U.S. patent application number 11/330894 was filed with the patent office on 2006-07-27 for floor panel.
Invention is credited to Ralf Eisermann.
Application Number | 20060162271 11/330894 |
Document ID | / |
Family ID | 35985273 |
Filed Date | 2006-07-27 |
United States Patent
Application |
20060162271 |
Kind Code |
A1 |
Eisermann; Ralf |
July 27, 2006 |
Floor panel
Abstract
The invention concerns a floor panel (1) comprising a carrier
panel portion (2, 24, 33, 43, 50a) that is provided at a top side
with a duty layer arrangement (3, 25, 34, 44), which duty layer
arrangement (3, 25, 34, 44) has at least one decorative layer (D)
and edge locking profiles (6a, 6b, 7a, 7b) at at least two mutually
opposite edges of the floor panel, wherein at least one edge
locking profile (6a, 6b, 7a, 7b) has at least one elastically
bendable locking means (V, V1, V2), and wherein material is removed
at least at one side edge portion at the top side of the floor
panel and formed thereby is an obtuse edge (8, 9) with a protection
surface (8a, 9a), and wherein the protection surface (8a, 9a) of
the obtuse edge (8, 9) is provided with a coating, wherein at least
the decorative layer (D) of the duty layer arrangement (3, 25, 34,
44) is bent over at the side edge portion of the floor panel and
that the coating on the protection surface (8a, 9a) of the obtuse
edge (8, 9) is formed by the bent-over decorative layer (D).
Inventors: |
Eisermann; Ralf; (Cochem,
DE) |
Correspondence
Address: |
WHITEFORD, TAYLOR & PRESTON, LLP;ATTN: GREGORY M STONE
SEVEN SAINT PAUL STREET
BALTIMORE
MD
21202-1626
US
|
Family ID: |
35985273 |
Appl. No.: |
11/330894 |
Filed: |
January 12, 2006 |
Current U.S.
Class: |
52/589.1 |
Current CPC
Class: |
E04F 2201/0153 20130101;
E04F 15/02033 20130101; E04F 15/02 20130101; E04F 2201/0115
20130101 |
Class at
Publication: |
052/589.1 |
International
Class: |
E04B 2/08 20060101
E04B002/08 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 12, 2005 |
DE |
10 2005 001 630.8 |
Claims
1. A floor panel comprising a carrier panel portion that is
provided at a top side with a duty layer arrangement, which duty
layer arrangement has at least one decorative layer and edge
locking profiles at at least two mutually opposite edges of the
floor panel, wherein at least one edge locking profile has at least
one elastically bendable locking means, and wherein material is
removed at least at one side edge portion at the top side of the
floor panel and formed thereby is an obtuse edge with a protection
surface, and wherein the protection surface of the obtuse edge is
provided with a coating, characterised in that at least the
decorative layer of the duty layer arrangement is bent over at the
side edge portion of the floor panel and that the coating on the
protection surface of the obtuse edge is formed by the bent-over
decorative layer.
2. The floor panel according to claim 1, characterised in that
there is a separate coating at least on the protection surface of
one of the obtuse edges at the side edge portion of the floor
panel.
3. The floor panel according to claim 2, characterised in that the
separate coating is in the form of a self-adhesive film.
4. The floor panel according to claim 1, characterised in that the
decorative layer is subdivided into different imaging regions.
5. The floor panel according to claim 1, characterised in that the
duty layer arrangement has a surface with a lacquer layer.
6. The floor panel according to claim 1, characterised in that
there is provided a relief having depressions and raised portions
at the surface of the duty layer arrangement.
7. The floor panel according to claim 6, characterised in that the
depressions are in overlapping relationship with given zones of the
decorative layer and the raised portions are in overlapping
relationship with other zones of the decorative layer.
8. The floor panel according to claim 6, characterised in that the
depressions of the relief are produced by a chemical.
9. The floor panel according to claim 6, characterised in that the
depressions of the relief are produced by mechanical embossing.
10. The floor panel according to claim 1, characterised in that the
decorative layer has at least one imitation intermediate joint,
which is in the form of a groove in the top side of the floor panel
and which subdivides the decorative layer into imaging regions.
11. The floor panel according to claim 10, characterised in that
the imitation intermediate joint is of the same free cross-section
as the free space that is afforded when two floor panels are
connected by the mutually adjoining obtuse edges thereof.
12. The floor panel according to claim 10, characterised in that
there is a coating provided on the surface of the groove of the
imitation intermediate joint.
13. The floor panel according to claim 1, characterised in that
there is provided an anti-wear means in the duty layer
arrangement.
14. The floor panel according to claim 13, characterised in that
the anti-wear means has abrasion-resistant particles.
15. The floor panel according to claim 13, wherein the duty layer
arrangement has a surface with a lacquer layer, characterised in
that the anti-wear means is embedded at least in the lacquer layer
at the surface of the duty layer arrangement.
16. The floor panel according to claim 15, characterised in that
the lacquered duty layer arrangement is processed in the form of a
prefabricated layer and joined in the finished condition to the
carrier panel portion.
17. The floor panel according to claim 15, characterised in that
the lacquered duty layer arrangement is attached to the carrier
panel portion with an adhesive.
18. The floor panel according to claim 1, characterised in that the
edge locking profile at at least two oppositely disposed edges of
the floor panel has locking means that act in positively locking
relationship.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention concerns a floor panel comprising a carrier
panel portion that is provided at a top side with a duty layer
arrangement, which duty layer arrangement has at least one
decorative layer and edge locking profiles at at least two mutually
opposite edges of the floor panel, wherein at least one edge
locking profile has at least one elastically bendable locking
means, and wherein material is removed at least at one side edge
portion at the top side of the floor panel and formed thereby is an
obtuse edge with a protection surface, and wherein the protection
surface of the obtuse edge is provided with a coating.
[0003] 2. Description of the Background
[0004] A floor panel of the general kind set forth is known from WO
01/96688 A1. It has a groove-and-tongue connection with an undercut
configuration that is intended to prevent joined floor panels from
moving away from each other. The walls of the groove project from
the edge of the floor panel by differing distances. That groove
wall, which projects further from the edge of the floor panel,
forms the elastically bendable locking means of the known floor
panel.
[0005] Material has been removed at the side edge portion at the
top side of the known floor panel. The material removal extends
into the material of the carrier panel portion. The carrier panel
portion is preferably a wood fiber panel. The obtuse edge is in the
form of a 45.degree. bevel in accordance with WO 01/96688 A1. A
beveled edge as a protection surface is less susceptible to damage
than a right-angled edge without material having been removed. The
coating on the bevel of the known floor panel must be applied, for
example, as a separate color print in a transfer printing process
or a self-adhesive strip is applied.
[0006] There is the disadvantage here that the coating on the
protection surface is very expensive. In addition, the quality of
the coating on the protection surface differs from the quality of
the duty layer arrangement, which is arranged on the top side of
the floor panel.
[0007] Furthermore, the separate layers, more specifically the duty
layer arrangement and the coating on the protection surface, form a
seam or a butt joint. That joint is susceptible to damage by virtue
of one layer or the other being peeled off. In the case of the
coating of WO 01/96688 A1 that applies to a particular degree to
the coating on the protection surface because it extends over the
edge of the duty layer arrangement and reaches the surface of the
duty layer arrangement. Admittedly, on the one hand the
susceptibility to damage of the upper edge of the known floor panel
is reduced by the provision of a 45.degree. bevel. On the other
hand, however, there is a detrimental butt joint in respect of the
separate coatings, which in turn is susceptible to damage because
this makes it easier for a layer to peel off. A damaged joint
between the duty layer arrangement and the protection surface
coating means that moisture or dirt can penetrate as far as the
carrier panel portion. The carrier panel portion is adversely
affected thereby.
SUMMARY OF THE INVENTION
[0008] Therefore, an object of the invention is to improve the
coating on the protection surface of the obtuse edge of the floor
panel.
[0009] According to the invention, that object is attained in that
the decorative layer of the duty layer arrangement is bent over at
the side edge portion of the floor panel and that the coating on
the protection surface of the obtuse edge is formed at least by the
bent-over decorative layer.
[0010] Two different things are achieved in that way. On the one
hand, the coating on the protection surface can be such that there
is no difference in quality in relation to the duty surface on the
top side of the floor panel, unless the bent-over portion of the
coating is to be deliberately of a different quality from the duty
layer arrangement on the top side of the floor panel. The latter
would be the case, for example, when the top side is provided with
an anti-wear means, whereas the anti-wear means is dispensed with
in the region of the coating on the protection surface because the
abrasion wear is less there. On the other hand, there is a bend
edge instead of the butt joint known from the state of the art. The
duty layer arrangement forms an integral transition into the
coating on the protection surface at the bend edge.
[0011] The one-piece configuration, according to the invention, of
the duty layer arrangement and the coating on the protection
surface avoids a butt surface that is endangered by a tendency to
peeling.
[0012] The elastically bendable locking means of the floor panel,
according to the invention, protects the edge locking profile from
fracture. In accordance with the invention, it can basically be
provided at various locations of the edge locking profile. If the
arrangement involves an edge locking profile in the manner of a
groove-and-tongue connection, at least one of the groove walls can
be of an elastically bendable nature. Alternatively, the tongue can
be elastically bendable. It is equally possible for both the tongue
and also at least one of the groove walls to be elastically
bendable. The arrangement with the elastically bendable locking
means is advantageous both for edge locking profiles that have an
undercut configuration that resists joined floor panels being
pulled away from each other, and also for those edge locking
profiles that do not have any such undercut configuration that
resists joined floor panels being pulled away from each other.
[0013] In a particular embodiment, it can be provided that there is
a separate coating at least on the protection surface of one of the
obtuse edges at the side edge portion of the floor panel. That can
be desirable if the structure involves a protection surface that is
short in comparison with other protection surfaces on the floor
panel and, as a result, it can be assumed that there is a reduced
susceptibility to damage to the coating.
[0014] The above-mentioned separate coating can be, for example, in
the form of a self-adhesive film.
[0015] A further benefit is enjoyed if the decorative layer is
subdivided into different imaging or representational regions. In
that way, for example, a floor panel can be designed with a wood
motif in which individual wood planks are represented in individual
imaging regions of the decorative layer. They can be arranged, for
example, in a plurality of juxtaposed rows, as in the case of the
bottom of a ship.
[0016] Advantageously, the duty layer arrangement has a surface
with a lacquer layer.
[0017] The floor panel can be further improved if there is provided
a relief having depressions and raised portions at the surface of
the duty layer arrangement. The depressions and raised portions
can, for example, be such that they correspond to or imitate a wood
grain effect.
[0018] The quality of the floor panel can additionally be improved
if the depressions are in overlapping relationship with given
imaging regions and the raised portions are in overlapping
relationship with other imaging regions of the decorative layer.
That gives a floor panel in which the optical impression and the
tactile impression taken together have a particularly genuine
effect. For example, when a floor panel of such a nature, with a
wood motif, includes a graphic representation of a branch, the
floor panel has a relief on the surface of the position of the
branch, in exact conformity with the graphic representation.
Equally, it is possible to imitate the surface of a tile covering
by graphic representations of tiles with joints therebetween being
provided and by the relief in overlapping relationship with the
graphics imitating, for example, recessed joints and raised tile
surfaces. In that case, a joint surface can be rough like sand and
the surface of tiles can be imitated with a corresponding
structure.
[0019] In a preferred embodiment, the duty layer arrangement has a
lacquer surface in which the depressions of the relief are produced
by a chemical. Reliefs can be produced in a particularly simple and
inexpensive fashion by that method. The chemical can, for example,
react with lacquer and break it down where it is applied.
[0020] An alternative provides that the floor panel is provided
with a relief, the depressions of which are produced by mechanical
embossing. That can be implemented with any suitable material to be
embossed for the duty layer arrangement, such as, for example, a
melamine resin-bearing layer arrangement or a suitable layer of
lacquer.
[0021] In addition, the area of use of the floor panel can be
enlarged by the decorative layer having at least one imitation
intermediate joint, which is in the form of a groove in the top
side and which subdivides the decorative layer into imaging or
representational regions.
[0022] Industrially produced floor panels are packaged and supplied
in packs consisting of a plurality thereof. For inexpensive
manufacture, it is advantageous for floor panels that are offered
in packs each to be of the same respective panel length. The
production of panels of differing lengths and the packaging of
different panel lengths in one pack can be avoided in that fashion.
Admittedly, panels of different lengths are required in the case of
floor panels of real wood in order to achieve good utilization of
the natural raw material, but that is inappropriate in the case of
an artificial decorative layer because that increases the cost of
production, storage, and sale. Production of the new floor panels
in contrast is inexpensive because it is possible to produce
uniform panel lengths, wherein one or more intermediate joints in
the top side of a panel can nonetheless give the impression as
though a laid floor covering consists of floor panels of differing
lengths.
[0023] It is desirable if the imitation intermediate joint is of
the same free cross-section as the free space that is produced when
joining two floor panels, by virtue of the mutually adjoining
obtuse edges thereof. That measure provides that the imitation
intermediate joint is substantially matched to an actual butt joint
forming a joint between mutually adjoining floor panels.
[0024] The effect of the intermediate joint can be further improved
by the provision of a coating on the surface of the groove of the
imitation intermediate joint. The visual appearance of the coating
can be matched to the decorative layer of the duty layer
arrangement. A possible way of achieving that provides that the
groove is produced prior to application of the decorative layer
and, in an additional working step, after application of the duty
layer arrangement with the decorative layer, the duty layer
arrangement in the region of the groove is introduced into the
groove. In that respect, it is helpful if the duty layer
arrangement that initially extends over the groove can be stretched
in order, for example, to be pushed or sucked into the groove. That
is possible, for example, with a film. Simpler coatings for the
groove can comprise, for example, a lacquer.
[0025] In regard to durability of the floor panel, it is desirable
if an anti-wear means is provided in the duty layer
arrangement.
[0026] Desirably the anti-wear means has abrasion wear-resistant
particles. This can involve, for example, corundum in powder form
that is embedded in finely distributed form in the duty layer
arrangement.
[0027] In an embodiment of the floor panel with a layer of lacquer
on the surface of the duty layer arrangement, the anti-wear means
is desirably embedded at least in the layer of lacquer. In
addition, anti-wear means can generally also be contained within
the decorative layer.
[0028] A particular benefit is achieved if the lacquered duty layer
arrangement is processed in the form of a prefabricated layer and
joined in the finished condition to the carrier panel portion. In
that way, the lacquered duty layer arrangement with the decorative
layer can be produced as a preliminary product. The manufacturer of
the floor panel then only joins the prefabricated duty layer
arrangement to a carrier panel portion to which the edge locking
profiles have been fitted or are fitted. The lacquered duty layer
arrangement can be easily attached to the carrier panel portion
with an adhesive. Any suitable single-component or multi-component
adhesive that sets cold or hot, chemically or physically, can be
used for that purpose.
[0029] If the edge locking profile has locking means that engage in
positively locking relationship at at least two oppositely disposed
edges of the floor panel, that is considered to be a further
advantage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The invention is illustrated by way of example hereinafter
in the drawings and described in detail with reference to
individual Figures of the drawings in which:
[0031] FIG. 1 shows an embodiment of a floor panel with obtuse
edges provided at all sides,
[0032] FIG. 2 shows an alternative embodiment of a floor panel with
obtuse edges provided at all sides,
[0033] FIG. 3 shows a floor panel with obtuse edges and with a
groove in the top side,
[0034] FIG. 4 shows an alternative embodiment of a floor panel with
obtuse edges and with a groove,
[0035] FIG. 5 shows a further alternative of a floor panel that has
both obtuse edges and also a groove in the top side,
[0036] FIG. 6 shows a view of a portion of edge locking profiles of
oppositely disposed edge locking profiles of a floor panel,
[0037] FIG. 7 shows a view of a portion of alternative oppositely
disposed edge locking profiles of a floor panel whose edge locking
profiles engage one behind the other,
[0038] FIG. 8 shows a view of a portion of a further embodiment of
edge locking profiles of an undercut configuration at oppositely
disposed edges of a floor panel,
[0039] FIG. 9 shows a view of a portion of oppositely disposed edge
locking profiles, which are without an undercut configuration, of a
floor panel, and
[0040] FIG. 10 shows a portion of a duty layer arrangement with
relief.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] FIGS. 1 to 5 show floor panels 1. The floor panels are
rectangular. They have a carrier panel portion 2. Provided in
mutually opposite relationship are two long edges and two
oppositely disposed short edges. A utility or duty layer
arrangement 3 is provided at the top side of the carrier panel
portion 2. The duty layer arrangement 3 has a decorative layer D
that represents a wood motif 4 or a plurality of wood motifs 4a,
4b, and 4c. The wood grain lines 5, 5a, 5b, and 5c of the wood
motifs 4, 4a, 4b, and 4c are illustrated.
[0042] Respective edge locking profiles 6a and 7a are illustrated
at the respective edges of the floor panels shown in FIGS. 1 to 5.
Respective corresponding edge locking profiles are arranged at the
oppositely disposed edges 6b and 7b. A plurality of those floor
panels can thus be joined to form a floor surface because further
floor panels can be locked to a floor panel at all sides.
[0043] The edge locking profiles 6a and 7a are shown in FIGS. 1 to
5, for example, in the form of a tongue-and-groove profile having
an elastically bendable locking means V. Each of the floor panels
shown in FIGS. 1 to 5 can alternatively have one of those
edge-locking profiles that are proposed hereinafter in the
description relating to FIGS. 6 to 9. FIGS. 1 to 5 serve
essentially to explain alternatives in respect of the configuration
of the top side of the floor panel and the side edge portions of
the top side of the floor panel 1.
[0044] Looking at FIG. 1, the top side of the floor panel 1 has a
utility or duty layer arrangement 3 with a decorative layer D whose
wood motif 4 extends without interruption over the entire surface
of the top side. The wood motif 4 represents, inter alia, a branch
in the wood grain effect. It will be appreciated that neither the
branch in itself nor the position of the branch is a necessary
constituent part of the wood panel. That applies both in regard to
FIG. 1 and also in regard to all other embodiments of FIGS. 2 to 5,
whose decorative layer has a branch or parts thereof.
[0045] Provided at the side edge portions of the top side of the
embodiment shown in FIG. 1 are obtuse edges 8 and 9 with protection
surfaces 8a and 9a. Those protection surfaces 8a and 9a are in the
form of a bevel. A bevel is thus an inclinedly arranged flat
protection surface at the edge of the floor panel.
[0046] All four side edge portions at the top side of the floor
panel 1 are provided with beveled protection surfaces. All those
protection surfaces have a coating. The coating embraces the
decorative layer D of the duty layer arrangement. For that purpose,
the decorative layer D is bent over, for example, at a bend edge K
at a side edge portion of the floor panel 1 and covers the
protection surface 9a. The same applies for the other side
edges.
[0047] It will be appreciated that it is possible for regions of
the edge of the floor panel, which extend beyond the protection
surface 9a, to be coated with that decorative layer D. An edge of
the floor panel 1 can be coated, for example, entirely or partially
with the bent-over decorative layer D.
[0048] Shown at the protection surface 9a of the long edge of the
floor panel is a wood grain line M that extends from the beveled
protection surface 9a over the bend edge K into the utility layer
arrangement 3 of the top side of the floor panel 1.
[0049] The floor panel shown in FIG. 2 differs from the floor panel
shown in FIG. 1 solely by the configuration of that protection
surface/bevel provided at the short edge. There, there is no
coating on the protection surface 8a. The surface of the protection
surface 8a simply comprises the surface produced by the removal of
material. The surface produced comprises in part the machined duty
layer arrangement 3 and in part the material of the carrier panel
portion 2. A more expensive alternative can have a protection
surface 8a for the short edge of the floor panel, which is provided
with a separate coating such as, for example, a lacquer or a
film.
[0050] The floor panel shown in FIG. 3 substantially corresponds to
that shown in FIG. 2. A difference lies in the top side of the
floor panel because there the floor panel has an imitation
intermediate joint 10. That intermediate joint 10 is in the form of
a groove 10a. The groove 10a severs the duty layer arrangement 3
and extends into the material of the carrier panel portion 2. The
surface of the groove 10a does not have any coating. The
cross-section of the groove 10a corresponds to the free space that
is produced by joining two short edges of such floor panels, as the
free space between the obtuse edges 8. As can already be seen from
FIGS. 1 and 2, the long edges of the floor panel 1 have a coating
that encloses the bent-over decorative layer D of the duty layer
arrangement 3.
[0051] The imitation intermediate joint in FIG. 3 subdivides the
top side of the floor panel or the decorative layer D into two
imaging or representational regions A and B. The imaging region A
has a wood motif 4a and the imaging region B has a wood motif 4b.
In the laid condition of a floor, the imitation intermediate joint
10 has the effect of an actual joint between separate wood
elements.
[0052] As shown in FIG. 3, the wood grain lines 5a of the wood
pattern 4a form a matching transition at the intermediate joint
into the wood grain lines 5b of the wood motif 4b. The wood motifs
4a and 4b each have parts of one and the same branch. The
intermediate joint 10 divides that branch into two parts. That
leads to the assumption that the two decorative regions are wood
that has been taken from a grown tree trunk and therefore match
each other.
[0053] It will be noted that the groove 10a of the intermediate
joint 10 can also have a separate coating that is independent of
the duty layer arrangement or the decorative layer.
[0054] The embodiment shown in FIG. 4 very substantially
corresponds to the embodiment shown in FIG. 3. In particular, the
configuration of the obtuse edges 8 and 9 with their protection
surfaces 8a and 9a as well as the configuration of the intermediate
joint 10 corresponds to the embodiment of FIG. 3. The only
difference lies in the wood motif of the imaging region B. That
imaging region B has a wood motif 4c that does not have any branch,
whereas the imaging region A has the same wood motif 4a with a part
of a branch, like the imaging region A in FIG. 3. The wood grain
lines 5a and 5c are independent of each other; they do not go into
each other. The imitation intermediate joint 10 leads to the
assumption that this involves two joined pieces of wood.
[0055] FIG. 5 illustrates an embodiment that also has an imitation
intermediate joint 10 with a groove 10a. The duty layer arrangement
3 at the top side of the floor panel 1 has the same wood motifs 4a
and 4c as shown in FIG. 4. The only difference in the embodiment of
FIG. 5 in relation to the embodiment of FIG. 4 lies in the coating
of the protection surface 8a, which is in the form of a bevel, at
the short edge of the floor panel 1, and in the coating of the
groove 10a of the imitation intermediate joint 10. The protection
surface 8a is provided with a coating. The coating encloses the
decorative layer D of the duty layer arrangement 3. The decorative
layer D is bent over and extends over the protection surface 8a.
That can be clearly seen because the wood grain lines 5a of the
decorative layer D, coming from the duty layer arrangement 3, go
into the coating on the protection surface 8a.
[0056] The groove 10a of the imitation intermediate joint 10 also
has a coating. This also encloses the decorative layer D of the
duty layer arrangement 3, which is bent over onto the surface of
the groove 10a. The wood grain lines 5a of the wood motif 4a pass
over a bend edge L1 of the groove 10a, and extend into the bottom
of the groove 10a. The wood grain lines 5c of the wood motif 4c
also pass over the other bend edge L2 of the groove 10a and extend
into the bottom of the groove 10a. Viewed from the top side of the
floor panel 1, the wood motifs 4a and 4c as well as the
intermediate joint 10 and the protection surfaces 8a and 9a of the
top side of the floor panel 1 afford a very good impression of
being authentic.
[0057] A further alternative of the floor panel 1, which is not
illustrated here, has a bent-over decorative layer D with separate
imaging or representational regions, in the area of the
intermediate joint 10. Those imaging regions are provided with
their own motifs that differ from those motifs that are to be found
on the top side of the floor panel 1. The same can apply for one or
more of the protection surfaces 8a and 9a, respectively, which can
also be coated with a bent-over decorative layer D that, in turn,
is provided with separate imaging regions for the protection
surfaces 8a and 9a, respectively.
[0058] In that way, it is possible to provide the motif of a
longitudinal section through a tree trunk, for example, for the top
side 3 of the floor panel 1, as is shown in FIGS. 1 to 5, whereas
the bent-over portions of the decorative layer D, at the
corresponding protection surfaces 8a and 9a, respectively, and the
intermediate joint 10, have such motifs that represent a section
transversely through a tree trunk.
[0059] Portions of two floor panels are shown in each of FIGS. 6 to
9. The portions show edge locking profiles in the connected
condition thereof. Each individual one of the illustrated floor
panels always has both edge locking profiles, namely one with a
groove and one with a tongue. The groove and the tongue are
respectively arranged at oppositely disposed edges of the floor
panel.
[0060] Reference will now be made to FIGS. 6 to 9 to describe, on
the one hand, different configurations of edge locking profiles. On
the other hand, different shapes of obtuse edges at a top side of a
floor panel are described and illustrated. In that respect, the
shape of the obtuse edges is independent of the configuration of
the edge locking profiles. Therefore, a floor panel with an obtuse
edge as shown in FIG. 6 can be combined with each of the edge
locking profiles shown in FIGS. 7 to 9. The shape of the obtuse
edge shown in FIG. 7 can be combined with each edge locking profile
of FIGS. 6 to 9. The same applies to the obtuse edges in FIGS. 8
and 9. They too can be combined with any edge locking profile as
shown in FIGS. 6 to 9. Furthermore, each of the edge locking
profiles of FIGS. 6 to 9 can be provided on any of the floor panels
of FIGS. 1 to 5. In that respect, the edge locking profiles are
always arranged in paired relationship at mutually opposite edges
of the floor panel. Oppositely disposed short edges of one of the
floor panels shown in FIGS. 1 to 5 can have either the same type or
a different type of edge locking profiles as shown in FIGS. 6 to 9,
which is provided at the long edges of the floor panel.
[0061] In FIG. 6, provided at a top side of floor panels 20 and 21
is a respective obtuse edge having a protection surface in the form
of a 45.degree. bevel 22 and 23, respectively. The 45.degree. bevel
22 of the floor panel 20 is an inclined plane produced by removal
of material at the edge, at the top side, of a carrier panel
portion 24 of the floor panel 20. A utility or duty layer
arrangement 25 having a decorative layer D is provided on the
carrier panel portion 24. The duty layer arrangement 25 is bent
over onto the 45.degree. bevel 22 at a bend edge N. Therefore, the
coating of the 45.degree. bevel 22 involves the same material
quality as the duty layer arrangement at the top side of the floor
panel 20. The 45.degree. bevel 23 of the floor panel 21 has the
same coating as the floor panel 20.
[0062] The edge locking profile shown in FIG. 6 has a
tongue-and-groove profile with a tongue 26 in the form of an
elastically bendable locking means V. The edge locking profile is
protected from fracture by virtue of the elastic bendability of the
tongue 26. Before another part of the edge locking profile
fractures, the tongue 26 adopts a bend. The tongue 26 is straight
in the unlocked condition whereas it is bent in the illustrated
locked position, following the shape of the groove 27 in a
direction towards the underside of the floor panel 20. This is not
a tongue-and-groove profile that has an undercut configuration
because the tongue 26 is not curved in the relieved condition.
[0063] FIG. 7 shows a top side of floor panels 30 and 31 that are
each provided with a respective obtuse edge with a protection
surface, each protection surface being in the shape of a rounded
configuration. The rounding 32 of the floor panel 30 is somewhat
shorter in cross-section than an arc formed by a quarter of a
circle. The rounding 32 is produced by removal of material at the
edge, at the top side, of a carrier panel portion 33 of the floor
panel 30.
[0064] Provided on the carrier panel portion 33 is a duty layer
arrangement 34 having a decorative layer D. The duty layer
arrangement 34 including the decorative layer D is bent around the
rounding 32 of the obtuse edge and forms the coating thereon. The
coating, however, also extends onto the top side of a tongue 35 of
the edge locking profile and reaches the end of the top side of the
tongue. The rounded shape of the protection surface of the floor
panel 31 corresponds to the rounding 32 of the floor panel 30. A
duty layer arrangement 37, inclusive of a decorative layer D, is
bent around that rounding 36 of the obtuse edge and extends as far
as an end edge of an upper groove wall of the groove profile of the
floor panel 31.
[0065] The coating on the protection surfaces involves the same
material quality as the duty layer arrangements 34 and 35 at the
top side of the floor panels 30 and 31.
[0066] The edge locking profiles shown in FIG. 7 are provided with
tongue-and-groove profiles that comprise an undercut configuration.
The undercut configuration resists the floor panels 30 and 31 being
pulled apart. The arrangement has two elastically bendable locking
means V1 and V2. One of the locking means V1 is formed by the
tongue 35 and the other elastically bendable locking means V2 is a
lower groove wall 38 of the groove profile, which is longer or
projects further from the edge of the panel than an upper groove
wall 38.
[0067] A further configuration of the top side of floor panels 40
and 41 can be seen from FIG. 8. Those floor panels 40 and 41 each
have a respective obtuse edge with a protection surface in the form
of a rounding 42 and 43, respectively. The geometry of the rounding
42 corresponds to the rounding shown in FIG. 7 of the floor panel
30. The rounding 42 is also produced by removal of material at an
upper edge of a carrier panel portion 43 of the floor panel 40. The
coating on the rounding 42, again, comprises a duty layer
arrangement 44 on the top side of the floor panel 40, which,
inclusive of a decorative layer D, is bent in one piece around the
rounding 42 of the obtuse edge. In the present embodiment, however,
the coating ends at the end of the rounding and is not taken
further over the edge onto the edge locking profile.
[0068] The edge locking profiles are provided with a groove 45 and
a tongue 46, wherein provided between the groove 45 and the tongue
46 is an undercut configuration that resists the floor panels 40
and 41 being pulled apart. There is provided an elastically
bendable locking means V, more specifically an elastically bendable
lower groove wall 47 for the groove 45, which is longer than the
upper groove wall 48 of the groove 45. The lower groove wall 47 is
free of any bend in the locked position as illustrated. Its elastic
bendability, however, is effective when an external loading is
applied to the connection between the groove and the tongue. The
elastic lower groove wall 47 protects the remaining regions of the
connection from fracture.
[0069] The embodiment shown in FIG. 9 involves the same
configuration in respect of the top side of floor panels 50 and 51,
as is to be seen from FIG. 8. Provided on a carrier panel portion
50a with a duty layer arrangement 50b is an obtuse edge with a
protection surface in the form of a rounding 52. The same applies
for the floor panel 51, which has a rounding 53. Both the geometry
of the roundings 52 and 53 and also the coatings thereon correspond
to the configuration of the rounding 42 shown in FIG. 8.
[0070] The edge locking profiles provided are equipped with a
groove 54 and a tongue 55, which do not have an undercut
configuration. The embodiment shown in FIG. 9 does not provide a
positively locking engagement relationship to prevent the floor
panels 50 and 51 from being pulled apart, as can be seen in FIGS. 7
and 8. Both the tongue 55 and also the groove 54 are of trapezoidal
cross-sections. A thinner lower groove wall 56 of the groove 54
forms an elastically bendable locking means V that, when an
external loading is applied to the connection, yields before a
fracture occurs at another location of the groove 54 or the tongue
55.
[0071] It will be appreciated that a conventional tongue-and-groove
profile that has joining surfaces for the groove, which are
arranged in parallel relationship with the top side of the floor
panel and with joining surfaces for the tongue, which are also
arranged in parallel relationship with the top side of the floor
panel, can also be supplemented by an elastically bendable locking
means. In that case, the elastically bendable locking means
protects the remaining regions of the groove and the tongue from
fracture if a loading is applied to the tongue-and-groove
connection. It is sufficient if, for example, the tongue or one of
the groove walls is of an elastically bendable nature.
[0072] For the purposes of describing the structure of a utility or
duty layer arrangement, FIG. 10 diagrammatically shows a portion of
a duty layer arrangement. The floor panels shown in FIGS. 1 to 5
can, for example, have a duty layer arrangement of the structure
shown in FIG. 10. The same applies for the duty layer arrangements
in FIGS. 6 to 9.
[0073] Referring to FIG. 10, the duty layer arrangement has a paper
61 that is printed with decorative graphics 62. The graphics 62 are
provided with differently colored zones 63 and 64. To protect the
graphics 62 from being worn off, they are coated with a transparent
lacquer. The thickness of the lacquer layer 65 and the thickness of
the paper 61 are shown without proportionality in FIG. 10. The
lacquer is transparent and is mixed with an abrasion-resistant
anti-wear means 66 for the purposes of affording a high level of
resistance to wear. The anti-wear means 66 has particles that
extend to the surface of the lacquer layer 65. The surface of the
lacquer also has a relief 67 that exactly matches the illustrated
graphics 62. Depressions 67a and raised portions 67b of the relief
are in overlapping relationship with respective given zones 63 and
64, respectively, of the graphics 62. The depressions 67a of the
relief 67 have been produced by a chemical that is applied prior to
the lacquer coating and which, after application of the lacquer,
reacts therewith. In FIG. 10, the lacquer layer 65 is thin in the
region of the depressions 67a whereas the lacquer layer 65 is
thicker in the region of the raised portions 67b. The depressions
67a of the relief 67 are in overlapping relationship with the zones
63 of the graphics 62. In that way, the tactile impression and the
visual impression supplement each other and that affords an
excellent imitation of a floor surface of real wood. A depression
67a in the lacquer layer 65 can extend at a maximum as far as the
printed paper 61. Such a depression 67a lacks the protective
lacquer layer. Such depressions 67a should preferably be of a small
area so that they are well protected from wear by the surrounding
raised regions.
[0074] A duty layer arrangement as shown in FIG. 10 is
prefabricated. To produce a floor panel, the prefabricated duty
layer arrangement is attached to a carrier panel portion, for
example, by means of an adhesive.
LIST OF REFERENCES
[0075] 1 floor panel [0076] 2 carrier panel portion [0077] 3 duty
layer arrangement [0078] 4 wood motif [0079] 4a wood motif [0080]
4b wood motif [0081] 4c wood motif [0082] 5 wood grain line [0083]
5a wood grain line [0084] 5b wood grain line [0085] 5c wood grain
line [0086] 6a edge locking profile [0087] 6b edge locking profile
[0088] 7a edge locking profile [0089] 7b edge locking profile
[0090] 8 short obtuse edge [0091] 8a protection surface [0092] 9
short obtuse edge [0093] 9a protection surface [0094] 10
intermediate joint [0095] 10a groove [0096] 20 floor panel [0097]
21 floor panel [0098] 22 45.degree. bevel [0099] 23 45.degree.
bevel [0100] 24 carrier panel portion [0101] 25 duty layer
arrangement [0102] 26 tongue [0103] 27 groove [0104] 30 floor panel
[0105] 31 floor panel [0106] 32 rounding [0107] 33 carrier panel
portion [0108] 34 duty layer arrangement [0109] 35 tongue [0110] 36
rounding [0111] 37 duty layer arrangement [0112] 40 floor panel
[0113] 41 floor panel [0114] 42 rounding [0115] 43 carrier panel
portion [0116] 44 duty layer arrangement [0117] 45 groove [0118] 46
tongue [0119] 47 lower groove wall [0120] 48 upper groove wall
[0121] 50 floor panel [0122] 50a carrier panel portion [0123] 50b
duty layer arrangement [0124] 51 floor panel [0125] 52 rounding
[0126] 53 rounding [0127] 54 groove [0128] 55 tongue [0129] 56
lower groove wall [0130] 61 paper [0131] 62 graphics [0132] 63 zone
[0133] 64 zone [0134] 65 lacquer layer [0135] 66 anti-wear means
[0136] 67 relief [0137] 67a depression [0138] 67b raised portion
[0139] A imaging region [0140] B imaging region [0141] D decorative
layer [0142] K bend edge [0143] L1 bend edge [0144] L2 bend edge
[0145] M wood grain line [0146] N bend edge [0147] V locking means
[0148] V1 locking means [0149] V2 locking means
* * * * *