AU2004320336B2

AU2004320336B2 - Panel, particularly floor panel

Info

Publication number: AU2004320336B2
Application number: AU2004320336A
Authority: AU
Inventors: Juergen Weber
Original assignee: Fritz Egger GmbH and Co OG
Current assignee: Fritz Egger GmbH and Co OG
Priority date: 2004-05-26
Filing date: 2004-05-26
Publication date: 2008-10-02
Anticipated expiration: 2024-05-26
Also published as: HRP20060191B1; PL379986A1; PL207167B1; UA81721C2; WO2005118978A1; RS20060401A; NO338807B1; NO20064283L; HRP20060191A2; AU2004320336A1

Description

PANEL, IN PARTICULAR FLOORING PANEL The invention is related to a panel, in particular a flooring panel, with the features of the preamble of claim 1, wherein said panel can be mechanically connected to other panels. Panels of this type are typically utilized as a floor covering, for example, parquetry or laminate flooring, or as a ceiling and wall sheeting.

In all instances the individual panels can be connected into a flat large-surface unit with the aid of a mechanical connection, so that the panels can be installed without adhesives or additional mechanical fastening elements, e.g., screws or nails. In this respect it is particularly advantageous that the panels can be installed without using adhesive and consequently removed again at a later time.

The panel is preferably utilized as a flooring panel and preferably manufactured from laminate flooring panels that consist of a wood material.

The panels may also be used for other applications, for example, as wall or ceiling panels.

Profile geometries that respectively contain a tongue-and-groove connection for vertically interlocking panels are known from the prior art disclosed in WO 94/26999 and WO 97/47834. In addition, the profiles are horizontally interlocked with the aid of a pair of interlocking surfaces that are usually aligned obliquely referred to the upper side of the panels. The interlocking surfaces for horizontally interlocking the panels are engaged with one another by a snap-in action when the panels are interconnected.

The term snap-in action means in this case, that the interlocking elements for the horizontal interlocking of the first lateral edge of a first panel come in contact with the interlocking surfaces of the second lateral edge of a second panel. This contact causes at least one element of the connection to bend during the interlocking action, so that the element will be locked into place, i.e., the element will be bent back. This means that the respective connections can 2 only be produced by overcoming a mechanical resistance, irrespective of the fact whether the panels are horizontally pushed toward one another or engaged with one another by means of a pivoting motion. This is the reason why the connections are also referred to as snap action or snap-in connections.

It is also known, in particular from WO 97/47834, to realize panel connections of this type in a force-locked fashion. This means that the interlocking elements are at least partially deflected in the connected state and exert a contracting force.

US 4,426,820 discloses another connection that has a purely form-locked profile geometry. In this case the connecting elements are not bent when the panels are joined, however it cannot be prevented in this case either that the elements of the horizontal connection abut against one another during the interconnection of the panels.

A highly precise fit between the elements is of the utmost importance, both with respect to the vertical interlocking by means of the tongue and groove as well as the horizontal connection. However, this fit is impaired by forces that are built up during the joining of the panels that may deform, in particular, the connecting elements of the horizontal connection. This results in a poor fit.

It is the object of the present invention to disclose a panel, in which the fitting accuracy of the vertical interlocking as well as the horizontal connection is improved.

According to the invention the above-defined objective is attained with a panel of this type which is realized in accordance with the features disclosed in the characterizing part of claim 1. Other advantageous embodiments are disclosed in the dependent claims and described in greater detail below.

The panel according to claim 1 of the invention has the following features.

A first lateral edge and an opposite situated second lateral edge are provided analogous to all rectangular panels. Although the invention primarily pertains to a pair of lateral edges, the profile geometries described below may also be arranged on both pairs of lateral edges. The profiles of the first and the second lateral edges are realized complementary and can be engaged with one another in order to produce the vertical interlocking and the horizontal connection.

The following portion of the description initially pertains to the first lateral edge and subsequently to the second lateral edge.

The first lateral edge has the following characteristics: a first contact surface that is arranged on the upper end of the first lateral edge, a groove that is formed on the first lateral edge, an upper lip that upwardly limits the groove, a lower lip that downwardly limits the groove, wherein the distal end of the lower lip protrudes past the distal end of the upper lip, a first fitting surface that is arranged on the upper lip, a second fitting surface that is arranged on the lower lip in the region of the groove bottom, and a second contact surface that is arranged on the lower lip in the region of the distal end.

The first fitting surface and the second fitting surface form the fitting surfaces for the vertical interlocking on the first lateral edge. The first contact surface and the second contact surface form the surfaces for producing the horizontal connection on the first lateral edge.

The second lateral edge has the following characteristics: 4 a third contact surface that is arranged on the upper end of the second lateral edge, a tongue that is arranged on the second lateral edge, a third fitting surface that is arranged on the upper side of the tongue, a fourth fitting surface that is arranged on the underside of the tongue in the region of the distal end, and a fourth contact surface that is arranged on the underside of the tongue and is spaced apart from the distal end.

The third fitting surface and the fourth fitting surface form the fitting surfaces for the vertical interlocking on the second lateral edge. The third contact surface and the fourth contact surface form the surfaces for producing the horizontal connection on the second lateral edge.

When two panels are connected to one another along two complementary lateral edges, the first and third contact surfaces, the second and fourth contact surfaces, the first and third fitting surfaces and the second and fourth fitting surfaces abut against one another in a paired fashion.

According to the invention it was recognized that the second and fourth fitting surfaces have a cross-sectional contour in the shape of a segment of a circle, wherein the centre of the circle lies in the region of the upper sections of the lateral edges and the circle has a predetermined radius referred to the centre, that the second contact surface and the fourth contact surface are spaced apart from the centre by a distance that is greater than the radius, and that the distance of the second contact surface and of the fourth contact surface from the centre becomes greater in the direction of the distal end of the lower lip.

This means that when two panels are connected along a first lateral edge and a second lateral edge, a new panel with a second lateral edge will be positioned first at an angle to the first lateral edge of a panel that is already installed on the floor. In this state the first panel and the second panel adjoin one another in the region of the upper corner of the lateral edges while the front end of the fourth fitting surface of the tongue simultaneously adjoins the lower lip. The second panel is then pivoted downward relative to the first panel such that the fourth fitting surface slides along the second fitting surface because they form a segment of a circle, while the panels abut against one another in the region of the centre and are pivoted about this centre.

Consequently, no particular expenditure of force is required during this pivoting movement, and the second and fourth fitting surfaces are not pressed against one another with an excessively high force.

During the aforementioned pivoting movement the geometry according to the invention ensures that the second contact surface and the fourth contact surface are spaced apart from one another. Because the second contact surface and the fourth contact surface have a contour, the distance of which from the centre of the pivoting movement continuously increases in the direction of the distal end of the lower lip, no surfaces exist that could abut against one another before the pivoting movement is completed. The geometry is chosen such that the second contact surface and the fourth contact surface do not come in contact with one another until the pivoting movement is completed or, due to manufacturing tolerances, shortly before the pivoting movement is completed.

The description of the profile geometry distinguishes between vertical interlocking and horizontal connection. This formulation was chosen in order to elucidate that in the case of the tongue-and-groove connection, in addition to the form-locking a press fit could also be present, so that a very firm vertical seat or interlocking can be achieved. The horizontal connecting means, in contrast, intentionally represent means only for producing a form-locked connection, a connection that does not result in a press fit within the permissible range of manufacturing tolerances. This combination of press fit for the vertical interlocking and form-locking for the horizontal connection has its own inventive character, independently from the actual design of the profile.

The panels described above can comprise various materials and composition of materials. As timber materials of laminate floor panels, inter alia a laminate, medium-density fibre boards (MDF), high density fibre boards (HDF), particle boards or oriented strand boards (OSB) could be considered. The panels can be also timber in the form of parquetry strips or panels or of plastic material. In lO particular core layers from polyethylene insulating mats, styropor, polyurethane-hard foam or polystyrene hard foam could be considered.

The present invention is described in greater detail below with reference to embodiments that are illustrated in the enclosed figures. The figures show: Figs.1-4 cross sections through a first embodiment, Figs.5-8 cross sections through a second embodiment, Figs.9-11 cross sections through a third embodiment, Fig.12a cross section through a fourth embodiment, Fig.13a cross section through a fifth embodiment, and Fig.14 a cross section through a sixth embodiment.

Figs.-4 show a first embodiment of the present invention. Fig.1 shows the exact profile geometry of the interconnected panels, Figs.2 and 3 separately show the first and the second lateral edge, and Figs.4a-4c show the pivoting movement during the joining of the two lateral edges.

Fig.1 shows two panels with corresponding lateral edges that can be mechanically connected to one another. The invention primarily pertains to 7 one individual panel, so that in the following the description of one panel with two different lateral edges is carried out based on two panels, illustrated in Fig. 1 adjacent to one another, the lateral edges of which are illustrated separately in Figs.2 and 3.

The panel 2 has a first lateral edge 4 that is shown in Fig.2 and an opposite second lateral edge 6 that is shown in Fig.3.

The first lateral edge 4 has a first contact surface 8 that is arranged on the upper end of the first lateral edge 4.

Furthermore, a groove 10 is provided, that comprises an upper lip 12 that upwardly limits the groove 10 and a lower lip 14 that downwardly limits the groove 10. The distal end of the lower lip 14 protrudes past the distal end of the upper lip 12.

A first fitting surface 16 is arranged on the upper lip 12 and a second fitting surface 18 is arranged on the lower lip 14 in the region of the groove bottom A second contact surface 22 is arranged on the lower lip 14 in the region of its distal end.

The second lateral edge 6 has a third contact surface 24 on its upper end.

Furthermore, the second lateral edge 6 is also provided with a tongue 26 that has a third fitting surface 28 on the upper side and a fourth fitting surface on the underside.

A fourth contact surface 32 is arranged on the underside of the tongue 26 and spaced apart from the distal end.

In the connected state of two complementary lateral edges 4 and 6 which is shown in Fig. 1, the first contact surface 8 and the third contact surface 24, the second contact surface 22 and the fourth contact surface 32, the first fitting surface 16 and the third fitting surface 28 as well as the second fitting surface 18 and the fourth fitting surface 30 adjoin one another in a paired fashion.

According to the invention, the second fitting surface 18 and the fourth fitting surface 30 have a cross-sectional contour in the shape of a segment of a circle. The centre M 1 of the circle lies in the region of the upper sections of the lateral edges 4 and 6, and the circle has a radius r, in the centre M 1 In a three-dimensional image, the second fitting surface 18 and the fourth fitting surface 30 consequently would have the shape of a partial cylinder segment.

Furthermore, the second contact surface 22 and the fourth contact surface 32 are spaced apart from the centre M 1 by a distance a that is greater than the radius rl. The distance a from the centre M 1 also increases in the direction of the distal end of the lower lip 14. This is elucidated with the arrows a and a 2 The distance a, from the groove bottom is shorter than any other distance a, all of which are, in turn, shorter than the longest distance a 2 In other words, the distance gradually increases outward from the inside in the direction of the distal end of the lower lip.

The broken auxiliary line H in Fig.1 symbolizes a segment of a circle that begins at the innermost point of the contact surfaces 22 and 32 and has a radius of the length The increasing distance between the auxiliary line H and the contact surfaces 22 and 32 elucidates the previously described geometry.

The pivoting movement during the joining of two lateral edges is described in greater detail below with reference to Figs.4a-4c.

In Fig.4a a first panel 2 is horizontally positioned on the floor, and another panel 2 is brought in contact from the right with the first panel 2. Both upper 9 corners of the lateral edges 4 and 6 contact one another, and the front region of the fitting surface 30 abuts against the fitting surface 18. In this position, the contact surfaces 22 and 32 are spaced apart from one another as indicated by the corresponding gap in Fig.4a. This also applies to the fitting surfaces 16 and 28, as well as the contact surfaces 8 and 24.

In Fig.4b, the panels 2 are already pivoted relative to one another by a certain distance, but the pivoting movement is not yet completed. The fitting surfaces 18 and 22 adjoin one another along a longer section 2 than in Fig.4a, and the lo contact surfaces 22 and 32 are still spaced apart from another, however, by a shorter distance than in Fig.4a. This also applies to the fitting surfaces 16 and 28, as well as the contact surfaces 8 and 24.

In the position shown in Fig.4c, the pivoting movement is completed and the described pairs of fitting surfaces and contact surfaces adjoin one another.

This means that a form-locked connection or, if the dimensions of the elements are chosen accordingly, a press fit is produced between the groove and the tongue 26. Otherwise a purely form-locked connection is produced in the region of the contact surface pairs 8, 24 and 22, 32 within the range of manufacturing tolerances.

The fitting surfaces and contact surfaces which are essential for producing the connection consequently are not subjected to high forces during the joining process and two panels can be engaged with one another along the lateral edges without damaging the interlocking and connecting elements.

One can also ascertain from Fig. 1 that the centre M 1 coincides with the upper corner of the lateral edges 4 and 6. This ensures that the fitting surfaces 18 and 30 are able to slide on one another during the pivoting movement and will not become wedged. In other words, the fitting surfaces 18 and 30 do not impair the pivoting movement.

One preferred embodiment of the present invention is illustrated in Figs.1-4, wherein the second contact surface 22 and the fourth contact surface 32 have a curved cross-sectional contour. Due to this measure, the contour of the contact surfaces 22 and 32 extends in the steepest fashion possible in the region of the distal end of the lower lip 14 and a good connection in the horizontal direction can be produced.

In particular at least sections of the second contact surface 22 and the fourth contact surface 32 have a cross-sectional contour in the shape of a segment of a circle. The centre M 2 of the circle is spaced apart from the first centre M 1 by a distance b (see Fig.1), namely in the direction of the distal end of the lower lip 14, toward the right in the figures and it is provided on the upper side of panel 2. In this case, the radius r 2 of the contour of the contact surfaces 22 and 32 is greater than the radius r, or equal to the radius rl. This ensures that the distance a of the contact surfaces 22 and 32 gradually increases toward the right in the figures.

Under certain circumstances it is even possible to choose the radius r 2 of the contour of the contact surfaces 22 and 32 smaller than the radius rl. This results in steeper contact surfaces 22 and 32 in the region of the distal end of the lower lip 14.

It is also possible to choose an elliptical cross-section for the contact surfaces 22 and 32. The result of this will be that the upper protruding end of the lower lip will have an increased steep progress and will improve the effect of the horizontal connection.

The following description pertains to variations of the first embodiment. In the respective figures, identical reference symbols respectively identify the same characteristics as those described above with reference to the first embodiment. The features that differ from the first embodiment are identified by apostrophes. Only the differences between the respective variations and the first embodiment are discussed below. Therefore the peculiarities and 11 advantages mentioned in conjunction with the first embodiment also apply to the further embodiments without specific references to them.

Figs.5-8 show a second embodiment of a panel 2 according to the invention.

In contrast to the first embodiment, the second contact surface 22" and the fourth contact surface 32" have a straight cross-sectional contour that extends obliquely upward in the direction of the distal end of the lower lip 14. This is an illustrated in Figs.5-7.

lo Despite this difference from the first embodiment, it is ensured that the distance between the contact surfaces 22" and 32" and the centre M 1 increases outward. This is elucidated in Fig.5 with the arrows al, a and a 2 as well as the auxiliary line H.

The pivoting movement illustrated in Figs.8a-8c is essentially identical to that in the first embodiment. The contact surfaces 22" and 32" do not come into contact with one another either until the pivoting movement is completed.

In other respects, the previous description of the first embodiment based on Figs.-4 applies analogously to Figs.5-8.

Figs.9-1 1 show another embodiment that essentially represents a combination of the features of the first two embodiments. In this case the contact surfaces 22"' and 32"' are respectively composed of curved sections 22"'a and 32"'a that, in particular, have the shape of a segment of a circle and straight sections 22"'b and 32"b.

The embodiment shown in Figs.12a-12c has fitting surfaces and contact surfaces that are identical to those in the first embodiment shown in Figs.l-4.

In this embodiment a strip 34 is additionally fastened in the region of the first contact surface 8. This strip consists of an elastic material, in particular a plastic material such as PVC and has the following geometry.

The strip 34 ends flush with the upper side 36 of the panel 2 and slightly protrudes past the first contact surface 8. During the pivoting movement shown in Figs.12a-12c the strip 34 is compressed in the direction of the upper side 36 due to the increasing contact pressure generated by the contact surface 24. This results in a sealed connection between the lateral edges 4 and 6, while a force that presses against the contact surfaces 22 and 32 is generated due to the elasticity of the strip 34. The strip 34 is externally visible and can be utilized for achieving visual effects.

The strip 34 may also be arranged in the region of the second contact surface 24 and compressed during the pivoting movement by the contact surface 8.

The fitting surfaces and contact surfaces of the embodiment shown in Figs.13a-13c are identical to those of the first embodiment according to Figs.1- 4.

An elastic element 38 that slightly protrudes past the second contact surface 22 is additionally provided in the region of the second contact surface 22. The elastic element 38 consists of an elastic material, in particular, a plastic material such as PVC, and has the following geometry.

The elastic element 38 is recessed into the contact surface 22 and slightly protrudes past the contact surface 22. During the pivoting movement shown in Figs. 13a-13c, the elastic element 38 is compressed in the direction of the contact surface 22 due to the increasing contact pressure generated by the contact surface 32. The elasticity of the element 38 generates a force that presses against the contact surfaces 8 and 24.

The elastic element 38 may also be arranged in the region of the fourth contact surface 32 and compressed during the pivoting movement due to the increasing contact pressure by the contact surface 22.

13 According to Figs.l, 4c, 5, 8c, 11lc, 12c, 13c and 14c in the joined state a hollow space 40 is formed between the abutting second and fourth fitting surfaces 18 and 30 and the abutting second and fourth contact surfaces 22 and 32. This merely represents an option because it would also be possible to choose the profile geometry such, that the fitting surface 18 and the contact surface 22 as well as the fitting surface 30 and the contact surface 32, seamlessly blend into one another.

Preferably a layer of adhesive 42 is applied within the hollow space 40 at the manufacturing site, so that an adhesive connection is produced when the lateral edges 4 and 6 are joined, that counteracts a separation of the lateral edges in addition to the interlocking and connecting elements.

Any conventional adhesive that is suitable for being applied in advance may be considered for this purpose.

In the case of the adhesive an easy-to-apply adhesive, a fully synthetic adhesive, a universal adhesive or an anaerobic adhesive may be considered.

An anaerobic adhesive has the advantage, that it hardens only in the absence of air and the hardening takes place only when the surfaces of the joint abut against one another and the transverse edges are connected with one another.

In a particularly preferred manner the adhesive is a contact adhesive, that deploys its adhesive effect only when pressure is applied to it. Such a contact adhesive the has the advantage, that such an adhesive, applied to the hollow space 40 at the manufacturing site is activated only when the corresponding counter-surface is contacted and does not interfere with the assembly.

In a further preferred embodiment the adhesive may be a two-component reaction adhesive, that achieves its adhesive effect only when both components are brought together. On this occasion it is a particular advantage when one of the components is introduced in capsules, while these capsules 14 00 0 are destroyed under external forces, for example by pressure or shearing N forces, and thus one component gets into contact with the other component, so that the adhesive deploys its adhesive effect. Thus the adhesive is C. activated only when during laying the surfaces of the joint get in contact with 00 one another and thus the necessary pressure or shearing forces are applied to the capsules. Such a reaction adhesive, wherein one component is encapsulated, makes possible, on the one hand, an assembly that will not be ahindered by the surfaces on the transverse edges to be adhered and, on the t other hand, it can be applied already at the manufacturing site during the production of the panels, without the danger, that the adhesive effect will be 1 impaired due to long storage times. In any case, other adhesives can also be applied at the manufacturing site.

Fig. 15 illustrates a further embodiment of a profile according to the invention.

The same reference numerals represent the same components as they had been explained above. The difference between it and the embodiment illustrated in Figs. 1-4 is the position of the centre M 2 The cross-sections of the second contact surface 22 and the fourth contact surface 32 have in this case also a cross-section, at least partly, of a segment of a circle. In the direction of the distal end of the lower lip 14, therefore to the right in the figures, the centre M 2 of the circle is at a distance b (see from the first centre M 1 However, the centre is not arranged on the upper side 36 of the panel 2, but in the body of the panel 2. Due to this the radius r 2 of the contour of the contact surfaces 22 and 32 can be chosen smaller than radius rl. By virtue of this steeper progress of the contact surfaces 22 and 32 is achieved in the region of the distal end of the lower lip 14. Notwithstanding, the condition, that the distance a will continuously increase in the distal direction of the lower lip 14, also applies.

It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.

Claims

2. The panel according to claim 1, characterized in that the centre coincides with the upper corner of the lateral edges.
3. The panel according to claim 1 or 2, characterized in that at least sections of the second contact surface and the fourth contact surface have a curved contour.
4. The panel according to claim 3, characterized in that at least sections of the second contact surface and of the fourth contact surface have a contour in the shape of a segment of a circle. The panel according to claim 4, characterized in that the centre of the circle is spaced apart from the first centre by a distance, in the direction of the distal end of the lower lip.
6. The panel according to claim 5, characterized in that the centre of the circle is arranged in the region of the upper side. 17 00 S7. The panel according to claim 5, characterized in that the centre of the C circle is arranged at a distance from the upper side. 00
8. The panel according to any one of claims 4 to 7, characterized in that the radius of the contour of the second contact surface and of the fourth Scontact surface is greater than the radius or equal to the radius.
9. The panel according to any one of claims 4 to 7, characterized in that the radius of the contour of the second contact surface and of the fourth N contact surface is smaller than the radius. The panel according to any one of claims 1 to 9, characterized in that at least sections of the second contact surface and of the fourth contact surface have a straight cross-sectional contour.
11. The panel according to claim 1 or 2, characterized in that the second contact surface and the fourth contact surface have a straight cross- sectional contour that extends obliquely upward in the direction of the distal end of the lower lip.
12. The panel according to any one of claims 1 to 11, characterized in that a strip is fixed to the first contact surface or the second contact surface.
13. The panel according to claim 12, characterized in that the strip ends flush with the upper side of the panel and slightly protrudes past the first contact surface and the second contact surface, respectively.
14. The panel according to any one of claims 1 to 13, characterized in that an elastic element is arranged in the region of the second contact surface and/or in the region of the fourth contact surface, wherein the elastic element slightly protrudes past the second and fourth contact surface, respectively. 18 00 The panel according to any one of claims 1 to 14, characterized in that C in the joined state a hollow space is formed between the second and fourth fitting surfaces abutting against one another and the second and 00 fourth contact surfaces abutting against one another.
16. The panel according to claim 15, characterized in that a layer of adhesive is applied within the hollow space at the manufacturing site. (N,