US20230193635A1

US20230193635A1 - Mechanical coupling means for flooring or covering panels and flooring or covering panel provided with such means

Info

Publication number: US20230193635A1
Application number: US17/912,596
Authority: US
Inventors: Livio BARBIERO
Original assignee: Interlocking SRLS
Current assignee: Interlocking SRLS
Priority date: 2020-03-27
Filing date: 2021-02-19
Publication date: 2023-06-22
Also published as: EP4127652A1; IT202000001333U1; WO2021190833A1

Abstract

A coupling device couples first and second edges of first and second flooring or covering panels. The coupling device includes a projection on at least a portion of the first edge and a groove in at least a portion of the second edge, the coupling device locking the first and second edges one in a first direction perpendicular to the lying plane of the panels and in a second direction parallel to the lying plane. The projection includes first and second retaining appendages, the first projecting from the first edge along an axis inclined by a first angle with respect to the main plane of the first panel, the second being arranged below the first appendage and projecting along an axis orthogonal to the lying plane of the first panel, the groove having a first and second retaining seats counter-shaped with respect to the first and second retaining appendages.

Description

TECHNICAL FIELD OF THE INVENTION

The present invention relates to mechanical coupling means, in particular for coupling a pair of modular flooring or covering panels, and a modular flooring or covering panel provided with such means.

State of the Art

Among the various alternatives that can be used to floor an environment, whether for residential or commercial use, the flooring with pre-finished parquet is the most appreciated.
Generally, pre-finished parquet floors are made by laying, in different ways and according to a desired geometry, a plurality of modular panels, up to covering a resting surface, commonly referred to as “substrate”, of the environment to be floored.
For convenience, these panels, also referred to as “strips”, are generally rectangular parallelepiped-shaped, of variable sizes and thicknesses, and they substantially consist of at least one support layer, often made of a multilayer of birch wood with thickness comprised between 7 and 10 mm, to whose top part there is applied a “hardwood” layer forming the walking surface, made of hardwood, having a thickness generally comprised between 2.5 and 4 mm, but sometimes even less. Furthermore, a “counter-balancing” layer may be optionally provided for beneath the support layer.
Currently, floorings with pre-finished parquet are made by freely installing modular panels in the substrate, coupling them to each other with a male-female coupling.
However, a flooring obtained with a male-female coupling of the aforementioned type reveals the drawback lying in the fact that the modular panels of the floor are subject to displacement, for example due to climatic and environmental factors, and as a result undesired openings or localised lifting can form.
In order to overcome this drawback, for example there can be provided for applying an adhesive agent at the connection point between two adjacent panels, so as to make the coupling more stable and durable; however, besides deteriorating the health of the environment and complicating the laying operations thereof, the use of adhesives complicates the subsequent removal or replacement of the modular panels.
Alternatively, when laying the floor, there can be provided for special connection brackets, preferably made of metal or polymeric material, suitable to be arranged at the joining point between two adjacent modular panels so as to hold them in mutual contact. However, such connection brackets entail additional costs and they require particular care when laying the floor.
Lastly, the mechanical coupling means of the “click” type which allow a fully dry laying of the floor, without the aid of adhesive agents have proven to be very handy and effective: such coupling means provide for a suitable shaping of the male-female couplings so that the coupling of two modular panels occurs by means of a roto-translation.
Therefore, such mechanical coupling means prevent the displacement of two modular panels previously coupled both in a perpendicular direction and also in a direction parallel to the plane defined by the panels. An example of such coupling means is shown in document WO9966151.
Although such mechanical coupling means operate in a rather satisfactory manner, being widely used in laying floating parquet floors throughout the world, creating special shapes to be conferred to the male and female coupling portions requires complex machining operations, carried out using machines provided with numerous tools.
Furthermore, machining waste is quite high, with a high economic loss, given the large number of the parquet flooring currently made.
The same drawbacks noted above are also observed in the manufacture and laying of covering panels for any type of surface, which generally consist of a single layer of the desired material, such as wood, polymeric material or other material, depending on the function they are designed for.
Therefore, the main object of the present invention is therefore to provide mechanical coupling means for flooring or covering panels which, considering the same sealing as that of the existing coupling means, allows to reduce the machining waste, allowing saving in economic terms.
In the context of the task outlined above, an object of the present invention is to provide mechanical coupling means for modular flooring or covering panels which are capable of effectively resisting against any movements due to dilations or contractions caused by thermo-hygrometric variations of the environment in which the panels are laid.
A further object of the present invention is to provide mechanical coupling means which allow to lay modular flooring or covering panels in a simple and rapid manner and which can be produced using machines and commonly used and low-cost material.
Another object of the present invention is to provide a flooring or covering panel that is functional and durable.
The tasks and objects outlined above, and others which will be more apparent from the following description, are attained by coupling means for flooring or covering panels as defined in claim 1, and by a modular flooring or covering panel as defined in claim 3.

BRIEF DESCRIPTION OF THE FIGURES

Advantages and characteristics of the present invention will be apparent from the following description, provided by way of non-limiting example, with reference to the attached figures, wherein:

FIG. 1 shows, according to a plan view, a floor portion made with a plurality of modular flooring panels according to the present invention;

FIG. 2 shows, with a plan view, a modular flooring panel provided with mechanical coupling means according to the present invention;

FIG. 3 shows the modular flooring panel according to FIG. 2 , sectioned along the plane A-A;

FIG. 4 shows, with sectional view, of the coupling means according to the present invention in a coupling step between a pair of modular flooring panels arranged adjacent.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the aforementioned figures, represented is a flooring panel 1, adapted to constitute the base module for creating a floor 100, such as for example a parquet floor of the pre-finished type and suitable to be laid dry. It is clearly understood that the present invention also relates to a modular covering panel for covering any resting surface.
In the following description, terms such as “above”, “under”, “higher”, “lower”, “high”, “low” or the like refer to a panel 1 in its normal operative configuration, i.e. in use, as shown in the attached figures.
FIG. 1 illustrates a floor portion 100 directly laid on a flat resting surface, referred to as “substrate”, consisting of a plurality of modular flooring panels 1 arranged side by side, for example in staggered rows (quincunx).
For practical reasons, each modular flooring panel 1 according to the present invention is preferably substantially parallelepiped-shaped, and furthermore it is advantageously provided with coupling means 8 by means of which it can be mechanically connected to adjacent modular panels 1 for forming said floor 100, as explained more in detail hereinafter.
As shown in FIG. 2 , said modular flooring panel 1 is advantageously perimetrically delimited by a pair of longitudinal side edges 2, 3 and by a pair of opposite transversal edges 4, 5 with respect to the longitudinal extension direction X-X of the panel 1, an upper walking or aesthetic surface 70 and a lower surface 60 for resting against the substrate, preferably flat and parallel to each other.
Preferably, the body of a flooring panel 1 comprises a body layer 6, for example made of a multilayer made of birch wood, MDF, HDF or other suitable material, defining, at the bottom part, the lower surface 60 and to whose top part there is coupled a surface covering layer 7 preferably made of wood, for example hardwood, suitable to form said upper surface 70.
The body layer 6 has a thickness S1 preferably comprised between 6 and 10 mm, and the covering layer 7 has a thickness S2 lower than the thickness S1 and preferably comprised between 2,5 and 4 mm, but sometimes even lower.
Alternatively, were said panel 1 to be a covering panel, it can consist of a single body layer 6 made of a suitable material, defining the upper 70 and lower 60 surfaces.
Preferably, as represented in FIG. 3 , at least on said pair of longitudinal edges 2, 3, but possibly even on said transversal edges 4, 5, mechanical coupling means 8 are provided, advantageously made in a single piece with the material forming the body layer 6 of said panel 1 and shaped so that two or more modular panels 1 can be mutually coupled to each other by means of said mechanical coupling means 8.
In particular, said coupling means 8 advantageously comprise a projection 8A, extending at least along a portion of a first longitudinal edge 2 of the panel 1, and preferably for the entire extension thereof, and a groove 8B extending at least along a portion of a second longitudinal edge 3 of the panel 1, and preferably for the entire extension thereof.
Preferably, said projection 8A and said groove 8B are obtained by removing the material forming said body layer 6 through special tools, such as in particular milling cutters arranged at a suitable angle.
Said mechanical coupling means 8 are advantageously shaped so that the projection 8A obtained on a first longitudinal edge 2 of a first panel 1 is adapted to be engaged, as explained more in detail hereinafter, with a groove 8B obtained on a second longitudinal edge 3 of a second panel 1, so as to couple the two modular panels.
Advantageously, as explained more in detail hereinafter, the coupling between two adjacent modular panels 1 can be obtained by means of at least one rotation of said projection 8A in the corresponding groove 8B.
As observable in FIG. 3 , said projection 8A is shaped so as to have a first and a second retaining appendage 9, 10, preferably directly connected.
Said first retaining appendage 9 is advantageously arranged in proximity of the upper surface 70 of the panel 1 and projecting from the first longitudinal edge 2 along an axis Y-Y having an inclination with a first angle α comprised between 10° and 30°, and preferably equal to about 20°, with respect to the lying plane defined by said panel 1.
Said first appendage 9 is configured so as to have an end head 9A that is advantageously rounded, lying on a curved surface having a radius of curvature R, advantageously equal to about 3.5 mm.
Said second retaining appendage 10, on the other hand, is advantageously arranged below said first appendage 9, proximal to said lower surface 60 of the panel 1, and projecting downwards from said first appendage 9 with an extension along an axis Z-Z essentially orthogonal to the latter. Also said second appendage 10 is preferably provided with a rounded end head 10A lying on a curved surface preferably having the same radius of curvature R as the head 9A of said first appendage 9.
Said first appendage 9 is connected to the upper surface 70 of the modular panel 1 through a first edge portion 11, preferably straight and lying on a first plane P1 orthogonal to the lying plane of said panel 1, said second appendage 10 is connected—at the bottom part—to said lower surface 60 through a second edge portion 12, preferably straight and lying on a second plane P2 advantageously parallel to said first plane P1 and arranged more receded toward the internal of the body of the panel 1 with respect to the latter by a distance D equal to about 3 mm.
Said second appendage 10 preferably extends in a space comprised between said first and second plane P1, P2.
Advantageously, arranged between said first edge portion 11 and said first appendage 9 is a connecting section 13, having an extension substantially parallel to the main lying plane of the panel 1, suitable to allow the recovery of clearance between two coupled adjacent modular panels 1, as explained more in detail hereinafter.
As regards said groove 8B, it is substantially counter-shaped with respect to said projection 8A. In particular, said groove 8B comprises a first and a second retaining seat 19, 20 preferably obtained in the body layer 6 of the modular panel 1. Said first seat 19 is adapted to receive said first appendage 9 and thus it extends recessed in the body layer 6 with respect to said longitudinal edge 3 along an axis Y-Y having an inclination with the same first angle α and it is provided with a rounded bottom surface 19A, advantageously lying on a curved surface having a radius of curvature R.
Said second seat 20, on the other hand, extends in proximity of the lower surface 60 of the panel 1, along a direction Z-Z orthogonal to the plane of the panel 1, and it is adapted to receive said second appendage 10. Advantageously, said second seat 20 is provided with a rounded bottom portion 20A, lying on a curved surface having a radius of curvature R.
Said first seat 19 is connected to the upper surface 70 of said panel 1 through a third edge portion 21 lying on a third plane P3 advantageously inclined toward the external by a second angle β, equal to about 2°.
On the other hand, said second seat 20 is directly connected to the lower surface 60 through a fourth edge portion 22 lying on a fourth plane P4 orthogonal to the latter and positioned more arranged more advanced toward the external of the of the body of the panel 1 with respect to the third plane P3.
Said second seat 20 preferably extends in a space comprised between said third and said fourth plane P3, P4.
As shown in FIG. 4 , in order to obtain the stable coupling between a pair of modular panels to be arranged adjacent, it is necessary to couple said coupling means 8 with a dry mechanical joint.
In particular, a first modular panel 1 is initially laid, so that the lower surface 60 rests on said resting surface and subsequently approaching the projection 8A of a second modular panel 1 to the groove 8B of the latter, by means of a translation movement indicated by the arrow T, keeping it inclined by about 20°, so as to allow said first appendage 9 to penetrate into the corresponding first seat 19.
As soon as said first appendage 9 engages into the first seat 19, it is sufficient to rotate said second modular panel 1, as shown by the arrow V of FIG. 4 , so that the entire profile of the projection 8A is received in the groove 8B.
Such rotary movement is advantageously guided by the rounded shape respectively of the end heads 9A, 10A of the appendages 9 and 10 and of the corresponding bottom portions 19A, 20A of the retaining seats 19, 20, thus making the coupling between two side by side panels fluid.
Once insertion has been completed, the second edge portion 12 of the second modular panel 1 is positioned substantially in abutment against the fourth edge portion 22 of the first modular panel 1.
Similarly, said third edge portion 21 is arranged partially in abutment against the first edge portion 11 of the adjacent panel but, thanks to the slight outward inclination thereof by second angle β, it is possible to confer continuity to the walking surface defined by the corresponding upper surfaces 70, by limiting the amplitude of the gap between the two panels. The connecting section 13 provided for on said projection 8A allows to recover the clearance between the two panels, keeping them firmly in contact with each other.
Advantageously, it is possible to obtain the de-coupling of said pair of modular panels 1 by proceeding with a reverse rotary and translation movement in the opposite direction with respect to the coupling direction.
In case that also said transversal edges 4, 5 of the panel 1 are provided with coupling means 8 such as those described above, it would still be possible to lay a floor or a covering by mutually connecting the transversal edges 4, 5 of panels 1 to each other according to the process described above, to form a row of adjacent panels; subsequently, the entire row can be moved to allow the coupling of the coupling means 8 provided for along said longitudinal edges 2, 3. Alternatively, said transversal edges 4, 5 may optionally be provided with different coupling means, or even without them.
In conclusion, in the light of the above it is clear that the present invention attains the objects and advantages initially provided for.
In fact, mechanical coupling means 8 for modular flooring or covering panels which allow to effectively stand against any movements due to dilations or contractions caused by thermo-hygrometric variations of the environment in which the panels are laid are provided.
Moreover, thanks to the particular configuration of the coupling means 8, in which retaining appendages 9, 10 oriented according to different directions are provided, a double resistance against stresses can be obtained, allowing to maintain the initial hardness of the coupling over time.
The coupling means 8 according to the present invention allow a quick and simple laying of the flooring or covering panels that are provided therewith, also making it easy to remove them for possible replacement. Furthermore, the entire floor 100 or covering can be removed and repositioned in a different environment, if necessary.
However, once coupled, said modular panels cannot be de-coupled either by means of a translation along a direction orthogonal to the lying plane of the panels, or by means of a translation along a direction parallel to the plane of the panels, thus ensuring the stable coupling thereof.
Lastly, as will be apparent to a man skilled in the art, the shape of the coupling means 8 can be easily obtained with simple machines equipped with a reduced number of tools.
Furthermore, given that the shape of said coupling means 8 is rather compact, the waste that is obtained for the provision thereof on a panel 1 is less than that of the prior art solutions, allowing to save material by about 3%; this, taking into account the large number of the parquet floors that are laid each year, allows considerable saving from an economic standpoint.
Obviously, the present invention is susceptible of numerous applications, modifications or variations without departing from the scope of protection, as defined in the attached claims. Furthermore, the materials and equipment used to implement the present invention, as well as the shapes and dimensions of the individual components, may be the most suitable depending on the specific requirements.

Claims

1. A coupling means for coupling a first edge of a first flooring or covering panel and a second edge of a second flooring or covering panel, both adapted to be arranged adjacent on a resting surface, the coupling means comprising a projection provided for on at least a portion of the first edge and a groove provided for on at least a portion of the second edge, the coupling means being shaped so as to lock the first and second edge one with the other in a first direction perpendicular to the lying plane of the panels and in a second direction parallel to the lying plane of the panels,

wherein

the projection comprises a first and a second retaining appendage, the first retaining appendage projecting from the first edge along an axis inclined by a first angle with respect to the lying plane of the first panel, the second retaining appendage being arranged below the first retaining appendage and projecting therefrom along an axis orthogonal to the lying plane of the first panel, the groove comprising a first and a second retaining seat counter-shaped with respect to the first and second retaining appendage.

2. The coupling means according to claim 1, wherein the first and the second retaining appendage each have a rounded end head lying on a respective curved surface having the same radius of curvature, the first and the second retaining seat each having a rounded bottom portion lying on a curved surface having the same radius of curvature as the end heads of the corresponding retaining appendages.

3. The covering or flooring panel comprising:

a parallelepiped-shaped body defining a lying plane of the panel and provided with a lower surface and an upper surface, opposite and parallel, the lower surface being adapted to be arranged on a resting surface; and

coupling means obtained at least on one pair of opposite longitudinal edges of the panel, so that different panels can be mutually coupled to each other, the coupling means comprising a projection obtained on at least a portion of a first longitudinal edge and a groove obtained on at least a portion of a second longitudinal edge,

wherein

the projection comprises a first and a second retaining appendage, the first retaining appendage projecting from the first longitudinal edge along an axis inclined by a first angle with respect to the lying plane of the panel, the second retaining appendage being arranged below the first appendage and projecting therefrom along an axis orthogonal to the lying plane of the panel, the groove comprising a first and a second retaining seat counter-shaped with respect to the first and second retaining appendage.

4. The panel according to claim 3, comprising at least one body layer, the coupling means being made in a single piece with the material forming the body layer.

5. The panel according to claim 4, wherein the body layer is made of a wooden multilayer having a first thickness, whereon a covering layer made of wood having a second thickness lower than the thickness of the body layer is coupled at the top part.

6. The panel according to claim 4, wherein the projection and the groove are formed by milling the material forming the body layer.

7. The panel according to claim 3, wherein the first and the second retaining appendage have a rounded end head lying on a respective curved surface having the same radius of curvature.

8. The panel according to claim 7, wherein the first and the second retaining seat having a rounded bottom portion lying on a curved surface having the same radius of curvature as the end heads of the corresponding retaining appendages.

9. The panel according to claim 3, wherein the first retaining appendage is connected at the top part to the upper surface through a first edge portion lying on a first plane orthogonal to the upper surface, the second retaining appendage being connected at the bottom part to the lower surface through a second edge portion lying on a second plane parallel to the first plane and arranged more receded toward the internal of the body of the panel with respect to the latter.

10. The panel according to claim 9, wherein between the first edge portion and the first retaining appendage a connecting section having an extension substantially parallel to the upper surface is provided.

11. The panel according to claim 3, wherein the first retaining seat is connected at the top part to the upper surface through a third edge portion lying on a third plane, the second retaining seat being connected at the bottom part to the lower surface through a fourth edge portion lying on a fourth plane orthogonal to the upper surface and arranged more advanced toward the external of the body of the panel with respect to the third plane.

12. The panel according to claim 11, wherein the third plane is inclined with respect to the upper surface toward the external of the body of the panel by a second angle.

13. The panel according to claim 1, wherein the coupling means are also provided for on a pair of opposite transversal edges of the panel, the projection being obtained on at least a portion of a first transversal edge and the groove being obtained on at least a portion of a second transversal edge.