EP2318614B1 - Plastic panel having a hook-type profile - Google Patents

Description

The invention relates to a floor panel according to the preamble of claim 1,

The generic floor panel is formed as a multilayer laminate and is for example from the DE 10 2006 058 655 A1 known. It can be considered in particular as a replacement for conventional floor panels with retaining profiles in which the core consists of a wood material such as MDF or HDF, which is covered with a decorative layer and a wear layer, the retaining profiles ensure at the side edges of the panel that the panel can be laid without glue and are held in the assembled state to each other such that there is a gap-free floor surface. The generic floor panel has the advantage that the plastic core or carrier already provides a comparatively effective impact sound, without in any case an additional impact sound damping layer on the underside of the panel must be arranged.

That in the DE 10 2006 058 655 A1 described panel comprises on two opposite side edges arranged retaining profiles in the form of an undercut and thus lockable tongue and groove profile, To ensure a high level of security of maintaining the lock laid panels are usually so large undercuts necessary that a single, horizontal joining movement of the panels to each other in the laying plane can not be performed for locking such panels. A so-called snap-laying, in which the panels are locked by means of a purely horizontal joining movement, is not possible. Instead, today such panels with undercut groove-tongue profile are locked so that a panel to be laid first added in an inclined position relative to a lying panel to the lying panel and subsequently in the plane of the lying down panel, whereby the tongue and groove connection is made and locked at the same time. If both pairs of opposite side edges are provided with such retaining profiles in the form of an undercut groove-and-tongue profile, they are very accurate to guide when assembling and locking the panels, otherwise they tilt.

Such a floor panel comprises a plastic support, for example made of PVC, polyolefin or polyurethane, which, depending on the specific embodiment, are comparatively elastic and flexible, at least in relation to the panels with a wood chip core. As a result, often results in the installation of such floor panels the problem that the panel deformed due to the external forces and tilt the complementary profiles, so that the joining of the panels is at least difficult. The publication US 2004/0128934 A1 describes a multilayer floor panel made of a NDF or HDF material with a decorative layer on which a cover layer is mounted, it being understood that the panel may be wholly or partly formed of a plastic material. The panel described has pairwise opposite side edges, each with complementary formed retaining profiles, wherein the retaining profiles of one of the two side edge pairs are designed as a form-fitting complementary hook profiles. In this case, a hook profile comprises a receiving hook, which faces the upper side of the floor panel, and the complementary hook profile has a locking hook arranged on the opposite side edge, which faces the underside of the floor panel, wherein the locking hook has a latching element on a distal side surface, which has a complementary latching element is associated with a proximal side surface of the hook profile having the receiving hook. The US 2005/0050827 A1 relates to a laminate panel consisting of wood, wood material, plastic or plastic materials, wherein a decorative layer is provided, which may be covered with a transparent layer. An embodiment is described in which complementary formed holding profiles are included, wherein a holding profile has a downwardly facing coupling element that in the joining movement form-fitting manner with a corresponding recess in a lower edge of the complementary retaining profile is engaged.

The invention has the object to further develop a generic floor panel such that it is easy to install, but at the same time a gap-free floor surface can be maintained.

In a surprisingly simple manner, this object is achieved by a floor panel, which is formed as a multilayer laminate with at least one plastic carrier, a decorative layer attached to the top of the plastic carrier, a transparent covering layer applied to the decorative layer and optionally a counteracting layer attached to the underside of the plastic carrier, wherein the panel comprises pairs of opposite side edges, each with complementary formed holding profiles.
If the plastic carrier of the panel according to the invention has at least one layer on the underside, for example a counteracting layer to avoid buckling of the panel due to layers on the top of the carrier, the plastic carrier acts as a plastic core, which acts on carries at least one more layer on both major surfaces.

The retaining profiles of at least one of the two side edge pairs are designed as positively acting complementary hook profiles, namely with a receiving hook, which faces an upper side of the floor panel, as well as with a arranged on the opposite side edge locking hook, which faces the underside of the floor panel, wherein the locking hook at a distal rare surface has a locking element which is associated with a complementary locking element on a side surface of the receiving hook having hook profile.

The floor panel according to the invention is characterized in that the receiving hook on a distal side surface has an inclined to the panel surface bearing and guide surface, which in producing a positive connection between the complementary hook profiles for guiding the panel with a complementary abutment and guide surface on a proximal side surface of the locking hook having hook profile cooperates.

Due to the design of the panels according to the invention it is achieved that they can be joined and locked at least on the side edge, which is formed with a hook profile, by a substantially vertical to the laying plane joining movement with the complementary hook profile, which greatly facilitates the installation. Characterized in that the locking hook itself is latched to a proximal side surface of the adjacent panel, a bulge of the locking hook can be avoided in the installed state, so that when laying a plane even on the connecting edges of adjacent panels panel surface results. To make the joining process even easier, the receiving hook on its distal side surface on the panel surface obliquely extending guide surface, which serves as abutment and sliding surface during the joining movement for establishing the positive connection between the complementary hook profile with the complementary guide surface on a proximal Side surface of the locking hook profile cooperates to guide the panels. In this design of the panels comes in the joining movement, the distal contact surface on the receiving hook only with the complementary contact surface in contact, which facilitates the entire joining process.
The floor panel according to the invention can be produced by means of a thermal lamination process. In a particular embodiment, however, it is also possible that, starting from the plastic carrier, the individual layers are applied in the manner of a paint spread. Depending on the embodiment of the invention, the thickness of the floor panels according to the invention is 3-10 mm, preferably 4-8 mm, particularly preferably 5-6 mm. Depending on the specific structure, the basis weight of the panels is between 1 and 2.5 kg per m ² per mm thickness, preferably between 1.6 and 1.8 kg per m ² per mm thickness.

The floor panel according to the invention can be produced, on the one hand, by applying the various layers to form a laminate panel, which subsequently saws to form a single panel main body becomes. In a subsequent step, the respective holding profiles are then machined on the side edges of the panel base body. Since the decorative layer and the cover layer have a very small thickness compared to the plastic carrier, together they are usually less than a tenth or even less than one fiftieth of the thickness of the plastic carrier, the locking hook is essentially formed by the material of the plastic core. If the floor panel according to the invention has no further layer on the underside of the plastic carrier, such as a counteracting layer, the receiving hook of the corresponding holding profile is completely formed by the material of the plastic carrier.

Appropriately, the receiving hook on a distal side surface on a locking element which is associated with a complementary locking element on a proximal side surface of the locking hook having hook profile. As a result, the hook profiles are latched both distally and proximally.

The specified locking elements, which are each arranged complementary to the distal side surfaces of the hooks or the proximal side surfaces of the profiles, may be formed, for example, as a latching projection or as a latching projection receiving latching pocket. In addition, however, all other known to those skilled locking elements are possible, which can ensure a snap action for the hook profiles.

Expediently, both the receiving hook and the locking hook each have an undercut surface, which act as a mutual guide surface during the joining movement for producing the positive connection between the hook profiles, wherein both undercut surfaces extend at an acute angle to the vertical of the panel surface. By this design measure simplifies the joining and locking process, since investment and sliding surfaces are provided.
It is particularly advantageous that in the joining movement, the distal contact surface on the receiving hook only comes into contact with the complementary proximal contact surface on the locking hook before the above-described undercut surfaces cooperate so that the interaction of the guide surfaces on the distal side surface of the receiving hook or on the proximal side surface of the Arretierhakenprofils a pre-adjustment of the panels to be joined before the above undercut surfaces on the receiving hook or on the locking hook interact with each other.

The floor panel of the invention may conveniently be used on all four side edges, i. each have holding profiles in the form of hook profiles on both side edge pairs, so that the floor panel according to the invention is joined and locked by a substantially planar and vertical to the laying plane extending joining movement of the panel.

In addition, according to the invention can also be provided on one of the two side edge pairs, in particular on the long side edge pair an undercut tongue and groove profile is provided, while the retaining profile has complementary hook profiles on the short side edge pair.

The panels according to the invention can be expediently laid so that a new panel on one side edge with an already lying in the laying plane

Panel is locked at its side edge with complementary to the new panel formed retaining profile, wherein the new panel is placed on the said side edge with the retaining profile, which has a locking hook on a receiving hook exhibiting holding profile of the side edge of the already lying panel, so that one on the receiving hook the already lying panel on a distal side surface to the panel surface obliquely extending guide surface comes with a complementary guide surface on a proximal side surface of the hook profile of the new panel and beyond the locking hook rests on the receiving hook, subsequently the new panel with its said guide surface on the proximal Side surface along the guide surface on the distal side surface of the receiving hook is moved obliquely to the panel surface, whereby the locking hook is pivoted out of the laying plane, so that an undercut ungsfläche the locking hook in contact device with an undercut surface on the receiving hook.

In this case, the new panel can be moved obliquely relative to the already lying panel by applying a substantially vertical force on the panel surface in the region of the holding profile along its guide surface, whereby the panels are forced towards each other.

In order to lock adjacent panels together, it can be provided that a force is applied approximately perpendicular to the panel surface on the locking hook, so that a locking element on a distal side surface of the locking hook of the new panel with a complementary locking element on a proximal side surface of the receiving profile of the already lying panel cooperates latching, such that the pivoted out of the laying plane out locking hook is pivoted back into the laying plane and locked. In this example, by means of a pressure roller, a vertical force is generated on the locking hook.

Figur 1

in einer Aufsicht ein Fußbodenpaneel 1 mit Blick auf die Oberseite;

Figuren 2 a, b

Teilschnittdarstellungen mit zwei komplementären Hakenprofilen;

Figur 3a, b

jeweils eine Teilschnittdarstellung mit zwei komplementären Hakenprofilen während des Fügevorganges in unterschiedlichen Fügesituationen; und

Figur 4

den beispielhaften Schichtaufbau eines erfindungsgemäßen Fußbodenpaneels

zeigt.The invention will be explained in the following by describing preferred embodiments with reference to the accompanying drawings, wherein

FIG. 1

in a plan a floor panel 1 overlooking the top;

FIGS. 2 a, b

Partial sectional views with two complementary hook profiles;

FIG. 3a, b

in each case a partial sectional view with two complementary hook profiles during the joining process in different joining situations; and

FIG. 4

the exemplary layer structure of a floor panel according to the invention

shows.

The described floor panels according to the invention have a tabular, rectangular basic shape, see Fig. 1 , wherein pairwise opposite side edges 3,4 and 5, 6 are formed in each case with complementary formed holding profiles, which simplify the illustration in FIG Fig. 1 are not specified. The side edges are provided for connecting a plurality of similar floor panels 1.

Fig. 2a shows a schematic partial section of a panel, in which substantially the locking hook having hook profile is shown, which faces the bottom 7 of the panel. The locking hook 10 has a web 10a which extends away from the panel body, wherein at the outer end of the web, a hook projection 10b is arranged, which extends downwardly towards the bottom 7 of the panel. The locking hook 10 has a distal side surface 11, ie a surface of the hook profile, which is arranged away from the panel body. Further, a proximal side surface 15 of the hook profile having the locking hook is indicated, ie a side surface of the hook profile, which is arranged close to the panel body. At the perpendicular to the panel surface and parallel to the side edge extending distal side surface 11 are two locking projections 12, 13th arranged between which a latching pocket 14 is seated. The inner undercut surface 10c of the locking hook 10 extends at an acute angle of a few degrees to the vertical of the panel surface.

The proximal side surface 15 of the hook profile has a guide surface 16 that also extends obliquely to the panel surface at an angle.

Fig. 2b shows the to the in Fig. 2a shown side edge opposite side edge with the complementary hook profile, which has the receiving hooks 9, which faces the top 2 of the panel. This also has on its distal side surface a latching projection 18 and a guide surface 19, which extends at an angle obliquely to the panel surface. Also, the receiving hook 9 has a web 9a and a hook projection 9b, which extends in the direction of the top 2 of the panel. At the in Fig. 2b shown hook profile with the receiving hook 9, the proximal side surface 20 of the profile has a latching projection 21 and two latching pockets 22, 23.

The in the FIGS. 2a, 2b shown complementary hook profiles are used to produce a positive locking state of two adjacent panels, which hereinafter with reference to Fig. 3a, b is explained. These put those in the FIGS. 2a, b In contrast, the respective receiving profile, ie the profile with the receiving hook is shown only in a joining position in order to preserve the clarity of the representation.

The starting point for the assembly of the panels or profiles is the in Fig. 3a shown situation in which the right panel, of which the receiving profile is shown, is already in the laying plane. Now, the new panel to be laid, ie the left shown in the partial section with a locking hook panel is placed with the hook profile on the hook profile of the already lying panel. This results in a situation in which the locking hook of the left panel in one position which corresponds to the hook, which in Fig. 2a designated by the reference numeral 10 and shown. As can be seen, the end face 10d of the hook projection 10b rests on the end face 9d of the hook projection 9b. The two superimposed holding profiles are simultaneously arranged and formed so that the guide surface 19 has just come into contact with the guide surface 16 on the proximal side surface of the locking hook holding profile in this joining situation on the distal side surface of the receiving hook. Like from the FIG. 3a shows, the two panels are parallel to each other, but offset with the distance h1 arranged.

In the next step of laying the new panel, ie in the FIG. 3a left panel along the surface 19 of the receiving hook moves, ie both in the horizontal and in the vertical direction to the panel surface. As a result, the locking hook 10 must escape upwards, which is caused by the elastic properties of the plastic material of the carrier. As a result of the described joining movement, the two panels to be locked are moved toward one another along their adjacent side edges. In the FIG. 2a a joint 10 'of the locking hook is shown. As already explained above, the second joining position of the already lying, ie the right panel in Fig. 3a not indicated for clarity of presentation. Instead, be up in this regard Fig. 3b Reference is made, in which again two joining positions 10 ', 10 "of the locking hook during the joining process, but only one joining position for the receiving hook of the already installed panel is shown Fig. 3a shown joining situation in which the locking hook assumes the position which is indicated by the reference numeral 10 '. As in Fig. 3b can be seen, arrive at this time just the undercut surface 9c of the receiving hook and the undercut surface 10c of the locking hook in contact. In this joining situation, the degree of mutual engagement of the complementary guide surfaces has increased 16/19 compared to the above starting situation, with the result that the horizontal distance h2 of the two panels to be joined to h1 is reduced.

Subsequently, the left panel is further moved vertically and obliquely, ie along the guide surface 19 of the already lying panel, so that a joining situation results for the locking hook, which is indicated by the reference numeral 10 "As can be seen, the joining process is already almost completed here When the joining movement is continued, a complete reception of the respective latching projections 12, 13 in the relevant latching pockets 22, 23 or of the latching projection 18 on the receiving hook in the latching pocket 24, which is arranged on the proximal side surface 16 of the hook profile, takes place includes, see Fig. 2a , Thus, the desired gap-free locking state of the adjacent side edges with complementary hook profiles adjacent panels is achieved.

To ensure that the joining and locking process is completed and accordingly the locking projections 12, 13, 18, 21 are engaged in their associated latching pockets, it may be advantageous if in accordance with the joining situation 3b (Arretierhaken 10 "and / or 10 ') with a rolling device in the manner of a wallpaper roller pressure from the top 2 of the panel on the locking hook 10', 10" is applied so that the latching action is supported.

The design according to the invention of the complementary hook profiles on two associated side edges of the panel allows, as described, a simple joining and locking of the panel by utilizing a present elasticity, which can be provided essentially by the elastic support of the panels. After completion of the joining and locking operation, the panels are connected to one another in a form-fitting manner both vertically on the panel surface and perpendicularly to their adjacent side edges.

Depending on the embodiment of the invention, the holding profiles of a side edge pair as shown in the Figures 2 . 3 be formed specified or both side edge pairs. In the first case, the second side edge pair may be formed, for example, with respect to its holding profiles as an undercut tongue and groove profile. Since in this profile a joining and locking by obliquely applying a new Floor panel is done with its side edge to a side edge of a lying floor panel and subsequent pivoting down of the new floor panel in the plane of the already lying floor panel, at the other two, opposite side edges, which in the FIGS. 2a, b and 3a, b specified hook profiles are arranged to be automatically mitverriegelt, since they essentially require a vertical joining movement. As a result, the hook profiles are then locked in the manner of a zipper, ie the locking is not done simultaneously over the entire side edge, but the joining and locking takes place at one end of the edge and then takes place gradually over the entire edge length to the other end.

However, both side edge pairs with the in the FIGS. 2a, b and 3a, b provided hook profiles shown, the installation is carried out differently from the above. In this case, the new panel can be aligned in parallel, but horizontally spaced from the laying plane, then the locking hook profile as in Fig. 3a (Arretierhaken 10) shown placed on the receiving profile over the entire respective side edge and thereafter, as already described, performed the joining and locking movement, in which in particular the surfaces 19 are moved to the receiving hook profile and the surface 16 on the locking hook to each other. The actual locking can also be carried out here in the manner of a zipper method.

Are both side edge pairs with the in the FIGS. 2a, b and 3a, b provided hook profiles provided, the new panel can initially also be aligned non-parallel to the laying plane, and thus placed obliquely with its locking hook on the receiving profile of the lying panel and then the described joining and locking movement are performed, in which in particular the surface 19 on the receiving hook profile and the Surface 16 are moved to each other on the locking hook profile. Also in this method, the joining and locking does not take place simultaneously over the entire respective side edge, but is carried out in the manner of a zipper method.

Fig. 4 The supporting element is a plastic carrier 30 which carries a decorative layer 31, for example in the form of a printed film, on which is a cover layer 32, for example in the form of a further film or a lacquer. On the underside of the plastic carrier 30 a Gegenzugsschicht 33 is provided to ensure a flatness of the floor panel according to the invention. Depending on the décor, the decorative layer can be a picture of a stone decor, a wood decor or an abstract pattern. In order to ensure a longevity of the floor panel, the cover layer usually has a high abrasion resistance by the admixture of abrasive substances. In the described embodiment, the thickness of the plastic core is 2.8 mm, that of the decorative layer and the cover layer together about 0.2 mm, and that of the Gegenzugschicht also 1 mm.

In one embodiment, not shown, it may also be provided that a damping layer, in particular a footfall sound damping layer, is arranged on the underside of the plastic carrier 30 in addition to the counteracting layer. Under certain circumstances, a single layer can also take on both functions.

LIST OF REFERENCE NUMBERS

1,

paneling

2,

Top of the panel

3, 4

Short side edge pair

5, 6

Long side edge pair

7

Bottom of the panel

9

receiving hook

9a

web

9b

hook projection

9c

Undercut surface of the pickup hook

9d

End face of the hook projection

10, 10 ', 10 "

locking hook

10a

web

10b

hook projection

10c

Undercut surface of the locking hook

10d

End face of the hook projection

11

distal side surface of the locking hook

12, 13

Detent projection of the locking hook

14

Latching pocket of the locking hook

15

proximal side surface of the locking hook profile

16

guide surface

17

distal side surface of the receiving hook

18

catch projection

19

guide surface

20

proximal side surface of the receiving hook profile

21

catch projection

22, 23

Rest case

24

Rest case

30

Plastic carrier / plastic core

31

decorative layer

32

topcoat

33

counteracting

Claims (17)

1. Floor panel (1) which is designed as a multi-ply laminate and comprises at least one plastic support (30), a décor layer (31) applied to a top face of the plastic support, a transparent covering layer (32) applied to the décor layer and possibly a backing layer (33) applied to the lower face of the plastic support, the panel having pairs of lateral edges (3, 4; 5, 6) comprising respective complementary holding profiles, wherein that the holding profiles of at least one of the two lateral edge pairs are designed as form-locking complementary hook-type profiles and comprise a receiving hook (9) which faces the top face (2) of the floor panel, and a locking hook (10), arranged on the opposite lateral edge, which faces the lower face (7) of the floor panel, the locking hook (10) comprising a snap-in element (12, 13, 14) on a distal lateral face (11), said snap-in element being associated with a complementary snap-in element (22, 23, 21) on a proximal lateral face (20) of the hook profile having the receiving hook, characterized in that on a distal lateral face (17) said receiving hook includes a contact and guide surface (19) that extends in an inclined fashion with respect to the panel surface and that co-acts with a complementary contact and guide surface on a proximal side face (11) of the hook-type profile having the locking hook, for guiding the panel during the establishment of the form closure between the complementary hook profiles.
2. Floor panel according to claim 1, characterized in that the receiving hook (9) comprises on a distal lateral face (17) a locking element (18) that is associated with a complementary locking element (24) on a proximal lateral face (15) of the hook-type profile having the locking hook.
3. Floor panel according to claim 1 or 2, characterized in that the complementary locking elements on the lateral faces of the hook-type profiles are designed as locking protrusion (12, 13, 18, 21) or as a locking pocket (22, 23, 24, 14) receiving said locking protrusion.
4. Floor panel according to one of the claims 1, 2 or 3, characterized in that both the receiving hook (9) and the locking hook (10) each comprise an undercut surface (9c, 10c) effective as a mutual contact and guide surface during the establishment of the form closure between the hook-type profiles, wherein both undercut surfaces extend at an acute angle with respect to the vertical of the panel surface.
5. Floor panel according to one of the claims 1 to 4, characterized in that on the distal lateral face (17) of the receiving hook a locking protrusion (18) is formed and is associated with a locking pocket (24) for the receiving the locking protrusion on the proximal lateral face (15) of the hook-type profile having the locking hook.
6. Floor panel according to one of the claims 1 to 5, characterized in that both pairs of complementary holding profiles are designed as complementary hook-type profiles acting in a form-fit fashion.
7. Floor panel according to one of the claims 1 to 5, characterized in that one of the two holding profile pairs is designed as a complementary undercut groove-and-tongue profile acting in a form-fit fashion.
8. Floor panel according to one of the claims 1 to 7, characterized in that the décor layer (31) comprises a printed décor film.
9. Floor panel according to one of the claims 1 to 7, characterized in that the décor layer (31) is directly printed on the plastic support (30).
10. Floor panel according to claim 9, characterized in that prior to printing, the plastic support (30) is provided with an intermediate layer in the form of a lacquer or primer.
11. Floor panel according to one of the claims 1 to 10, characterized in that the transparent covering layer (32) comprises two partial layers in the form of one layer having a high abrasion resistance and one lacquer layer that forms the front surface of the panel.
12. Floor panel according to one of the claims 1 to 11, characterized in that the covering layer (32) comprises a single, substantially homogenous layer of high abrasion resistance.
13. Floor panel according to one of the claims 1 to 12, characterized in that the backing layer (33) comprises a lacquer layer and/or a plastic film.
14. Process of installing and locking floor panels according to one of the claims 1 to 13, wherein a new panel is locked at one lateral edge thereof to an already installed panel in the installation plane at the lateral edge thereof that has a holding profile complementary to the new panel, wherein the new panel at said lateral edge that comprises its holding profile having a locking hock (10) is placed onto the holding profile having a receiving hook (9) of the lateral edge of the already installed panel, so that a guide surface (19) on the receiving hook of the already installed panel which extends in an inclined fashion with respect to the panel surface (2) on a distal lateral face (17) comes into contact with a complementary guide surface (16) on a proximal lateral face (15) of the hook profile of the new panel, and the locking hook (10) is supported, moreover, on the receiving hook (9) and thereafter the new panel displaced in an inclined fashion with respect to the panel surface with said guide surface (16) on the proximal lateral face along the guide surface (19) on the distal lateral face of the receiving hook, whereby the locking hook (10) is pivoted out of the installation plane so that an undercut surface (10c) on the locking hook (10') comes into contact with an undercut surface (9c) on the receiving hook (9).
15. Process according to claim 14, characterized in that, by applying a substantially vertical force on the surface of the new panel, the same is displaced in an inclined fashion relative to the already installed panel along its guide surface (16) in the region of the holding profile.
16. Process according to claim 14 or 15, characterized in that a force is applied on the locking hook (10', 10") approximately vertically to the panel surface, so that a snap-in element (12, 13, 14) on a distal lateral face of the locking hook of the new panel co-acts in an interlocking fashion with a complementary snap-in element (22, 23, 22) on a proximal lateral face (20) of the receiving profile of the already installed panel in such a manner that the locking hook that has been pivotally moved out of the installation plane is pivoted back to and locked in the installation plane.
17. Process according to one of the claims 14 to 16, characterized in that the step of applying a vertical force on the locking hook is performed using a pressure roller.

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