KR102180904B1 - Mechanical locking system for floor panels - Google Patents

Abstract

A floor panel is disclosed having a vertical locking system on a short edge with a displaceable tongue that is displaced in one direction into a tongue groove during vertical displacement of the two panels.

Description

Mechanical locking system for floor panels {MECHANICAL LOCKING SYSTEM FOR FLOOR PANELS}

The present invention relates generally to the field of mechanical locking systems for floor panels and building panels. The present invention discloses a floorboard, a locking system, an installation method and a manufacturing method.

The present invention is formed of a floor panel integral with the floor panel, i.e. mechanically coupled with a factory-mounted locking system, and is formed of one or more top layers of veneers, decorative laminate powder-based surfaces or decorative plastic materials, wood- It is particularly suitable for use on a floating floor consisting of an intermediate core of fiber-based or plastic material and preferably a lower balancing layer on the rear side of the core.

Accordingly, the following description of known techniques, problems of known systems and features of the present invention is a non-limiting example and is, among other things, elongated, intended to be mechanically coupled to each other in this field of application, especially on elongated and short edges. We will aim for a panel formed as a rectangular floor panel with an edge and a short edge.

Long edges and short edges are mainly used to simplify the description of the invention. The panel may also be square. The invention is preferably used on short edges. The present invention may be used on any floor panel, and may be combined with any type of known locking system formed on an elongated edge, wherein the floor panel connects the panels in a horizontal direction and a vertical direction on at least two adjacent sides. It should be emphasized that it is intended to be engaged using a mechanical locking system.

The invention also provides a parquet floor, a printed and preferably also varnished surface, for example with a solid wood floor, a core of wood or wood-fibre based material and a surface of wood or wood veneers, etc. It can also be applied to floors having a surface layer of plastic or cork, linoleum, rubber. Even floors with hard surfaces such as stone, tile and similar materials and floors with a soft wear layer, for example needle felt glued to the board, are included. The invention may also be used for joining building panels preferably comprising board materials, such as for example wall panels, ceilings, furniture components and the like.

Laminate flooring generally comprises a core of 6 to 12 mm fiber board, an upper decorative surface layer of a laminate of 0.2 to 0.8 mm thick, and a lower balancing layer of a material such as laminate, plastic, paper, etc. of 0.1 to 0.6 mm thick. The laminate surface is composed of melamine-impregnated paper. The most common core material is fiberboard with high density and good stability, generally referred to as HDF-high density fiberboard -. Sometimes also MDF-medium density fiberboard-is used as the core.

Traditional laminate floor panels of this type have been joined by glue-bonded tongue-and-groove joints. In addition to these traditional floors, floor panels have been developed that do not require the use of glue and are instead mechanically joined by a so-called mechanical locking system. These systems include locking means for locking the panels horizontally and vertically. Mechanical locking systems are generally formed by machining the core of the panel. Alternatively, the part of the locking system may be formed of a separate material such as aluminum or HDF that is integral with the floor panel, ie in connection with its manufacture.

The main advantage of floating floors with mechanical locking systems is that they are easy to install. These floating floors can also be easily removed again and used once more in different locations.

Definition of some terms

In the text below, the visible surface of the installed floor panel is referred to as "front", while the opposite side of the floor panel facing the sub floor is referred to as "rear". The edge between the front and rear is referred to as "joint edge". By "horizontal plane" is meant a plane extending parallel to the outer portion of the surface layer. The immediately juxtaposed upper portion of the two adjacent joint edges of the two joined together floor panels defines a "vertical plane" perpendicular to the horizontal plane. By "vertical locking" is meant locking parallel to the vertical plane in the D1 direction. By "horizontal locking" is meant locking parallel to the horizontal plane in the D2 direction.

“Upward” means facing the front, “downward” means facing the rear, “inward” means mainly facing the inside and center of the panel horizontally, and “outward” means mainly facing the panel It means horizontally spaced from the center of.

By "locking system" is meant a synergistic connecting element connecting the floor panels vertically and/or horizontally.

For the mechanical coupling of short edges as well as elongated edges in the first horizontal direction perpendicular to the edge and in the vertical direction, a number of methods may be used. One of the most used methods is the angle-snap method. The elongated edge is installed by angling. The panel is then displaced in a locked position along the elongate side. The short edge is locked by a horizontal snap connection. Vertical connections are generally tongues and grooves. During horizontal displacement, the strip with the locking element is bent, and when the edges are in contact, the strip resiliently restores and the locking element enters the locking groove to lock the panels horizontally. This snap connection is complicated because the hammer and tapping block may need to be used to overcome the friction between the elongated edges and bend the strip during the snapping action.

Similar locking systems may also be made with rigid strips, which are connected by an angling-angling method in which both the short edge and the elongate edge are angled to the locking position.

In recent years, new and highly efficient locking systems have been introduced with individual flexible or displaceable integral tongues on short edges that allow installation only by angling action, generally referred to as "vertical folding". Such a system is described in WO 2006/043893 (Vaelinge Innovation AB).

A number of versions are in use on the market as shown in Figures 1A-1F. 1A, 1B show a flexible tongue 30 with a flexible snap tab extending from the edge. 1C, 1D show a displaceable tongue having an inner flexible portion that is horizontally bendable in a cross section of the tongue or along a joint. These systems are referred to as vertical snap systems, and these systems provide automatic locking during the folding action.

The locking system may also be locked by a lateral pressing action such that the displaceable tongue 30 is urged from the elongated lateral edge to the locked position when the adjacent short lateral edge is folded to the bottom. This side pressing action can be difficult to combine with simple angling, and the friction can be too strong for a wide panel.

Figure 1e shows a folding system with a core and a flexible tongue 30 that is manufactured as a single piece. Figure 1f shows an elongated edge locking system of a folding system in connection with angling.

While this system is very efficient, there is still room for improvement. The vertical snap system is designed to have a tongue on the strip panel. The reason is that an inclined sliding surface can only be formed on the folding panel when the upper edge is manufactured without the inclined portion, which is a common case. It is difficult to insert individual tongues 30 during manufacture into grooves 40 over strips 6 comprising locking elements 8. The locking force depends on the snap connection resistance. A high locking force can be achieved by a high snap connection resistance only when the tongue is pressed inward and when snapped back into the tongue groove 40. This creates a separating force that tends to press apart the panels during folding. Locking may lose its strength as the flexibility and pressing force of the tongue decrease over time. Flexibility should be conceivable and should allow the flexible tongue to be displaced 1-2 mm in two directions. The materials used to make these tongues are slightly expensive, and glass fibers are generally used to reinforce flexible tongues.

The main advantage would be if individual tongues could be secured to the folding panel, and if snap connections could be excluded within the system that automatically locks during folding.

The overall object of an embodiment of the present invention is a mainly rectangular floor with elongated and short edges installed in parallel rows, allowing the short edges to be automatically locked to each other without snapping action that creates the locking resistance and separating force of the short edges during folding. It is to provide a locking system for panels. A specific purpose is a locking system with individually displaceable tongues on the folded panel which may be locked without any contact with the sharp upper edge of the strip panel and the tongue is displaced essentially in one direction and outwardly only from the inner part of the groove. Is to provide.

The above objects of the embodiments of the invention are achieved in whole or in part by a locking system and a floor panel according to the independent claims. Embodiments of the invention are apparent from the dependent claims and from the detailed description and drawings.

A first aspect of the present invention is a building panel having a locking system for vertical locking of first and second building panels by vertical displacement of the panels relative to each other. Laterally open tongue grooves are provided at the edge of the first building panel. The strip projects outwardly below the tongue groove and past the upper portion of the edge of the first panel. A displaceable tongue is provided in a displacement groove that opens laterally at the edge of the second building panel. The displaceable tongue is located in the main body extending along the edge of the second panel and preferably in the upper and outer portions of the displaceable tongue and contacts the groove locking surface of the tongue groove for vertical locking of the first and second building panels. And a tongue locking surface configured to cooperate with the groove locking surface. The displaceable tongue includes an inner portion spaced inwardly from an upper portion of the edge of the second panel, the inner portion comprising a tongue pressing surface configured to cooperate with the strip pressing surface on the strip. The displaceable tongue is configured to be displaced into the tongue groove when the tongue pressing surface and the strip pressing surface are displaced perpendicular to each other to obtain vertical locking.

The displaceable tongue is preferably an injection molded tongue.

The displaceable tongue may be asymmetric and include a protrusion, and the second panel may include a cavity for receiving the protrusion.

The protrusion may comprise a flexible portion.

The strip may have a locking element that contacts and cooperates with the downwardly open locking groove formed on the second panel, for locking the first and second building panels in the horizontal direction.

The tongue pressing surface is preferably located on the protrusion, and the strip pressing surface is preferably located on the locking element.

The strip pressing surface is most preferably located on an inclined surface of the locking element directed towards the edge of the first building panel.

The locking system may include a cavity extending from the displacement groove to the locking groove.

The strip pressing surface and tongue pressing surface may be inclined with respect to the horizontal plane at an angle of 25 to 75 degrees.

The displacement groove may be inclined or may include an inner portion extending downward.

The building panels may be vertically locked by two pairs of cooperating surfaces each including a groove locking surface and a tongue locking surface, an upper portion of the strip and a lower portion of the edge of the second panel, and the two pairs of Each pair of cooperative surfaces can contact each other.

The groove locking surface and tongue locking surface may be inclined with respect to the horizontal plane.

The groove locking surface and tongue locking surface may be inclined at an angle of 10 to 60 degrees with respect to the horizontal plane.

The displaceable tongue may have a flexible friction element.

The displaceable tongue may comprise at least two protrusions extending from the main tongue body, and each protrusion may comprise said tongue pressing surface located on an outer portion of the protrusion that contacts a locking element provided on the strip during locking. have.

The building panel may be a floor panel, and the outer part of the displaceable tongue is preferably in an unlocked position located within the displacement groove.

The displaceable groove may extend vertically above the locking groove.

The locking groove may be positioned vertically below the upper portion of the displacement groove.

The upper portion of the locking element may be located below the tongue locking surface of the displaceable tongue.

The upper portion of the locking groove may be located below the tongue locking surface of the displaceable tongue.

The innermost portion of the displaceable tongue may be under the outermost portion of such tongue.

The tongue pressing surface may be located under the tongue locking surface.

The upper part of the locking element may be located in the lower half of the first building panel.

The strip may be flexible to bend downward during locking.

The cavity may be larger than the protrusion so that a space S of at least 1 to 3 mm exists.

The displaceable tongue may be progressively inserted into the tongue groove from a tongue portion adjacent to the installed elongate edge to another tongue portion adjacent to the elongate edge that is free.

The present invention will be described in more detail below in connection with exemplary embodiments with reference to the accompanying exemplary drawings.

1A to 1F show a locking system according to a known technique,
2A-2D illustrate a short edge locking system according to an embodiment of the present invention,
3A to 3D show a short edge locking system according to a preferred embodiment of the present invention,
4a to 4e show a preferred embodiment of a short edge locking system,
5A to 5E show vertical folding of three panels according to an embodiment of the present invention,
6A-6E show a preferred embodiment of a flexible and displaceable tongue of a locking system during locking,
7A-7C are diagrams illustrating a tongue blank according to an embodiment of the present invention comprising a plurality of displaceable tongues.

To facilitate understanding, a number of locking systems in the figures are schematically illustrated. It should be emphasized that improved or different functions may be achieved using a combination of preferred embodiments.

All embodiments may be used individually or in combination. Angles, dimensions, rounded portions, spaces between surfaces, etc. are just examples and may be adjusted within the basic principles of the present invention.

2A-2D show a short edge locking system with a flexible and displaceable tongue 30 in the edge of the second panel 1'that is inserted in the displaceable groove 40 and extends along the edge of the second panel. Shows a first preferred embodiment of the. The displaceable tongue 30 contacts the groove locking surface 21 located in the inner and upper portions of the tongue groove 20 formed in the adjacent edge of the first panel 1 and cooperates with the groove locking surface 21. It has tongue locking surfaces 31 located in the upper and outer parts. The locking surface locks the panels in the first vertical direction. The locking surfaces are preferably inclined to have an angle A2 of 10 to 60 degrees. The displacement groove is preferably also inclined, and the outer portion is closer to the panel surface than the inner portion.

The first panel 1 comprises a protruding strip 6 extending outwardly through a vertical plane VP. The strip comprises a locking element (8). The second panel 1 ′ comprises a locking groove 14 which contacts and cooperates with the locking element 8 and locks the panel in a horizontal direction. The strip 6 has an upper part 6 ′ which contacts the lower part 37 of the adjacent edge and locks the panel in a second vertical direction.

The displaceable tongue 30 comprises a protrusion 34 extending from the main tongue body 36. The first panel 1 ′ includes at least one cavity 35 for receiving the protrusion. The cavity extends from the displacement groove to the locking groove 14. The cavity may be formed by a screw cutter or by a displaceable saw blade. The protrusion comprises a tongue pressing surface 32 that cooperates with a strip pressing surface 33 on the locking element. The strip pressing surface 33 and the tongue pressing surface 32 are inclined at an angle A1 which is preferably 25 to 75 degrees with respect to the horizontal plane HP.

The displaceable tongues are displaced essentially in one direction towards the tongue groove 20 when the inclined pressing surfaces slide relative to each other during the vertical displacement of adjacent edges. The tongue may be locked with a strong pressure against the groove locking surface 21, and the locking element 8 prevents the tongue from sliding back into the displacement groove.

One major problem associated with the "press lock system" as described above is the risk that the panel may be split by a crack 50 between the displacement groove 40 and the locking groove 14 as shown in FIG. 2D. . Thus, the locking groove 14a and the upper part of the locking element 8a preferably have a center line C dividing the floor panel into two identical parts, one upper part UP and one lower part LP. ) Under, it is preferred to be manufactured in the lower part of the floor panel. It is also preferred that the tongue pressing surface 32 is located below the tongue locking surface 31. The tongue pressing surfaces and tongue locking surfaces are preferably vertically offset and are preferably located on different horizontal planes H2, H1. It is also preferred that the upper part of the locking element 8a and/or the upper part of the locking groove 14a is located below the tongue locking surface 31. The innermost part of the displaceable tongue 30 is preferably located below the outermost part of this tongue.

The cavity 35 is preferably formed by a rotating saw blade and preferably comprises an upper rounded portion having an outer portion 35b located above the inner portion 35a, as shown in FIG. 2D. The cavity is preferably formed so as to intersect the inner part 14b of the locking groove 14.

3A to 3D show the locking function during vertical displacement of the second panel 1 ′ relative to the first panel 1. The displaceable tongue 30 is gradually pressed into the tongue groove 20 by the cooperating pressing surfaces 32, 33, and the panels are two pairs of cooperating locking surfaces, the tongue locking surfaces 31 and the groove locking surfaces. It is vertically locked by 21 and the upper part 6'of the strip 6 and the lower part 37 of the adjacent edge 1'.

4A-4E show different embodiments. Figure 4a shows a displaceable tongue 30 with a protrusion 34 located below the main tongue body. The locking groove 14 is located vertically below the upper portion of the displacement groove 40. Fig. 4b shows the tongue pressing surface 32 which locks against the strip pressing surface which does not activate during horizontal locking. Figure 4c shows that the same locking surface 33 on the locking element 8 may be used as a locking surface for horizontal locking and as a pressing surface. 4D shows that a strip pressing surface may be formed on an individual pressing rod 42. 4E shows a locking element comprising a protrusion 34 comprising a curved cross section and an upper portion 44 formed as a localized protrusion protruding into the cavity 35 and over the inner portion of the locking groove 14.

5A-5E show that the elongated edges 2, 2'are connected by angling, and the short edges 1, 1'are of three panels connected by a scissor-like motion combining angling and vertical displacement. Vertical folding is shown. Fig. 5b shows that the displaceable tongue is gradually inserted into the tongue groove 20 from one part of the edge adjacent the elongated edge 2 to the other free elongated edge. Figure 5c shows the tongue in cross-sections A-A, and Figures 5d, 5e show the tongue position in cross-sections B-B and C-C. The strip 6 and the locking element 8 are designed in this embodiment so that they bend backwards during locking, which facilitates locking because the required flexibility may be provided partially or completely by such strip bending. The locking groove is located vertically below the lower portion of the displacement groove 40.

6A shows that the locking system may be formed so that a number of parts, for example the protrusion 34, the locking strip 6 and the locking element 8, are flexible. This flexibility may be used to reduce or eliminate manufacturing tolerances and to facilitate easy and strong locking. Figure 6a shows that the strip 6 may be bent downward, and the locking element 8 may be curved downward and outward. Such strip flexion may facilitate locking, which may be achieved with a displaceable tongue that includes limited flexibility, such as a tongue that essentially includes wood fiber material. Locking may be achieved by the flexibility in which the part of the displaceable tongue 30 is slightly bent or compressed, for example only 0.1 to 1.0 mm in the horizontal direction.

6B and 6C show an embodiment of a tongue. The displaceable tongue 30 may be fixed in the displaceable groove by means of a friction connection 38. The protrusion 34 may include a flexible portion 39 that creates a pre-tension for the tongue groove 20. The cavity 35 may be significantly larger than the protrusion, and there is a space S, which may preferably be 1 to 3 mm.

6D shows a locking system with a running surface 45 protruding past a vertical plane VP. The tongue groove 20 is preferably formed on the inclined edge surface 46. This embodiment provides the advantage that the displaceable tongue 30 may be pressed inward, and a conventional two-way snap connection action may be combined with a one-way pressing motion that may be used to create the final locking.

FIG. 6E shows a second panel comprising an upwardly extending snap tab 47 that cooperates with a downwardly extending running surface 45 located on the first panel 1 and protrudes beyond the upper edge and vertical plane VP. The individual tongue 30 is shown located in the laterally open groove 40 on 1'). The second panel 1 ′ preferably comprises an inclined edge surface 46 ′ located above and/or below the tongue 30. An easy snap connection may also be obtained by a panel with straight and sharp top adjacent edges. The snap tab may be replaced with a displaceable tongue comprising a flexible snap connection protrusion along its length. The locking system shown in FIG. 1D may also be adjusted to include an inclined edge surface, and this design may be used to increase the strength of the joint.

The locking system according to the invention may also be formed without locking grooves 14 and locking elements 8 only to lock the edges in the vertical direction. The locking element 8 may also be replaced by a localized projection in a locked position extending upward from the strip 6 and located in the cavity. Short edges may be locked horizontally by friction between the elongated edges.

All locking systems can be designed such that they can be unlocked by angling and/or sliding along the edge.

7A, 7B show a tongue blank 43 comprising a number of displaceable tongues, which are preferably asymmetrical along the length of the tongue. 7A shows an injection molded tongue 30, and FIG. 7B shows a displaceable tongue 30 made of a wood-based material that is preferably machined and punched.

Preferably, the cavity 35 formed by the rotating saw blade includes a rounded upper portion, and may include an inner portion positioned below the outer portion. The locking system may be formed partially or completely by means of a carving tool.

Claims (28)

A locking system for vertical locking of the first building panel 1 and the second building panel 1'is provided by vertical displacement of the first building panel 1 and the second building panel 1'with respect to each other. As architectural panels,
Laterally open tongue groove 20 provided at the edge of the first building panel 1 and below the tongue groove 20 and past the upper part of the edge of the first building panel 1 A strip 6 protruding outward; And
And a displaceable tongue 30 provided in a displacement groove 40 that is laterally opened at an edge of the second building panel,
The strip 6 is configured to cooperate with a downwardly open locking groove 14 formed on the second building panel for locking the first and second building panels 1, 1'in the horizontal direction. Contains element (8),
The displaceable tongue 30 includes a main body extending along an edge of the second building panel, and a tongue locking surface 31 located at the upper and outer portions of the tongue, and the tongue locking surface Is configured to cooperate with the groove locking surface 21 of the tongue groove 20 for vertical locking by contacting the groove locking surface 21 of the tongue groove 20,
The displaceable tongue comprises an inner portion 34 spaced inwardly from an upper portion of the edge of the second building panel 1'
The inner part comprises a tongue pressing surface 32 configured to cooperate with the strip pressing surface 33 on the strip 6, thereby preventing locking of the first and second building panels 1, 1' To obtain, when the tongue pressing surface 32 and the strip pressing surface 33 are displaced perpendicular to each other, the displaceable tongue 30 is displaced into the tongue groove,
The locking surface 33 on the locking element 8 is a locking surface and a pressing surface for horizontal locking,
Architectural panels.
The method of claim 1,
The displaceable tongue 30 is asymmetric and includes a protrusion 34, and the second panel 1 ′ includes a cavity 35 for receiving the protrusion,
Architectural panels.
The method of claim 2,
The protrusion 34 comprises a flexible portion 39,
Architectural panels.
The method according to claim 2 or 3,
The tongue pressing surface 32 is provided on the protrusion 34, and the strip pressing surface 33 is provided on the locking element 8,
Architectural panels.
The method of claim 4,
The strip pressing surface 33 is provided on an inclined surface of the locking element 8 directed towards the first edge,
Architectural panels.
The method according to any one of claims 1 to 3,
The strip pressing surface (33) is provided in the upper part of the locking element (8),
Architectural panels.
The method according to claim 2 or 3,
The cavity 35 extends from the displacement groove 40 to the locking groove 14,
Architectural panels.
The method according to any one of claims 1 to 3,
The displacement groove 40 extends vertically above the locking groove 14,
Architectural panels.
The method according to any one of claims 1 to 3,
The upper part (8a) of the locking element (8) is located below the tongue locking surface (31) of the displaceable tongue (30),
Architectural panels.
The method according to any one of claims 1 to 3,
The uppermost portion of the locking element is located in the lower half of the first building panel,
Architectural panels.
The method according to any one of claims 1 to 3,
The first and second building panels (1, 1') are vertically locked by the first and second pair of cooperating surfaces,
The cooperating surfaces of each pair of the first and second pair are in contact with each other,
The first pair comprises a tongue locking surface 31 and a groove locking surface 21, and the second pair is the upper part 6'of the strip 6'and the edge of the second panel 1'. Including the lower part of (37),
Architectural panels.
The method according to any one of claims 1 to 3,
The groove locking surface 21 and the tongue locking surface 31 are inclined with respect to the horizontal plane,
Architectural panels.
The method according to any one of claims 1 to 3,
The displaceable tongue 30 includes at least two protrusions 34 extending from the main body 36, each protrusion including the tongue pressing surface 32 on an outer portion of the protrusion, and each The tongue pressing surface is configured to contact a locking element provided on the strip during locking,
Architectural panels.
The method according to any one of claims 1 to 3,
The tongue pressing surface 32 is located under the tongue locking surface 31,
Architectural panels.
The method according to any one of claims 1 to 3,
The displaceable tongue 30 is configured to be progressively inserted into the tongue groove 20 from a tongue portion adjacent to the installed elongate edge 2 to another tongue portion adjacent to the elongated edge free from,
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