WO2016097303A1

WO2016097303A1 - Modular flooring

Info

Publication number: WO2016097303A1
Application number: PCT/EP2015/080513
Authority: WO
Inventors: Greger SCHOLANDER
Original assignee: Panelterra Investments Ltd.
Priority date: 2014-12-19
Filing date: 2015-12-18
Publication date: 2016-06-23
Also published as: EP3256668A1; SE539824C2; SE1451623A1

Abstract

A support structure (100, 200) for a flooring element (110, 210) of an interlockable flooring module (10) is disclosed. The support structure comprises a fastening means (120) adapted to engage with a receiving structure (140) at an underside of the flooring element such that the flooring element is secured to the support structure at least in a vertical direction and a first lateral direction (A) of the flooring module. Further, a positioning means (130, 230) is arranged to secure the flooring element at least in a second lateral direction (B) of the flooring module. The disclosed flooring element may be pushed into position and secured to the support structure without using any additional attachment members.

Description

MODULAR FLOORING

TECHNICAL FIELD

The present disclosure generally relates to the field of floorings, and in particular floorings comprising flooring modules with flooring elements and a support structure.

BACKGROUND

Modular floorings are known, comprising a plurality of flooring modules that can be arranged side by side to form a covering of an underlying floor or ground surface. A flooring module may e.g. comprise flooring elements, such as boards, slats or one or several tiles, which are attached on a support structure by e.g. screw connections. In WO 2013/156626 A1 a flooring module is disclosed, comprising a finishing element that is attached to a support element. Each finishing element comprises an upper side that is intended to be exposed, an opposing lower side and side faces with which attachment members of the support element are engaged to attach the finishing element to the support element.

There is however a need for a flooring module and a support structure being less expensive and easier and more straightforward to manufacture and assemble. An object of the invention is therefore to provide a support structure and a flooring module being less expensive to manufacture. In particular, it is an object to enable a flooring module that is easier and more straightforward to manufacture and assemble SUMMARY OF THE INVENTION

The above-mentioned object is achieved by the present invention according to the independent claims. Preferable embodiments are defined in the dependent claims.

Hence, according to a first aspect, a support structure for a flooring element of an interlockable flooring module is provided. The support structure comprises a fastening means and a positioning means, wherein the fastening means is adapted to engage with a receiving structure at an underside of the flooring element such that the flooring element is secured to the support structure at least in a vertical direction and a first lateral direction of the flooring module. Further, the positioning means is adapted to abut an edge of the flooring element so as to secure the flooring element at least in a second lateral direction of the flooring module.

According to a second aspect, a flooring module is disclosed which comprises at least one flooring element and a support structure according to the first aspect. The present aspects are based on the insight that by providing a fastening means that is adapted to engage with a receiving structure of a flooring element, the flooring element may be secured or snap-locked to the support structure when pushed into position and without using any additional fastening devices or means such as screws, bolts, nails or adhesives. The flooring element may be secured to the support structure in a vertical direction, e.g. a direction facing away from an exposed surface of the resulting flooring, and in a first lateral direction, i.e. in a direction parallel to the exposed flooring surface. The term "snap-lock" should be understood as an automatic fastening of the flooring element when it is pushed into position, preferably in the vertical direction. In one example the support structure may rest on e.g. the ground as the flooring element is pushed into position from above. Further, by providing a positioning means adapted to abut an edge or side surface of the flooring element, the flooring element may be secured in a second lateral direction. Preferably, the second lateral direction may be substantially orthogonal to the first lateral direction such that the flooring element may be prevented from moving in any lateral direction. The flooring element may hence be assembled and secured to the support structure in a single move by pushing the flooring element into position, which allows for an easier and more straightforward manufacturing process. The manufacturing process may also be faster, since no additional securing or adjusting of the floor element to the support structure is needed. Further, reducing the number of components, such as screws, nails or bolts, and also the need for additional fastening means such as e.g. adhesives, allows for a reduction of cost. In the context of the present application, the term "fastening means" may be understood as a protruding mechanical means or structure that can be inserted in, or engaged with, an underside of a flooring element, preferably in a recess, hollow or cavity of the flooring element, in order to fasten or secure the flooring element to the support structure in at least two different directions, i.e. vertically and in a lateral direction. The fastening means may e.g.

comprise hooks or barbs or other projections adapted to make extraction of the fastening means from the receiving structure difficult. Alternatively, or additionally, the engagement may be achieved by means of gluing or a frictional fitting between the fastening means and the receiving structure.

By the term "secure" should be understood an engagement preventing, impeding or at least reducing relative motion between a flooring element and the support structure. Further, the term "positioning means" may refer to a protruding member or structure supporting one or several flooring elements in at least one lateral direction. The positioning means may be securely fastened to the support structure or arranged as a separate part between two neighbouring flooring elements. The positioning means may e.g. be formed or act as a spacer block maintaining a distance between two or several flooring elements. Further, the positioning means may be provided with a slanting surface on which the flooring element may slide and thus being guided into its position during the assembling.

The receiving structure may e.g. be formed by removing material from a portion of the underside of the flooring element, i.e. the side of the flooring element intended to face the underlying floor surface or ground, so as to form a recess. The recess or receiving structure may e.g. be formed as a milled groove, which may be formed in connection with the assembling of the flooring module or provided in advance. The milling of the receiving structure may be performed in parallel and simultaneously on one or several flooring element(s) so as to increase throughput of the manufacturing process.

A groove-shaped receiving structure allows for one or several receiving structures to be provided in a single, continuous move through a profiling and/or edge processing equipment, such as e.g. a milling tool. By using edge processing and/or profiling tools instead of e.g. drilling tools, the process may hence be faster and more efficient. Further, edge processing and profiling may typically be performed on thinner flooring elements as compared to drilling. Hence, the present embodiment allows for reduced manufacturing costs in terms of shorter processing time and reduced material consumption. According to one embodiment, the fastening means and the positioning means are integrally formed with the support structure. Forming the fastening means, the positioning means and the support structure in one piece is advantageous in that the number of parts, and hence the bill of material, for producing the support structure and/or the flooring module may be reduced. The support structure may e.g. be formed of a plastic or metallic material and may e.g. be provided by molding or milling. During e.g. molding, the fastening means, the positioning means and the support structure may be formed simultaneously and in the same mold. According to some embodiments, the fastening means is adapted to be form- fitted with the receiving structure. The receiving structure may e.g. be formed as a groove adapted to engage with a complementary, tongue-shaped fastening means.

According to one embodiment, the fastening means is formed as a tongue having a sideward projecting shoulder adapted to engage with a

complementary recess of the receiving structure. During assembling, wherein the flooring element may be pushed into position on the support structure or vice versa, the shoulder may be pushed or forced into position in the recess so as to establish the engagement.

According to one embodiment, the fastening means may have a length extension along the second lateral direction of the flooring module. In other words, the fastening means may have an extension along a direction that is different from the lateral direction in which the fastening means secures the flooring module on the support structure. In one example, the fastening means may be formed as a prolonged protrusion extending laterally in the second direction and engaging with a corresponding recess of the receiving structure such that the flooring element is prevented from moving or sliding in a lateral direction orthogonal to the lateral extension of the fastening means. In a further example, the fastening means may be configured to allow a motion of the flooring element in the second lateral direction, i.e. parallel to the length extension of the fastening means. The flooring element may hence be allowed to slide in the second lateral direction during assembling, which may make it easier to adjust or guide the flooring element into a desired lateral position. According to one embodiment, the flooring element may be elongated, i.e. having a main, longitudinal extension. Further, the first lateral direction of the flooring module may be parallel to the longitudinal extension of the flooring element. In other words, the flooring element may be formed as a slat or board which is secured in its length direction by the fastening means and e.g. in its width or transverse direction by the positioning means.

According to one embodiment, the support structure is adapted to support a plurality of flooring elements. The flooring elements may e.g. be slat-formed or board-formed, and may e.g. be mounted on or attached to the support structure sequentially, i.e. one by one, or in a single processing step. During the mounting process, a flooring element may be placed and possibly aligned on the support structure. The flooring element may then be pushed into position by means of an applied force so as to bring the fastening means into engagement with the receiving structure. Several or all of the flooring elements of a flooring module may be pushed into position in a single stroke or processing step to reduce a cycle time of the mounting process. It will however be realized that the support structure may be placed and aligned on one or several flooring elements, and then pushed into

engagement with the flooring elements by e.g. a force applied to the support structure. According to one embodiment, the support structure may comprise a grid, i.e. framework of spaced bars or bridges that are parallel to, or crossing, each other. The grid may be adapted to support a plurality of flooring elements and to prevent, impede or at least reduce relative motion of the flooring elements. The bars of the grid may be arranged to extend parallel, transverse or any other suitable direction relative to the flooring elements.

According to one embodiment, the support structure may be adapted to be interlocked with other support structures by means of mutually engageable projections and recesses, such as latches and hooks.

Further, it will be appreciated that the flooring element may be formed of wood, plastic, stone, ceramics, or any other suitable flooring material. It is noted that embodiments of the invention relates to all possible

combinations of features recited in the claims. Further, it will be appreciated that the various embodiments described for the support structure according to the first aspect are all combinable with embodiments of the flooring module as defined in accordance with the second aspect.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects will now be described in more detail with reference to the appended drawings showing embodiments.

Figure 1 a shows a perspective view of a support structure according to an embodiment.

Figure 1 b shows a perspective view of flooring elements according to another embodiment.

Figure 2 shows a top view of a flooring module comprising a support structure on a flooring element according figure 1 a and b. Figures 3a-c show cross sectional side views of a receiving structure according to some embodiments.

Figure 4 show a perspective view of a flooring comprising a plurality of flooring modules according to an embodiment.

All the figures are schematic, not necessarily to scale, and generally only show parts which are necessary in order to elucidate the embodiments, wherein other parts may be omitted or merely suggested. Like reference numerals refer to like elements throughout the description. DETAILED DESCRIPTION

The present aspects will now be described more fully hereinafter with reference to the accompanying drawing, in which currently preferred embodiments are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness, and fully convey the scope of the present aspects to the skilled person. A support structure according to an embodiment will be described with reference to figure 1 a. The support structure 100 is formed of a grid structure, such as a plastic net, having a lateral extension in a first lateral direction, indicated by arrow A in figure 1 , and a second lateral direction, indicated by arrow B.

The support structure may comprise one or several fastening means 120 which according to the present embodiment may be formed as vertically protruding flanges or tounges adapted to engage with a receiving structure at an underside of a flooring element (not shown in figure 1 a) in order to secure the flooring element on the support structure in a vertical direction. The fastening means 120 may have a lateral extension along the second lateral direction B, and may be adapted to secure the flooring element at least in the first lateral direction A. Further, the fastening means 120 may be integrally formed with the support structure 100.

The support structure 100 may further comprise positioning means 130 projecting in a vertical direction from the support structure and being adapted to position and secure or support flooring modules in the second lateral direction B. The positioning means 130 may be adapted to abut a vertical side surface or portion of a flooring element, thereby acting as a spacer

maintaining lateral position of the flooring element and a distance between neighbouring flooring elements. According to one example, a positioning means 130 may be provided with a slanting surface portion or a peaked portion for guiding a flooring element into its position as the flooring element is being arranged on the support structure. The slanting surface or peak may be directed upwards, i.e. away from the support structure 100, and adapted to guide the flooring element into position by allowing it to slide on the slanting surface or peak. The positioning means 130 and the support structure 100 may be formed in one piece.

Further, the support structure 100 may comprise mutually engageable connectors, such as latches 150 and hooks 160, which may be arranged at side portions or edges of the support structure 100 so as to allow the support structure 100 to be interlocked with neighbouring support structures.

Figure 1 b shows flooring elements 1 10 according to some embodiments. The flooring elements 1 10 may e.g. be formed as slats or boards which may be arranged with their length extension along the first lateral direction A.

Receiving structures 140 may be formed as recesses or grooves at the underside of a flooring element 1 10 and may e.g. extend along the entire width of the flooring element 1 10. As shown in figure 1 b, a flooring element 1 10 may comprise four grooves 140 - one groove 140 at each end portion and two grooves 140 distributed therebetween.

Each one of the four grooves 140 may be adapted to engage with a corresponding flange 120 of the support structure so as to secure the flooring elements 1 10 to the support structure 100 in the first lateral direction A, i.e. the length direction of the flooring elements 1 10, and in a vertical direction. The flooring elements 1 10 may e.g. be attached to the support structure 100 (or vice versa) by means of an applied force, or, in other words, by pushing the flooring elements 1 10 (or support structure 100) into position. The grooves 140 may e.g. be formed by means of a milling tool, which may be adapted to simultaneously produce several grooves 140 in one or several flooring element 1 10 in parallel. Figure 2 shows a top view of a flooring module 10 according to an

embodiment. The flooring module 10 may be formed of one or several flooring elements, such as five wood slats 210, arranged on an underlying support structure 200. The flooring elements 210 and the support structure 200 may be similarly configured as the flooring elements and support structure described with reference to figures 1 a and b.

As indicated in figure 2, the positioning means 230 may be arranged to abut vertical side portions of the wood slats 210 so as to secure them in the second lateral direction B and to maintain a desired distance between each wood slat 210. The postioning means 230 may have a vertical extension, i.e. an extension in the direction of the thickness of a wood slat 210, that is less than the thickness of the wood slat 210. The positioning means 230 may therefore provide lateral support without projecting out from the upper surface of the flooring module 10.

The flooring module 10 may also be provided with connectors, such as hooks 250 and latches 260, for interlocking flooring modules to each other so as to form a flooring.

Figures 3a to c are vertical cross sections of a portion of a flooring element according to figures 1 b and 2, wherein the cross sections are taken along the second lateral direction B.

Figures 3a and b illustrate a cross sectional profile of the receiving structure 140, which e.g. be formed as a groove having a neck or shoulder 142 close to the lower surface of the flooring element 1 10. The neck 142 may be adapted to engage with a corresponding shoulder 122 of a fastening means 120 as shown in figure 3b. The fastening means 120 may be at least partially elastic such that the fastening means 120 can be pushed into position in the receiving structure 140 by means of an applied force. The fastening means 120 may e.g. be formed of a plastic material that can be slightly deformed during insertion in the receiving structure 140.

As shown in figure 3c, a receving structure or groove 140 may be arranged at an end portion of a flooring element 1 10. Such groove 140 may be provided with a shoulder 142 so as to secure the end portion to the support structure.

It will however be appreciated that the fastening of the fastening means into the receiving structure may be realised by other mutual engageable configurations, such as frictional fittings, or adhesive means.

Figure 4 shows an example of a flooring 20 comprising a plurality of interlocked flooring modules 10 similar to the flooring module described with reference to figure 2. The flooring modules 10 may be arranged side by side and attached to each other by means of connectors (not shown) so as to form a desired flooring.

The person skilled in the art realises that the present invention by no means is limited to the preferred embodiments described above. For example, the number of flooring elements may vary from one single piece to any suitable number. Furter, the flooring element(s) do not necessarily have to extend from edge to edge of the support structure. In the contrary, any number and sizes of flooring element(s) may be combined to partly or fully cover the support structure. Additionally, variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope.

Claims

1 . Support structure (100, 200) for a flooring element (1 10, 210) of an interlockable flooring module (10), the support structure comprising:

a fastening means (120); and

a positioning means (130, 230);

wherein the fastening means is adapted to engage with a receiving structure (140) at an underside of the flooring element so as to snap lock the flooring element to the support structure at least in a vertical direction and a first lateral direction (A) of the flooring module when the flooring element is pushed in the vertical direction into position;

the positioning means is adapted to abut an edge of the flooring element so as to secure the flooring element at least in a second lateral direction (B) of the flooring module.

2. The support structure according to claim 1 , wherein the fastening means and the positioning means are integrally formed with the support structure.

3. The support structure according to claim 1 or 2, wherein the fastening means is adapted to be form-fitted with the receiving structure.

4. The support structure according to any one of the preceding claims, wherein the fastening means is formed as a tongue adapted to engage with a receiving structure formed as a groove.

5. The support structure according to any one of the preceding claims, wherein the fastening means is formed as a tongue having a shoulder (122) adapted to engage with a complementary recess (142) of the receiving structure.

6. The support structure according to any one of the preceding claims, wherein the fastening means has a length extension along the second lateral direction of the flooring module.

7. The support structure according to any one of the preceding claims, wherein the first lateral direction is parallel to a longitudinal extension, extending along an axis/direction (A), of the flooring element.

8. The support structure according to any one of the preceding claims, wherein the support structure is adapted to support a plurality of slat-formed flooring elements.

9. The support structure according to any one of the preceding claims, wherein the support structure is formed as a grid.

10. The support structure according to any one of the preceding claims, wherein the support structure is adapted to be interlocked with other support structures by means of mutually engageable connectors (150, 160, 250, 260).

1 1 . The support structure according to any one of the preceding claims, wherein the support structure is formed of a plastic material.

12. A flooring module (10) comprising at least one flooring element (1 10, 210) and a support structure (100, 200) according to claim 1 .

13. The flooring module according to claim 12, comprising a plurality of flooring elements formed of wood slats.