EP1971735B1

EP1971735B1 - A flooring system comprising a set of floorboards with a decorative joint portion comprising a U- or V-shaped groove

Info

Publication number: EP1971735B1
Application number: EP06835900A
Authority: EP
Inventors: Niclas HÅKANSSON
Original assignee: Valinge Innovation AB
Current assignee: Valinge Innovation AB
Priority date: 2006-01-11
Filing date: 2006-12-22
Publication date: 2013-01-23
Anticipated expiration: 2026-12-22
Also published as: CN101365852B; WO2007081260A1; EP1971735A1; SE0600041L; CN101365852A

Description

AREA OF INVENTION

The present invention relates to a flooring system comprising a floorboard with a decorative joint portion comprising a U or V-shaped groove.

BACKGROUND OF INVENTION

In particular, yet not restrictive manner, the invention concerns a flooring system with a laminate floorboard comprising a mechanical locking system, formed at least at two opposite edges and a decorative joint portion comprising an U or V-shaped groove only at one of two opposite edges of the floorboard. The following description of prior-art technique, problems of known systems and objects and features of the invention will above all, as a non-restrictive example, be aimed as the field of the application. It should be emphasised that the invention can be applied to any floorboard and combined with all types of known locking system, where the floorboards are intended to be joined using a mechanical locking system connecting the panels in the horizontal and vertical directions on at least two adjacent edges.
A flooring is known with floorboards that is provided with a decorative joint portion, in the form of a bevel at both adjacent joined edges of the floorboards, for example as described in WO 03/078761 . Another embodiment described in WO 03/078761 is a flooring comprising floorboards that is provided with a decorative joint portion, in the form of a lower flat portion only at one of two adjacent joined edges of the floorboards. A floorboard with a U or V-shaped groove is shown in DE 102 32 508 C1 .

SUMMARY OF THE INVENTION

The present invention aims at a flooring system comprising a floorboard with a decorative joint portion, in particular a laminate floorboard, which provides for new embodiments according to different aspects offering respective advantages. Flooring and floorboards with a decorative joint portion known up to now have several disadvantages. The bevelled joint edge and the joint edge with a lower flat portion, both have the disadvantage that they collect moisture and dust, which penetrates into the joint down to the moisture sensitive core. The dust creates a gap in the joint when the panels move, e.g. due to humidity changes. The flooring system according to the invention is defined in claim 1. Preferred embodiments are defined in the dependent claims. The floorboards with the decorative joint portion according to the invention result in a more resilient edge, which make it possible to provide a tighter joint, and prevent dust and moisture to enter into the joint.
According to a first aspect, the invention provides for a flooring system with laminate floorboards comprising a front face a rear face, a surface layer of resin-impregnated sheets, a wood-based core and a decorative joint portion comprising a U or V-shaped groove. The joint edge being provided with a cut under the groove, forming a clearance when the edge of the floorboard is joined to an adjacent edge of another adjacent floorboard, the edges become more resilient and tighter. A deeper grove also makes the joint more resilient.
Laminate flooring usually consists of a core of a 6-9 mm fibreboard, a 0.2-0.8 mm thick upper decorative surface layer of laminate, preferably comprising sheet material impregnated with thermosetting resins and a 0.1-0.6 mm thick lower balancing layer of laminate, plastic, paper or like material. The surface layer provides appearance and durability to the floorboards, and preferably contains at least one layer imprinted with a pattern, for example a wood pattern printed on a paper layer. The core provides stability, and the balancing layer keeps the board plane when the relative humidity (RH) varies during the year. The floorboards are generally laid floating, i.e. without gluing, on an existing subfloor.
A first advantage consists in that there are no dust or moisture collecting lower parts at the edge closest to the joint. A second advantage is that the U or V-shaped groove makes a joint gap less visible. A third advantage is that the joint with the U or V-shaped groove looks like a traditional joint with bevels, but is cheaper to manufacture since only one of the two adjacent joined edges is worked. A fourth advantage is that the groove, due to the upwardly directed ribbon closest to the joint, and the cut make the edge more resilient, which makes the joint tighter and prevents dust and moisture to enter into the joint.
According to the invention a mechanical locking system is formed at least at two opposite edges of the floorboard, which facilitates the joining of a similar floorboard. Mechanical locking system are for example known from WO 94/26999 , and another locking system, comprising a flexible tongue, especially advantageous at the short sides of rectangular floor boards, is descibed in PCT/SE2005/001586 , owner Välinge Innovation AB. Other shapes of floorboards are also possible. Other mechanical locking system are also known, and possible to use, which are joined by Angling-Angling, Angling-Snapping or Snapping-Snapping. Floorboards with a mechnical locking system are generally laid floating, i.e. without gluing, on an existing subfloor. Floorboards according to the invention are especially beneficial in flooring istalled semi-floating, with floorboards with overlapping edges. A semi-floating flour, which allows movement between the floorboards, is described in WO 2005/068747 .
The document DE 102 32 508 discloses floorboards with grooves for reducing the risk of swelling of the joint. The document WO 2005/068747 discloses locking systems for floorboards exhibiting great dimensional changes as the relative humidity changes.
According to the invention, only one of two opposite edges of the floorboard is provided with the groove. A rectangular floorboard is preferably provided with the groove at only one long edge. It is also possible to provide only one of the long and only one of the short edges. Other shapes of the floorboards are also possible, e.g. a floorboard with 3, 5, 6, 7 and 8 edges.
Preferably the wood based core is made of MDF or HDF or a particleboard and the groove extends down to the core, which optionally is coloured.
The groove is according to another embodiment treated with oil or varnish or filled with a filling material.
It is also possible to replace the resin-inpregnated sheets with a wood veneer, preferably treated with oil or varnish.
According to a second aspect, the invention provides floorboards comprising a solid wood body, a front face a rear face, a decorative joint portion comprising a U or V-shaped groove.
A mechanical locking system is formed at the edges.
Optionally the floorboard is treated with oil or varnish and/or the groove is filled with a filler.
According to a third aspect of the invention, the floorboard provided with the decorative joint portion comprising a U or V-shaped groove is further provided with an horizontally protruding part configured such that it overlaps an adjacent edge of an adjacent similar floorboard when the floorboard is joined to the similar adjacent floorboard. The protruding part prevents dust and moisture to penetrate in to the joint. However, the joint still looks like a traditional joint with bevels, but is cheaper to manufacture.
With the invention, the decorative joint portion prevents dust and moisture to enter into the joint and also is cheap and easy to manufacture.
All references to "a/an/the [element, device, component, means, step, etc]" are to be interpreted openly as referring to at least one instance of said element, device, component, means, step, etc., unless explicitly stated otherwise.

BRIEF DESCRIPTION OF DRAWINGS

Figures 1a - 2 show floorboards with a decorative joint portion known in the prior art.
Figures 3a-b show embodiments of a floorboard according to the invention comprising a decorative joint portion.
Figures 4a-b show embodiments of a floorboard comprising a decorative joint portion.
Figure 4c shows one embodiment of a floorboard used in the invention, comprising a decorative joint portion.
Figure 5 shows an embodiment of the floorboards mechanically joined to a flooring.
Figures 6a-c show a floorboard and a flooring according to one embodiment of the invention.
Figures 7a-b show a floorboard and a flooring a according to one embodiment of the third aspect, which embodiment does not form part of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS

As represented in figures 3-6, the invention relates to a flooring system with a floorboard provided with a decorative joint portion comprising a U or V-shaped groove.
Figure 1a - 2b show floorboards with decorative joint portions known in the prior art. Figure 1a shows a floorboard 1 according to WO 03/078761 , to be joined with a similar floorboard 1' at a joint plane extending in the vertical plane, comprising a front face 3 and a rear face 4 extending in the horizontal plane, a surface layer 80, a core 6 and a balancing layer 7. Adjacent edges 12a, 13a and/or 12b, 13b (see fig. 6) of the floorboards 1, 1' to be joined are provided with a decorative joint portion 2, 2', comprising a lowered horizontal surface. A mechanical looking system is formed along edges 12a, 13a and/or 12b, 13b of the floorboard, comprising a tongue 8 with a locking element 9, a tongue groove 10, and a locking groove 11.
Figure 1b shows another embodiment according to WO 03/078761 , with decorative joint portions 2, 2' comprising a bevelled edge 15, 15' at both adjacent joint edges 12b, 13b and/or 12a, 13a.
Figure 1c shows another embodiment according to WO 03/078761 , with a decorative joint portion 2, comprising a lowered horizontal surface at one of the adjacent joint edges 12b, 13b and/or 12a, 13a of the floorboards to be joined. In this embodiment, the mechanical locking system comprising a locking strip 17 with a locking element 9, a tongue 8 and a tongue groove 10.
Figure 2a shows a floorboard 1 intended to be joined semi-floating with an adjacent floorboard 1 according to WO 2005/068747 , with a horizontally protruding and overlapping part 21 at the joint edge and a decorative joint portion 2, 2', comprising a bevel, at both adjacent joint edges intended to be joined.
Figure 2a shows another embodiment according to WO 2005/068747 , intended to be joined semi-floating, with a decorative joint portion, comprising a lowered horizontal surface, at one of the adjacent joint edges 12b, 13b and/or 12a, 13a of the floorboards to be joined. The horizontally protruding and overlapping part 21 is thin and consists of the high strength layers of the resin-impregnated sheets of the surface layer and optionally a part of the core, which preferably also is impregnated with resin
According to a first aspect of the invention, represented in figure 3a-b, a laminate floorboard 1, to be joined with a similar floorboard 1' at adjacent joint edges at a joint plane extending in the vertical plane VP, comprising a front face 3 and a rear face 4 extending in the horizontal plane HP, a surface layer 80, a wood-based core 6 and preferably a balancing layer 7. The joint edge 12a, 13a or 12b, 13b (see fig. 5) of the floorboard 1 to be joined are provided with a decorative joint portion 2, comprising a U or V-shaped groove 31. The U- or V-shaped groove is provided only at one of two opposite edges of the floorboard. If the floorboard is rectangular, preferably only one of the long edges is provided with the U or V-shaped groove, certainly it is also possible provide one of the long and one of the short edges with the groove 31. Other shapes of the board are also possible, e.g. 3, 5, 6, 7 and 8 edges.
A mechanical locking system is formed along the joint edges 12a, 13a and/or 12b, 13b of the floorboard. One embodiment of the locking system is represented in figure 3a, and comprising a tongue 8 with a locking element 9 at one of the adjacent joint edges to be joined, and a tongue groove and a locking groove, not shown, at the other edge, alike as shown in figure 1a-1b. Another embodiment of the locking system is represented in figure 3b, and comprising a tongue 8 and the locking groove at one of the adjacent joint edges to be joined, and a tongue groove and a locking element, at the other edge. Other known locking systems are also possible to use.
The joint edge is provided with a cut 34, under the groove and above the connecting means, which in combination with groove 31, makes the edge more resilient and tighter. A deeper grove also makes the joint more resilient. In figure 3a the groove creates a ribbon 32 along the joint edge, which in this embodiment has a flat upper tip 35. In figure 3b the ribbon 33 has a sharp upper tip, comprising the surface layer. Other shapes of the ribbon are shown in figure 4a-b, comprising rounded edges and different height levels of the tip and with or without the surface layer. The embodiments of Figs 4a-4b do though not form part of the invention. All the features of the shown shapes are possible to combine. The grooves shown in figures 4a-b are U-shaped, but is possible to replace with a V-shape or vice verse in figures 3, 5, 6 and 7.
The wood-based core is preferably a particle, MDF or HDF board.
A second aspect of the invention, represented in figure 4c, comprising floorboard with a body of solid wood, and a U or V-shaped groove along a joint edge of the floorboard. The mechanical locking system, the cut 34 and shapes of ribbon 32, 33 and groove described in connection with the first aspect is applicable also to the second aspect. Preferably the front face of the floorboard is treated with oil or varnish.
In figure 5 a floorboard 1 according to the first or second aspect, joined at two opposite edges 12a, 13a and 12b, 13b, is shown. The edges of the floorboard are joined with a mechanical locking system to adjacent floorboards 1', 1". The floorboard is provided with the decorative U or V-shaped groove only at one of the two opposite edges of the floorboard.
In figure 6b an embodiment is shown according to the first aspect, comprising a rectangular floorboard 1 with a mechanical locking system at long 13a, 13b and short edges 12a, 12b and an a U or V-shaped groove 31 along only one of the long edges and along only one of the short edges, which are filled with a filler. Additional V-shaped grooves 61 between the short edges are provided. Figure 6a is a cross section or the floorboard in figure 6b, perpendicular to the long edges, joined to similar floorboards 1' and 1". Figure 6c is a cross section of the floorboard in figure 6b, perpendicular to the short edges, joined to similar floorboards 1' and 1". Certainly it is possible to fill the grooves 31 with a filler also at a floorboard according to the second aspect and provide it with the additional grooves 61.
According to a third aspect, represented in figure 7a-b, not forming part of the invention, a floorboard 1, 1', 1" is provided with a decorative joint portion comprising an U or V-shaped groove 31 at an edge and a horizontally protruding part 73 at another opposite edge. The protruding part is configured such that it overlaps an adjacent edge, with a decorative joint portion, of an adjacent similar floorboard when the floorboard is joined to the similar adjacent floorboard. The protruding part prevents dust and moisture to penetrate in to the joint.
A semi-floating embodiment, not forming part of the invention, is shown in figure 7a-b. One of the floorboard 1 is joined along two opposite edges with a mechanical locking system to similar floorboards 1', 1''. The floorboard is provided with the U or V-shaped groove at only one of the opposite edges. An outer relative joint position 71 and an inner relative joint position 72 are shown. In the outer relative joint position 72 the distance between the adjacent and joined floorboards 1', 1 is the largest possible and in the inner relative position 72, the distance between the adjacent and joined floorboards 1, 1" is the smallest possible. The joints are provided with overlapping and horizontally extending edges, which in both the inner and outer relative positions cover the joint gaps. Figure 7b shows an embodiment of the overlapping edge comprising a bevelled edge 74.
The invention has mainly been described above with reference to a few embodiments. However, as is readily appreciated by a person skilled in the art, other embodiments than the ones disclosed above are equally possible within the scope of the invention, as defined by the appended parent claims.
Generally, all terms used in the claims are to be interpreted according to their ordinary meaning in the technical field, unless explicitly defined otherwise herein.

Claims

A flooring system comprising a set of floorboards, each floorboard (1) in said set comprising a front face (3), a rear face (4), a decorative joint portion (2) at an edge (12a, 12b, 13a, 13b) and at the front face (3) of the floorboard, and connecting means arranged at least at two opposite edges of the floorboard for connecting the floorboard with a similar floorboard (1') in vertical and horizontal directions, the connecting means for vertical locking being in the form of a tongue (8) and a tongue groove (10) adapted to receive the tongue (8) of a similar floorboard (1'), the connecting means for horizontal locking being in the form of a locking element (9) and a locking groove (11) adapted to receive the locking element (9) of a similar floorboard (1'), whereby when the floorboard (1) is joined to the similar adjacent floorboard (1')
the locking element (9) and the locking groove (11) are positioned at a horizontal distance from a vertical joint plane (VP) that is formed between the joined edges of the two floorboards (1, 1'), wherein the floorboard (1) is provided with the decorative joint portion (2) only at one of said two opposite edges,
characterised in
that the decorative joint portion comprises an U- or V-shaped groove (31, 41, 42, 44),
that the edge with the decorative joint portion is provided with a cut (34) under the U- or V-shaped groove (31, 41, 42, 44) and above the connecting means, said U- or V-shaped groove and said cut being arranged on the same edge of the floorboard as the tongue (8) and creating a ribbon (32, 33) along the joint edge, the cut (34) forming a clearance when the edge of the floorboard is joined to the adjacent edge of the similar, adjacent floorboard,
and that the U- or V-shaped groove (31, 41, 42, 44), the cut (34) and the locking element (9) and the locking groove (11) are configured to obtain a resilient edge and a tight joint.
A flooring system as claimed in claim 1,
characterised in that the floorboard (1) is quadrilateral and has a decorative joint portion (2) only at one edge (12a, 13a, 12b, 13b), or only at two adjacent (12a, 13a, 12b, 13b) edges.
A flooring system as claimed in any one of the preceding claims, characterised in that the floorboard is a laminate floorboard comprising a core (6) of a wood-based material and a surface layer (80).
A flooring system as claimed in claim 3,
characterised in that the core (6) comprises one of the materials: HDF, MDF or particleboard.
A flooring system as claimed in any one of claims 3-4, characterised in that the floorboard comprises a surface layer (80) of wood veneer or that the floorboard comprises a surface layer of resin impregnated sheets.
A flooring system as claimed in any one of claims 3-5, characterised in that the groove (31, 41, 42, 44) intersects the surface layer (80) and extends into the core, or that the groove (31, 41, 42, 44) is formed solely in the surface layer.
A flooring system as claimed in any of claims 1-2, characterised in that the floorboard is substantially of solid wood.
A flooring system as claimed in any one of the preceding claims, characterised in that an edge of the floorboard is provided with a horizontally protruding part (73) configured such that it overlaps an adjacent edge of an adjacent similar floorboard when the floorboard is joined to the similar adjacent floorboard.
A flooring system as claimed in any one of the preceding claims, characterised in that the ribbon (32, 33) is formed between the groove (31, 41, 42, 44) and the tip of the floorboard edge, and that the tip (35) of the ribbon is substantially at the same height level as the front face (3).
A flooring system as claimed in any of the preceding claims, characterised in that the groove (31, 41, 42, 44) is formed in the edge of the floorboard above the connecting means.
A flooring system as claimed in any one of the preceding claims, characterised in that there are one or more decorative grooves (61) between the edges of the floorboard.
A flooring system in accordance with any one of claims 1-11 characterised in that only one edge of two joined and adjacent floorboard edges comprises the U- or V-shaped groove (31, 41, 42, 44).
A flooring system in accordance with any one of claims 1-12, characterised in
that the edge comprising the U- or V-shaped groove (31, 41, 42, 44) is provided with a flat horizontal surface between the U or V-shaped groove (31, 41, 42, 44) and the outer edge of the floorboard and
that the adjacent edge comprises a horizontally protruding part (73) configured to overlap the edge of the floorboard with the decorative joint portion comprising the U- or V-shaped groove and to cooperate with the flat horizontal surface.