking element.
  • [0050]
    Said second horizontal mechanical connection may comprise a friction element located on the upper part of the locking element that cooperates with a friction groove.
  • [0051]
    The friction groove may comprise a flexible material.
  • [0052]
    Said second horizontal mechanical connection may comprise friction cavities located at the locking element.
  • [0053]
    Said second horizontal mechanical connection may comprise compressible material that is applied in the locking system at surfaces that do not comprise cooperative active locking surfaces that lock the panels vertically and horizontally.
  • [0054]
    The short edge locking connection may be locked with a vertical snap action where the separate tongue is displaced in the fixation groove during vertical displacement.
  • [0055]
    The short edge locking connection may be locked when the separate tongue is displaced in the fixation groove along the short edge.
  • [0056]
    According to a first preferred embodiment the locking system at the long edges comprises a locking element and locking groove with two sets of cooperating locking surfaces. A first set is located closer to a vertical plane and the upper joint edges than a second set. The locking surfaces are preferably inclined such that a lower part of the locking element is larger than an upper part. It is preferred that there is a space between the upper part of the locking element and the locking groove. Such a space may be used to give more production tolerances. Preferably the vertical extension of the second set of locking surfaces is essentially the same or larger than the vertical extension of the first set of locking surfaces.
  • [0057]
    According to a second embodiment of the invention the long edge locking system comprises a flexible material located in a vertical groove that prevents displacement along the edges. The flexible material is preferably located between cooperating surfaces of the locking element and the locking groove.
  • [0058]
    According to a third embodiment of the invention the long edge locking system comprises at least three sets of cooperative locking surfaces between a locking element located on a strip and a locking groove. The first and the second sets are located in the upper part of the locking element wherein the first set is closer to the upper edges than the second set. The third set is located on the lower and outer part of the strip. This geometry is used to accomplish a strong press fit between the locking element and the locking groove and the panels will be tightly secured to each other such that displacement along the long edges and perpendicular to the short edges will be prevented.
  • [0059]
    Such a locking system with a press fit may be made much stronger than conventional locking systems with hooks at the short edges.
  • [0060]
    A second aspect of the invention is two floor panels provided with a locking system comprising a tongue and a tongue groove for mechanically locking together adjacent edges vertical to the horizontal plane, thereby forming a vertical mechanical connection between the panels. A locking element at an edge and a locking groove at an opposite second edge form a first horizontal mechanical connection between adjacent edges locking the panels to each other in a direction parallel to the horizontal plane and at right angles to said adjacent edges. The tongue may be separate tongue, preferably at least partly flexible and/or displaceable, inserted in a fixation groove at an edge of a panel. The edges is provided with a second horizontal mechanical connection locking the panels to each other along said adjacent edges, in a direction parallel to the horizontal plane and parallel to said adjacent edges, when the panels are laying flat on a sub floor.
  • [0061]
    Said second horizontal mechanical connection at the edges may comprise a locking element and locking groove with two sets of cooperating locking surfaces, wherein a first set is located closer to a vertical plane (VP) and the upper joint edges than a second set.
  • [0062]
    The two sets of locking surfaces may be inclined such that a lower part of the locking element is larger than an upper part.
  • [0063]
    The vertical extension of the second set of locking surfaces may be essentially the same or larger than the vertical extension of the first set of locking surfaces.
  • [0064]
    The locking system may comprise a third set of cooperating locking surfaces located at the outer and lower part of the strip.
  • [0065]
    There may be a space between the upper part of the locking element and the locking groove.
  • [0066]
    Said second horizontal mechanical connection may comprise a flexible material which is applied in an essentially vertical groove.
  • [0067]
    Said second horizontal mechanical connection may comprise a flexible material, which is compressed horizontally in two opposite directions
  • [0068]
    Said second horizontal mechanical connection may comprise a flexible material, which is located in an essentially vertical groove that is complementary with a wedge shaped locking element.
  • [0069]
    Said second horizontal mechanical connection may comprises a friction element located on the upper part of the locking element that cooperates with a friction groove.
  • [0070]
    The friction groove may comprise a flexible material.
  • [0071]
    Said second horizontal mechanical connection may comprise friction cavities located at the locking element.
  • [0072]
    Said second horizontal mechanical connection may comprise compressible material that is applied in the locking system at surfaces that do not comprise cooperative active locking surfaces that lock the panels vertically and horizontally.
  • [0073]
    The edges may be locked with a vertical snap action where the separate tongue is displaced in the fixation groove during vertical displacement.
  • [0074]
    The edges may be locked when the separate tongue is displaced in the fixation groove along the short edge.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • [0075]
    The disclosure will in the following be described in connection to exemplary embodiments and in greater detail with reference to the appended exemplary drawings, wherein:
  • [0076]
    FIGS. 1 a-f illustrate locking systems according to known technology.
  • [0077]
    FIGS. 2 a-e illustrate a short edge locking system according to the invention.
  • [0078]
    FIGS. 3 a-3 d illustrate a long edge locking system according to preferred embodiments of the invention.
  • [0079]
    FIGS. 4 a-c illustrate an preferred embodiment of short edge locking system.
  • [0080]
    FIGS. 5 a-d illustrate separate tongues that may be used in to lock short edges.
  • [0081]
    FIGS. 6 a-f illustrate preferred embodiments of the invention.
  • [0082]
    FIGS. 7 a-c illustrate a long edge locking system according to the invention.
  • [0083]
    FIGS. 8 a-8 b illustrate vertical folding with a conventional locking system and a locking system according to the invention. FIGS. 8 a-8 b
  • [0084]
    FIGS. 9 a-9 d illustrate preferable embodiments of the invention.
  • DESCRIPTION OF EMBODIMENTS OF THE INVENTION
  • [0085]
    To facilitate understanding, several locking systems in the figures are shown schematically. It should be emphasised that improved or different functions may be achieved using combinations of the preferred embodiments.
  • [0086]
    The inventor has tested all known and especially all commercially used locking systems on the market that are installed with vertical folding in all type of floor panels, especially laminate and wood floorings and the conclusion is that at least all these known locking systems which have one or more locking elements cooperating with locking grooves may be adjusted to a system with a slide lock on the long edges which prevents displacement along the adjacent edges and with fold down locking system on short edges that only locks vertically.
  • [0087]
    The most preferable embodiments are however based on floorboards with a surface layer of laminate, powder based paper free surfaces or wood surfaces, a core of HDF or wood and a locking system on the long edge with a strip extending beyond the upper edge which allows locking by angling combined with a tongue and groove joint on the short edges comprising a separate tongue which preferably only locks vertically.
  • [0088]
    All embodiments may be used separately or in combinations. Angles, dimensions, rounded parts, spaces between surfaces etc. are only examples and may be adjusted within the basic principles of the invention.
  • [0089]
    FIGS. 2 a -2 e show a first preferred embodiment of a short edge locking system provided with a flexible and displaceable tongue 30 in a first edge 1 inserted in a fixation groove 40 that cooperated with a tongue groove 20 in an adjacent second panel 1′ and locks the panels in a first vertical direction according to known technology. The first panel 1 (strip panel) comprises a protruding strip 6 that extends outwardly beyond a vertical plane VP. The second panel 1′ comprises a locking cavity 7 that cooperates with the locking strip 6 and locks the panels in a second vertical direction. FIG. 2 e show that the panels are only locked vertically and that they may be released or connected horizontally in essentially the same plane since there is no locking element on the strip and no hook connections in the locking system that prevents such horizontal displacement.
  • [0090]
    FIGS. 3 a and 3 b show a slide lock system according to one preferred embodiment comprising a tongue 10 and a tongue groove 9, a locking strip 6, a locking element 8 and a locking groove 14. A flexible and compressible material 16 such as synthetic or natural rubber or plastic foam is applied in the upper part of the locking groove 14 as a layer or in local spots. The upper part of the locking element 8 is formed such that preferably two horizontally opposite edges press against the compressible material 16 a, 16 b. In a wood floor with a lamella core the locking element and the locking groove will be formed across the fibre orientation. The swelling and shrinking in the horizontal direction along the wood fibres is extremely small and will not cause any dimensional changes of the fitting tolerances between the locking element 8 and the locking groove 14. The counter pressure will not have any effect on the locking tolerances and swelling and shrinking of this part of the locking system will easily be compensated by the flexibility of the compressible material even in other wood based materials such as HDF. It is preferred that the upper part of the locking element is wedge formed and that it cooperates with a complementary groove 14. It is preferred that the inner part of the groove 14 is smaller than the groove opening. This design may be used to create a friction connection even without compressible material.
  • [0091]
    FIGS. 3 c and 3 d show a locking system with at least three sets of cooperative locking surfaces between the locking element 8 and the locking groove 14. The first 11,12 and the second 21,22 sets are located in the upper part of the locking element wherein the first set is closer to the upper edges 4,5 than the second set. The third set 23,24 is located on the lower and outer part of the strip 6. The locking surfaces are essentially flat but they may also be curved. The locking surfaces are preferably inclined. Preferably the angle Al against a horizontal plane of the first set of cooperated surfaces should be slightly smaller than the angle A3 of the third set. This geometry may be used to accomplish a strong press fit between the locking element 8 and the locking groove 14 and the panels will be tightly secured to each other such that displacement along the long edges and perpendicular to the short edges will be prevented. Such a locking system with a press fit may be made much stronger than conventional locking systems with hooks at the short edges. A horizontally extending groove 35 may be formed in a wall or the locking groove 14 in order to increase the flexibility of one of the locking surfaces 23 in the third set of locking surfaces.
  • [0092]
    The locking element and the locking groove may be formed in a very precise manner if high precision profiling is used where several tools are positioned at the same tool station such that the upper edge 4 and the locking element are formed at the same time in order to eliminate turning of the panels during machining. The locking groove and the upper edge 5 may be formed in the same way.
  • [0093]
    FIG. 4 a-4 c show that the separate tongue may be attached to the fold panel 1′.
  • [0094]
    FIGS. 5 a-5 d show that all known tongues may be used in the short edge locking system. FIG. 5 a shows a bow shaped tongue and FIG. 5 b shows a bristle tongue. Such tongues are bended in length direction during locking. FIG. 5 c shows a wedge tongue that is displaced with a side push action from the long edge such that it is displaced both along and perpendicular to the edge into the tongue groove 20. FIG. 5 d shows as side push rigid tongue that is only displaced along the edge such that the protrusions on the tongue overlap the protrusions formed in the tongue groove 20.
  • [0095]
    FIGS. 6 a-6 f show that all known fold down systems may be adapted to a locking system according to the invention by removing a part the locking element and preferably a part of the strip 6. This will provide cost savings due to less waste and a stronger joint. It is also possible to form a fold down system in very thin floorboards for example with a thickness of 4-6 mm. FIG. 6 d shows a side push system with a wedge shaped tongue and FIG. 6 e shows a side push system with a tongue comprising protrusions. Even one-piece systems with a machined tongue as shown in FIG. 6 f may be used. A short strip provides a much easier machining of the undercut groove 41.
  • [0096]
    FIGS. 7 a-7 b show preferred embodiments. The long side locking system comprises a friction element 15, which in this embodiment is located on the upper part of the locking element 8, and that cooperates with a friction groove 17. The advantage is that no compressible material 16 is applied in the active locking surfaces 9 a,9 b,10 a,10 b,3,4,11,12 that lock the panels vertically and horizontally.
  • [0097]
    FIG. 7 c shows that the friction may be improved if friction cavities 18 are formed on the upper part of the locking element 8 or in the friction element 15. Such cavities form expansion spaces for the flexible material 16 that may be applied with lower requirements on production tolerances. The cavities are preferably formed with a screw cutter as describe in WO2010087752. Friction cavities 18′ may also be formed on other parts of the locking system for example the outer part of the strip 6.
  • [0098]
    FIGS. 8 a and 8 b show that present locking systems, as shown in FIG. 8 a may easily be converted to a locking system according to the invention, as shown in FIG. 8 b, and that the new locking system may be compatible with the old locking system. Friction cavities 18 are formed in the upper part of the locking element with a screw cutter, compressible material 16 is preferably inserted essentially in the groove along the whole long edge or in parts thereof and the locking element on the short edges is removed.
  • [0099]
    The panels are installed such that a long edge 2″ of a new panel in a second row is put at an angle against a long edge 2 of a first panel installed in a previous row and displaced until its short edge 1′ is in contact with a short edge 1 of a second panel installed in the second row. The new panel is angled down whereby the flexible tongue locks 30 the short edges 1,1′ vertically. The long edges comprise a locking system with a friction connection that prevents displacement of the panels along the long edges 2, 2′, 2″.
  • [0100]
    FIG. 9 a shows that several friction elements 15, 15′ and friction grooves 17,17′ with compressible material 16,16, may be provided.
  • [0101]
    FIG. 9 b shows that the strip 6 may be replaced by overlapping upper edges 32, 33 above the separate tongue 30. It is of course possible to use both overlapping edges and a locking strip 6 cooperating with a locking cavity 7.
  • [0102]
    FIG. 9 c shows that flexible and compressible material 16 may be applied on the friction element 15.
  • [0103]
    The long edge locking along the edge may be accomplished with a tight fit, with high friction or with all known methods to prevent displacement along the joint.
  • [0104]
    Wood floor with a lamella core that generally has a rough surface may be formed with a locking system with tight fit and with rather large cooperating locking surfaces. No flexible materials are needed to obtain sufficient friction. Such long side locking system is extremely difficult to displace, especially when the floor boards are long, for example 1.8-2.4 m and the friction force is generally sufficient to accomplish a locking which keeps the short edges together during the lifetime of the floor.
  • [0105]
    The locking strength of the slide lock may be increased considerably with a locking strip that is slightly bended and that causes a permanent vertical pressure as shown in FIG. 9 d. Sufficient friction may be created even in HDF material that generally is formed with rather smooth surfaces. A strip 6 that in locked position is bended backwards will press the locking element 8 into the locking groove 14 when people walk on the floor or when furniture is applied on the surface. This will increase the locking strength of the second horizontal connection along the long edges. The locking strength may be increased further if for example a pressing protrusion 23 is formed on the lower part of the strip, preferably under the locking element. Such pressing protrusion 23 may be applied as a separate material on essentially the whole strip 6 or on separate parts along the edge.
  • [0106]
    Wedge shaped locking elements 8 that are pressed into a cooperating locking groove 14 as shown in FIG. 9 d may create a sufficient friction even without a compressible friction material. FIG. 9 d shows embodiment that comprises a locking element 8 and locking groove with two sets of cooperating locking surfaces. A first set 11,12 is located closer to the vertical plane than a second set 21,22. The locking surfaces are preferably inclined such that a lower part of the locking element is larger than an upper part. The locking surfaces may be essentially plane or curved. It is preferred that there is a space S between the upper part of the locking element and the locking groove. Such a space S may be used to give more production tolerances. The angle A1,A2 of the cooperating surfaces, or tangent line in case the surfaces are curved, should preferably be larger than about 45 degrees.
  • [0107]
    Preferably the vertical extension of the second set 21,22 of locking surfaces is essentially the same or larger than the vertical extension of the first set 11,12 of locking surfaces. The second set should preferably extend downwards to a level, which is below the first set.
  • [0108]
    A flexing groove 34, 34′ may be formed in the locking element 8 and/or behind the locking groove 14 in order to increase the flexibility of the walls of the locking element 8 or the locking groove 14. Such flexing groove may also be filled with a flexible material that increases the flexibility further.
  • [0109]
    A wedge shaped locking element as described above may be used to position the upper edges with a small play of for example of about 0.01-0.10 mm. Such a play will allow the top edges to swell and damages on the upper edges or squeaking sound will be eliminated. Such locking system is also very suitable to use in glue down floor installations or in combination with bevels between the upper joint edges.
  • [0110]
    The above-described embodiment may of course be combined with friction cavities 18 and flexible material 16 may be inserted between the locking element and the locking groove.
  • [0111]
    The locking system may be formed with two or more sets of locking elements and locking grooves in order to increase the friction. Small friction grooves 23 parallel with the joint edge may also increase the friction.
  • [0112]
    Glue or wax that cures after some time is also possible to use and may eliminate problems with shrinking and swelling of a pre tensioned locking system. Wax mixed with aluminium oxide particles, which are applied in the locking system, increases the friction considerably.
  • [0113]
    The long edge locking system may be used with all known vertical folding systems that lock the short edges vertically and horizontally.
  • [0114]
    The separate tongues are generally factory connected into an edge. Separate lose tongues that are inserted prior to folding or when two short edges are laying flat on the sub floor are not excluded.
  • [0115]
    The long edge locking system may be formed such that it is displaceable in an angle of 3-5 degrees. This facilitates installation around doors and similar.
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Clasificaciones
Clasificación de EE.UU.52/588.1, 52/582.2
Clasificación internacionalE04B5/00, E04C2/38
Clasificación cooperativaE04F2201/0547, E04F2201/0169, E04F15/107, E04F15/02038
Eventos legales
FechaCódigoEventoDescripción
17 Sep 2012ASAssignment
Owner name: VALINGE FLOORING TECHNOLOGY AB, SWEDEN
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:PERVAN, DARKO;REEL/FRAME:028971/0773
Effective date: 20120914
27 Abr 2016ASAssignment
Owner name: CERALOC INNOVATION AB, SWEDEN
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:VAELINGE FLOORING TECHNOLOGY AB;REEL/FRAME:038394/0897
Effective date: 20160425