BRPI0621182A2 - floor covering system - Google Patents

Abstract

FLOOR COATING SYSTEM. Floor panels (2) are shown with discontinuous surface layers (31), which are mechanically interconnected along a pair of adjacent edges, said floor panel comprising at least two floor elements (1, 1 '), with at least one of the floor elements is not rectangular.

Description

"FLOOR COATING SYSTEM" Technical Field

The present invention generally relates to the field of floor covering systems and laminate floor panels which can be installed to advanced standards, especially floor panels which can be locked and unlocked with mechanical locking systems. The present invention relates to improvements to the floor covering systems and floor panels described in WO 03/089736.

Field of Application of the Invention

The present invention is particularly suitable for use on floating floors, which are applied to subfloors and consist of mechanically joined floor panels through a locking system integrated with the floor panel itself, ie factory assembled, consisting of one or more layers of printed and structured material, such as decorative plastic or decorative laminate material, an intermediate core of wood fiber based material, and preferably an equilibrium layer on the underside of the core. The following description of the prior art, known system problems, objects and aspects of the invention, without limitation, is intended above all for this field of use, and in particular for laminate flooring.

It should be emphasized that the invention can be used with any floor panel and / or combined with all known types of locking systems, where the floor panels are joined by a mechanical locking system that connects the panels in horizontal and horizontal directions. at least two adjacent sides. Therefore, the invention may also be applicable, for example, to solid wood floors, wood-core parquet, a wood fiber-based material, and a wood surface or wood varnish, etc., and to floors with a decorative surface, preferably varnished, floors with a surface layer of plastic or cork, linoleum, rubber, or the like. Even hard floors, such as stone, ceramic, etc., are included, and floors with a soft wear layer, for example, needled felt glued to a board. Which principle also applies to floors glued or nailed to a subfloor.

Invention History

A laminate floor comprises rectangular floor panels having a 6mm Fiberboard core, an upper decorative surface layer 0.2 to 0.8mm thick, and a lower balance layer 0.1. 0.6 mm thick laminate, plastic, paper, or similar material. A laminate surface comprises a printed and pressed melamine impregnated paper which is pressed with an embossed sheet. The most common core material is the high-density, high-stability fiber board, the High Density Fiberboard (HDF), and sometimes the Medium Density Fiberboard (MDF). Medium Density)) is used in the core. Traditional laminate floor panels of this type have gained a large market share, mainly due to the advanced printing and compression technology employed which provides very similar copies of wood parquet. Laminate floors look a lot like natural wood, but are more durable and cheaper.

In addition to such floor panels, installed with tongue-groove and glue joints, the floor panels have been designed to dispense glue, that is, instead of being glued together, they are mechanically joined by a mechanical locking system.

These systems comprise locking means which lock the panels horizontally and vertically.

Mechanical locking systems are usually produced by machining the panel core. Alternatively, parts of the locking system could be made from a different material, for example - Aluminum or HDF, applied to the floor panel, i.e. to the floor panel, during manufacture.

The main advantage of floating floors with mechanical locking systems is that they are easy to install and easily disassembled and used again elsewhere. Definition of Some Terms

The term "Horizontal Plane" or "Main Plane" refers to a plane that extends parallel to the outside of the surface layer. The immediately juxtaposed upper parts of two adjacent joint edges of the two joined floor panels define "Vertical Plane" (V) perpendicular to the horizontal plane. The term "Horizontally" means parallel to the horizontal plane, and "Vertically" parallel to the vertical plane. The term "Locking Systems" refers to cooperative connecting means that connect floor panels vertically and / or horizontally. The term "Mechanical Locking System" refers to a system where the joint is made without glue.

The term "Discontinuous Surface Layer and Core" refers to the surface layer and the core of two interconnecting elements to form a panel, or two interconnected panels to form a floor, and therefore the core and surface layer of the elements and of the panels are respectively discontinuous. A joint being detectable between the two elements or panels in the discontinuity.

Prior Art and Its Problems

Printing and compression technology has recently undergone major development, providing very natural copies of stones, ceramics, and parquet that are being introduced to the market.

However, there are several designs and standards whose production and installation are not possible with the current printing, compression and mechanical locking technique.

Most designs that contain patterns or structures where the parts need to be aligned with the shape of the floor panel are difficult to achieve because the bending and shrinking of the printed paper and the positioning of the printed and compression sheet is difficult. to control, hindering the attainment of the desired pattern, which is a continuous design, giving the arrangement an unnatural appearance.

It is well known that some advanced patterns could be produced with small rectangular panels which in turn could be connected to floor units. Such patterns and floor panels are described in WO 03/08973. This known technology is not suitable for patterns that copy, for example, stone or ceramic floors. U.S. Patent No. 6,729,091 describes small panels of polygonal shape, however these panels are difficult and expensive to produce and time consuming to install. Summary of the Invention

A first overall objective of the present invention is to provide a floor covering system and floor panels preferably with mechanical locking systems, which can be installed to more advanced standards, and where standards could be obtained to a large extent by size, shape, and mechanical work of panels and elements and not just by printing and compression technology.

More specifically, the object of the invention is to provide a floor system and floor panels with a mechanical locking system, where one or more of the following advantages may be obtained.

Preferably, the floor panel should allow its mechanical installation on a floor surface, which would generally be achieved only by applying small pieces of wood of different sizes or non-parallel edges and non-floating panels glued or nailed to the sub floor. -floor. Floor panels should be easy to install, although the floor pattern comprises a number of small panels of different sizes and different shapes than traditional rectangular panels. The substantial leftovers that result from the manufacture of floor panels and the mechanical floor locking system comprising the use of small non-rectangular panels should be reduced as much as possible. The above objectives are achieved either wholly or partially by a mechanical locking system and floor panels according to the independent claim. The embodiments of the invention will be apparent from the dependent claims and the following description in connection with drawings. According to the invention there is provided a floor system comprising a plurality of floor panels having a core and a discontinuous surface layer. The floor panels are mechanically interconnected along the length of a pair of adjacent edges and each floor panel comprises at least two floor elements, where at least one of the floor elements is not rectangular.

The floor elements are factory attached to a floor panel and carried, preferably packaged, to the installation site as pre-assembled parts. The interconnection between the floor elements must be such that the various floor elements are kept in a predetermined position in the installation. This interconnection must be such that the floor elements are permanently interconnected, for example by glue or a locking system that keeps the floor elements in the correct position during installation.

A floor panel made up of several individual floor elements provides a number of advantages. A series of patterns can be created that could not be produced by linear machining or edge printing. Installation becomes very easy as several floor elements could be installed at the same time. The joint between the floor elements is simple and inexpensive and yet strong and reliable since the floor elements are interconnected at the factory where special equipment can be used. The large floor is pre-assembled at the factory and the individual elements could be interconnected very efficiently. Much of the difficult and time-consuming installation work, where the installer has to work near the floor, could be transferred to a factory controlled environment.

Brief Description of the Drawings

Figures 1a to 4b illustrate prior art locking systems;

Figures 4c to 5 illustrate a first embodiment of the invention; and

Figures 6a to 9d illustrate other embodiments of the invention.

Description of Invention Settings

For ease of understanding, various floor panels and locking systems are shown in the drawings schematically. It should be emphasized that different or improved functions may be achieved by combinations of preferred configurations. The inventor has tested all known locking systems and particularly all commercially available locking systems on the market with all types of floor panels, especially laminate or wood floors, and has come to the conclusion that at least all these known locking systems with one or more tabs and grooves, and floor elements cooperating with the locking grooves, could be used to connect floor elements to a floor panel and to connect floor panels to a floor.

Note that angles, dimensions, rounded parts, etc. These are only examples and could be adjusted to the principles of the invention.

Figures 1a to Ic show known mechanical locking systems which could be locked or snapped. These locking systems have a tongue 10 and groove 9 for vertical locking of adjacent edges parallel to the vertical plane V and a locking groove 12 and a locking element 8 for horizontal locking parallel to the horizontal plane Η. The locking element may be located on a tongue 10 or a strip 6.

Figures 2a to 2c show mechanical locking systems that could be horizontally locked. The mechanical locking elements could be made integrated with the core in a single piece, as in figure 2c, or from a different material, which will be called "Two Piece Fitting" as in figures 2a and 2b. These interlocking systems have low interlocking strength and provide high locking strength and are therefore highly suitable for use in floor panels according to the invention. Figures 3a to 3c show mechanical interlocking systems Such systems could only have means for horizontal locking, as in Figure 3a, which will be called "Vertical Hook Systems", or a small one-piece tongue 10, as in Figure 3b, which will be called “Flexible Reed Systems.” Figures 4a and 4b show traditional locking systems, which are locked vertically with a tongue 10 and groove 9, and horizontally with glue 7. Figure 4c shows how a tongue and groove joint can be adjusted for use on a factory floor element connection. Tongue 10 is made smaller as special glue applied with controlled equipment can be used. Lower lip 6 is slightly longer and extends beyond upper lip 6 '. This simplifies the application of glue, and the lower lip 6 can be made to create a certain vertical pretension, and hold the floor elements together until the glue has cured.

Figure 5 schematically illustrates a cross section of a floor panel 2, comprising two separate floor elements 1 and 1 ', which have been factory-connected with a tongue and groove locking system. The floor panel 2 has a surface layer 31 and a core 30, which are discontinuous, and edges which in this preferred configuration could be angled locking. The floor elements have a decorative groove 40, bevel, or the like on one edge. When the floor elements are connected to the floor panels, very advanced groove patterns are obtained, which are impossible to produce at a suitable cost if made with an individual traditional floor panel.

All of these locking systems could be used in various combinations to connect floor elements 1 and 1 'or two or several adjacent edges of the floor panels. Mechanical locking systems could be adjusted to lock, for example, floor elements by a simple snapping action only by holding the panels together until the adhesive has cured. Preferred configurations for locking floor elements make use of glue locking systems as the panels could easily be positioned correctly horizontally at the factory. Floor elements could also be attached with a tape on the back side or glued to a sub-layer 16 which may be foam, cork, various types of plastic, wood, wood-based sheet materials, wood veneer, or the like.

Figure 6 shows two rectangular floor elements 1, 1 'connected to a floor element 2, as shown in figures 6a and 6b. The floor elements may have a surface of the same material, for example laminate, but may also have surface layers of different materials, such as laminated wood, laminated plastic material, wood, cork, etc., with more than two different materials. could be combined. The floor elements have decorative grooves 40 at the three edges. An advanced floor panel with decorative grooves, which in this configuration form an angle other than 90 degrees, produced by linear machining. Figure 6d shows how floor panels 2 could be installed from A-H through combinations of angulation, snapping, and vertical folding. Preferably, simple locking systems could be used as long as the irregular shape of the panels can be used to prevent displacement of the length of the panels. Figure 6e shows a floor with an advanced pattern according to the invention. Such a floor is as easy to install as traditional rectangular panels. It is obvious that 6 or 8 or more floor elements could be connected to a floor panel by supplying the straight edge start and end pieces.

It is also obvious that all configurations could be used to provide a floor where floor panels are made from a single floor element. A practical test shows, however, that a 4-element floor panel is installed four times faster than a floor panel having only one element.

Figure 7a shows a floor element 1 used to form a floor panel 2, similar to that of figure 6. Floor panel 2 has 9 pairs of edges (4a-4i and 5a-5i). The floor panel 2 comprises 6 pairs of adjacent edges (4c-4d, 4d-4e, 4g-4h, 5b-5c, 5e-5f and 5f-5g) inclined at an angle (A) greater than 90 degrees.

Panels could be locked in many ways. Parallel edges (4b-5b, 4d-5d, 4f-5f, and 4h-5h), for example, may have one or more locking systems and the other edges may have one system. traditional tongue and groove. Alternatively all edges could be locked horizontally.

Two pairs of adjacent edges (4b-5b and 4f-5f) could have an angle system, and two pairs (4d-5d and 4h-5h) could have a flexible tongue system. All other edges could have a vertical or flexible tongue or vertical hook system, or any other system that allows vertical folding. The floor panel comprises two straight edge protrusions (PI, P2) positioned along a straight line L. Such protrusions block the mutual displacement of connected panels. The straight edges 4b, 4f of these protrusions could have a mechanical locking system which could be locked by angling to opposite parallel edges 5b and 5f of a similar panel, and the other edges could be locked with vertical folding. Figures Ic-It show different configurations according to the same principles. In Figure 7d, nine pairs of adjacent edges (4a-4i and 5a-5i) could be connected, and two pairs of adjacent edges (4c-5b, and 4g-5f) could be connected, for example, by angulation. In Figure 7f, eleven adjacent pairs of edges (4a-4k and 5a-5k) could be connected together, and there are three protrusions PI, P2, P3 with three edge pairs (4d -5a, 4g-5d, and 4j- 5g) which could be connected to each other, for example by angling, and the other edges could be connected, for example, with vertical folding.

All configurations, where some edges are angled and others vertically folded, provide a simple installation, providing angling only around the outer edges (4d, 4g, 4f) that are positioned along the length of the straight line L, such as shown in figure 7f.

Alternatively, all edges could be connected with flexible tongue systems.

Claims (19)

1. Floor covering system comprising a plurality of floor panels (2 ', 2) comprising at least two factory connected floor elements (1,1'), the panels having a discontinuous core (30) and surface layer (31), said floor panels being mechanically interconnectable along a pair of adjacent edges, characterized in that at least one of the floor elements comprises sloping adjacent edges with an angle (A) greater than -90 degrees. and the first adjacent pair of edges of the two floor panels is provided with a mechanical locking system, preferably a horizontal locking system, or an angled or vertical folding configured to lock the panels in the horizontal and vertical directions. . System according to Claim 1, characterized in that said first pair of said two floor panels is provided with an angled locking system and a second pair of adjacent edges of said two floor panels is provided. with a vertical folding locking system. System according to Claim 1, characterized in that said first pair of said two floor panels is provided with the horizontal snap locking system, and a second pair of adjacent edges of said two floor panels. be provided with a tongue and groove joint. System according to any one of claims 1 to 3, characterized in that the floor panel comprises at least two pairs of adjacent edges which are inclined from an angle (A) of greater than 90 degrees. System according to any one of claims 1 to 4, characterized in that at least one of the floor elements comprises a surface layer which is a printed layer. System according to any one of claims 1 to 5, characterized in that at least one of the floor elements comprises a surface layer of laminate. System according to any one of claims 1 to 6, characterized in that at least one of the floor elements comprises a surface layer of thermoplastic material or wood. System according to any one of claims 1 to 7, characterized in that at least two floor elements have a decorative groove (40) on at least one edge and at least two decorative grooves form a different angle. 90 degrees. System according to any one of claims 1 to 8, characterized in that the floor elements have different sizes. System according to any one of claims 1 to 9, characterized in that the floor panel comprises at least two floor elements and that the floor elements are interconnected with a tongue (10), a slot ( 9), and glue. System according to any one of claims 1 to 10, characterized in that the floor panel comprises at least three floor elements and at least two floor elements have 6 or 8 edges. System according to any one of claims 1 to 11, characterized in that one of the floor elements has eight edges and another floor element has four edges. System according to any one of claims 1 to 12, characterized in that two panels in a connected state are prevented from sliding together. System according to any one of claims 1 to 13, characterized in that the floor panel comprises at least two straight-edge protrusions (PI, P2) which are positioned along a straight line L. System according to any one of claims 1 to 14, characterized in that at least one of the floor elements comprises 5 to 12 edges. System according to any one of claims 1 to 14, characterized in that at least one of the floor elements comprises 6 or 8 edges. System according to any one of claims 1 to 16, characterized in that the surface layer of the elements is of different materials. System according to Claim 17, characterized in that one of the different materials is wood. System according to Claim 17, characterized in that one of the materials is a laminate layer.