EA039386B1 - Set of building panels - Google Patents

Abstract

The invention relates to a set of building panels, wherein the building panels comprise a surface (2) and a core (3), provided with a locking system for vertical and horizontal locking of a first edge (1) of a first building panel to an adjacent second edge (1') of a second building panel. The upper parts of the first and the second edges in a locked position together define a vertical plane (VP) perpendicular to a horizontal plane (HP), which is parallel to the surface (2). The locking system is configured to enable assembling of the first and the second edges (1, 1') by angling the first and the second building panels relative each other. In the provided set the adjacent edges are automatically guided into a correct position during rotation, thus providing strong locking and production of panels with minimal cut of material.

Description

Embodiments of the invention generally relate to the field of mechanical locking systems for building panels, in particular to sets of building panels. More specifically, embodiments of the invention relate primarily to the type of building panels that have a core and a decorative surface layer on the upper side of the core.

Scope of the invention

Embodiments of the present invention are particularly suitable for use in floating floors, which are formed from floor panels mechanically connected by a locking system integral with the core, and consisting of one or more top layers of veneer, decorative laminate or decorative plastic, an intermediate core of material based wood fiber or plastic and preferably a lower leveling layer on the back side of the core, and made by sawing large panels into several panels. The following description of known technology, problems of known systems, objects and features of embodiments of the invention thus relates, by way of non-limiting example, primarily to this field of application and in particular to flooring from a laminate formed in the form of rectangular floor panels, mechanically connected both on the long sides and on the short sides.

However, it should be emphasized that the invention can be used for any floor panels or building panels intended to be locked together at two adjacent edges horizontally and vertically by a mechanical locking system allowing locking, preferably by a pivoting movement. Embodiments of the invention can also be applied, for example, to solid wood floors, parquet floors with a core of wood lamellas or wood fiber material and the like, which are made as separate floor panels, for floors with a printed and preferably also lacquered surface and like them. Embodiments of the invention can also be used to connect building panels, such as wall panels and furniture blanks.

Prerequisites for the creation of the invention

A multi-layer flooring usually includes a 6-11 mm thick fibreboard core, a 0.1-0.8 mm laminate top decorative surface layer, and a 0.1-0.6 mm thick leveling layer of laminate, plastic , paper or similar material. The surface layer provides the floor panels with appearance and durability. The core provides strength and the leveling layer keeps the panel flat after pressing and when the relative humidity (RH) changes throughout the year. The floor panels are laid floating, i.e. without sticking to the existing subfloor. Conventional solid floor panels of this type are usually connected using tongue and groove glued joints. However, the majority of all sandwich floor panels are now mechanically connected using so-called mechanical locking systems. These systems contain connection means that fix the panels horizontally and vertically. Mechanical locking systems are usually formed by tooling the core. Alternatively, the parts of the locking system may be formed from separate materials, such as aluminum or plastic, which are combined with the floor panel at the factory.

The main advantages of floating floors with mechanical locking systems are that they can be installed quickly and easily with various combinations of twist and click. They can also be easily dismantled again and reinstalled elsewhere.

The most common core material is high density fibreboard with good strength, commonly referred to as high density fibreboard (HDF). Sometimes (MDF)-medium density fibreboard (MDF) is also used as the core.

A sandwich panel comprising a surface of melamine-impregnated decorative paper, plastic, wood, veneer, cork and the like is produced by applying a surface layer and preferably a leveling layer to a core material which, in addition to HDF, can be made of plywood, chipboard, plastic and various composite materials. Recently, a new panel has been developed in which a powder containing fibers, a binder, abrasion-resistant particles, and a coloring pigment are dispersed onto a core material and processed by heat and pressure to obtain a paper-free hard surface.

As a rule, the above methods result in a sandwich panel, which is divided by sawing into several panels, which are then tooled to provide them with a mechanical locking system along the edges. A sandwich panel that has a size that does not require separation can be produced using the method described above. The manufacture of individual floor panels is usually done when the panels have a surface layer of wood or veneer.

Floor panels with mechanical locking systems can also be made from solid materials such as solid wood.

In all cases, the aforementioned floor panels are individually machined along their edges to obtain floor panels. Edge tooling is performed on modern sawmills, in which the floor panel is positioned flat between one or more chains or belts to provide the floor panels with the ability to move at high speed and with high precision through several sawmills equipped with rotating diamond or metal tools that tool process the edges of the floor panel. By using several sawing machines operating at different angles, improved joint patterns can be formed at speeds in excess of 200 m/min and with an accuracy of approximately ±0.05 mm. In the vertical direction, the accuracy is usually better than in the horizontal direction, since it is difficult to avoid the so-called floating that occurs when the panels move in the horizontal direction relative to the chain/tape during cutting.

Definition of some terms

In the following text, the visible surface of a laid panel, such as a floor panel, is referred to as the front side, while the opposite side of the floor panel facing the subfloor is referred to as the back side.

The horizontal plane means a plane that runs parallel to the front side. The immediately adjacent tops of two adjacent joining edges of two panels joined together define a vertical plane perpendicular to the horizontal plane.

The outer parts of the floor panel at the edge of the floor panel between the front side and the back side are called the joint edge. Typically, a bonding edge has multiple bonding surfaces, which may be vertical, horizontal, oblique, rounded, rounded, and the like.

The locking system means cooperating connecting means connecting the panels vertically and/or horizontally. The mechanical locking system means that the connection can be made without glue.

Pivot means a connection that is made by a pivoting movement that changes the angle between two parts to be connected or separated. When pivoting refers to joining two floor panels, the angular movement typically occurs when the top portions of the joining edges are at least partially in contact with each other during at least part of the movement.

Up or up means towards the front side and down or down means towards the back side. Inward means towards the center of the panel, and outward means in the opposite direction.

Cutting means a method of forming a groove or protrusion on the edge of a panel by cutting a portion of the edge to its final shape with a combination of one or more cutting tools containing a plurality of non-rotating and fixed chip removal surfaces arranged along the feed direction.

Known technology and its problems

In order to facilitate understanding of the embodiments of the present invention, a known mechanical locking system will be described with reference to FIG. 1a-1e. In the applicable parts, the following description of known technology also refers to the embodiments of the present invention described below.

As shown in FIG. 1, the floor panels have a tongue 10 and a groove 9 which fix the edges in the vertical direction. The strip 6, which extends along the first edge 1, protrudes from the edge and has a locking element 8 cooperating with a locking groove 14 in the adjacent second edge 1', and locks the edges horizontally.

From this figure and FIG. 1b, it is clear that since mechanical locking systems have parts, such as a tongue 10 and a strip 6, projecting beyond the upper joint edges, expensive trimmings W are generated when a large panel 1b is sawn by a saw blade 20 into several floor panels and when a locking system is formed.

Even when individual floor panels are made, such as solid wood floors, as shown in FIG. 1c, significant cuts (W) are due to the formation of band 6 and ridge 10.

These systems and manufacturing methods suffer from several disadvantages, primarily cost and functionality.

The cutoffs are mainly related to the long edge of the locking system, which is usually installed by turning. In general, trims can be about 10 mm or more, or about 5% in floor panels having a width of about 200 mm. Cutoffs in narrow floor panels having a width of eg 100 mm can be approximately 10%.

Various methods are used to overcome these problems. The most important way is to limit the size of the protruding part. This usually leads to a decrease in the strength of fixation and difficulties in laying or undocking the floor panels.

Another way is to use special materials such as aluminum or plastic to form a strip or ridge. Such materials are generally not economically viable in low cost floors with a surface layer and core made of very economical materials such as impregnated paper and high density fibreboard, respectively.

It is known that the locking system can be formed with overlapping edges A, B and bottom ridge C, as shown in FIG. 1d (WO 2005/068747 Valinge Innovation AB). This locking system does not reduce trimming. Overlapping edges or small ridge B are used primarily to promote horizontal offset between edges. In FIG. 1e shows a known locking system (WO 2006/043893 Valinge Innovation AB) having a separate movable tongue 10 fixed over a strip 6, and which is primarily intended for short-edge locking by vertical folding or vertical snap-in.

Brief description of embodiments of the invention and its objectives

It is an object of the embodiments of the present invention to provide a locking system integral with the core which automatically guides adjacent edges into the correct position during rotation, which has a high locking strength and which can be made with minimal material trimming occurring when cutting a large panel and finishing the edges. and mechanical locking system.

A further object of the embodiments of the invention is to provide a rational and economical method of manufacturing by dividing the panels into floor panels, which are tooled in a second manufacturing step to provide them with a mechanical locking system.

The above objectives can be solved in whole or in part by using lock systems, floor panels and manufacturing methods in accordance with embodiments of the invention.

A first aspect of the invention is a method for separating a panel into a first panel and a second panel, the method comprising the step of moving the panel and separating the panel with a fixed tool, such as a scraper or cutting tool.

The method preferably comprises the step of forming a first, vertically open slot in the rear side of the panel and an offset second, vertically open slot in the front side of the panel.

A fixed tool or saw blade may form the first, vertically open slot.

The second, vertically open slot may be formed by a fixed tool or a saw blade. The second, vertically open groove is preferably made by sawing in order to obtain a smooth edge with less burr on the front side edge since the edge can be visible when the panel is installed.

The method may comprise the step of forming, with a fixed tool, a first, horizontally extending groove that extends horizontally under the front side and/or back side of the panel.

The first, horizontally extending groove may extend from the second groove towards the first groove.

The first, horizontally extending groove may extend from the first groove towards the second groove.

The first horizontally extending slot may connect the first vertically open slot and the second vertically open slot.

The method may comprise the step of forming with a fixed tool a second, horizontally extending groove that extends horizontally under the front side and/or back side of the panel, the second, horizontally extending groove extending from the second, vertically open groove towards the first, vertically open groove, and the first, the horizontally extending slot extends from the first vertically open slot towards the second vertically open slot.

The first, horizontally extending grooves can be connected to the second, horizontally extending grooves.

The formation of a second, vertically open groove can be performed by sawing with a rotating saw blade.

The formation of the first groove is preferably carried out before the second groove is cut, and the first groove is made with a fixed tool. The step of moving the panel through the fixed tool is preferably performed prior to the sawing step, since this facilitates the absorption of the forces caused by the fixed tool when the groove is formed.

The method may include the step of placing the panel on a means of transport, such as a conveyor belt/chain, preferably provided with a pushing device, such as a stop or rib. A pushing device, such as a stop or a rib, increases the force with which the building element can be pushed towards the fixed tool.

The front side of the panel may be located on the transport means and facing down. The front side is preferably positioned downward and is supported by a means of transport such as a conveyor belt/chain. If the aforementioned steps result in a part of the locking system with increased manufacturing tolerances, the main locking surfaces can be manufactured with high tolerances.

The fixed tool may comprise a plurality of cutting teeth arranged to be formed in various vertical and/or horizontal positions.

The method may comprise the step of removing chips generated by the fixed tool with compressed air, preferably with a compressed air nozzle, and preferably collected with a suction device.

The panel may be a wood-based panel, a sandwich panel, such as a floor element containing a HDF or MDF core, a decorative layer and a leveling layer, a plywood panel, or a panel containing a plastic core and preferably a decorative layer.

The sandwich panel may comprise a core provided with a decorative surface layer and a leveling layer.

The method may include the step of removing chips generated during machining, preferably by means of a plurality of compressed air nozzles, and preferably sorting and placing the chips from the core and the leveling layer and/or the decorative layer into separate containers.

The second aspect of the invention is a method for forming a mechanical locking system for fixing the first and second panels, the method comprising the following steps:

separating the panel into first and second panels in accordance with the methods described herein, and thereby forming a lower protrusion on the first edge of the first panel and a lower groove on the second edge of the second panel;

forming a locking element on the lower protruding part;

formation of a locking groove in the lower groove.

The third aspect of the invention are building panels, each of which contains a top surface and a core provided with a locking system for vertically and horizontally fixing the first edge of the first building panel with an adjacent second edge of the second building panel. The upper parts of the first and second edges jointly define in a fixed position a vertical plane which is perpendicular to a horizontal plane parallel to the upper surface of the first and second building panels. The locking system is configured to ensure assembly of the first and second edges by turning the first and second building panels at the required angle relative to each other. The locking system comprises a comb made integral with said core, and a groove for the comb, made with the possibility of interacting for vertical fixation, and a strip on the first edge, made integral with the core, provided with a locking element and made with the possibility of interacting for horizontal fixing with the locking element open downwards. groove formed in the second edge. The first and second building panels can occupy a relative position with a gap between the first and second edges, while in said position the upper surfaces of the first and second building panels (1, 1') are in the same horizontal plane, and the edge part of the second edge is located vertically above the top part of the locking element, and there is also a vertically extending gap S of at least approximately 0.5 mm between the locking element and all parts of the second edge located above the locking element.

The edge part can be located on a vertical plane.

The locking element may include a locking surface cooperating with the locking surface on the locking groove for horizontal locking, and the edge part is located vertically above the locking surface of the locking element.

The gap may be greater than 0.6 mm.

The gap may be the same or greater over the outside of the locking element than over the top of the locking element.

The edge portion may comprise a lower portion inclined downward and inward.

The edge portion may comprise the lower portion of the ridge.

The construction panel may be a floor panel.

The fourth aspect of the invention is a method for separating a panel containing a core and a surface, the method comprising the following steps:

forming in the core first and second substantially vertical grooves that are horizontally offset, the first groove having an opening towards the front side and the second groove having an opening towards the back of the panel;

dividing the panel into a first floor panel with a first edge and a second floor panel with a second edge, the first edge being adjacent to the second edge; and forming on the first and second edges of the locking system, containing a strip, a locking element and a locking groove for horizontal fixing and a ridge and a groove for a ridge for vertical

- 4 039386 commits.

The second groove may be formed with a cutting tool.

The panel can be split using a cutting tool.

The panel can be split using cutting tools inserted into the first and second slots.

The cutting tool that separates the panels can cut a substantially horizontally extending groove that forms an angle of less than 45° with the horizontal plane HP.

The first or second slots may be formed with a cutting tool with cutting teeth offset horizontally with a gap of at least about 0.2 mm.

A fifth aspect of the invention is building panels comprising a surface and a core provided with a locking system for vertically and horizontally fixing a first edge of a first building panel with an adjacent second edge of a second building panel. The upper parts of the first and second edges in a fixed position jointly define a vertical plane perpendicular to a horizontal plane that is parallel to the surface. The locking system is configured to ensure assembly of the first and second edges by turning the first and second building panels at the required angle relative to each other. The locking system comprises a comb made integral with said core, and a groove for the comb, made with the possibility of interacting for vertical fixation. The first edge comprises a strip made integral with the core, which is provided with a locking element configured to cooperate for horizontal locking with a locking groove open downwards formed in the second edge. The tongue provided on the first edge cooperates with the lower protrusion of the tongue groove, which is provided on the second edge, and contains the lower vertical locking surfaces. The locking element and the locking groove cooperate on the horizontally locking surfaces. The ridge protrudes outwardly outside the vertical plane, and the ridge slot contains an upper projection. The horizontal extension of the lower protrusion relative to the upper protrusion is less than the horizontal extension of the ridge.

Building panels may comprise horizontally interacting locking surfaces that lock edges both horizontally and vertically with horizontal and vertical pretension.

The building panels may include a ridge that engages with an upper protrusion on the upper, vertically locking surfaces.

The tongue and groove for the tongue may comprise upper and lower vertically locking surfaces that are substantially parallel to the horizontal plane and offset horizontally such that a portion of the upper vertically locking surfaces is horizontally closer to the locking element than the lower vertically locking surfaces.

The lower protrusion may extend beyond the upper protrusion and the vertical plane.

The horizontal extension of the ridge may be at least about twice the horizontal extension of the lower lip.

The tongue and groove for the tongue may comprise guiding surfaces configured to be in contact with each other during rotation assembly when the edge portion of the second edge is in contact with the strip and/or the locking element.

The guide surfaces may be inclined with respect to a vertical plane and located on the top and/or bottom of the tongue and groove for the tongue.

The horizontal locking surfaces may be located below the plane of the horizontal strip that intersects the top of the strip located substantially vertically under the outer portion of the ridge.

Horizontally fixing surfaces can be located both below and above the plane of the horizontal strip.

Horizontally locking surfaces may be located above the horizontal plane of the strip.

The lock system may include a gap between the upper part of the strip and the edge portion of the second panel, located essentially under the ridge.

The upper, vertical locking surfaces can be moved horizontally relative to the horizontal locking surfaces.

The vertically and horizontally locking surfaces can be displaced horizontally by a horizontal distance greater than the horizontal extension of the ridge.

The core may contain HDF, chipboard, plastic or plywood.

The horizontally locking surfaces may have a locking angle of approximately 40-60° relative to the horizontal plane.

The sixth aspect of the invention is a method for separating a panel containing a core and a surface, the method comprising the following steps:

forming in the core a first and a second substantially vertical groove, offset horizontally, the first groove having an opening towards the front side and the second groove having an opening towards the rear side of the panel;

dividing the panel into a first floor panel with a first edge and a second floor panel with a second edge, the first edge being adjacent to the second edge; and forming a fixing strip and ridge for vertically and horizontally fixing the first and second floor panels, wherein the fixing strip and ridge protrude horizontally beyond the top of the first edge of the first panel.

The panel can be split using knives.

The panel can be separated by scraping the core.

The panel may comprise a plywood core that splits at least partially along one of the veneers.

The panel may comprise a plywood core that splits substantially along one of the layers, which contains fibers oriented substantially in the direction from one slot to the other slot.

The first or second slot may be formed with a rotary tool and the other slot by cutting or scraping.

The second groove can be formed by cutting or scraping.

The first and second grooves may be formed by cutting or scraping.

A seventh aspect of the invention is a building panel, such as a floor panel according to the third or fifth aspects, and manufactured according to the first, second, fourth or sixth aspects.

A locking system containing a tongue on the same edges as the protruding strip and allowing the separation of the panels by cutting two offset grooves provides significant material savings. The connection configuration described above ensures accurate edge guidance during locking and strong locking when the edges are rotated into the locked position.

Brief description of the drawings

The present invention will be described in more detail by way of example with reference to the accompanying schematic drawings, which show embodiments of the present invention.

Fig. 1a-e illustrate known technology.

Fig. 2a-d illustrate a locking system according to an embodiment of the invention.

Fig. 3a-f show alternative embodiments of the invention.

Fig. 4a-f show alternative embodiments of the invention.

Fig. 5a, b show a preferred embodiment of the locking system.

Fig. 6a-g show the division of the panel into several floor panels according to an embodiment of the invention.

Fig. 7a, b show separation with a band saw according to an embodiment of the invention.

Fig. 7c shows a method for dividing a panel into two panels with a fixed tool, such as a cutting or scraping tool, in accordance with an embodiment of the invention.

Fig. 8a-e show a locking system and a method for separating panels with a cutting tool in accordance with embodiments of the invention.

Fig. 9a-f show how conventional lock systems can be adapted and separated in accordance with embodiments of the invention.

Fig. 10a, b show a cutting tool according to an embodiment of the invention.

Fig. 11a, b show the cutting of horizontal and vertical grooves in accordance with embodiments of the invention.

Description of embodiments of the invention

A first embodiment of floor panels 1, 1' provided with a mechanical locking system according to the invention is shown in FIG. 2a-d.

The building panel shown in this embodiment is a floor panel with or without a surface 2 attached to a core 3. The floor panel is provided with a locking system for vertical and horizontal fixing of the first 1 and second 1' edges of adjacent edges of the panel. The upper parts of the two edges 1, 1' of the two connected floor panels jointly define the vertical plane VP. The vertical plane is perpendicular to the horizontal plane HP, which is parallel to the panel surface. The locking system is configured to lock the edges 1, 1' by turning two adjacent edges relative to each other. The locking system contains a comb 10, made integral with the said core 3, interacting with the groove 9 for the comb in the adjacent

- 6 039386 edge 1' for vertical fixation. The tongue groove 9 comprises a lower projection 9a and an upper projection 9b above the lower projection. The first edge 1 comprises a strip 6 integral with the core 3 and provided with a locking element 8 which cooperates with a downwardly open locking groove 14 formed in the second adjacent edge 1' for horizontal locking. The ridge 10 is located on the first edge 1 above the strip 6 and protrudes outwardly beyond the vertical plane VP. In FIG. 2b shows that the tongue 10 and the tongue slot 9 comprise an upper 12 and a lower 13 vertically cooperating locking surface.

The locking element 8 and the locking groove 14 comprise horizontally cooperating locking surfaces 15 which perform horizontal locking and prevent horizontal separation of the adjacent edges 1, 1'.

The twist lock system configuration is limited in many respects by the twist movement required to complete the lock. The locking surfaces, during the last stage of the pivoting movement, turn around circles C1, C2, which have a center of rotation on a vertical plane at the top of the connecting edges. The tangent defines the free angle A, which is the angle at which the edges can be locked and separated in the absence of any overlapping locking surfaces that prevent such locking or separation. The free angle A increases when the locking element 8 is closer to the surface and/or further horizontally from the vertical plane VP. This means that a small locking angle allows for a compact and economical locking system. However, this has a negative effect on the strength of the fixation and the final guidance to the fixed position. An additional rotation through locking angles L greater than the free angle may be used if the locking surfaces are small and the material is partially compressible. Generally, the horizontal locking surfaces 15 should have a locking angle of greater than about 30° to provide sufficient strength and guidance. Large locking angles are even more desirable and high quality locking systems should typically have a locking angle in the order of 45-60°. Locking systems with large locking angles, which can reach up to 90°, provide a very strong lock. All such locking angles can be provided by the locking system in accordance with the described invention.

The ridge 10 and the ridge slot 9 must also be formed and rotatable during the final locking step. Rounded locking surfaces are optimal for twist locking, but are not applicable in practice due to manufacturing tolerances. Therefore, the ideal configuration is substantially flat locking surfaces, parallel to the surfaces, which allows rotating tools to move horizontally without affecting the vertical position of the top edges. Therefore, the locking system preferably has in this embodiment a lower lip 9 located under the ridge 10, extending beyond the upper lip 9b, and allowing the formation of flat, vertical locking surfaces 12, 13 that are substantially parallel to the horizontal plane HP. The tongue 10 and the tongue groove 9 preferably comprise top 12 and bottom 13 vertical locking surfaces that are essentially parallel to the horizontal plane HP and offset horizontally so that part of the upper vertical locking surfaces 12 is closer to the locking element 8 than the lower vertical locking surfaces. surfaces 13.

The horizontal extension TE of the tongue 10 is greater than the horizontal extension LE of the lower projection 9a extending beyond the upper projection 9b. The locking system can also be formed with the lower lug 9b not extending beyond the upper lug 9b, or even with the upper lug 9b extending horizontally beyond the lower lug 9a. By minimizing the elongation LE of the lower protrusion 9b, it is possible to ultimately limit the material cutoffs. Preferably, the elongation of the lower protrusion 9 does not exceed the elongation TE of the ridge 10 by more than about 0.5 times. The slight extension of the lower projection 9b does not create additional trimmings, as the saw blade must normally cut a short distance from the edge in order to allow final tooling of the edges to remove the burrs left by the saw. This finished edge distance is also used for tooling and cutting banana edges to straight edges. The slight elongation LE, approximately 1 mm, thus does not increase material waste, but can be used to form locking surfaces and/or guiding surfaces in the lower ledge 9a. A high vertical locking force can be obtained in a wood or HDF core with vertical locking surfaces 12, 13 having a horizontal extension of approximately 1 mm and even less, for example 0.5 mm may be sufficient in some applications.

The locking system preferably comprises a gap S between the upper part of the strip 6 and the second edge 1'. It can be used to eliminate the need for precise tool placement for tooling. The gap S is preferably located vertically under the ridge 10.

The locking system must be able to guide the edges into the correct position during installation. Floor panels are often warped and bent, and the locking system must be able to straighten out the curvature and guide the edges into the correct position.

The tongue 10 and the groove 9 preferably comprise guide surfaces 17a, 17b which are in contact with each other during rotation when the edge portion EP of the second edge 1' is in contact with the strip 6 and/or the locking element 8, as shown in FIG. 2s.

The guide surfaces 17a, 17a', 17b, 17b' are preferably inclined with respect to the vertical plane VP and may be located on the top and/or bottom of the tongue 10 and the tongue groove 9. The guide surfaces may also be rounded. The at least two cooperating guide surfaces 17a, 17b should preferably be in contact with each other when the second edge 1' is at an angle of approximately 10-20° to the horizontal plane and the edge portion EP is in contact with the strip and/or the locking element , as shown in FIG. 2s.

The upper vertical locking surfaces 12 are preferably offset horizontally with respect to the lower horizontal locking surfaces 13 by a distance LD. Preferably, this distance LD is greater than zero. The distance LD is preferably greater than 20% of the horizontal extension TE of the tongue 10.

The upper vertical locking surfaces 12 are preferably offset horizontally from the lower horizontal locking surfaces 15 by a distance D. Preferably, this distance D is greater than the horizontal extension TE of the ridge.

In this preferred embodiment, the horizontal locking surfaces 15 are located below the horizontal plane HPS of the strip intersecting the top 6a of the strip 6. This top is preferably positioned substantially vertically under the outer part of the ridge 10. This configuration simplifies edge formation as it can be used, for example , only vertically and horizontally rotating tools. This provides maximum material savings, as further described below.

In FIG. 3a-f show that the locking system can be made more compact if the locking element 8 is moved towards the top of the floor panel.

In FIG. 3c shows that the horizontal locking surfaces 15 can be located either below or above the horizontal plane HPS of the strip.

In FIG. 3e shows that the horizontal locking surfaces 15 can also be located above the horizontal plane HPS of the strip. Fixation angle B in this embodiment is approximately 60°. The free angle is approximately 50°, which means that this locking system contains an additional rotation of approximately 10°. The strip 6 has a back side 6b which is slightly inclined upwards and where the leveling layer and/or core has been removed. This increases the flexibility of the strip and allows for slight bending during fixation and release. It can also be used to create a strip with a given flexibility, which can be used to create inward and upward pretension. This can be used to increase the angle of the horizontal fixing surfaces and eliminate some manufacturing tolerances. The floor panels may also be nailed to the subfloor, and the tongue 10 provides a strong base for the nail 24. Nail grooves 26 may be formed on the back to prevent splitting of the back.

The floor panels can have chamfers 4 or a decorative groove 5 on the upper edges. Preferably, the decorative groove 5 is formed on the second edge 1', where saw blade burrs are most critical.

Fig. 4a-f describe embodiments of the invention. In FIG. 4a shows that the locking system can be formed without a protruding lower projection and without a gap between the strip 6 and the lower part of the adjacent edges. In FIG. 4c shows that vertical locking is provided by lower vertical locking surfaces 13 located on the lower part of the ridge 10 and on the upper part 16 of the strip 6 and the lower part of the second edge 1'.

In FIG. 5a, b show that only the lower vertical locking surfaces 13 and the horizontal locking surfaces 15 can also be used for vertical locking. There may be a gap S above the tongue 10 and between the top of the strip 6 and the bottom of the second edge 1'. The band can be used to apply a pretension P inward P1 and upwards P2 by means of the inclined locking surfaces 15 on the locking element 8. This pretension can create a pressure force P3 pressing the lower locking surface 13. In the locked position, the band is slightly curved downward. This further eliminates the need for tight manufacturing tolerances. Only the position of the lower fixing surfaces 13 must be strictly controlled in order to produce a floor without so-called wood sags on the upper joining edges.

To create such a horizontal and vertical pretension, a locking angle of approximately 40-60° is preferred. The vertical pretension may also be provided by the upper part of the locking element 8a which presses the inside of the locking groove 14a.

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In FIG. 5b shows that essentially the same connection configuration can be used even if the floor thickness is increased. The lower part of the strip 6b may be such that the thickness of the strip is reduced. Alternatively, a horizontal slot may be formed in the strip below the locking element to increase flexibility.

All of the described embodiments may be partially or completely combined into alternative embodiments. Locking systems can be used to secure long and/or short edges with a twisting motion. The locking system can also be configured to be horizontally snap-fitted, in which the strip 6 is folded back during the snap-on when the lower guide surfaces on the ridge and the lower lip interact with each other. This can be used, for example, to connect a long edge to a short edge, or to snap in long edges when rotation is not possible.

The lock system can also be connected by turning the first edge 1, in which the strip 6 is inserted under the lower ledge.

In FIG. 6a-g show several technological processes for dividing panels. The panel, which may be a sandwich panel comprising a core 3, a top surface 2 preferably containing a decorative layer, and a bottom surface preferably containing a leveling layer, is divided into first and second panels with first and second adjacent edges 1,1'. Two adjacent edges 1,1' are formed, containing a locking system that provides vertical and horizontal fixation. The first and second panels may be, for example, a building panel or a floor panel.

Methods may be used to divide a panel into first and second panels. The first panel has a first edge 1 adjacent to a second edge 1' of the second panel. The first edge comprises an extension 10, 6, 8 which protrudes horizontally beyond the top of the first edge 1. First and second vertically open grooves 19, 18 are formed in the panel by, for example, rotating saw blades 20. The grooves are horizontally offset.

The second, vertically open slot 18 contains an opening towards the front side of the panel, and the first vertical slot 19 contains an opening towards the rear side of the panel. A panel can be divided into several panels in various ways.

In FIG. 6b shows the separation or splitting which can be carried out by turning or pushing the edges 1, 1' apart. This method is very suitable when HDF is used as the core because the fibers are oriented horizontally and the tear is essentially horizontal. The same method can be used in a plywood core with another ply that can be made to create a controlled tear along one of the plies of the veneer. Preferably, the orientation of the fibers is substantially directed from one slot to the other slot.

Separating methods may also include the step of cutting with a fixed tool or fixed tools, such as knife(s) 21 and/or scraping and/or cutting tool(s) 22, as shown in FIG. 6s.

A preferred embodiment comprises the step of forming a horizontally extending slot in a first vertically open slot and/or a second slot using a fixed tool 22. The horizontally extending slot extends from one first slot or a second vertically open slot towards another first slot or a second vertically open slot. . The horizontally extending slot extends under the front side of the panel and/or over the back side of the panel. In FIG. 6c shows an embodiment comprising the step of forming a first horizontally extending slot that extends from the first vertically open slot towards the second vertically open slot and forming a second horizontally extending slot that extends from the second vertically open slot towards the first, vertically open groove. Embodiments may include the step of cutting a portion of the first and/or second vertically open slot with a saw blade prior to cutting the first and/or second horizontally extending slot with a fixed tool.

In FIG. 6d shows that a first vertically open slot can be formed with a rotating saw blade 20 and a second vertically open slot can be formed with a scraping or cutting tool 22. FIG. 6e shows that a knife 21 can be used to separate the first and second panels.

In FIG. 6f and g show an embodiment including forming a first, vertically open slot and a second, vertically open slot that overlap each other. The second, vertically open slot may be formed with a saw blade and the first, vertically open slot with a scraper or cutting tool 22. The step of splitting or forming a horizontal slot is not required in this embodiment.

In FIG. 7a and b show that the final separation can be carried out with a band saw 23 which cuts the core. This separation gives a well controlled cut and can be used for materials that are difficult to separate, cut or cut.

In FIG. 7c shows an option for dividing the panel into a first panel 1 and a second panel 1' by means of

- 9 039386 moving the panel through a fixed tool 22, such as a cutting or scraping tool. The panel may be provided with a leveling layer and/or a decorative layer, and the fixed tool allows the sorting and removal of chips from the core and the leveling layer and/or the decorative layer into separate containers. Chips are preferably removed using a plurality of compressed air nozzles. Adjacent edges of the first and second panels preferably overlap vertically and comprise a lower projection on the first edge of the first panel and a lower groove on the second edge of the second panel. A mechanical locking system, such as described herein, may be formed at adjacent edges by, for example, milling, cutting, or scraping. A locking member may be formed on a lower protrusion that is configured to cooperate with a locking slot that may be formed in the lower slot. Vertical overlapping edges can reduce panel material loss caused by panel separation and mechanical locking. The method illustrated in FIG. 7c is preferably used to separate HDF or MDF or panels containing plastics such as PVC.

In FIG. 8a shows a preferred locking system with tongue 10 on side 1 of the strip. In FIG. 8b shows that the edges 1, 1' can take such a relative position in which the upper surfaces 2 are located along the same horizontal plane HP and in which the edge part EP of one of the adjacent edges is located vertically above the upper part 8a of the locking element 8, and there is a vertically extending a gap S of at least about 0.5 mm between the locking element 8 and the entire adjacent edge above the locking element 8. The gap S can be smaller, but this makes the final separation much more expensive and difficult.

This edge configuration as shown in FIG. 8b makes it possible to split the panel into the floor panels with a cutting tool that can be of sufficient size to split the panel at high speed and with sufficient precision, and ensure tool life. In FIG. 8c shows that the overlap OL of the finished edge portions can be even greater if the connection configuration is such that the necessary clearance S above the locking element 8b exists on and along the vertical plane VP. Even greater overlap and savings can be achieved if a gap S exists when the edge part EP is located on the vertical plane VP and vertically above one of the horizontal locking surfaces 15a on the locking element 8.

In FIG. 8e shows that the first 19 and/or the second 18 vertically open slot can be formed using a rotating saw blade 20 and/or a cutting tool 22. In this preferred embodiment, the second vertical slot 18 is formed using a rotating saw blade 20 and the first using the cutting tool 22a.

Preferably, the second groove 18 is made by sawing with a rotating saw blade 22 and that the first groove 19 is made before the second groove 18 is cut.

The panels are finally separated by upper and lower cutting tools 22c, 22b, which are inserted into pre-formed grooves and which form substantially horizontal grooves.

This non-straight separation, combined with overlapping edges OL, can be used to reduce material waste W in all types of interlock systems. The trimmings W of the material in the laminated floor may be less than the thickness T of the floor. It is possible to reduce trimmings to approximately 5 mm or less in a sandwich floor with a thickness of approximately 6-12 mm.

The panel may be placed on a means of transport, such as a conveyor belt/chain, preferably provided with a pushing device, such as a stop or a rib (not shown). The decorative surface of the panel may be located on the means of transportation and face down (not shown). The pushing device can be used to overcome sufficiently large cutting counter forces when creating a groove with non-rotating cutting tools.

In FIG. 9a-f show that significant material savings W can be achieved with a non-straight panel split and with overlapping edges OL, even if the ridge 10 is formed on the second edge 1', as in conventional locking systems, as shown in FIG. 9a, 9b. In FIG. 9b shows that the W trims can be reduced by offsetting the vertical slots and a small notch. In FIG. 9c shows that it is possible to modify the locking system so that it is compatible with the previous locking system and that increased edge overlap can be obtained, as shown in FIG. 9d. Part of the lower part of the ridge 10 and the upper outer part of the locking element 8 can be removed with a small rotary milling tool that can be tilted, and more preferably with a cutting tool, so that a gap S can be created when the edges 1, 1' are in overlapped position as described above. Preferably, the gap S is larger over the outside of the locking member than over the top of the locking member so that a strong and sufficiently large cutting tool edge 22b can be used to separate the panels. In FIG. 9e, f show that further savings and greater overlap can be achieved if the ridge 10 is moved upwards.

In FIG. 10a shows a cutting tool with four cutting teeth 30a-30d. The teeth are attached to the body 31 of the tool.

Several methods can be used to increase performance and flexibility.

Each cutting tooth can be mounted in an adjustable tool holder. Multiple cutting teeth can be the same length and the cut depth can be adjusted with an adjustable tool holder.

To be able to quickly change teeth, tool holders can be attached to the tool body on a rotating disc or on other cassette tooling systems.

In FIG. 10b shows that the tool body can be tilted slightly so that each tooth is cut to a depth of, for example, 0.2 mm when the panel is moved in the feed direction relative to the attached cutting tool. Each tooth can be configured to cut a distance of, for example, 0.2-0.6 mm into the wood core. High density fibreboard is especially suitable for carving.

In FIG. 11a shows how the first tooth 30a makes a first cut under the protective layer of the laminate 11. The edges of the tooth comprise three cutting edges forming a slot bottom 31a and two side walls 31b, 31c. Preferably, the teeth have a gradually decreasing width along the feed direction. V-notches can be used to provide a smoother cut with less burr on the laminate. This reduces tool wear and heat that can occur at high feed rates.

In FIG. 11b shows the cutting of a substantially horizontal groove which provides the final separation. The groove angle in the finished groove can vary from zero to 45° relative to the horizontal plane HP.

The locking systems described above are specifically designed to economically separate panels in order to reduce offcuts W. As can be seen from the drawings, offcuts can be significantly reduced. In most applications, scrap reductions of approximately 40-50% can be achieved compared to conventional manufacturing methods.

Embodiments of the invention are particularly suitable for use in solid wood floors where material costs are high and where a protruding ridge creates high trim costs. A floor containing small individual rectangular parquet strips 10x50 cm wide and 10x50 cm long or less can be produced in a very economical manner with significantly fewer scraps.

Embodiments of the invention can be used to form all types of lock systems on long and/or short edges, which can be connected by various combinations of rotation and/or horizontal snap and/or vertical folding.

Embodiments of the invention are also suitable for panels, such as building panels and floor panels, with digitally printed surfaces. The advantage is that it is not necessary to adjust the printed panel pattern on the paper to the size of the panels made by splitting the panel by adjusting the print cylinder. The formation of vertical grooves can be done with thinner tools because the digitally printed surface layer is usually easy to cut. Panels, such as building panels and floor panels, can also be formed without a decorative surface. The decorative surface and the protective layer can be applied, for example, by digital printing after the lock system has already been formed. This method reduces the cutting surface to a minimum.

Mechanical locking systems can be formed using rotating tools that typically have a diameter of approximately 20 cm or more. Rotary tool combinations are driven by tool-rotating motors, which have a large cost in the total cost of investment in a production line, they are also energy-intensive, have a complex electrical control system, and require intensive maintenance. Rotating tools produce a lot of dust that needs to be removed. The dust contains a mixture of scraped chips and dust. A disadvantage of even advanced dust extraction systems for rotary tool combinations is that dust particles and chips that enter the transport system cause wear and adversely affect the smooth operation of the transport system. All of these problems can be reduced if rotating tools replace cutting tools.

In accordance with embodiments of the invention, it is possible to separate the panels and form a complete locking system with a tongue 10, a tongue groove 9, a strip 6, a locking element 8 and a locking groove 14, as shown in FIG. 8e using only cutting tools. Chamfers or decorative grooves on the top edges can also be created by cutting.

Cutting to final separation may, in accordance with embodiments of the invention, form several parts of the lock system or even the entire lock system. Scraping the top edges with V-cutting tools can produce a very neat and smooth edge.

- 11 039386

It is also possible to form, for example, a locking groove 14 prior to the separation of the panels. The locking groove can, in the next fabrication step, be used to guide the panels into the correct position and this can be used to further reduce the OL overlap and save even more material.

CLAIM

Claims (14)

CLAIM 1. A set of building panels, in which the building panels contain a surface (2) and a core (3) provided with a locking system for vertical and horizontal fixing of the first edge (1) of the first building panel with an adjacent second edge (1') of the second building panel, in which the upper parts of the first and second edges in a fixed position jointly define a vertical plane (VP), perpendicular to the horizontal plane (HP), which is parallel to the surface (2), while said locking system is configured to ensure the assembly of the first and second edges (1, 1 ') rotating the first and second building panels at the desired angle relative to each other; and the locking system comprises a tongue (10) integral with said core (3) and a tongue slot (9) cooperating for vertical locking; wherein the first edge (1) comprises a strip (6) made in one piece with the core and provided with a locking element (8) configured to cooperate for horizontal locking with a locking groove (14) open downwards formed in the second edge (1') ; the tongue (10) provided in the first edge is configured to cooperate with the lower protrusion (9a) of the tongue groove (9) provided in the second edge; the locking element (8) and the locking groove (14) are made with the possibility of interaction on the horizontally locking surfaces (15); the ridge (10) protrudes outside the vertical plane (VP); the groove (9) for the ridge contains the upper ledge (9b); the lower ledge (9a) protrudes beyond the upper ledge (9b) and the vertical plane (VP); the horizontal extension (LE) of the lower lip (9a) relative to the upper lip (9b) is less than the horizontal extension (TE) of the ridge (10) from the vertical plane (VP); and the locking system comprises a gap (S) between the upper part of the strip (6) and the edge portion (EP) of the second edge (1') located substantially below the ridge (10). 2. A building panel set according to claim 1, wherein the cooperating horizontal locking surfaces (15) lock the edges both horizontally and vertically with horizontal (P1) and vertical (P2) pretension. 3. A set of building panels according to claim 1 or 2, in which the tongue (10) and the groove (9) for the tongue contain upper (12) and lower (13) vertical fixing surfaces that are essentially parallel to the horizontal plane (HP) and offset horizontally so that part of the upper vertical locking surfaces (12) is horizontally closer to the locking element (8) than the lower vertical locking surfaces (13). 4. A set of building panels according to claim 3, in which the tongue (10) interacts with the upper ledge (9b) on the upper vertical locking surfaces (12). 5. Building panel set according to any one of the preceding claims 1 to 4, wherein the horizontal extension (TE) of the ridge (10) is at least approximately twice that of the horizontal extension (LE) of the lower protrusion (9a). 6. A set of building panels according to any one of the preceding claims 1 to 5, wherein the tongue (10) and tongue groove (9) comprise guide surfaces (17a, 17b) configured to be in contact with each other during assembly by rotation when the edge portion (EP) of the second edge (1') is in contact with the strip (6) and/or the locking element (8). 7. A set of building panels according to claims 1 to 6, in which the guide surfaces (17a 17b) are inclined relative to the vertical plane (VP) and are located on the upper and/or lower part of the ridge (10) and the groove (9) for the ridge. 8. A set of building panels according to any of the preceding claims 1 to 6, wherein the horizontal locking surfaces are located below the plane (HPS) of the horizontal strip that intersects the top (6a) of the strip (6) located essentially vertically under the outer part of the ridge ( ten). 9. A set of building panels according to any one of the preceding claims 1 to 6, wherein the horizontal fixing surfaces are located both below and above the plane of the horizontal strip that intersects the upper part (6a) of the strip (6) located essentially vertically under the outer part comb (10). 10. A set of building panels according to any of the preceding claims 1-6, in which horizontally 11. A set of building panels according to any one of the preceding claims 1 to 10, wherein the upper vertical locking surfaces are offset horizontally with respect to the horizontal locking surfaces. 12. Construction panels according to any one of the preceding claims 1 to 11, wherein the vertically and horizontally the locking surfaces are offset horizontally by a distance (D) which is greater than the horizontal extension (TE) of the tongue (10). - 12 039386 locking surfaces are located above the plane of the horizontal strip, which crosses the upper part (6a) of the strip (6), located essentially vertically under the outer part of the ridge (10). 13. A set of building panels according to any of the preceding claims 1 to 12, wherein the core comprises HDF, chipboard, plastics or plywood material. 14. A set of building panels according to any of the preceding claims 1 to 13, wherein the horizontal locking surfaces (15) have a locking angle of approximately 40-60° relative to the horizontal plane (HP).