U.S. patent application number 10/562491 was filed with the patent office on 2007-03-22 for panel comprising a locking system.
Invention is credited to Hans-Jurgen Hannig.
Application Number | 20070065293 10/562491 |
Document ID | / |
Family ID | 33559787 |
Filed Date | 2007-03-22 |
United States Patent
Application |
20070065293 |
Kind Code |
A1 |
Hannig; Hans-Jurgen |
March 22, 2007 |
Panel comprising a locking system
Abstract
The invention relates to a panel (1, 2) comprising a
quadrangular panel portion of coated wood material wherein mutually
opposite edges of the panel (1, 2) have mutually complementary
positively locking profiles (3, 4) so that similar panels (1, 2)
can be assembled, wherein the surface of at least one of the
positively locking profiles (3, 4) has at least in region-wise
manner raised portions (5, 6, 7) and recesses (8, 9), the raised
portions (5, 6, 7) during assembly of two panels (1, 2) can be
ground down by friction, and the recesses (8, 9) are of a volume in
which resulting abrasion particles (5a, 6a, 7a) from the
projections (5, 6, 7) can be received.
Inventors: |
Hannig; Hans-Jurgen;
(Bergisch Gladbach, DE) |
Correspondence
Address: |
WHITEFORD, TAYLOR & PRESTON, LLP;ATTN: GREGORY M STONE
SEVEN SAINT PAUL STREET
BALTIMORE
MD
21202-1626
US
|
Family ID: |
33559787 |
Appl. No.: |
10/562491 |
Filed: |
July 2, 2004 |
PCT Filed: |
July 2, 2004 |
PCT NO: |
PCT/DE04/01419 |
371 Date: |
August 18, 2006 |
Current U.S.
Class: |
417/1 |
Current CPC
Class: |
E04F 2201/07 20130101;
E04F 15/04 20130101; E04F 2201/0153 20130101; E04F 2201/041
20130101 |
Class at
Publication: |
417/001 |
International
Class: |
F04B 49/00 20060101
F04B049/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 2, 2003 |
DE |
103 29 686.7 |
Claims
1-7. (canceled)
8. A panel comprising a quadrangular panel portion of coated wood
material, wherein mutually opposite edges of the panel have
mutually complementary positively locking profiles so that similar
panels can be assembled, and wherein the surface of at least one of
the positively locking profiles has at least in region-wise manner
raised portions and recesses, characterized in that the raised
portions are provided with an overdimension, that the overdimension
can be ground away by friction during assembly of two panels, and
that the recesses are of a volume in which resulting abrasion
particles from the raised portions can be received.
9. The panel according to claim 8 characterized in that the
positively locking profile is in the form of a groove profile with
an undercut configuration and the oppositely disposed positively
locking profile is in the form of a tongue profile with an undercut
configuration.
10. The panel according to claim 9 characterized in that the raised
portions and recesses are provided on the tongue profile and the
groove profile has a smooth surface which is in contact with the
raised portions in the positively lockingly assembled
condition.
11. The panel according to claim 10 characterized in that the
raised portions and recesses are arranged at a tongue underside
which faces towards a laying surface.
12. The panel according to claim 8 characterized in that the
stiffness of the positively locking profiles and the abrasion
resistance of the raised portions are so matched to each other that
forces which occur during the assembly procedure can cause the
raised portions to be rubbed away but cannot cause elastic
deformation of the positively locking profiles.
13. The panel according to claim 8 characterized in that there is
provided a sealing and lubricating agent at least in the
recesses.
14. The panel according to claim 13 characterized in that the
sealing and lubricating agent forms a lubricating film.
Description
[0001] The invention relates to a panel comprising a quadrangular
panel portion of coated wood material, wherein mutually opposite
edges of the panel have mutually complementary positively locking
profiles so that similar panels can be assembled.
[0002] Panels of the general kind set forth are used for example
for the production of floor coverings, so-called laminate panels.
Equally panels of that kind can be designed in the form of wall or
ceiling panels. Predominantly the panels comprise medium-density
fibreboard (MDF) or high-density fibreboard (HDF), on to which
further layers, mostly resin-impregnated cellulose layers, are
laminated. Frequently the positively locking profiles are provided
integrally on the panels, for example by being milled thereon. In
general terms the panels are of a rectangular configuration with
two long edges which are in mutually opposite relationship and two
short edges which are in mutually opposite relationship.
[0003] The thickness of the laminate panels is generally less than
the thickness of parquet panels. Usual thicknesses are in a range
of between 5 and 8 mm. Thinner or thicker laminate panels are rare.
It will be noted however that parquet panels have in the meantime
also been provided with positively locking profiles. Therefore the
positively locking profiles of the proposed new panel can also be
provided on parquet panels.
[0004] The complementary positively locking profiles of the one
panel are restricted by the thickness of the panel and are fairly
small. They therefore have to be produced very accurately in terms
of shape and fit so that they fit one into the other. A high degree
of fitting accuracy in respect of the complementary positively
locking profiles is an important requirement in order to ensure in
particular a closed joint on a top side of the interlocked panels
because the surface is visible to the user of a finished floor
covering. Particularly for floors it is desirable to have a smooth
surface in which the joints between the panels do not form any gaps
but the edges are in closely mutually butting relationship and are
in contact with each other.
[0005] In the case of almost all panels with positively locking
profiles, one of the complementary positively locking profiles can
be viewed as an inner portion and the associated profile can be
viewed as an outer portion. The relationship of an outer portion to
an associated inner portion prior to the portions being joined
together is referred to as the fit. Both the outer portion and also
the inner portion involve given nominal dimensions, wherein
tolerances are allowed for each nominal dimension. Each positively
locking profile whose actual dimension is within the tolerance can
be used. In accordance with a system fits are divided into three
different kinds: a clearance fit, an interference fit and a
transition fit. The subdivision is always based on the dimensional
relationship of the outer portion with its tolerance to the inner
portion with its tolerance prior to joining of the two
portions.
[0006] In the case of a clearance fit the tolerances even in the
worst case scenario are such that at any event after joining there
is a clearance between the outer portion and the inner portion.
[0007] In the case of an interference fit the tolerances are such
that at any event after the joining operation there is an
overdimension between the outer portion and the inner portion and
there must therefore be elastic deformation of the portions being
joined.
[0008] The situation is referred to a transition fit if the
tolerance ranges which are allowed for the outer portion and the
inner portion partially overlap. Without knowledge of the precise
actual dimensions of the outer portion and the inner portion the
combination of an outer portion which is within its tolerance with
an inner portion which is also within its tolerance, in the
assembled condition, can give either a clearance or an
overdimension or in the ideal case an exact fit which has neither
clearance nor overdimension.
[0009] In order in the case of panels always to have a closed joint
on the top side of the panels which is visible in the laid
condition, it is known from WO 97/47834 to provide on a positively
locking profile elastic deformation which produces prestressing of
the panels. By means of that prestressing, the panels are forced
towards each other and in that way the joint is held in a closed
condition at the top side of the panels. The panel known from WO
97/47834 involves a modified tongue-and-groove panel, wherein the
tongue and the groove are each of an undercut configuration. The
geometry of the positively locking profiles gives rise to elastic
deformation at one of the groove walls, namely the lower groove
wall which in the laid condition is towards the surface on which
the panel is laid. The deformed lower groove wall flexes like a
beam which is gripped at one end. In the assembled condition of two
panels flexing of the groove wall is at least partially retained.
The closed nature of the joint is achieved by spring resiliency of
the lower groove wall and by virtue of a particular geometry of the
groove wall and the tongue, which involves the action of inclined
surfaces which bear against each other.
[0010] There is the disadvantage in accordance with the teaching of
WO 97/47834 that the internal cohesion of the wood material is
weakened by the permanent flexing effect. The higher the degree of
deformation, the correspondingly `softer` becomes the wood material
in the flexurally deformed region. A further disadvantage is that,
in the event of a loading applied over a long period of time,
relaxation of the wood material occurs in the flexurally deformed
region. Absorption of moisture on the part of the wood material
promotes the relaxation effect, just like an action by heat.
Admittedly, positively locking profiles of panels are usually
impregnated with agents which are intended to prevent the
absorption of moisture, but depending on the respective quality of
the impregnation and the nature and location of use of the panel a
gradual absorption of moisture cannot be prevented.
[0011] The object of the invention is to propose a panel whose
positively locking profiles are of such a configuration that panels
have closed joints in the assembled condition without at the same
time producing elastic deformation of a positively locking profile,
such as to put a strain on wood material.
[0012] According to the invention that object is attained in that
the surface of the positively locking profiles has at least in
region-wise manner raised portions and recesses, that the raised
portions can be ground away by friction during assembly of two
panels, and that the recesses are of a volume in which resulting
abrasion particles from the raised portions can be received.
[0013] In the joining operation the raised portions are ground away
to the required dimension. A closed joint is formed at the top side
of the panel. In addition, a uniform heightwise level without
heightwise displacement at the joint is achieved.
[0014] Due to the action of heat, the positively locking profiles
can be increased in size or they can swell up due to the action of
moisture. Due to use in the specified manner, namely on a soft,
footstep noise-attenuating support, in those cases grinding of the
raised portions continues. That provides for renewed adaptation of
the fitting shape of the positively locking profiles and
accordingly affords a suitable fit without overdimension and
without clearance.
[0015] Desirably, one of the positively locking profiles is in the
form of a groove profile with an undercut configuration and the
oppositely disposed positively locking profile is in the form of a
tongue profile with an undercut configuration. The undercut
configurations of the tongue profile and the groove profile can be
fitted one into the other by virtue of inclined positioning of the
panels. Subsequent pivoting of the panels into a common plane locks
them. The locking effect is operative in the plane of the panels to
prevent them from being pulled apart in a direction perpendicular
to the positively locking profiles. During the laying operation,
the usual procedure is for a panel to be laid flat on a laying
surface and then a new panel is attached in an inclined position to
the laid panel. Pivoting the new panel into the common plane is
effected by lowering it on to the laying surface. The undercut
configurations of the groove profile and the tongue profile engage
behind each other. In that way the panels are locked together.
[0016] If the effect of grinding away the raised portions by the
joining operation is not sufficient, that is to say if too little
material is ground away by the joining movement of pivoting a fresh
panel downwardly into the plane of the lying panel, the positively
locking profiles are ground together by a subsequent reciprocating
pivotal movement until fitting accuracy in respect of the groove
profile and the tongue profile is achieved. For that purpose it is
also helpful if the panels are pivotably connected together, that
is to say if the tongue profile is mounted similarly to a
connecting joint member in the groove profile which forms a kind of
pivoting joint socket. In that way the panels can be pivoted out of
an angular position of 180.degree. relative to each other both in
the positive direction and also in the negative direction. The
pivotal mobility permits a particularly good reciprocating grinding
movement. Before the panels are definitively laid on the laying
surface, they can be loosely assembled for example on a table to
ascertain the required degree of grinding so as to achieve fitting
accuracy. During the laying operation, fitting accuracy can be
checked at the respective free end of the laid panel surface
because it is there that the connection of the positively locking
profiles is visible from the side. It is possible to look closely
to investigate whether deformation of the positively locking
profiles has occurred. For objective investigation as to whether
the situation involves such deformation, it is possible for example
to take a measurement of the total thickness of the locked panels
in the region of the connected positively locking profiles. If the
total thickness exceeds a predetermined limit dimension the
grinding operation has to be continued.
[0017] Preferably the raised portions and the recesses are provided
on the tongue profile and the groove profile has a smooth surface.
The smooth surface of the groove profile is in contact with the
raised portions of the tongue profile in the condition in which the
panels are assembled in positively locking relationship. Desirably
the raised portions and recesses are arranged at an underside of
the tongue profile which is towards a surface on which the panels
are laid. In that way the shape of the profile is adapted to the
desired function. Because a panel is joined by inclinedly attaching
a tongue profile to the groove profile of a panel lying on a laying
surface, the construction makes use of that joining movement for
grinding away and adapting the raised portions. Both in the case of
the subject-matter of claim 1 and also in the case of the
development with raised portions and recesses at an underside of
the tongue, adaptation of the fitting dimensions and the fitting
shape of the positively locking profiles takes place during the
assembly procedure. In the condition prior to joining for example
the positively locking profile with the raised portions has a
`surplus` of material. In relation to the complementary positively
locking profile, there is an overdimension prior to the joining
procedure. During the joining procedure material is ground away
from the raised portions and the overdimension is removed. In that
case the result is a connection in which there is neither an
overdimension nor a clearance. Rather, that provides for exact
adaptation of the positively locking profiles, which ensures a
closed joint. The stiffness of the positively locking profiles as
well as the abrasion resistance of the raised portions are
desirably so matched to each other that forces which occur during
the assembly operation can admittedly provide for abrasion removal
of the raised portions, but not elastic deformation of the
positively locking profiles.
[0018] The raised portions and recesses on the positively locking
profile or profiles can be in the form of a microstructure which is
incorporated into the surface of the positively locking
profiles.
[0019] A further advantage is afforded by a sealing and lubricating
agent which is provided at least in the recesses. Assembly of the
panels by a rotating joining movement is made easier by the
lubricant effect.
[0020] In addition the raised portions on the positively locking
profile can be better ground away by virtue of the wetting action,
than in the dry condition. In the dry condition the raised portions
can break off. Such breakage is prevented by the lubrication
effect.
[0021] The grindability of the raised portions depends
substantially on the shape thereof. A broad raised portion is less
at risk of breaking off during the assembly procedure than a narrow
raised portion. In the case of a narrow raised portion however
there is desirably less material which has to be ground away for
the purposes of an accurate fit. Together with a lubricating agent,
narrow raised portions have proven to be desirable because simple
adaptation is possible without the raised portions breaking
off.
[0022] The invention is illustrated by way of example hereinafter
in a drawing and described in detail with reference to the Figures
in which:
[0023] FIG. 1 shows a view of portions of complementary positively
locking profiles of two panels prior to the joining operation,
[0024] FIG. 2 shows the beginning of a joining operation for the
positively locking profiles of FIG. 1,
[0025] FIG. 3 shows a joining operation which is advanced in
relation to FIG. 2,
[0026] FIG. 4 shows a portion-wise enlargement of two locked
positively locking profiles,
[0027] FIG. 5 shows two positively locking profiles in a hingedly
pivoted condition, and
[0028] FIG. 6 shows the positively locking profiles of FIG. 5 with
lubricant.
[0029] FIG. 1 shows a view of a portion of two panels 1 and 2
comprising a coated panel portion of wood material. Each of the
panels 1 and 2 has at mutually opposite sides positively locking
profiles which are milled integrally on the panel portion or
portions. The positively locking profiles involve a groove profile
3 of an undercut configuration and a tongue profile 4 of an
undercut configuration. Each of the panels 1 and 2 has a respective
complementary profile at mutually opposite edges. The panel 1 is
thus provided at the edge in opposite relationship to its groove
profile 3 with a complementary tongue profile and equally the panel
2 with the tongue profile 4 is provided at the edge opposite to the
tongue profile 4 with a complementary groove profile. The panels 1
and 2 are rectangular. These kind of complementary profiles are
also provided for the other two edges of the panels. The positively
locking profiles 3 and 4 are shown in FIG. 1, prior to being
joined. The panel 1 is disposed on a laying surface V. The panels
are coated. A decorative coating comprising a plurality of layers
is arranged at a top side A of each of the panels, being the side
which is away from the laying surface V in the laid condition. An
underside B which is in opposite relationship to the top side is
provided with a counteraction layer.
[0030] The tongue profile 4 of the panel 2 has a tongue underside
4a with raised portions 5, 6 and 7 and recesses 8 and 9. The tongue
underside 4a faces towards the laying surface V in the assembled
condition of the panels 1 and 2. The groove profile 3 of the panel
1, towards the laying surface V, has a lower groove wall 10 and an
upper groove wall 11. The lower groove wall 10 has a channel-shaped
receiving means 10a on its inward side. The channel-shaped
receiving means 10a receives the tongue underside 4a of the panel 1
in the assembled condition.
[0031] The channel-shaped receiving means 10a is provided with a
concavely curved surface which is without raised portions and
recesses. The complementary configuration of the positively locking
profiles relates to the basic shapes of the groove profile 3 as an
outer portion and the tongue profile 4 as an inner portion which
fit one into the other. The raised portions 5, 6 and 7 and the
recesses 8 and 9 at the tongue underside 4a are not in the form of
a negative shape in the channel-shaped receiving means 10a of the
groove profile. In spite of those differences between the
positively locking profiles 3 and 4, they are referred to in
accordance with the invention as complementary positively locking
profiles.
[0032] The free end of the groove wall 10 projects from the edge of
the panel 1 further than the upper groove wall 11. The free end of
the upper groove wall 11 projects from the edge of the panel
approximately as far as the lowest point of the channel-shaped
receiving means 10a. The lowest point of the channel-shaped
receiving means 10a is that point which is at the smallest spacing
relative to the underside B of the panel 1, perpendicularly to the
plane of the panel. On its inside the upper groove wall 11 has a
bevel 11a. The bevel means that the thickness of the upper groove
wall decreases from the free end thereof towards the bottom of the
groove 3.
[0033] Prior to the operation of joining the positively locking
profiles 3 and 4 the raised portions 5, 6 and 7 shown in FIG. 1 at
the tongue underside 4a of the tongue profile 4 involve an
overdimension in relation to the shape and dimensions of the groove
profile 3.
[0034] In the assembled condition, the connection of the tongue
profile 4 to the groove profile 3 of the panel 1 forms a hinge
joint G. The hinge joint G permits an angular movement of the
panels 1 and 2 relative to each other. In a basic position the
panels 1 and 2 are at an angle of 180.degree. relative to each
other. The panels 1 and 2 can be pivoted out of that basic position
both into a position involving an angle of greater than 180.degree.
relative to each other and also into a position involving an angle
of less than 180.degree.. A position of the panels 1 and 2 at an
angle of greater than 180.degree. relative to each other is
described hereinafter with reference to FIG. 5.
[0035] FIG. 2 shows how the positively locking profiles are joined
together by engaging one into the other. A panel 1 is lying on the
laying surface 4 and is disposed with its groove profile 3 facing
towards a new panel 2. The new panel 2 is inserted with its tongue
profile 4 into the groove profile 3 of the lying panel 1, in which
case the new panel 2 is set in an inclined position or is angled
with respect to the lying panel 1. As illustrated a first raised
portion 5 of the tongue underside 4a of the panel 2 comes into
contact with the lower groove wall 10 of the groove profile 3. When
that happens the tip of the raised portion 5 rubs against the
surface of the channel-shaped receiving means 10a and is ground
away thereat. Abrasion particles 5a which are produced pass into
the recess 8 and are entrained therein during the further joining
movement.
[0036] FIG. 3 shows the joining operation in a further stage. A
second raised portion 6 has come into contact with the surface of
the channel-shaped recess 10a and is ground away thereat. Abrasion
particles 6a which are produced are stored in the recess 9 which is
arranged behind the second recess 6 in the joining direction of the
tongue profile 4. In that way the shape of the tongue profile 4 is
adapted to the shape of the groove profile 3 during the assembly
procedure.
[0037] The finished assembled condition of the positively locking
profiles 3 and 4 is shown in FIG. 4. In that case a third raised
portion 7 has also come into contact with the surface of the
channel-shaped recess 10a of the groove wall 10 and has been ground
away thereat. Abrasion particles 7a which are produced in that
situation are disposed in an intermediate space between the lower
groove wall 10 of the groove profile 3 and the tongue profile 4. A
closed joint F is produced at the top side A of the panels, which
is away from the laying surface V. The joint F is formed by an end
face 11b of the upper groove wall 11 of the groove profile 3 and by
a contact face 12 which is provided on the tongue profile 4 and
which extends from the tongue top side 4b to the surface of the
panel 2. In that condition the end face 11b bears without pressure
against the contact face 12. The inner portion--tongue profile
4--of the panel 2 fits without clearance into the outer
portion--groove profile 3--of the adjacent panel 1. Elastic
deformation which strains the positively locking profile does not
occur.
[0038] The particularity of the structure is that the relationship
of the fitting shapes of the positively locking profiles to be
joined changes during the assembly procedure. In the present
embodiment the fitting shape of the tongue profile 4 is matched to
that of the groove profile 3. Alternatively however it is also
possible for the groove profile to be provided with raised portions
and recesses which grind each other away. It is immaterial in terms
of the function of the connection, at what location adaptation
takes place by virtue of material being ground away. The number of
raised portions is not fixed at three. It is possible for example
to provide a microstructure comprising a plurality of raised
portions which are substantially smaller than those of the
described embodiment.
[0039] Prior to the joining operation there is a `surplus` of
material in the region of the raised portions 5, 6 and 7 of the
tongue profile 4. That overdimension is ground away during the
assembly procedure for the positively locking profiles until the
fitting shape of the inner portion is adapted to that of the outer
portion.
[0040] For that purpose the stiffness of the positively locking
profiles 3 and 4 and the abrasion resistance of the raised portions
5, 6 and 7 are so matched to each other that forces which occur
during the assembly procedure can admittedly cause the raised
portions 5, 6 and 7 to be rubbed away, but they cannot give rise to
elastic deformation of the positively locking profiles 3 and 4
respectively.
[0041] If the degree to which the raised portions 5, 6 and 7 are
ground away by the joining operation is not sufficient, that is to
say, if too little material is ground away by the joining movement
involving pivotal movement of the panel 2 down into the plane of
the lying panel 1, then the positively locking profiles 3 and 4
must be ground in against each other until fitting accuracy is
achieved, by a subsequent reciprocating pivotal movement. For that
purpose it is extremely helpful if the panels 1 and 2 are hingedly
connected and can be pivoted from an angular position of
180.degree. relative to each other both in the positive direction
and also in the negative direction. The pivot joint G and the
mobility thereof are indicated in FIG. 5 in which the panels 1 and
2 are at an angle relative to each other which is larger than
180.degree.. That permits a particularly good reciprocating
grinding movement. Prior to the panels 1 and 2 being definitively
laid on the laying surface V, they can be for example loosely
assembled on a table in order to ascertain the extent to which they
have to be ground in against each other so as to achieve fitting
accuracy. During the laying operation, fitting accuracy can be
checked at the respective free end of the locked panel surface.
There, the connection between the positively locking profiles 3 and
4 is visible from the side. It is possible to examine the
arrangement to ascertain whether deformation of the positively
locking profiles 3 and 4 has occurred. For the purpose of
objectively checking whether deformation is present, it is possible
for example to take a measurement of the total thickness of the
panels 1 and 2 in the region of the joined positively locking
profiles 3 and 4. If the total thickness exceeds a predetermined
limit dimension the grinding-in operation has to be continued.
[0042] FIG. 6 shows an embodiment of panels 1 and 2 whose
positively locking profiles 3 and 4 are treated with a so-called
insulating wax. This involves an agent which provides lubrication
for the joining movement of the positively locking profiles 3 and
4. In addition the insulating wax is squeezed into free
intermediate spaces 13a, 13b and 13c within the locked positively
locking profiles 3 and 4 and is pressed for example in the form of
a thin film into the joint F at the top side of the panels 1 and 2.
In that way the insulating wax acts as a sealing agent. The sealing
agent is applied in an amount which at least partially covers the
surface of the positively locking profiles. That prevents the
ingress of moisture into the joint F and thus into the wood
material. Otherwise the wood material would swell due to the
absorption of moisture. The amount of insulating wax can fill up
the intermediate spaces 13a, 13b and 13c or can be of a somewhat
smaller quantity so that free spaces remain. In addition its
lubricating property provides that creaking or grating noises do
not occur in the region of the positively locking profiles 3 and 4
of the panels 1 and 2 because a lubricant film is formed. Creaking
or grating noises occur in the case of panels 1 and 2 when a
relative movement takes place between the positively locking
profiles 3 and 4. That is the case for example when laying floor
panels on a flexible, footstep sound-damping support, because the
panels 1 and 2 sink into the flexible support when loaded at the
connecting location.
LIST OF REFERENCES
[0043] 1 panel [0044] 2 panel [0045] 3 groove profile [0046] 4
tongue profile [0047] 4a tongue underside [0048] 4b tongue top side
[0049] 5 raised portion [0050] 5a abrasion particle [0051] 6 raised
portion [0052] 6a abrasion particle [0053] 7 raised portion [0054]
7a abrasion particle [0055] 8 recess [0056] 9 recess [0057] 10
groove wall [0058] 10a channel-shaped recess [0059] 11 groove wall
[0060] 11a bevel [0061] 11b end face [0062] 12 contact face [0063]
13a intermediate space [0064] 13b intermediate space [0065] 13c
intermediate space [0066] A top side [0067] B underside [0068] F
joint [0069] G pivot joint [0070] V laying surface
* * * * *