SE519791C2 - System for forming a joint between two floorboards, floorboards therefore provided with sealing means at the joint edges and ways of manufacturing a core which is processed into floorboards - Google Patents

Abstract

In a floor panel comprising a core (30), a surface layer (31) and, at opposite joint edge portions, connecting means for joining the floor panel with similar floor panels in the vertical direction, it is foreseen that at least one of said opposite joint edge portions is provided with a joint seal means (55a,55b) for counteracting penetration of moisture, this joint seal means being made of parts of the floor panel portions located above said connecting means, being made of an elastic sealing material that is secured in the floor panel, being made by machining in connection with the forming of said connecting means and being adapted to be elastically compressed when the floor panel is joined with a similar floor panel.

Description

b: U'1 519 791 2 is mechanically joined on both long and short sides. It should be pointed out, however, that the invention can be used in optional floorboards with optional joint systems where the floorboards have a core and are assigned their final shape by cutting machining. The invention can thus also be applied to homogeneous wooden floors and wooden floors, which have two or more layers of wood or wood fiber-based material and a decorative surface layer of wood. The invention mainly deals with problem areas which are related to moisture penetrating into the joint system from the front of the floorboard. The systems and methods indicated for solving these moisture problems are also applicable when it comes to preventing moisture from penetrating into the joint system from the back of a floorboard.

Background of the invention Laminate flooring generally consists of a core of a 6-9 mm thick wood fiber board, a 0.2-0.8 mm thick upper decorative surface layer of laminate and a 0.1-0.6 mm thick lower balance layer of laminate , plastic, paper and the like. The surface layer creates the appearance and durability of the floorboards.

The core provides stability, and the balance layer pours the disc flat, when the relative humidity (RH) varies over the scar. RH can vary between 15% in winter and 90% in summer. The floorboards are laid floating, ie. without gluing, on an existing subfloor that does not have to be completely smooth or flat. Any irregularities are eliminated with the help of base material in the form of, for example, cardboard or foam that is laid between the floorboards and the subfloor.

Traditional hard floorboards in floating floors of this type are usually joined by means of glued tongue / groove joints (ie joints with a tongue on a floorboard and a tongue groove on adjacent floorboards) on the long and short sides. During installation, the discs are brought together horizontally, whereby a projecting tongue along the joint edge of a disc is inserted into a tongue groove out AJ Å fi af ~ viiv ~~ fl ßd ^ fl- J ~ f ~ åï ^ f ~ fav ~ lCLl C11 GJLBLQLLDQJJ. C DIXLVGD 'I - \ - \ A A21 LKJEjD- fl llt. SGJlll Q lCtkJbl. used on both long and short side. 10 15 20 25 30 U.) UI 519 791 3 In addition to such traditional floors, which are joined together by means of glued tongue / tongue rail joints, floorboards have later been developed which do not require the use of glue but are instead joined together mechanically by means of so-called mechanical joint systems. These systems contain the locking means that read the discs horizontally and vertically. The mechanical joint systems can be formed by machining the core of the board. Alternatively, parts of the reading system can be formed from a separate material that is integrated with the floorboard, ie joined to the floorboard already in connection with the manufacture of this.

The main advantages of floating floors with mechanical joint systems are that they can be laid easily and quickly through various combinations of angling and snapping. They can also be easily picked up again and reused elsewhere.

An additional advantage of the mechanical joint systems is that the edge portions of the floorboards can be designed in materials that do not have to have good gluing properties. The most common core material is in parquet flooring wood and in laminate flooring wood fiber board with high density and good stability, commonly referred to as HDF - High density fiberboard. Sometimes MDF - medium density fiberboard - is also used as a core.

Laminate floors and also many other floors with a surface layer of plastic, wood, wood veneer, cork and the like are manufactured by applying surface layers and balance layers to a core material. This application can take place by gluing an already manufactured decorative layer, for example when the wood fiber board is provided with a decorative high-pressure laminate, which is produced in a separate operation where several impregnated paper sheets are compressed under high pressure and high temperature. Today, however, the most common method in the manufacture of laminate flooring is direct lamination, which is based on a modern principle where both the production of the decorative laminate layer and the attachment to the fibreboard take place in one and the same manufacturing step. Impregnated paper sheets are applied directly to the board and compressed under pressure and heat without any gluing. 10 15 20 25 30 U.) UI 519 791 4 In addition to these two methods, a number of other methods are used to provide the core with a surface layer. A decorative pattern can be printed on the surface of the core, which is then painted with a wear layer, for example. The core can also be provided with a surface layer of wood, veneer, decorative paper or plastic foil, and these materials can then be coated with a wear layer.

As a rule, the above-mentioned methods result in a panel blank in the form of a large board which is then cut into, for example, about 10 floor panels, which are then processed into floorboards. The above-mentioned methods can in some cases result in finished floor panels and termination is then not necessary before the processing into a finished floorboard is carried out. Manufacture of individual floor panels occurs most when the panels have a surface layer of wood or wood veneer.

In all cases, the above floor panels are edge-processed individually into floorboards. Edge machining is done in advanced milling machines, where the floor panel is precisely positioned between one or more ball-bearing chains and belts, so that it can be passed with a high speed and precision past a number of milling motors, which are equipped with diamond tools or metal tools, which process the floor panel edge. By using several milling motors that operate at different angles, advanced joint geometries can be formed at speeds in excess of 100 m / min and with an accuracy of i0.02 mm.

Definition of certain terms In the following text, the visible surface of the finished floorboard is referred to as "front", while the opposite side of the floorboard, facing the subfloor, is referred to as "back". The sheet-shaped starting material used is called a "core". By "wood fiber core" is meant a core material which contains wood fibers, for example homogeneous wood, MDF, HDF, chipboard, flakeboard, plywood and the like. 791 5 it forms a semi-finished product called “floor panel” or “panel blank” in the case where the semi-finished product in a subsequent operation is divided into a number of the above-mentioned floor panels. When the floor panels are edge-worked so that they have obtained their final shape with the joint system, they are called "floorboards". layers "which are mainly intended to give gol-" Wear layer "refers to layers which are primarily intended to improve the decorative appearance of the front wear.

The outer parts of the floorboard at the edge of the floorboard between the front and the back are called "joint edge". the floorboard and the joint system, eg laminate, metal wood fiber boards, wood, plywood plastic (especially aluminum) or sealing material.

"Joint" or "joint system" refers to cooperating coupling means, which connect the floorboards vertically and / or horizontally.

Laminate floors but also wooden floors are often laid in kitchens, halls and public areas where they are continuously exposed to water, for example in connection with people walking on the floor with wet shoes and in connection with cleaning with water and the like. In recent years, laminate flooring has also begun to be used in bathrooms. Laminate and wood floors are sold all over the world and are installed in humid climates where the relative humidity RH can exceed 90%.

When water penetrates a material or when evaporated or condensed water is present on or in the material, it is generally referred to as "moisture". 10 15 20 25 30 LA) Ul 519 791 6 "Moisture-proof material" generally means material which absorbs moisture only to a limited extent or material which is not damaged by moisture.

Moisture in floors When laminate floors with a wood-fiber-based core are exposed to moisture to a limited extent in the above spaces, the moisture can penetrate into the upper parts of the joint system closest to the front via the joint between adjacent floorboards and thus penetrate the core and its wood fibers. If the moisture supply is small, the water usually evaporates after a while, but the result can be permanent swelling of the joint edge portion, edge erection of the upper joint edge portion and cracks in the surface layer, especially if the core is not of high quality and if the laminate is thin. The edge erection also leads to high wear in the surface layer around the joint edges. In wooden floors, the joint edges can also swell at high relative humidity and cause damage to the joint edges.

If the moisture supply is extensive or if it occurs regularly for a long time, moisture can also penetrate the entire joint system and into the subfloor and cause significant damage, including in the form of mold. This can happen even if the floorboard is made of a moisture-proof core, as this moisture-proof core usually only counteracts swelling of the joint edge portions or prevents moisture from spreading into the core. The moisture-proof core cannot prevent moisture from migrating through the joint system and into the subfloor. This moisture migration through the joint system is enhanced if the geometry of the mechanical joint contains many joint surfaces on one floorboard, which have no contact with the corresponding joint surfaces on the adjacent floorboard. Such a geometric design facilitates e.g. manufacturing and facilitates the displacement of a floorboard in a read position along the joint edge of an adjacent floorboard, but such a geometric shape is not advantageous when it comes to counteracting the moisture's ability to penetrate the joint system. 10 15 20 25 30 b.) UI 519 791 7 A common misconception is that mechanical joint systems are more sensitive to moisture than traditional joint systems with glue, because it is believed that glue prevents moisture from penetrating into the joint system. Glued floors with environmentally friendly water-based gluing systems can not prevent moisture from entering the joint system either. One reason is that glue usually only occurs in parts of the joint system. Another misconception is that moisture, which comes into contact with the adhesive layer, dissolves the adhesive joint. Moisture penetrates the joint system, and the boards come loose in the joint.

Laminate floors and wood floors could take a significantly larger market share, especially from plastic floors and tiles, if they had a better ability to withstand the effects of high relative humidity and water present on the surface.

Known technology and problems with this When a laminate floor is exposed to water on the surface, a moisture-proof surface layer will prevent moisture from penetrating through the surface and down into the core. The limited amount of moisture that penetrates the surface layer and down into the core will generally not cause any damage. In the joints, moisture will penetrate between the upper joint edges of adjacent floorboards, and when the moisture passes the moisture-proof surface layer and reaches the significantly more moisture-sensitive core, the moisture will spread into the core and at the same time continue downwards towards the back of the floorboard. If the core contains wood fibers, these will swell.

The result is that the thickness of the floorboard within the joint edge portions increases and that the surface layer rises. This vertical swelling in turn causes damage to the floor. If additional moisture is added, the moisture will migrate downwards towards the back, until it has passed the joint system and reaches the baseboard and the subfloor. This can cause even greater damage.

Various methods have been used to counteract these problems. Penetration of moisture into the floorboard from the joint edge has been attempted to prevent by coating the joint surfaces with a moisture-sealing material, eg wax or silicone.

Attempts have been made to counteract this type of solution in, among others, WO9426999 (Välinge and EP090345l (Unilin Beheer B.V.). Moisture migration from the front of the floorboards to their back side Aluminum AB)

Such solutions are described in, inter alia, WO9747834 B.V.).

(Unilin Beheer Man has thus used a number of methods to improve the joint systems' ability to withstand the effects of water and moisture in various ways.

The most common method is to design the core of the floorboard from a high-quality HDF board with regard to, for example, density and moisture safety. The moisture safety of the core can also be improved by mixing in special binders, often in combination with the use of special wood fibers in the production of the core. This method can significantly reduce but not completely eliminate the swelling upon moisture penetration. The main disadvantage of this method is the cost. The entire floorboard is of the same high quality, despite the fact that these special properties are only used in a limited part of the floorboard in connection with the joint edge. Another disadvantage is that this method does not provide any protection against moisture migration through the joint system from the front of the floor to its underside.

It is also known that it is possible to counteract the penetration of moisture into the core of the floorboards by spraying or otherwise applying special chemicals, which impregnate or strengthen the wood fibers in the joint system. This application of chemicals takes place after the joint has been given its final design and geometric shape by processing. The impregnation usually takes place directly in connection with the machining of the edges of the floorboards, since it is desirable to use that ratio -vf b- fi- C _ ___-___ .. --.-, _ .. -: Ä., - vv- .f-. fi Ås. '' "'that tiklvctll at dutta .Lllvcixxiiiiigaatcg kept l ratt pOSl- t tion of drive chains or belts in the processing equipment. 10 15 20 25 30 b) U' | 519 791 9 The impregnation materials can be applied in the joint system by various methods that can The most common impregnation materials are molten wax and liquids of various types such as oils, polyurethane-based impregnating agents and a number of other chemicals, all of which help to prevent moisture penetration from the joint edge into the core in order to so on. ways to reduce the risk of swelling, when moisture penetrates between the upper joint edges.

All application methods are complicated, costly and give an unsatisfactory result. It is especially difficult to achieve moisture-proof corners. If spraying on a moving floorboard, for example, starts too late, part of the edge closest to the corner will lack impregnation. If the spraying is stopped too late, impregnation liquid will spray out into the open air, and this will lead to unwanted degradation of equipment and also to the spread of unwanted solvents or impregnation materials in the air and the premises where the production takes place. In addition, it is difficult to impregnate the core at the joint edge immediately below the surface layer without at the same time achieving a sagging of the floorboard surface closest to the joint edge. It is also difficult to achieve a deep and even impregnation in the areas directly below the surface layer that are most exposed to moisture and to swelling. All this is considerably complicated by the fact that machining and subsequent impregnation take place at very high speeds and with the surface layers of the floorboards facing downwards. Additional disadvantages are that the impregnation, especially if it is water-based and environmentally friendly, can lead to fibers swelling or that a layer of solidified impregnating agent settles in the joint system so that the geometry of the joint changes in an uncontrolled manner.

In addition, the above-mentioned methods do not provide a reliable seal against odor vents from the front of the floorboards to the back of the floorboards. Nor can H22s 10 15 20 25 30 DJ Uf] 519 791 10 solve the problem of swelling of upper joint edge portions in wooden floors.

It is also known that you can use core materials of plastic which do not swell and which do not absorb moisture.

This provides a perfect seal against moisture migration horizontally out of the joint between two interconnected floorboards.

The disadvantages of plastic are that sheets of plastic material are significantly more expensive than wood fiber boards and that it is difficult to glue or directly laminate a decorative surface layer on a sheet of plastic material. In addition, machining of plastic is much more difficult than machining of wood-fiber-based material for the design of the coupling members of the floorboards around all four edges.

The above-mentioned publication WO9426999 (Välinge Aluminum AB) discloses a system for counteracting the penetration of moisture into the floorboards from the joint edges and for counteracting moisture migration from the front of the floorboards to their rear side. In this document, the use of silicone or other sealing compound, rubber strip or other sealing device is applied, which is applied in the joint system before laying. The system specified in WO9426999 (Välinge Aluminum AB), ie moisture seal with sealing compound or a sealing device, which is applied in the joint in connection with the manufacture, also has disadvantages. The disadvantages are in principle the same as those which occur during edge impregnation by spraying or coating. In addition, it is difficult to handle boards with a sticky sealant. The properties of the sealant can also change over time. If the sealing compound is applied in connection with laying, the laying will be difficult and expensive.

One possibility of achieving a seal against moisture penetration and penetration is to insert a sealing device in the form of, for example, a sealing strip of rubber in the joint in connection with the installation. This method is also cumbersome and costly. When the sealing means is applied in the joint in connection with the manufacture, it is not known how this means is to be designed to function optimally, how 10 15 20 25 30 LA) U '| 519 791 ll the application must be made in a rational manner and how the corners are to be designed so that the seal can work around the entire joint edge of the floorboard both on the long sides and on the short sides. In the above-mentioned publication WO9747834 (Unilin Beheer B.V.) it is shown in Fig. 10 how sealing means have been applied visibly between the upper joint edges, so that a narrow gap appears between the adjacent floorboards.

The use of inlaid elastic sealing members in joints is also known in connection with joining floor-high wall elements. This is evident from, for example, GB2l178l3, which, however, is not suitable for floorboards to be laid without (Ostrovsky), which shows a joint system, larger visible joint cracks.

It is also known (according to WO9966152, Välinge Aluminum AB) that the edge of the core on the long or short side can be provided with separate materials which are attached to the core and which are then processed to achieve special functions in the locking system such as strength, moisture safety or bendability. hot. However, it is not known how these materials are to be applied and shaped to optimally solve the moisture problems described above.

A special problem, which is related to the penetration of moisture into floorboards from the joint edges, occurs in connection with wooden floorboards, which have several layers of wood with different fiber directions, since wood swells more transversely than along the fiber direction. This means that in a wooden floor, which has a surface layer with its fiber direction in the longitudinal direction of the floorboard and a core with a different fiber direction, for example across the floorboard and which is installed in an environment that is humid or has a high relative humidity, the surface layer to swell more in the width of the floorboard than the core does. The result is that the upper joint edge portions and especially the parts closest to the joint surface swell and expand parallel to the floor ski surface of the joint; the floorboards are separated from each other, while the joint system formed by the core largely retains its shape. This can lead to damage, for example by the decorative layer (surface layer) that the joint system is broken or that the reading function of the reading system is compressed, which is completely or partially lost.

It can therefore be stated that the moisture problems in connection with joined floorboards are mainly related to> Vertical and horizontal swelling of the joint edge portions> moisture penetration through the joint system.

In summary, it can be said that when it comes to achieving a seal against moisture migration into the floorboards from the joint edges, there are several known methods, none of which give a result which is satisfactory in terms of both quality and cost. When it comes to sealing against moisture migration along the joint from the front of the floorboards to their back, there are no known solutions, which enable an integrated design where the board is already provided with a seal in connection with the manufacture that counteracts such moisture migration.

Brief description of the invention and object of this The invention is based on the insight that it concerns several different types of seal that are needed in primarily a moisture-proof locking system for floorboards which can be joined together, namely a> "material seal" which counteracts swelling of joint edges, > "Material seal" and "joint seal" which counteract swelling and moisture penetration through the joint system,> "compensation seal" which compensates for swelling and shrinkage of joint edges.

“Material seal” means a seal that prevents or prevents the spread of moisture from the joint edge of a floorboard into the floorboard. By "joint seal" is meant a seal which prevents or counteracts the "entry" of moisture through the joint along the joint surfaces. "Compensation seal" refers to a seal that adapts to moisture-related material movements in a floorboard (swelling and shrinkage) as a result of changes in moisture content, for example through changes in relative humidity in the ambient air , and which counteracts compressive stresses and the formation of a visible gap between the upper joint edges of adjacent floorboards as a result of such moisture-related material movements.

As can be seen from the above, known solutions to moisture-related problems in connection with floorboards and floor materials are not entirely satisfactory. Some of the solutions are insufficient in terms of intended effect, others have shortcomings that lead to difficulties in connection with manufacturing or installation, and still others are unsatisfactory from a cost point of view.

An object of the present invention is therefore to eliminate or greatly reduce one or more of the remaining moisture sealing problems in connection with the manufacture and use of floorboards. A further object of the invention is to provide a rational and cost-effective manufacturing method for the manufacture of floorboard cores, floor panel blanks, floor panels and floorboards.

These and other objects of the invention are achieved with a system according to claim 1, a floorboard according to claim 19 and a method of manufacturing a core, which is intended for the manufacture of floor panels or panel blanks according to claim 30. Embodiments of the invention appear from the dependent claims and from the following description.

The invention is particularly suitable for use in floorboards with mechanical locking systems as well as in floorboards made from panel blanks which are divided into a plurality of panels before processing. However, the invention can also be used for floors with joint systems that are glued and for floorboards that are manufactured directly as separate floor panels for processing into floorboards and which are thus not manufactured by dividing large panel blanks before subsequent processing of the individual floor panels. 10 15 20 25 30 DJ U '| 519 791 14 Thus, the core can be provided with inlaid and firmly anchored sealing means within portions, which are later to be machined for the design of the coupling means of the finished floorboard. The sealing material will thereby be processed simultaneously with or in connection with the processing of the remaining parts of the joint system. This means that the sealing material can be formed into carefully placed and carefully dimensioned seals to form the above-mentioned joint seals.

With suitable methods such as sawing or milling, the core can preferably be preprocessed before the application of the surface layer (eg a decorative surface layer) so that, for example, one or more grooves are formed in the surface in the areas where edge processing of the joint system will later take place. Thereafter, a suitable sealing material is suitably applied to the groove by extrusion. The sealing material has the property that it changes to a solid, moisture-proof surface. The surface layer can then be applied to the surface of the core over the groove with sealing and elastically deformable material. terialet. According to this aspect, the sealing material can also be applied after the surface layer has been applied.

The groove is then made in the panel blank or floor panel in the surface layer and the core or only in the core of the floor panel if the surface layer of the floor panel can be placed on the core with high accuracy. When the panel blank is sawn up into floor panels, the edges will contain the sealing material.

In principle, all sealing materials available on the market can be used, which can be applied in liquid form or in semi-solid form by extrusion, such as foam or the like, and which after application are malleable, elastically deformable and moisture-proof.

It is an advantage if the sealing materials have properties that enable adhesion to the core. However, this adhesion is not necessary because the sealing material can also be attached in, for example, undercut grooves.

The subsequent processing in the manufacture of the floorboards is carried out in such a way that the sealing material b.) UI 519 791 15 the material is only partially removed or reshaped. The sealing material can be formed, for example, by cutting machining into an elastically deformable joint seal, which will be precisely positioned over the entire long side and the entire short side and in the corners and also precisely positioned in relation to the surface layer.

The joint seal and especially its active part, which provides the moisture seal, can be designed with an optional external geometry by cutting machining which can be done with very tight tolerances in connection with the joint system otherwise being designed.

If the joint system between the decorative layer and the joint seal also has a material seal, the result is a floor with floorboards that all have moisture-proof joints on the long and short sides and in the corners. If the floor is also provided with moisture-resistant skirting boards of, for example, plastic material which in connection with the floor has a suitable sealing material or sealing strip, the floor will be completely moisture-proof in all joints and around the walls.

In addition to the impregnation described above, the material seal between the surface layer and the joint seal can be achieved in many different ways, for example:> The core can consist of a moisture-proof material. > In a directly laminated floor, the upper part of the core can be impregnated immediately below the decorative layer according to the method described above. > Impregnation material can also be applied in the grooves of the core where the joint seal is also applied. > In a high-pressure laminate floor, the reinforcement layer of phenol-impregnated kraft paper under the decorative layer can form a material seal. > Another alternative is to apply a moisture-proof plastic layer between the core and the decorative surface layer throughout the board.

In the same way as the joint seal is applied, materials with other properties, for example non-compressible materials, can also be applied to protect the joint edge and to form a material seal.

The material seal can consist of one or more materials that cover the entire core surface and which are also resilient and noise-reducing. The advantage is that for the same cost you can achieve moisture sealing, noise reduction and softer floors. Parts of the joint seal can also constitute a material seal.

Finally, all or part of the joint seal can also constitute a material seal.

As shown above, this aspect is suitable for core materials that are wood fiber-based, but also for moisture-proof core materials, for example of plastic and various combinations of plastic and wood fiber-based materials.

As non-limiting examples of materials which can be used to provide a joint seal may be mentioned acrylic plastic-based material, elastomers of synthetic rubber, urethane rubber, silicone rubber or the like, or polyurethane-based hot melt adhesive.

In order to function optimally, the floorboards should have a mechanical joint system which for a long time and during swelling and shrinkage of the floorboards holds the joint edge together with the sealing material in close contact with another sealing member or with the other joint edge. The method and system can also work in a traditional glued tongue-and-groove joint, but it is considerably more expensive and more difficult to achieve a tight joint than with a mechanical joint system.

It should be obvious that in connection with laying it is possible to apply glue, sealing material and the like in the joint system described above in order to, for example, further strengthen the joint's strength or moisture safety in parts of or in the entire floor.

Within the scope of the invention, long and short sides can be designed in different ways. The reason may be that the interconnection method for installation may be different for long and short sides. For example, the long side can be read by angling and the short side by snapping, and this may require different material properties, joint geometries and sealing geometries, where one side is optimized for angling and the other for snapping. Another reason is that each square meter of floor contains significantly more long-side joints than short-side joints, if the boards are elongated.

An optimization of the material cost can give different joint designs.

Impregnation and edge reinforcement of the core in certain areas before application of surface layers and balance layers can also be used on the back to, for example, strengthen the part where the lower parts of the joint system are designed. This can be used, for example, to form a strong and flexible strip or lower lip and a strong locking element, when the strip or the lower lip is formed in one piece with the core. For example, if the strip is made of a material other than the core, for example aluminum, impregnation from the back can be used to reinforce critical parts, where the strip is attached or where the board cooperates with the locking element.

According to another aspect, the above manufacturing methods can also be used to produce a mechanical joint system which contains elastic locking means. These elastic locking members can be compressed when adjacent upper joint edges swell and can expand as they shrink.

In this way, the horizontal swelling problems and the appearance of visible cracks in a dried floor can be counteracted. Since this swelling problem is mainly related to the long side, no higher demands are placed on the corners. The elastically deformable material can therefore also be applied in solid form in the groove mechanically, for example by snapping or pressing in undercut grooves or by gluing in the edge of the groove. These elastic locking means will thus act as an "elastic compensation seal".

The manufacturing method described above to provide a partial material seal in specific areas of a core can also be used in connection with the manufacture of the disc-shaped core. Impregnation material is then applied 10 15 20 25 30 Lu LT! 519 791 18 either in the pulp of wood fiber and binder formed into a core or in connection with the core taking its final shape in the manufacturing process.

Brief description of the drawings Figs.

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Fig. 1a-d 2a-e 3a-c 4a-c 5a-C 6a-c 7a-d Sa-e 9a-d 10a-c 11a-c a floorboard. shows the construction of laminate flooring with a surface of high-pressure laminate and direct laminate. shows examples of different mechanical joint systems and moisture migration. shows edge impregnation according to known technology. shows impregnation to form a material seal according to the invention. shows impregnation of upper joint edges according to the present invention. shows an embodiment of a material seal according to the invention. shows the production of a joint seal in a mechanical joint system according to the invention. shows the production of a mechanical joint system with material sealing and joint sealing as well as edge reinforcement of the parts of the joint system according to the invention. shows compression of a joint seal according to the invention. shows alternative embodiments of material and joint seals according to the invention. shows alternative embodiments of material and joint sealing according to the invention. shows floorboards with joint sealing on two sides according to the invention. shows mechanical locking systems, Fig. 14a showing prior art and Figs. 14b-e showing mechanical locking systems with a compensation device 1 in the form of an elastic locking member according to the invention. Figures 15a-c show a preferred embodiment of the invention.

Figs. 16a-c show a joint system which is designed according to the invention and has a high strength.

Figs. 17a-d show sealing of corner portions of adjacent floorboards.

Description of preferred embodiments Figs. 1a-d show in four steps the production of a floorboard. Fig. 1a shows the three basic components surface layer 31, core 30 and balance layer 32. Fig. 1b shows a panel blank 3, where the surface layer and the balance layer have been applied to the core. Fig. 1c shows how floor panels 2 are manufactured by dividing the panel blank. Fig. 1d shows how the floor panel 2 after edge processing gets its final shape and 7 'on the long sides 4a, 4b, which joint system in this case is mechanical. becomes a finished floorboard 1 with a joint system 7, Fig. 2a shows the production of high-pressure laminate. A wear layer 34 of a transparent material with high wear resistance is impregnated with melamine with admixture of alumina. Under this layer 34 is laid a decorative layer 35 of paper impregnated with melamine. One or more layers of reinforcing layers 36a, 36b, formed of backing paper and impregnated with phenol, are laid under the decorative layer 35, and the whole package is laid in a press, where it is cured under pressure and heat to an approx. 0.5-0 , 8 mm thick surface layer 31 of high-pressure laminate.

Fig. 2c shows how this surface layer 31 and a balance layer 32 are then glued to a core 30 to form a panel blank 3.

Figs. 2d and 2e show direct lamination. A wear layer 34 in the form of an overlay and a decorative layer 35 of decorative paper are laid directly on a core 30, after which all three _1-1, ____ __1_ _ '__- _ uelar Uun 1 Legs n- A ,. 1 ._ .. 1 ..,., _ K..1 - .., ..-. 1-4 "'avc-: Iï a uanic Ualauaamikt 32 lâggS ln 1 in a press, where they under heat and pressure cured to a panel blank 3 with a decorative surface layer 31 with a thickness of about 0.2 mm.

Figs. 3a-c show known mechanical joint systems and how the moisture according to the inventors' studies affects the joint systems.

In Fig. 3a, the floorboard 1 consists of a directly laminated surface layer 31, (HDF) which locks a core 30 of wood fiber-based material and a balance layer 32. The vertical locking member, the panels 1 and 1 'consists of a groove 9 and in the D1 direction, a spring 10. The horizontal locking means, which locks the boards parallel to the surface layer 31 in the D2 direction, consists of a strip 6, which cooperates which has a locking element 8, with a locking groove 12. The strip is made by a machining of the floorboard core 30 and in this embodiment of the invention is therefore formed in one piece with the core 30. Dashed arrows MPM show how moisture can penetrate from the joint edge into the core 30, when the moisture penetrates into the joint system from the front or top of the floor.

Fig. 3b shows an embodiment in which both the vertical and horizontal locking means are designed as a groove 9 with a locking groove 12 and a spring 10 with a locking element 8. A dashed arrow MPJ shows how moisture can penetrate the parts of the locking system.

In Fig. 3c, the floorboard is formed with a surface layer 31 of high-pressure laminate, a core 30 of HDF and a balance layer 32 of high-pressure laminate. The vertical locking member also in this embodiment consists of a groove 9 and a spring 10, which are formed from the core 30 of the floorboard. The horizontal locking member consists of a strip 6 and the locking element 8, which are made of aluminum and mechanically fixed to the core 30.

In all the above cases, the joint systems are integrated with the core, ie formed or assembled in the factory, and at least a part of the joint system is always formed by cutting machining the core 30 of the floorboard. snapping in an angled position. Figs. 4a-4c show impregnation of joint edges 82, 83 according to the prior art, in which the processed joint is impregnated by spraying an impregnation material 24 from the side.

To facilitate understanding, the floorboards in all the figures are depicted with the surface layer facing upwards. In the actual production, on the other hand, the floorboards are usually turned with their front (top) facing downwards in the processing machines and during the subsequent impregnation.

In the known type of impregnation the disc is passed past a fixed spray nozzle 40. It is difficult to direct the jet of the impregnation material 24, so that the edge of the jet is placed immediately below the surface layer 31 in connection with the upper adjacent joint edges 16 in order to provide a material seal 20. if the application can take place using protective plates 43, which protect the surface, it is difficult to provide effective protection. The strip 6 and the locking element 8 are often an obstacle, and it is difficult to apply the impregnation material 24 with sufficient accuracy and to obtain a sufficiently deep penetration in the area directly below the surface layer 31 at the upper adjacent joint edges 16. The impregnation depth thus varies and is smaller at immediately below the surface layer and furthest from the surface layer, as shown in Figs. 4a-4d.

Figs. 5a-5c show impregnation to provide a material seal according to the invention. Impregnation material 24 is applied in a suitable manner in strip-shaped areas 44 on the core surface 33, before other layers, ie decorative and wear layers, have been applied. The application can take place, for example, by spraying, rolling on, etc., preferably first in the longitudinal direction L in lanes, where the future long sides of the floor panel will later be formed.

Suitably, one long side 4 of the core 30 is used as a guide surface, which is then also used as a guide surface to facilitate positioning in connection with application of surface layer 31, sawing and machining. In this way, 10 15 20 25 30 br) U! 519 791 22 it is easier to ensure that the material seal 20 is correctly positioned in relation to the finished joint edge.

Fig. 5b shows the corresponding impregnation of the parts which will later form the short sides 5 of the floor panels.

In this impregnation, the core is moved in the width direction W perpendicular to the longitudinal direction L. Here too, one short side 5 of the core 30 can be used as a guide surface in the subsequent manufacture.

Fig. 5c shows an enlargement of a portion which will form the corner of the floorboard and which will be completely impregnated parallel to both the future long side and the future short side. The dividing lines 45 indicate the saw cuts along the long side and the short side for dividing the panel blank into floor panels.

Figs. 6a-6c show in greater detail how the impregnation is performed and penetrates into the core and how the impregnation area is located in relation to the future coupling means, which are indicated by dashed lines in Figs. 6a and 6b. Fig. 6c shows the edges of two floorboards, which are formed by the panel blank, after this has been cut into individual floor panels by sawing along the line 45.

Fig. 6a shows how the impregnating material 24, when applied by means of a spray nozzle 40, will penetrate the core 30 from the core surface 33 and towards the central portion of the core to form a material seal 20.

The penetration of the impregnating material 24 into the core 30 can be facilitated by establishing a vacuum on the underside of the core by means of a vacuum device 46.

The vacuum device 46 may, for example, consist of a stationary vacuum table or movable vacuum belts. If the core 30 is stationary during the application of the impregnation material 24, for example, movable spray nozzles 40 are used.

Fig. 6b shows how the impregnating material 24 is positioned in the core 30 of the panel blank 3 after the layer surface 31 has been applied. The impregnating material then forms a material seal 20. The dividing line 45 shows the intended sawmill. the cut.

Fig. 6c shows the joint edges 82, 83 of the floorboards 1, 1 'after machining. To simplify the illustration, the floorboard has a mechanical joint only along one side. The material seal 20 will be precisely positioned along both the perpendicular sides and in the corner, and it is in the embodiment shown in the upper joint edge portions 80, 81.

A wood fiber-based core 30, for example HDF, is manufactured by mixing ground wood fibers with binder, for example melamine, after which a board is formed by means of pressure and heat. Alternatively, the impregnating material 24 can be applied to the board in connection with this manufacture, whereby the application takes place within special portions which will later constitute joint portions in the floorboard.

Figs. 7a-7d show in detail the various manufacturing steps for providing a material seal 20 in a mechanical joint system.

According to Fig. 7a, impregnation material 24 is applied from the core surface 33 in the portions 86, 87 (dashed) which in the finished floorboard will form joint edge portions, which are generally designated 86 and 87 and in which the joint system 9, 10 is formed.

A considerable part of the upper joint edge portions 80, so that a material seal 81 is impregnated, 20 is formed.

Fig. 7b shows the panel blank 3 with surface layer 31, balance layer 32 and a material seal 20 in the core 30 below the surface layer 31. This figure also shows the intended saw section 45 and the contours of the final coupling means with dashed lines.

Fig. 7c shows the edges of the floor panel 2, 2 'after sawing. The sawing tolerance does not affect the final position of the material seal 20 closest to the joint edge. In the subsequent processing, no additional equipment is needed to provide a material seal 20 in the upper joint edge portions 80, 81 of a locking system, since this material seal 10 15 20 25 30 La) U '| 519 791 24 has already been achieved before the application of the various surface layers to the core 30.

Fig. 7d shows the machined joint with a material seal 20 directly below the surface layer 31. HP denotes a horizontal plane parallel to the surface layer of the board. The joint edges of the floorboard 1, 1 'have generally been designated 82, 83 and can have an optional joint system. In the preferred embodiment shown, the joint edges are formed as a mechanical tongue-and-groove joint, which can be read with angling and snapping. VP denotes a vertical plane (joint plane), which extends perpendicular to the horizontal plane HP at the upper joint edges 80, 81 closest to the surface layer. T indicates the thickness of the floorboard. The largest amount of impregnating material 81 immediately, i.e. within the most moisture-friendly material 20, is in the upper joint edge portions 80, below the wear layer 31, critical area. This concentration of impregnating material immediately below the wear layer 31 is obtained as a result of the impregnating material being caused to penetrate into the core from the core surface during the impregnation.

The upper joint portions 80, 81 are thus characterized in that the material seal 20 is not only located in the core surface 33 closest to the surface layer 31 between the vertical plane or joint plane VP and a lower plane at a distance P2 from the core surface 33 but is also all the way in the horizontal direction from the vertical plane. VP to a plane at a distance P1 from the vertical plane VP. This entire volume of the core 30 below the core surface 33 is thus impregnated to form the material seal 20. Such placement and extension of a material seal is not possible by means of the known impregnation methods in which impregnation material 24 is applied to or sprayed. against the upper joint edges 84, 85 at the vertical plane VP, when these upper joint edges are already provided with surface layer 31 and machined to their final shape, Ef 1 -v \ -v ~ 1 \ rv. If the impregnating material 24 penetrates from the core surface 33 of the FT, the concentration of the impregnating material will be particularly large closest to the core surface 33. In normal cases, the concentration of impregnating material decreases downward from the core surface 33. the core surface 33, as shown schematically in Figs. 4a-4d.

The material seal 20 should, for mainly cost reasons, be limited to a part of the floorboard 1, where the future coupling means are designed, and therefore preferably not cover the entire core surface 33.

With this method it is possible to provide a material seal 20 below the surface layer 31 in a considerable part of the parts of the joint system. With regard to the extent of the material seal in width, ie across the joint plane VP and along the horizontal plane HP, it can be mentioned that P1 can exceed 0.2 times the floor thickness T and without difficulty can amount to 1 times the floor thickness T or more. In many embodiments, the distance P1 can be so large that all parts of the joint edge pairs which contain parts of the coupling means of the floorboard are impregnated with the material seal 20.

The impregnation depth, ie the distance P2, may suitably be 0.1-0.3 times the floor thickness T. However, it is often preferred that the impregnation depth is such that at least upper parts of the coupling means will consist of impregnated core material.

According to the invention, the joint system is characterized in that the material seal 20 is located in the core surface 33 at the vertical plane VP and at a distance P1 from VP and that the sealing properties in this area are substantially similar or homogeneous, ie the core surface 33 has been coated with substantially the same amount of impregnation material 24 per unit volume. core material 30. This is a significant difference from the prior art when applying from the vertical plane VP, the concentration of impregnating material, as illustrated in Figs. 4a-4d, decreasing from the joint edge at the vertical plane VP and towards the disc parallel to the surface. layer 31 at the distance P1 and where the penetration depth in W ndre closest to the vessel surface 33 and 1101 isontalpla in greater at a distance therefrom. 10 15 20 25 30 bJ U '| Figs. 8a-8e show another embodiment of the invention. In this case, a groove 41 is formed in the core surface 33, for example in the area where the upper and inner part of the spring 10 is later to be formed. A sealing material 50 is then applied to the groove 41, which has the property that after application it acquires a solid shape, is moisture-proof, is elastically deformable and is preferably possible to form by cutting machining.

As shown in Fig. 8b, the core 30 with the groove 41 and the sealing material 50 is then coated with a surface layer 31 and preferably also with a balance layer 32 to form a panel blank. The panel blank 3 is then sawn into floor panels by cutting along line 45 and processed into floorboards 1, 1 'with a joint system. These floorboards are shown in Figs. Bc-Be, and the interconnection of the floorboards according to this particular embodiment is described in more detail below.

The sealing material 50 is formed into a joint seal 55, preferably by cutting machining by means of tools which are specially adapted to form elastically deformable synthetic materials.

As previously mentioned, there are a number of sealing materials on the market that can be used. As a non-limiting example, materials with the following properties can be used.

Sealing compound based on acrylic plastics, elastomers of synthetic rubber, silicone rubber or the like, having the properties that they can be applied in the groove 41 as a mass by extrusion, that they can adhere to the core material (possibly after applying a primer layer thereon), that they have good heat resistance, that they are moisture-proof, that they can withstand detergent, and that after application they can be cured or dried and change to a solid, elastically deformable form. The properties of the materials should be optimized so that they are both sufficiently elastically deformable and at the same time preferably possible to process rationally with the help of cutting tools. 10 15 20 25 30 b) UT 519 791 27 Various types of polyurethane-based hot melt adhesives which are applied by heating and extruding can also be used to form the joint seal. When such materials solidify, they change to a solid, elastically deformable form. These materials can later be formed by cutting machining but also by the use of heated rollers or towing tools of suitable shape, which are passed along and in contact with the sealing material 50 to form it into a suitable geometry.

Combinations of cutting roughing and finishing using hot wiping or rolling tools are also possible as well as a two-step application, where the first application is made with a thin liquid material penetrating into the core, and where the subsequent second application takes place with a material which is more viscous and which has good adhesion to the former material. Different types of primer systems can also be used to improve the adhesion of the joint sealing material to the floorboard.

Different materials, application methods and forming methods can be used on opposite joint edges and on the long and short side, respectively, in order to optimize function and cost.

Fig. 8c shows the machined joint edge with a mechanical locking system 9, 10, 6, 8, 12 and an elastically deformable joint seal 55. As can be seen from this figure, the joint seal 55 is compressed in connection with the laying of the floorboard. In this embodiment, which shows angle, the compression and deformation only begins when the locking element 8 is already in initial engagement with the locking groove 12 and when the spring 10 is already in engagement with the groove 9. Both the vertical and horizontal locking functions in the mechanical locking system are thus effective while the compression is in progress. This means that the compression in connection with laying can be called A Å 'with extremely little force and the need for compression therefore does not complicate the laying. Fig. 8d shows how two floorboards 1, 1 'are connected by snapping, where compression of the joint seal 55 can take place in the same way as described above by a cooperation of groove 9 and spring 10, and where a side displacement along the joint plane has been facilitated and where a flexible strip 6, a locking element 8 and a locking groove 12 cooperate in the compression of the joint seal will therefore compress the joint seal in connection with the snapping.

It is an advantage if the joint seal 55 is designed so that the compression can start, when the guide part 11 of the locking element 8 engages with the guide part 13 of the locking groove 12. This engagement is facilitated if the guide part 11 of the reading element is designed as a rounded or chamfered part. in the upper parts of the locking element. Likewise, the steering and also the compression are facilitated, if the locking groove 12 has been designed with a correspondingly rounded guide part 13 in the lower part of the locking groove 12 closest to the joint edge.

In connection with the laying, the joint seal 55 is pressed against an opposing cooperating joint surface 56 in the joint system. In the embodiment shown in Figs. Ba-8e, this joint surface 56 has an inclination of 45 ° to the horizontal plane HP of the disc. This is shown in Fig. 8e. The press pressure from the joint seal 55 will therefore be distributed equally on the vertical (9, 10) and horizontal (6, 8, 12) locking means in the joint system.

This is an advantage, as it is desirable to reduce the pressure both in connection with laying and in read position.

Excessive pressure horizontally in the locked position can lead to the floorboards separating and the joint having an undesired joint gap at the adjacent upper joint edges 16. Excessive vertical pressure in the locked position can lead to the joint edge portion 80 in the upper part 9 of the groove 9 rising.

Figs. 9a-9d show how the material seal 20 and the joint seal 55 can be combined into a moisture-proof locking system. In this case, a groove 41 has been formed in the upper side of the core 30 after the impregnation to form the material seal 20. In this embodiment, both the groove side 9 and the spring side 50b. The embodiment is also characterized in that the impregnating material 24 is provided with sealing material 50a, acts as a binder and increases the strength of the core 30. In this embodiment (see Fig. 9a), the impregnating material 24 has been applied in a plurality of areas on the core 30. These areas will form a material seal 20 and also material reinforcement of the upper joint edge portions 80, 81.

The impregnation will also provide an edge reinforcement 21a, 21b in the portions where the strip 6 is fixed, and within an area 21c in the core 30 at the locking groove 12, where the loading groove 12 cooperates with the locking element 8.

Fig. 9b shows how the sealing material 50a, 50b can be applied in the groove 41. After the core 30 has been provided with surface layer 31 and balance layer 32 9c), 50b to a joint seal 55a, (fig. The joint edge and the sealing material 50a, 55b are formed (Fig. 9d) .

The strip 6 can be shaped and attached to the core 30 in various ways [eg those shown and described in EP1061201 (Välinge Aluminum AB) or WO9824995 (Välinge Aluminum AB)], so that the mechanical locking system for interlocking the floorboards 1, 1 ' in the vertical and horizontal direction will comprise partly the tongue 10 and the groove 9, partly the joint seals 55a and 55b, partly the material seal 20, partly the strip 6 with its locking element 8, partly the edge-reinforced fastening parts 21a, 2lb for the strip 6 and partly a edge-reinforced locking surface 14 in the locking groove 12.

The floorboards 1, 1 'according to this embodiment will then have upper joint edge portions 80, 81 which at the vertical plane VP have a reinforced material seal 20 directly below the surface layer 31 and joint seals 55a, 55b in connection with the material seal 20. The material seal 20 and the joint seals 55a 55b together with the moisture-proof surface layer 31 prevents moisture from penetrating into the core 30 and moisture from penetrating through the joint system. The result is a moisture-proof floor. As mentioned above, the vertical (9, 10) and horizontal (6, 8, 12) locking units should preferably be designed so as to be able to pour the elastically deformable joint seals 55a, 55b compressed and elastically deformed throughout the life of the floor without deforming the locking means. It is especially important that the groove 9 is not too deep in the horizontal direction and that the upper part or lip 15 of the groove 15 is rigid so that it does not rise. In addition, the locking element 8 and the strip 6 should be designed so that they can withstand the pressure from the joint seals 55a, 55b without the floorboards 1, 1 'separating to form a visible joint gap at the upper joint edge portions 81, 82. The sealing material 50a, 50b should also be selected so that during the entire life of the floor it exerts a pressure and prevents moisture migration through the joint system.

As shown in Fig. 9d, the core 30 is impregnated and 21b and 21c are attached and where the reading element 8 reads against the reading barrier reinforced in the areas 21a where the strip 6 12. This allows the use of cheaper core materials 30, which may be of lower quality. and which is reinforced by means of impregnation in order to obtain a higher pour strength in the critical areas. In this way, high quality can be combined with low cost.

Several variants of this moisture-proof locking system are possible. The joint seals 55a, 55b can be placed optionally in the joint system, but it is advantageous if the joint seal is placed invisibly from the surface near the surface layer 31. They can be placed optionally on the groove side (9) or on the spring side (10), and they can the embodiment shown is in both joint parts. Of course, several joint seals 55 may be present on each joint portion above and next to each other.

Furthermore, the contact surface between the joint seal 55 and the opposite part of the joint system can be designed in any way with geometries which are, for example, toothed, triangular, semicircular and the like. In principle, all the shapes normally used in the design of sealing strips of elastic synthetic material or rubber can be used.

Using vacuum technology, as described in connection with the embodiment according to Fig. 6b, the entire joint system b) from the surface layer 31 to the balance layer 32 can be provided with a material seal and edge reinforcement 20. This can increase the joint. strength and moisture safety, can give the machined strip better flexibility, can enable machining to smoother surfaces and can enable a reduction of the frictional forces when displacing one floorboard relative to another in the locked position. It is also possible to impregnate wood fibers with plastic material in such a way that the wood fibers together with the impregnation material have such properties that they can be formed into a joint seal.

The sealing material 50a, 50b can alternatively be applied in grooves, which can also be made in the panel blank 3 or in the floor panel 2, before the coupling parts are formed. The groove 41 can then be made in both the core 30 and the surface layer 31.

Sealing material 50a, 50b can also be applied to the edge of the floor panel 2 or the floorboard 1, when all or parts of the joint system have been designed, and final design of the joint seal 55a, 55b can also take place in a separate manufacturing step, when the floorboard 1 is otherwise already obtained. lit its final form.

By changing the angle of the pressure surfaces between the 55b, the direction and distribution of the compression pressure can be regulated between a completely horizontal and a completely vertical direction. It is an elastically deformable joint seal 55a, advantageous if the pressure surfaces are not perpendicular but inclined in relation to the horizontal plane HP, so that the pressure is distributed with vertical and horizontal force components, so that the pressure distribution is optimized in relation to the possibilities of a rigid upper groove 15 and a strong horizontal joint 6, 8, 12.

Figures 10a-10c show in detail how compression can be achieved in connection with angling. The active part 54 of the joint seal 55 is formed with a convex outer part, which begins to be compressed when the locking groove 12 engages with the locking element 8. Such a position is shown in Fig. 10b. In connection with the final lower angle and the reading, the final compression of the joint seal takes place against an opposing cooperating joint surface 56. This joint surface 56 can for instance be coated with wax or other similar materials. after the joint system has been designed. This can facilitate displacement along the joint edge in the read position and contribute to improving the functions of the material seal and the joint seal.

As can be seen from Fig. 10c, the joint system may have one or more expansion spaces 53a, 53b, where the joint seal 55 may swell during compression. The joint seal 55 can thus be formed with a certain excess, and if the joint system 53b the joint seal 55 can be formed with less demands on tolerances and with retained function. has been designed with suitable expansion spaces 53a. In this embodiment, the material seal 20 in the upper joint edges has been made with a considerable depth from the core surface 33, so that the entire area from the upper parts of the joint seal 55 to the core surface 33 is moisture-proof. In this embodiment, the major part of the joint edge portion between the groove 9 and the core surface 33 will form a material seal 20.

Figs. 11a-11c show different embodiments of the invention.

Fig. 11a shows an embodiment according to the invention, where the joint seal 55 is designed to minimize edge erection and separation of the joint edges. The contact surface of the joint seal 55 with opposing cooperating joint surface 56 has a small angle to the plane of the disc, which means that the main part of the compression force will be directed substantially vertically in the direction of the arrow A. However, the joint edge above the spring is rigid and the risk of edge rising is small.

In the embodiment in Fig. 11b, the elastically deformable joint seal 55a, 55b is placed immediately below the surface layer 31, which thus covers the joint seal. The upper part of the seal 55a, 55b can in this case constitute the material seal, p. _ _: __, ___ _ _; __,. . - as a result of the odor penetrating the core 31, while the lower parts of the seal 55a, 55b may constitute the actual joint seal. B) UT 519 791 33 The embodiment according to Fig. 11c is characterized in that separate materials 58a, 58b, which can form a material seal, are applied above the elastically deformable joint seals 55a, 58b can also be used in decorative purpose by the surface layer 31 55b. These separate materials 58a, for example, are given a chamfer 60, so that the separate materials 58a, 58b become visible in the joint.

The sealing principles work even without the mechanical joint system, if glue is applied between the groove 9 and the spring 10.

Fig. 12a shows an embodiment according to the invention, where the core 30 is coated with three different surface layers with different functions. The surface of the floorboard 1, 1 'comprises a transparent hard and durable wear layer 34 of plastic material, an intermediate decorative layer 35 of plastic foil and a reinforcing layer 36, which is formed of an elastic material and which can be both moisture-proof and sound-absorbing. The decorative layer 35 of plastic foil can be replaced by decorative patterns, which are printed directly on the underside of the transparent wear layer 34 or on the top side of the elastic reinforcing layer 36.

The joint seal 55a on the spring side has an active part 54 in the form of a convex bulge, which presses against the opposing elastic cooperating joint surface 56. The active part 54 of the joint seal 55a has been made small, and this helps to reduce the friction associated with lateral displacement when the short sides of the floorboards must be read with a snap. The friction can also be reduced by coating the joint seals 55a, 55b with different types of friction reducing agents.

Fig. 12b shows an embodiment with the same surface layer 31 as in Fig. 12a, but where the joint seals 55a, 55b are formed in the elastic and deformable reinforcement layer 36 closest to the core 30. If the wear layer 34 is harder than the reinforcement layer 36, the deformation of the joint layer the seal 55b to take place mainly in the lower part 57 of the joint seal closest to the core 30 and partly no significant deformation of the wear layer 34 to take place. The result is a moisture-proof and sound-absorbing floor. Also in this embodiment, the sealing means in the form of material seal and joint seal can be designed in many different ways as mentioned earlier.

It is obvious that the embodiments described above according to Figs. 6-12 can be combined. For example, the sealing means according to Figs. 12a and 12b or 10a and 12b may be present in the same joint system. The strip 6 can be made of aluminum etc.

Fig. 13 shows a floorboard 1 with mechanical joint system on the long sides 4a, 4b and on the short sides 5a, 5b and with a joint seal 55a and 55b on a short side 5a and on a long side 4b. When the floorboard 1 is connected to other identical floorboards 1 'on both long sides 4a, 4b and on both short sides 5a, 5b to a floor, the result is a joint seal on all sides.

In addition, if the joint edges have a material seal according to previously described, preferred embodiments, the joint system of the floorboards will counteract moisture penetration into the joint system on all sides 4a, 4b, Sa, 5b and in all corner portions 38a, 38b, 38c, 38d.

Linear machining of long and short sides makes it possible to design the corner portions 38a, 38b, 38c, 38d with the same tight tolerances as the sides 4a, 4b, 5a, 5b of the floorboards 1. The joint seal in the corners 38a, 38b, 38c, 38d has an exact fit, and the angular errors between the short sides 5a, 5b and the long sides 4a, 4b as well as the deviations from parallelism between the long sides 4a, 55b can be deformed when the floorboards are joined. 4b which may occur, is compensated if it is ensured that the joint of the joint seals 55a exceeds these production tolerances.

Fig. 14a shows a cross section through conventionally designed floorboards 1, 1 ', the section being taken across a joint along a longitudinal side of a wooden floor. The floorboards 1, 1 'have a surface layer 31 of wood with a main fiber direction parallel to the long side and a core 30 with another fiber direction substantially perpendicular to the long side. The long side edges of the floorboard 1, 1 'have a mechanical joint system 9, 10, 6, 8, 12. In a humid environment the upper joint edge portions 80, 81 swell across the fiber direction (ie across the joint between the adjacent floorboards 1, 1') more than the core 30 does. This means that the floorboards 1, 1 'along the long sides are pushed apart and that the strip 6 is bent backwards. This entails a risk that the upper joint edge portions 80, 81 or the cooperating locking surfaces 14, 18 will be compressed or damaged. When the floorboards 1, 1 'then dry and shrink in winter (when the humidity drops), this in turn can lead to a joint gap occurring between the upper joint edge portions 80, 81.

Figs. 14b-14e show how to compensate for this risk of the occurrence of joint cracks by using an elastic compensation seal 52, which is inserted into the horizontal locking member 6, 8, 12 in order to counteract the effects of swelling and shrinkage of the joints. upper joint edge portions 80, 81.

Fig. 14b shows an embodiment of a floor panel 2 ', which is suitable for forming a joint system with a compensation seal according to the invention. The contour lines of the future joint system are indicated by dashed lines in Fig. 14b. The surface layer 31, the core 30 and the balance layer 32 are displaced laterally on both the groove side 9 and the spring side 10 in order to minimize the material waste when machining the joint edges. In the underside of the floor panel 2 a groove 41 is formed in the core 30. In the groove 41 an elastic material 51 is applied and fastened by, for example, extrusion or the like according to previously described methods or alternatively by gluing or mechanical fastening by, for example, pressing material into a track.

In the subsequent processing, the elastic material 51 is only partially removed or formed and formed into an elastic compensation seal 52, which forms the active locking surface in the locking groove 12 and which is operative in the locking groove 12. horizontal direction D2 This is shown in Fig. 14c.

When the joint edge portions 80, 81 swell, the elastic compensation seal 52 is compressed by its locking surface 14 pressing against the locking surface 18 of the locking element 8. Hereby the mechanical locking system can compensate for large moisture movements in the upper joint edge portions 80, 81 without damaging - time, when the floor has dried and shrunk.

The problem of swelling of the upper joint edges becomes greater if the thickness WT of the surface screen 31 is significant and if this thickness is more than, for example, 0.1 times the floor thickness T.

A joint system according to the above design is especially suitable for use with underfloor heating and in environments where the relative humidity varies greatly during the year. The elastic locking member or compensation seal 52 may optionally be mounted on the locking member 8 (as in Fig. 14d) or in the locking groove 12 (as in Fig. 14c and Fig. 14e) or in both of these parts, and may be formed with a variety of geometries. with different angles and radii that can facilitate angling and displacement. The elastic locking member or compensation seal 52 can also be combined with a material seal 20 and a joint seal 55 according to the previously described embodiments of the invention.

Fig. 14d shows an embodiment in which the elastic locking member or compensation seal 52 also functions as a joint seal which seals against moisture. In this case, the seal 52 during compression will also absorb the movements caused by swelling and shrinkage of the upper joint edge portions 80, 81. The compression and thus sealing ability of the elastic seal 52 will thus increase when the floorboards are in a humid environment. which, however, in this case there is a material seal 20, is not shown specifically in this figure but which extends down to at least the upper parts of the coupling means in the same way as shown in e.g. Fig. 7d.

Fig. 14e shows an embodiment in which the elastic compensation seal 52 is compressed by a reading element 8, which consists of a material other than the core 30. In this embodiment, the strip 6 and the locking element 8 can be made of aluminum or other suitable metal. This construction has a flexibility which is greater than when the strip 6 is made in one piece with the core of the floorboard. The invention can also be used in this embodiment. One of the advantages of this design is that the friction when moving sideways in the read position is low.

Figs. 15a-15e show a preferred embodiment of a joint system with joint seal 55, which is applied in a groove 41 in the core 30 at the upper and inner part of the spring 10 and which is formed with a tool 70.

Figs. 15a and 15b show the critical tolerance which lies in the position of the Tool 70 when forming, for example, a groove 41 in the core 30 or the panel blank relative to the future vertical plane VP in the floorboard 1 '. The innermost position of the tool 70 is delimited by a flat TP1. Fig. 15b shows the outer position of the tool 70 which is delimited by a plane TP2 outside the vertical plane VP. As can be seen from these two figures, the contact surfaces of the joint seal 55 for contact with opposing cooperating joint portions 56 can be designed with great accuracy even though the manufacturing tolerance TP1-TP2 for the horizontal placement of the groove 41 relative to the future joint edge at the vertical plane VP is rather large and can exceed 0.2 times floor thickness T. With modern production equipment it is possible to cope with a horizontal side positioning with these tolerances in the entire manufacturing chain from the manufacture of surface layers 31 and panel blank 3 to finished floorboard 1 '. The positioning of the tool 70 in the vertical direction is less critical, since the tolerance mainly depends on the thickness tolerances of the materials and because these are generally small in relation to the tolerances in connection with the side positioning ring. 10 15 20 25 30 b.) In this embodiment it is also possible to use the core surface 33 or the surface of the surface layer 31 as a reference surface. The groove 41 and the sealing material 50, which are then formed into the joint seal 55, can therefore be placed with high accuracy in the vertical direction. The joint system and the effective contact surfaces of the joint seal 55 can therefore be manufactured with very narrow manufacturing tolerances, which can be less than 0.01 times the floor thickness T, despite the fact that the original placement of the sealing material 50 is made with significantly less tolerance requirements.

Such an embodiment is characterized in that the production tolerance between the active part 54 of the joint seal and the upper adjacent joint edges 16 will be substantially lower than the tolerance between another part of the joint seal, which is not active, and the above-mentioned upper adjacent joint edge 16 This facilitates rational production and enables high quality manufacturing.

Fig. 15c shows the joint seal 55 in a compressed state with expansion spaces 53a and 53b on either side of the joint seal.

Fig. 15d shows how the joint seal 55 can be formed to facilitate processing of the surface layer 31, when it consists of a laminate. When machining the upper joint edge 80 with a diamond tool 71, counted, which works horizontally ie perpendicular to the vertical plane VP according to the arrow R, a large wear is obtained at the point 72 of the diamond tool, which works against the wear layer 35 of the laminate, which contains alumina. To utilize a larger part of the active surface of the diamond tool, the tool is moved from its starting position 71, for example, stepwise downwards towards the spring 10. The starting position of the tool is indicated by the position 71 and its end position by the position 71 '. If the joint seal 55 is located at the upper and inner part of the spring 10 in the groove 41 shown and if its upper limit UP is at such a distance SD from the surface of the surface layer 31 which, for example, exceeds 0.2 times the floor thickness T, a joint seal 55 can be provided which is so designed that 10 15 20 25 30 U.) U '| 519 791 39 the machining of the joint edge at and below the surface layer 31 is facilitated. This shape and placement of the joint seal 55 at a distance from the surface layer 31 also makes it possible to form locks by simple machining of the spring 10 by means of the tool 73 (see Fig. 15e) and the opposing and cooperating joint portion 56 on the opposite joint edge. - the theme with radii and angles in a way that facilitates a snap-in and / or angle function of the locking system.

Figs. 16a-166 show locking systems having several horizontal locking means. These locking systems can be used in connection with moisture-proof reading systems but also only as ordinary mechanical locking systems to achieve a locking system with high horizontal strength. The basic principles can be used in locking systems, which are joined by angling or snapping in and with strips 6, which are optionally made in one piece with the core 30 or made of a separate material, for example aluminum, and then anchored to the frame.

Different combinations of the preferred systems can be used on the long and short side. The locking elements 8a, 8b, 8c and the locking latches 12a, 12b, 12c can be designed with different angles and radii in, for example, wood, wood fiber-based materials, plastic materials and similar board materials with strips which are machined from the core or which consist of separate materials, and the locking elements can be designed for installation of the floorboards by angling or snapping.

The locking system according to Fig. 16a has two strips 6a and 6b, two locking elements 8a, 8b and two locking grooves 12a, 12b. The locking element 8a and the locking latch 12a enable both a locking with high strength and a good control in connection with, for example, angling. The locking element 8b mainly provides a high strength and can significantly increase the horizontal locking force. It can be designed so that it is effective when the horizontal tensile force is so great that the upper joint edges begin to separate, for example when a joint gap of 0.05 mm or 0.10 mm occurs. 10 The locking system according to Fig. 16a has two strips 6a and 6b, two locking elements 8a, 12b. The locking element 8a and the locking latch 12a enable both a locking 8b and two locking latches 12a, with high strength and a good guide in connection with, for example, angling. The locking element 8b mainly provides a high strength and can significantly increase the horizontal locking force. It can be designed so that it is effective when the horizontal tensile force is so great that the upper joint edges begin to separate, for example when a joint gap of 0.05 mm or 0.10 mm occurs.

Fig. 16b shows a locking system with three horizontal locking means with the locking elements 8a, 8b, 8c and the locking latches 12a, 12b, 12c which can be designed according to these basic principles.

This design consists of a locking member with good control l2a, l2b and Bc, l2c which contributes to increasing the strength of the joint system 8a, and two locking members 8b, at horizontal tensile load. This joint system can hold the joint edges together during compression of the joint seal 55.

Several locking elements can be designed according to this method in the upper and lower parts of the spring 10 and in the strip 6 and they can be adapted to facilitate angling, snapping and steering and to increase the strength.

Fig. 16c shows that a separate locking member 8b, 12b and or 8c, 12c can be used, for example, to limit separation in a joint system where parts of the locking groove 12a may consist of an elastic locking member 52.

The reading systems according to Figs. 16a and 16b are primarily intended for insertion, but they can be adapted with minor changes to the angles and radii of the locking systems so that they become easier to angle.

Fig. 16d shows a locking system with two horizontal 12a and 8b, locking means 8a, 12b which are suitable for, for example, the long side which is preferably laid by angling.

Fig. 16e shows a locking system for, for example, short- .__ __. _. . can so iaggs by snapping. The system according to fig. 16e differs from fig. is deeper, and the upper locking element 8b has a locking surface which is more inclined in relation to the surface layer.

The latches l2b and l2c can be manufactured with advanced shapes with the help of tools that do not necessarily have to rotate. Fig. 16f shows the manufacture of the undercut groove 12c in a joint system according to Fig. 16b. According to the prior art from metalworking, the board can be moved past a stationary locking tool 74, which in this embodiment has teeth 75, which work perpendicular to the surface layer 31. When the floorboard 1 moves in the direction of the arrow B, the floorboard will pass the locking tool 74, which is threaded into the groove 9 and whose teeth 75 make the final design of the undercut groove 12 with its locking surface. The majority of the groove groove 9 is formed in a conventional manner with large rotating diamond tools, before the disc reaches such a position that the groove tool 74 is operative. In this way, in principle, all geometric shapes can be created in the same way as when extruding plastic or aluminum profiles. This technique can also be used to make the groove 41 in the core where the sealing material is applied.

Figs. 17a-17d show an enlargement of the corner portion 38a of the floorboard, previously depicted in Fig. 13, and show a joining of three floorboards 1, 1 'and 1'. The corner sections are one of the critical parts of a moisture-proof floor. In order to counteract a penetration of moisture into the joint system through the corner, it is a great advantage if the joint seal 55a, 55b is unbroken in at least one corner 38a according to Fig. 17a. In addition, the joint seal in the corner 38d of the floorboard 1 'should be placed and shaped so that its active part 54 is not completely removed in connection with the machining of the various parts of the joint system and especially the groove 9.

Figs. 17c and 17d show the joint system in a section along the line C1-C2 in Fig. 17b, i.e. the short end and the corner portion 38a of the disc 1 'are shown in end view, while the disc 1 is shown in cross section along this line C1-C2. In this embodiment, the active part 54 of the joint seal 54 is intact in the disc 1 'at the outer end of the upper lip of the groove 9b. This is because the active part 54 is placed in a plane SA, which lies between the surface layer 31 and the upper part of the groove, which in this case is a undercut groove 9b. The active part 54 of the joint seal thus comes in this plane to be in contact with an opposing cooperating joint surface 56 of the third floorboard 1 ”.

This embodiment means that the corner 38a has an area SA, where the sealing material 55a is in one or more planes and where the joint seal 55a is unbroken. There will thus be no cracks or cavities where moisture can penetrate from the surface and spread into the joint system.

This design is thus characterized in that the floorboard has two corners 38b, 38d, where the joint seals 55a, 55b are in unbroken contact with opposing cooperating joint surfaces. The active part 54 of the joint seal 55 is thus continuous along the entire long side and the entire short side and in the corners between these long and short sides.

Claims (32)

10 15 20 25 30 b) U1 519 791 43 PATENT REQUIREMENTS A system for forming a joint between two adjacent edges of floorboards (1, 1 '), which have a core (30) and a surface layer (31) applied to the upper side (33) of the core, their adjacent joint edge portions (86, 87) has a coupling element which consists of at least one layer, and which at the groove (9, 10) for connecting the floorboards with var- (D1) sanding joint edges (16) meet in a vertical joint plane (VP), characterized therefrom, others in the vertical direction and the upper abutment of which at least one of the joint edge portions (86, 87) of the floorboards (1, 1 ') facing each other, when the floorboards are interconnected, has a joint (55, 55a, 55b) moisture along the joint edges. joint surfaces between adjacent floorboards (1, 1 '), and that this joint seal is formed by a seal to counteract the penetration of elastic sealing material (51) and is anchored in at least one of the floorboards (1, 1') and designed in connection with the design of the joint edges of the floorboards (82, 83) and compressed, when adjacent floorboards are joined together charge. System according to claim 1, characterized in that the joint sealing means (55, 55a, 55b) are designed 6,8, 12) and / or parts of the floorboards above and / or below coupling of parts of the coupling means (9-10 , the parts lie and are formed of an elastic sealing material (50, 50a, 50b), which is anchored in the floorboards and formed by machining in connection with the design of the coupling means and which is compressed, when adjacent floorboards (1, 1 ') are co - uncoupled System according to claim 2, characterized in that the design of the joint seal (55) is carried out by machining in connection with the design of the coupling means so that the tolerance within a floorboard and / or between different floorboards is less between joints. the active part (54) of the seal and the upper adjacent joint edges 10 15 20 25 30 h) Uï 519 791 44 (16) said upper adjacent joint edges. than between another part of the joint seal and (55) System according to one of Claims 1 to 3, characterized in that the joint seal (55) is formed by parts of the vertical coupling means (9-10) and / or parts of the floorboards above the vertical coupling means. horizontal parts. System according to any one of claims 1-4, the active part 54 (55) is formed at one of the upper joint edge parts, characterized in that a part of the joint seal 80,81 and that these active part 54 are closer to the surface layer. 31 than the vertical coupling means (9-10). System according to one of Claims 1 to 5, characterized in that the active part (54) of the joint seal (55) is formed at a distance from the decorative layer (35) of the surface layer (31) and that the joint edge portion between the active part of the joint seal and the decorative layer has a material seal (20) which counteracts moisture penetration from the joint edges (82, 83) (30). System according to claim 6, and into the core characterized in that the material seal (20) is a plastic material. 8. A system according to claim 6, characterized in that the material seal is a reinforcing (36) A system according to any one of claims 1-8, (30) of phenol impregnated paper. k ä n n e - t e c k n a t of the fact that the core is a core of wood fiber material. System according to any one of claims 1-9, can - (9 ~ 10, 6-8-, are designed for mechanical interconnection of drawn 12, 14, ice) adjacent floorboards (1, 1 ') around a vertical joint - (VP) the front of the floorboard. hence, that the coupling means plane both perpendicular thereto and perpendicular thereto 11. ll. System according to one of Claims 1 to 10, characterized in that the floorboards (1, 1 ') are four-sided and in that each floorboard has joint sealing means 10 (5, 55a). 55b) at least along a longitudinal and a short side, so that when joined together they are surrounded by joint sealing means (55, 55a, 55b) along all their opposite joint edge portions. System according to any one of claims 1-11, characterized in that the coupling means (6-10, 12, 14, 18) are designed for interconnection of a floorboard (1) with an already laid floorboard (1 '). by angling and / or snapping to the read position. System according to claim 12, characterized in that the coupling means (6-10, 12, 14, 18) comprise (6), piece with the core (30) and are included in the mechanical cups a lower lip or reading strip which is formed in a lingsorganen. k ä n n e t e c k nha d (6-10, 12, 14, 18) formed by another A system according to claim 12, wherein the coupling means (6), (30) formed along one of them comprise an integrated reading strip material other than the core (21a, zib), each of the opposite joint edge portions of the floorboard. and which is attached to fasteners 15. A system according to any one of claims 1-14, characterized in that the coupling means (6-10, 12, 14, 18) are formed by cutting machining. A system according to any one of claims 1-15, characterized in that it comprises a step sound insulation layer (36) of plastic between the core (30) and the decorative and wear layer (34). 17. A system according to claim 16, characterized in that the free surface portions of the step sound insulation layer (36) facing the joint (VP) are formed by cutting machining in connection with the design of the coupling means (6-10, 12, 14, 18) and designed as joint sealing means (55, 55a, 55b), which are compressed when adjacent floorboards (1, 1 ') are interconnected. System according to any one of claims 1-17, characterized in that the joint sealing means (55, 55a, 10 l5 20 25 30 b) U 1 519 791 46 55b) are formed with contact surfaces which are inclined towards the top of the floorboards. in an interconnected state. A floorboard having a core (30) and a surface layer (31) applied to the upper side (33) of the core, which consists of at least one layer, the floorboard at opposite joint edge portions (86, 87) having coupling means (9, 10). ) for interconnecting the floorboard with similar floorboards in the vertical direction (D1), so that interconnected floorboards (1, 1 ') (16), joint planes characterized therefrom, have upper joint edges which meet in a vertical (VP), to at least stone one of the opposite joint edge portions of the floorboards (see, (55, 55a, 55b) of penetration of moisture along the joint surfaces of the joint edges between 87) has a joint seal for counteracting adjacent floorboards (1, 1 '), and that this joint seal (50, 50a, 50b) and anchored in the floorboard and designed in connection with is formed of elastic sealing material the design of the coupling members (9, 10 of the floorboards and is elastically deformed, when the floorboard is connected to a similar floorboard. Floor panel according to claim 19, characterized in that the joint sealing means (55, 55a, 55b) are formed by parts of the coupling means (6-10, 12, 14, 18) and / or parts of the floorboards above the coupling means (6 -10, 12, 14, 18) lying parts and are formed by a (50, 50a, 50b), anchored in the floorboards and formed by machining in elastic sealing material which is connected to the design of the coupling means (6-10, 12, 14, 18) and which is compressed when adjacent floorboards (1, 1 ') are interconnected. Floorboard according to claim 19 or 20, (30) characterized in that the core is a core of wood fiber material. Floorboard according to one of Claims 19 to 21, characterized in that (6-10, 12, 14, 18) are designed for mechanical interconnection of nets, such as that the coupling means adjoin floorboards (1, 1 ') around a vertical joint. 10 15 20 25 30 U) U1 floor (VP) 519 791 47 the front of the floorboard. Floorboard according to one of Claims 19 to 22, both perpendicular to it and perpendicular to the jaw - characterized in that it is four-sided and has joint sealing means (6-10, 12, 14, 18) along all its opposite joint edge portions . Floorboard according to one of Claims 19 to 23, characterized in that the coupling means (6-10, 12, 14, 18) are designed for connecting a floorboard (1) to an already laid floorboard (1 '). by angling and / or snapping to the locked position. n a d thereof, that the coupling means (6-10, 12, 14, grasp a lower lip or locking strip Floor board according to claim 24, (6), characterized in that it is formed in one piece with the core (30) and is included in the mechanical coupling means (6-10, 14, 18). Floor panel according to claim 25, 12, characterized in that the coupling means (6-10, 12, 14, 18) comprise an integrated locking strip material other than the core elements (21a, (6). (6) 21b), which is formed by one and which is attached to fasteners formed along one of the opposite parallel joint edge portions of each floorboard. n e t e c k n a d thereof, Floor panel according to one of Claims 19 to 26, characterized in that it comprises a step sound insulation layer (36) of plastic between the core (30) and the decorative and wear layer (34). n a t Floorboard according to claim 27, in that the characteristics of the step sound insulation layer - (36), free surface portions facing the joint are formed by cutting machining in connection with the design of the coupling means (6-10, 12, (55a, 14), 18) adjacent floorboards are interconnected 55a, L Floor board according to any one of claims 19-28, c: C n 1.1 a d. Thereof, 55b) are formed with contact surfaces, that the joint sealing means (and are designed as joint seal 55b), which are compressed when inclined to the top of the floorboards in an interconnected condition. A method of manufacturing a core (30), which is intended for the manufacture of floor panels or panel blanks for division into floor panels, which in turn are intended for chip-cutting processing into floorboards (1) with opposite joint edge portions (86, 87). ), which core (30) is formed of a sheet-shaped material, in particular sheet-shaped wood fiber material, characterized in that the sheet-shaped material within strip-shaped areas (44), from which the coupling means (9, 10) of the future floorboards for vertical joining (D1) is intended to be formed, is provided with grooves (41) extending from the surface of the disc-shaped material and that an elastic sealing material (50, 5a, 59b) is inserted in these grooves. 31. A method according to claim 30, characterized in that the elastic sealing material (50, 50a, 50b) is cast or extruded in said groove (41) for firm anchoring in the core (30). A method according to claim 30 or 31, characterized in that the elastic sealing material (50, 50a, 50b) is formed of acrylic plastic-based material, elastomers of synthetic rubber, urethane rubber, silicone rubber or the like, or of polyurethane-based hot melt. glue.