U.S. patent application number 13/544281 was filed with the patent office on 2013-09-12 for mechanical locking system for floor panels.
This patent application is currently assigned to VALINGE FLOORING TECHNOLOGY AB. The applicant listed for this patent is Darko Pervan. Invention is credited to Darko Pervan.
Application Number | 20130232905 13/544281 |
Document ID | / |
Family ID | 47518107 |
Filed Date | 2013-09-12 |
United States Patent
Application |
20130232905 |
Kind Code |
A2 |
Pervan; Darko |
September 12, 2013 |
MECHANICAL LOCKING SYSTEM FOR FLOOR PANELS
Abstract
Floor panels are shown, which are provided with a vertical
folding locking system on short edges that only locks vertically
and a mechanical locking system on long edges that prevents
displacement along the long edges.
Inventors: |
Pervan; Darko; (Viken,
SE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Pervan; Darko |
Viken |
|
SE |
|
|
Assignee: |
VALINGE FLOORING TECHNOLOGY
AB
Viken
SE
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20130014463 A1 |
January 17, 2013 |
|
|
Family ID: |
47518107 |
Appl. No.: |
13/544281 |
Filed: |
July 9, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61506282 |
Jul 11, 2011 |
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Current U.S.
Class: |
52/588.1 ;
52/582.2 |
Current CPC
Class: |
E04F 15/02038 20130101;
E04F 2201/0169 20130101; E04F 2201/0547 20130101; E04F 15/107
20130101 |
Class at
Publication: |
52/588.1 ;
52/582.2 |
International
Class: |
E04B 5/00 20060101
E04B005/00; E04C 2/38 20060101 E04C002/38 |
Claims
1. A flooring system comprising a plurality of rectangular floor
panels with short edges and long edges, the panels are adapted to
be installed on a sub floor and connected to each other with a long
edge mechanical locking system for locking the panels vertically
and horizontally, said locking system comprising a tongue and a
tongue groove for mechanically locking together adjacent edges
vertical to the horizontal plane, forming a vertical mechanical
connection between the panels, and a locking element at a first
long edge and a locking groove at an opposite second long edge
thereby forming a first horizontal mechanical connection between
adjacent long edges locking the panels to each other in a direction
parallel to the horizontal plane and at right angles to said
adjacent long edges, wherein the panels are provided with a short
edge locking connection comprising a separate tongue, for locking
adjacent short edges in a first vertical direction, inserted in a
fixation groove at a short edge of a panel, wherein the separate
tongue is at least partly flexible and/or displaceable, and a
locking strip and a locking cavity for locking adjacent short edges
in a second vertical direction, wherein the short edge locking
connection is configured to lock the adjacent edges in the vertical
directions only, wherein the long edges are provided with a second
horizontal mechanical connection locking the panels to each other
along said adjacent long edges, in a direction parallel to the
horizontal plane and parallel to said adjacent long edges, when the
panel are laying flat on the sub floor.
2. The flooring system as claimed in claim 1, wherein said second
horizontal mechanical connection at the long edges comprises a
locking element and locking groove with two sets of cooperating
locking surfaces wherein a first set is located closer to a
vertical plane and the upper joint edges than a second set.
3. The flooring system as claimed in claim 2, wherein the two sets
of locking surfaces are inclined such that a lower part of the
locking element is larger than an upper part.
4. The flooring system as claimed in claim 2, wherein the vertical
extension of the second set of locking surfaces is essentially the
same or larger than the vertical extension of the first set of
locking surfaces.
5. The flooring system as claimed in claim 2, wherein the long edge
locking system further comprises a third set of cooperating locking
surfaces located at the outer and lower part of the strip.
6. The flooring system as claimed in claim 2, wherein there is a
space between the upper part of the locking element and the locking
groove.
7. The flooring system as claimed in claim 1, wherein that said
second horizontal mechanical connection comprises a flexible
material which is applied in an essentially vertical groove.
8. The flooring system as claimed in claim 7, wherein said flexible
material is compressed horizontally in two opposite directions.
9. The flooring system as claimed in claim 7, wherein said
essentially vertical groove is complementary with a wedge shaped
locking element.
10. The flooring system as claimed in claim 1, wherein said second
horizontal mechanical connection comprises a friction element
located on the upper part of the locking element that cooperates
with a friction groove.
11. The flooring system as claimed in claim 10, wherein the
friction groove comprises a flexible material.
12. The flooring system as claimed in claim 1, wherein said second
horizontal mechanical connection comprises friction cavities
located on the locking element.
13. The flooring system as claimed in claim 1, wherein said second
horizontal mechanical connection comprises compressible material
that is applied in the locking system at surfaces that do not
comprise cooperative active locking surfaces which lock the panels
vertically to the horizontal plane and horizontally in a direction
parallel to the horizontal plane and at right angles to said
adjacent long edges.
14. The flooring system as claimed in claim 1, wherein the short
edge locking connection is locked with a vertical snap action where
the separate tongue is displaced in the fixation groove during
vertical displacement.
15. The flooring system as claimed in claim 1, wherein the short
edge locking connection is locked when the separate tongue is
displaced in the fixation groove along the short edge.
16. A flooring system comprising a plurality of rectangular floor
panels with short edges and long edges, the panels are adapted to
be installed on a sub floor and connected to each other with a long
edge mechanical locking system for locking the panels vertically
and horizontally, said locking system comprising a tongue and a
tongue groove for mechanically locking together adjacent edges
vertical to the horizontal plane, forming a vertical mechanical
connection between the panels, and a locking element at a first
long edge and a locking groove at an opposite second long edge
thereby forming a first horizontal mechanical connection between
adjacent long edges locking the panels to each other in a direction
parallel to the horizontal plane and at right angles to said
adjacent long edges, wherein the panels are provided with a short
edge locking connection comprising a separate tongue, for locking
adjacent short edges in a first vertical direction, inserted in a
fixation groove at a short edge of a panel, wherein the separate
tongue is at least partly flexible and/or displaceable, and a
locking strip and a locking cavity for locking adjacent short edges
in a second vertical direction, wherein the long edges are provided
with a second horizontal mechanical connection locking the panels
to each other along said adjacent long edges, in a direction
parallel to the horizontal plane and parallel to said adjacent long
edges, when the panel are laying flat on the sub floor, wherein
said second horizontal mechanical connection at the long edges
comprises a locking element and locking groove with two sets of
cooperating locking surfaces wherein a first set is located closer
to a vertical plane and the upper joint edges than a second set,
wherein the two sets of locking surfaces are inclined such that a
lower part of the locking element is larger than an upper part.
17. The flooring system as claimed in claim 16, wherein the
vertical extension of the second set of locking surfaces is
essentially the same or larger than the vertical extension of the
first set of locking surfaces.
18. A flooring system comprising a plurality of rectangular floor
panels with short edges and long edges, the panels are adapted to
be installed on a sub floor and connected to each other with a long
edge mechanical locking system for locking the panels vertically
and horizontally, said locking system comprising a tongue and a
tongue groove for mechanically locking together adjacent edges
vertical to the horizontal plane, forming a vertical mechanical
connection between the panels, and a locking element at a first
long edge and a locking groove at an opposite second long edge
thereby forming a first horizontal mechanical connection between
adjacent long edges locking the panels to each other in a direction
parallel to the horizontal plane and at right angles to said
adjacent long edges, wherein the panels are provided with a short
edge locking connection comprising a separate tongue, for locking
adjacent short edges in a first vertical direction, inserted in a
fixation groove at a short edge of a panel, wherein the separate
tongue is at least partly flexible and/or displaceable, and a
locking strip and a locking cavity for locking adjacent short edges
in a second vertical direction, wherein the long edges are provided
with a second horizontal mechanical connection locking the panels
to each other along said adjacent long edges, in a direction
parallel to the horizontal plane and parallel to said adjacent long
edges, when the panel are laying flat on the sub floor, wherein
said second horizontal mechanical connection at the long edges
comprises a locking element and locking groove with two sets of
cooperating locking surfaces wherein a first set is located closer
to a vertical plane and the upper joint edges than a second set,
wherein the long edge locking system further comprises a third set
of cooperating locking surfaces located at the outer and lower part
of the strip.
19. A flooring system comprising a plurality of rectangular floor
panels with short edges and long edges, the panels are adapted to
be installed on a sub floor and connected to each other with a long
edge mechanical locking system for locking the panels vertically
and horizontally, said locking system comprising a tongue and a
tongue groove for mechanically locking together adjacent edges
vertical to the horizontal plane, forming a vertical mechanical
connection between the panels, and a locking element at a first
long edge and a locking groove at an opposite second long edge
thereby forming a first horizontal mechanical connection between
adjacent long edges locking the panels to each other in a direction
parallel to the horizontal plane and at right angles to said
adjacent long edges, wherein the panels are provided with a short
edge locking connection comprising a separate tongue, for locking
adjacent short edges in a first vertical direction, inserted in a
fixation groove at a short edge of a panel, wherein the separate
tongue is at least partly flexible and/or displaceable, and a
locking strip and a locking cavity for locking adjacent short edges
in a second vertical direction, wherein the long edges are provided
with a second horizontal mechanical connection locking the panels
to each other along said adjacent long edges, in a direction
parallel to the horizontal plane and parallel to said adjacent long
edges, when the panel are laying flat on the sub floor, wherein
said second horizontal mechanical connection comprises a flexible
material which is applied in an essentially vertical groove that is
complementary with a wedge shaped locking element, wherein said
flexible material is compressed horizontally in two opposite
directions.
20. A flooring system comprising a plurality of rectangular floor
panels with short edges and long edges, the panels are adapted to
be installed on a sub floor and connected to each other with a long
edge mechanical locking system for locking the panels vertically
and horizontally, said locking system comprising a tongue and a
tongue groove for mechanically locking together adjacent edges
vertical to the horizontal plane, forming a vertical mechanical
connection between the panels, and a locking element at a first
long edge and a locking groove at an opposite second long edge
thereby forming a first horizontal mechanical connection between
adjacent long edges locking the panels to each other in a direction
parallel to the horizontal plane and at right angles to said
adjacent long edges, wherein the panels are provided with a short
edge locking connection comprising a separate tongue, for locking
adjacent short edges in a first vertical direction, inserted in a
fixation groove at a short edge of a panel, wherein the separate
tongue is at least partly flexible and/or displaceable, and a
locking strip and a locking cavity for locking adjacent short edges
in a second vertical direction, wherein the long edges are provided
with a second horizontal mechanical connection locking the panels
to each other along said adjacent long edges, in a direction
parallel to the horizontal plane and parallel to said adjacent long
edges, when the panel are laying flat on the sub floor, wherein
said second horizontal mechanical connection comprises a friction
element located on the upper part of the locking element that
cooperates with a friction groove.
21. The flooring system as claimed in claim 20, wherein the
friction groove comprises a flexible material.
22. A flooring system comprising a plurality of rectangular floor
panels with short edges and long edges, the panels are adapted to
be installed on a sub floor and connected to each other with a long
edge mechanical locking system for locking the panels vertically
and horizontally, said locking system comprising a tongue and a
tongue groove for mechanically locking together adjacent edges
vertical to the horizontal plane, forming a vertical mechanical
connection between the panels, and a locking element at a first
long edge and a locking groove at an opposite second long edge
thereby forming a first horizontal mechanical connection between
adjacent long edges locking the panels to each other in a direction
parallel to the horizontal plane and at right angles to said
adjacent long edges, wherein the panels are provided with a short
edge locking connection comprising a separate tongue, for locking
adjacent short edges in a first vertical direction, inserted in a
fixation groove at a short edge of a panel, wherein the separate
tongue is at least partly flexible and/or displaceable, and a
locking strip and a locking cavity for locking adjacent short edges
in a second vertical direction, wherein the long edges are provided
with a second horizontal mechanical connection locking the panels
to each other along said adjacent long edges, in a direction
parallel to the horizontal plane and parallel to said adjacent long
edges, when the panel are laying flat on the sub floor, wherein
said second horizontal mechanical connection comprises friction
cavities located on the locking element.
23. A flooring system comprising a plurality of rectangular floor
panels with short edges and long edges, the panels are adapted to
be installed on a sub floor and connected to each other with a long
edge mechanical locking system for locking the panels vertically
and horizontally, said locking system comprising a tongue and a
tongue groove for mechanically locking together adjacent edges
vertical to the horizontal plane, forming a vertical mechanical
connection between the panels, and a locking element at a first
long edge and a locking groove at an opposite second long edge
thereby forming a first horizontal mechanical connection between
adjacent long edges locking the panels to each other in a direction
parallel to the horizontal plane and at right angles to said
adjacent long edges, wherein the panels are provided with a short
edge locking connection comprising a separate tongue, for locking
adjacent short edges in a first vertical direction, inserted in a
fixation groove at a short edge of a panel, wherein the separate
tongue is at least partly flexible and/or displaceable, and a
locking strip and a locking cavity for locking adjacent short edges
in a second vertical direction, wherein the long edges are provided
with a second horizontal mechanical connection locking the panels
to each other along said adjacent long edges, in a direction
parallel to the horizontal plane and parallel to said adjacent long
edges, when the panel are laying flat on the sub floor, wherein
said second horizontal mechanical connection comprises compressible
material that is applied in the locking system at surfaces that do
not comprise cooperative active locking surfaces which lock the
panels vertically to the horizontal plane and horizontally in a
direction parallel to the horizontal plane and at right angles to
said adjacent long edges.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of Provisional Application
No. 61/506,282, filed Jul. 11, 2011.
TECHNICAL FIELD
[0002] The disclosure generally relates to the field of mechanical
locking systems for floor panels and building panels. Furthermore,
floorboards, locking systems, installation methods and production
methods are shown.
FIELD OF APPLICATION OF THE INVENTION
[0003] The present invention is particularly suitable for use in
floating floors, which are formed of floor panels which are joined
mechanically with a locking system integrated with the floor panel,
i.e. mounted at the factory, are made up of one or more upper
layers of veneer, decorative laminate or decorative plastic
material, an intermediate core of wood-fibre-based material or
plastic material and preferably a lower balancing layer on the rear
side of the core. The following description of prior-art technique,
problems of known systems and objects and features of the invention
will therefore, as a non-restrictive example, be aimed above all at
this field of application and in particular at laminate flooring
formed as rectangular floor panels with long and shorts edges
intended to be mechanically joined to each other on both long and
short edges. The long and short edges are mainly used to simplify
the description of the invention. The panels may be square. It
should be emphasised that the invention may be used in any floor
panel and it may be combined with all types of known locking
systems, where the floor panels are intended to be joined using a
mechanical locking system connecting the panels in the horizontal
and vertical directions on at least two adjacent sides. The
invention may thus also be applicable to, for instance, powder
based floors, solid wooden floors, parquet floors with a core of
wood or wood-fibre-based material and a surface of wood or wood
veneer and the like, floors with a printed and preferably also
varnished surface, floors with a surface layer of plastic or cork,
linoleum, rubber. Even floors with hard surfaces such as stone,
tile and similar materials are included and floorings with soft
wear layer, for instance needle felt glued to a board. The
invention may also be used for joining building panels which
preferably contain a board material for instance wall panels,
ceilings, furniture components and similar.
BACKGROUND OF THE INVENTION
[0004] Laminate flooring usually comprise a core of a 6-12 mm fibre
board, a 0.2-0.8 mm thick upper decorative surface layer of
laminate and a 0.1-0.6 mm thick lower balancing layer of laminate,
plastic, paper or like material. A laminate surface may comprise
melamine-impregnated paper. The most common core material is
fibreboard with high density and good stability usually called
HDF--High Density Fibreboard. Sometimes also MDF--Medium Density
Fibreboard--is used as core.
[0005] Traditional laminate floor panels of this type have been
joined by means of glued tongue-and-groove joints.
[0006] In addition to such traditional floors, floor panels have
been developed which do not require the use of glue and instead are
joined mechanically by means of so-called mechanical locking
systems. These systems comprise locking means, which lock the
panels horizontally and vertically. The mechanical locking systems
are usually formed by machining of the core of the panel.
Alternatively, parts of the locking system may be formed of a
separate material, for instance aluminium or HDF, which is
integrated with the floor panel, i.e. joined with the floor panel
in connection with the manufacture thereof.
[0007] The main advantages of floating floors with mechanical
locking systems are that they are easy to install. They may also be
disassembled and used once more at a different location.
DEFINITION OF SOME TERMS
[0008] In the following text, the visible surface of the installed
floor panel is called "front side", while the opposite side of the
floor panel, facing the sub floor, is called "rear side". The edge
between the front and rear side is called "joint edge". By
"horizontal plane" is meant a plane, which extends parallel to the
outer part of the surface layer. Immediately juxtaposed upper parts
of two adjacent joint edges of two joined floor panels together
define a "vertical plane" perpendicular to the horizontal plane. By
"vertical locking" is meant locking parallel to the vertical plane
in D1 direction. By "horizontal locking" is meant locking parallel
to the horizontal plane in D2 direction. By "first horizontal
locking" is meant a horizontal locking perpendicular to the joint
edges in D2 direction. By "second horizontal locking" is meant a
horizontal locking in the horizontal direction along the joint
which prevents two panels to slide parallel to each other when they
are laying in the same plane.
[0009] By "locking systems" are meant co acting connecting
elements, which connect the floor panels vertically and/or
horizontally. By "mechanical locking system" is meant that joining
may take place without glue. Mechanical locking systems may also be
joined by gluing. By "integrated with" means formed in one piece
with the panel or factory connected to the panel.
RELATED ART AND PROBLEMS THEREOF
[0010] For mechanical joining of long edges as well as short edges
in the vertical and in the first horizontal direction perpendicular
to the edges several methods may be used. One of the most used
methods is the angle-snap method. The long edges are installed by
angling. The panel is then displaced in locked position along the
long side. The short edges are locked by horizontal snapping. The
vertical connection is generally a tongue and a groove. During the
horizontal displacement, a strip with a locking element is bent and
when the edges are in contact, the strip springs back and a locking
element enters a locking groove and locks the panels horizontally.
Such a snap connection is complicated since a hammer and a tapping
block may need to be used to overcome the friction between the long
edges and to bend the strip during the snapping action.
[0011] Similar locking systems may also be produced with a rigid
strip and they are connected with an angling-angling method where
both short and long edges are angled into a locked position.
[0012] Recently new and very efficient locking systems have been
introduced with a separate flexible or displaceable integrated
tongue on the short edge that allows installation with only an
angling action, generally referred to as "vertical folding". Such a
system is described in WO 2006/043893 (Valinge Innovation AB.
[0013] Several versions are used on the market as shown in FIGS.
1a-1f. 1a, 1b shows a flexible tongue 30 with a flexible snap tab
extending from the edge. FIG. 1c, 1d shows a displaceable tongue
with an inner flexible part that is bendable horizontally in a
cross section of the tongue or along the joint. Such systems are
referred to as vertical snap systems. The locking system may also
be locked with a side push action such that a displaceable tongue
30 is pushed into a locked position from the long side edge when
adjacent short side edges are folded down to the sub floor. FIG. 1e
shows a fold down system with a flexible tongue 30 that is made in
one piece with the core. FIG. 1f shows a long edge locking system
in a fold down system that is connected with angling.
[0014] All such locking systems comprise a horizontal locking,
which is accomplished by cooperating hook element in the form of a
strip with a locking element cooperating with a locking groove.
[0015] Several versions of fold down systems are described in
WO2006104436, WO2007015669, WO2008004960, WO2010087752 (Valinge
Innovation AB) and they constitute a part of this description.
[0016] Although such systems are very efficient, there is still a
room for improvements. It is difficult to insert the separate
tongue 30 during production into a groove 40 over a strip 6
comprising a locking element 8. The locking groove 14 reduces the
strength and the edges may crack. The protruding locking strip with
the locking element causes a waste when the edges are machined and
such waste may be considerable in wide tile-shaped floorboards.
[0017] It is a major advantage if the strip 6 is more compact and
shorter and if the locking element 8 and the locking groove 14 are
eliminated.
[0018] One of the main advantages with the fold down systems is
that there is no requirement that the long edges should be
displaceable. In fact it is an advantage if the long edges do not
slide during angling since a flexible tongue that is used in some
systems presses the short edges apart during folding.
[0019] WO 2006/043893 describes a fold down system with an
essentially horizontal protruding strip that does not have a
locking element. Such fold down system has no horizontal connection
and the short edges may be locked by for example gluing or nailing
to the sub floor. It would be an advantage if such floorboards
could be installed in a floating manner.
[0020] Such a floating installation may be accomplished according
to this invention with a locking system that comprises long edges
that are locked in a first horizontal direction perpendicular to
the edge and in a second horizontal direction along the edge. Long
edges that are not displaced after locking will also keep the short
edges together and prevent separation.
[0021] It is known that a separation of short edges of floor panels
may be prevented with increased friction or with projections and
spaces between the long edges that will counteract mutual
displacements along the edge and consequently prevent the short
edges to slide apart.
[0022] It is for example known from Wilson U.S. Pat. No. 2,430,200
that several projections and recesses between a tongue and a groove
in a mechanical locking system may be used to prevent displacement
along the joint. Such projections and recesses are difficult to
produce, the panels can only be locked in well-defined positions
against adjacent long edges and they cannot be displaced against
each other in angled position when top edges are in contact.
[0023] Terbrack U.S. Pat. No. 4,426,820 describes a locking system
with a tight fit in a panel made of plastic material. The tight fit
prevents displacement along the joint. A system with tight fit
between all surfaces is difficult to produce and does not give a
safe and reliable locking over time, especially if the locking
system is made of wood fibre based material such as HDF, which
swells and shrink when the humidity varies over time.
[0024] WO1994026999 (Valinge Innovation AB) describes a mechanical
locking system that locks vertically and horizontally and where a
rubber strip or any other sealing device is applied in the groove
or between the flat projection part of the strip and the adjacent
panel edge as shown principally in FIG. 1f. It is obvious that a
rubber strip may be used to increase friction along the joint.
[0025] WO98/22677 (Golvabia) describes a tongue and groove joint
where several different types of materials are used to increase
friction in order to prevent the edges from sliding apart
perpendicularly to the edge. Example of materials inserted or
applied in the tongue and groove joint are flock, strip-shaped
bands of rubber, plastic, foamed rubber adhesive coated surfaces in
which friction-increasing material is fixed such as sand, plastic
or rubber particles. Roughened or coarsened surfaces may also be
used.
[0026] WO03025307 and WO03089736 (Valinge Innovation AB) describe
that displacement along long edges may be counteracted or prevented
by means of high friction, glue, mechanical means etc. and that the
short edges may be formed merely with vertical locking means or
completely without locking means. WO03012224 (Valinge Innovation
AB) describes that flexible elastic sealing compounds based on
acrylic plastics, elastomers of synthetic rubber,
polyurethane-based hot-melt adhesives etc may be applied between
the horizontal locking surfaces in order to compensate moisture
movements due to swelling or shrinking. Such elastically material
will increase the friction and prevent displacement of long edges
along the joint.
[0027] Wernersson WO2004/083557 discloses floor panels with
mechanical locking means wherein predetermined surfaces of the
edges are provided with splines. There is no disclosure of the
geometry of such mechanical locking means, how such splines are
formed and on which surfaces they are applied.
[0028] WO 2006/123988 (Valinge Innovation AB) describes a panel
with a slide locking system comprises a plurality of small local
protrusions that prevents displacement along the joint edges when
the panels are laying flat on the sub floor. The protrusions may
lock against a flexible rubber material at the adjacent panel. The
short edges are provided only with a vertical locking comprising a
tongue made in one piece with the core. The panels may be locked
with vertical folding and the slide lock prevents sliding along the
joint after folding. A folding system at the short edges that only
locks vertically and which comprise a flexible separate tongue is
not described.
[0029] These known technologies to prevent displacement along the
long edges suffer from several disadvantages. Friction created by
pressure and small hard materials is not reliable since swelling
and shrinking in wood fibre based panels may change the friction
forces, thus the panels may as time goes slide and the short edges
separate from each other. Friction material that is applied on
surfaces that form active horizontal locking surfaces, such as the
locking surfaces of the locking element and the locking groove and
upper adjacent joint edges may change the locking geometry and
prevent an easy installation.
SUMMARY
[0030] A first overall objective of the present invention is to
provide a locking system for primarily rectangular floor panels
with long and short edges installed in parallel rows, which allows
that the short edges may be locked to each other with a vertical
movement without a horizontal connection and that such horizontal
connection is accomplished by the locking system on the long edges
comprising a first and second horizontal locking perpendicular to
the edges and along the edges.
[0031] The invention is based on the understanding that since
displacement of the long edges is not needed in a fold down locking
system, there is more freedom to design the long edges locking
system.
[0032] The costs and functions should be favourable compared to
known technology. An essential part of the overall objective is to
improve the function and costs of those parts of the locking system
that locks in the second horizontal direction along the joint when
panels are installed on a sub floor.
[0033] More specifically the object is to provide a second
horizontal locking system on the long edges, hereafter referred to
as "slide lock" where one or several of the following advantages
are obtained.
[0034] The slide lock on the long edges should be activated when a
panel is brought in contact with an already installed panel and
then angled down to the sub floor.
[0035] The slide lock function should be reliable over time and the
panels should be possible to lock and unlock in any position when
two adjacent long edges are brought into contact with each
other.
[0036] The slide lock should be strong and prevent short edges of
two locked panels from separating when humidity changes or when
people walk on a floor.
[0037] The slide lock should be possible to lock with high
precision and without the use of tools.
[0038] The locking system and the slide lock should be designed in
such a way that the material and production costs are low and that
flexible materials may be applied in a safe way without the risk
that such separate materials will be included in the active locking
surfaces in an uncontrolled way.
[0039] The invention is based on a general approach that the
locking element and the locking groove at the long edges should be
used to accomplish a horizontal locking perpendicular to the edge
but also along the edge.
[0040] The above objects of the invention are achieved wholly or
partly by locking systems, floor panels, and installation and
production methods according to the disclosure herein. Embodiments
of the invention are evident from the description and drawings.
[0041] A first aspect of the invention is a flooring system
comprising a plurality of rectangular floor panels with short edges
and long edges. The panels are adapted to be installed on a sub
floor and connected to each other with a mechanical locking system
for locking the panels vertically and horizontally. Said locking
system comprising a tongue and a tongue groove for mechanically
locking together adjacent edges vertical to the horizontal plane,
thereby forming a vertical mechanical connection between the
panels. A locking element at a first long edge and a locking groove
at an opposite second long edge form a first horizontal mechanical
connection between adjacent long edges locking the panels to each
other in a direction parallel to the horizontal plane and at right
angles to said adjacent long edges. The panels are provided with a
short edge locking connection comprising a separate tongue for
locking adjacent short edges in a first vertical direction,
inserted in a fixation groove at a short edge of a panel. The
tongue is preferably at least partly flexible and/or displaceable.
The short edge locking connection further comprises a locking strip
and a locking cavity for locking adjacent short edges in a second
vertical direction. The short edge locking connection is configured
to lock the adjacent edges in a vertical direction only. The long
edges are provided with a second horizontal mechanical connection
locking the panels to each other along said adjacent long edges, in
a direction parallel to the horizontal plane and parallel to said
adjacent long edges, when the panel are laying flat on the sub
floor.
[0042] Said second horizontal mechanical connection at the long
edges may comprises a locking element and locking groove with two
sets of cooperating locking surfaces, wherein a first set is
located closer to a vertical plane (VP) and the upper joint edges
than a second set.
[0043] The two sets of locking surfaces may be inclined such that a
lower part of the locking element is larger than an upper part.
[0044] The vertical extension of the second set of locking surfaces
may be essentially the same or larger than the vertical extension
of the first set of locking surfaces.
[0045] The long edge locking system may comprises a third set of
cooperating locking surfaces located at the outer and lower part of
the strip.
[0046] There may be a space between the upper part of the locking
element and the locking groove.
[0047] Said second horizontal mechanical connection may comprise a
flexible material which is applied in an essentially vertical
groove.
[0048] Said second horizontal mechanical connection may comprise a
flexible material, which is compressed horizontally in two opposite
directions
[0049] Said second horizontal mechanical connection may comprise a
flexible material, which is located in an essentially vertical
groove that is complementary with a wedge shaped locking
element.
[0050] Said second horizontal mechanical connection may comprise a
friction element located on the upper part of the locking element
that cooperates with a friction groove.
[0051] The friction groove may comprise a flexible material.
[0052] Said second horizontal mechanical connection may comprise
friction cavities located at the locking element.
[0053] Said second horizontal mechanical connection may comprise
compressible material that is applied in the locking system at
surfaces that do not comprise cooperative active locking surfaces
that lock the panels vertically and horizontally.
[0054] The short edge locking connection may be locked with a
vertical snap action where the separate tongue is displaced in the
fixation groove during vertical displacement.
[0055] The short edge locking connection may be locked when the
separate tongue is displaced in the fixation groove along the short
edge.
[0056] According to a first preferred embodiment the locking system
at the long edges comprises a locking element and locking groove
with two sets of cooperating locking surfaces. A first set is
located closer to a vertical plane and the upper joint edges than a
second set. The locking surfaces are preferably inclined such that
a lower part of the locking element is larger than an upper part.
It is preferred that there is a space between the upper part of the
locking element and the locking groove. Such a space may be used to
give more production tolerances. Preferably the vertical extension
of the second set of locking surfaces is essentially the same or
larger than the vertical extension of the first set of locking
surfaces.
[0057] According to a second embodiment of the invention the long
edge locking system comprises a flexible material located in a
vertical groove that prevents displacement along the edges. The
flexible material is preferably located between cooperating
surfaces of the locking element and the locking groove.
[0058] According to a third embodiment of the invention the long
edge locking system comprises at least three sets of cooperative
locking surfaces between a locking element located on a strip and a
locking groove. The first and the second sets are located in the
upper part of the locking element wherein the first set is closer
to the upper edges than the second set. The third set is located on
the lower and outer part of the strip. This geometry is used to
accomplish a strong press fit between the locking element and the
locking groove and the panels will be tightly secured to each other
such that displacement along the long edges and perpendicular to
the short edges will be prevented.
[0059] Such a locking system with a press fit may be made much
stronger than conventional locking systems with hooks at the short
edges.
[0060] A second aspect of the invention is two floor panels
provided with a locking system comprising a tongue and a tongue
groove for mechanically locking together adjacent edges vertical to
the horizontal plane, thereby forming a vertical mechanical
connection between the panels. A locking element at an edge and a
locking groove at an opposite second edge form a first horizontal
mechanical connection between adjacent edges locking the panels to
each other in a direction parallel to the horizontal plane and at
right angles to said adjacent edges. The tongue may be separate
tongue, preferably at least partly flexible and/or displaceable,
inserted in a fixation groove at an edge of a panel. The edges is
provided with a second horizontal mechanical connection locking the
panels to each other along said adjacent edges, in a direction
parallel to the horizontal plane and parallel to said adjacent
edges, when the panels are laying flat on a sub floor.
[0061] Said second horizontal mechanical connection at the edges
may comprise a locking element and locking groove with two sets of
cooperating locking surfaces, wherein a first set is located closer
to a vertical plane (VP) and the upper joint edges than a second
set.
[0062] The two sets of locking surfaces may be inclined such that a
lower part of the locking element is larger than an upper part.
[0063] The vertical extension of the second set of locking surfaces
may be essentially the same or larger than the vertical extension
of the first set of locking surfaces.
[0064] The locking system may comprise a third set of cooperating
locking surfaces located at the outer and lower part of the
strip.
[0065] There may be a space between the upper part of the locking
element and the locking groove.
[0066] Said second horizontal mechanical connection may comprise a
flexible material which is applied in an essentially vertical
groove.
[0067] Said second horizontal mechanical connection may comprise a
flexible material, which is compressed horizontally in two opposite
directions
[0068] Said second horizontal mechanical connection may comprise a
flexible material, which is located in an essentially vertical
groove that is complementary with a wedge shaped locking
element.
[0069] Said second horizontal mechanical connection may comprises a
friction element located on the upper part of the locking element
that cooperates with a friction groove.
[0070] The friction groove may comprise a flexible material.
[0071] Said second horizontal mechanical connection may comprise
friction cavities located at the locking element.
[0072] Said second horizontal mechanical connection may comprise
compressible material that is applied in the locking system at
surfaces that do not comprise cooperative active locking surfaces
that lock the panels vertically and horizontally.
[0073] The edges may be locked with a vertical snap action where
the separate tongue is displaced in the fixation groove during
vertical displacement.
[0074] The edges may be locked when the separate tongue is
displaced in the fixation groove along the short edge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0075] The disclosure will in the following be described in
connection to exemplary embodiments and in greater detail with
reference to the appended exemplary drawings, wherein:
[0076] FIGS. 1a-f illustrate locking systems according to known
technology.
[0077] FIGS. 2a-e illustrate a short edge locking system according
to the invention.
[0078] FIGS. 3a-3d illustrate a long edge locking system according
to preferred embodiments of the invention.
[0079] FIGS. 4a-c illustrate an preferred embodiment of short edge
locking system.
[0080] FIGS. 5a-d illustrate separate tongues that may be used in
to lock short edges.
[0081] FIGS. 6a-f illustrate preferred embodiments of the
invention.
[0082] FIGS. 7a-c illustrate a long edge locking system according
to the invention.
[0083] FIGS. 8a-8b illustrate vertical folding with a conventional
locking system and a locking system according to the invention.
FIGS. 8a-8b
[0084] FIGS. 9a-9d illustrate preferable embodiments of the
invention.
DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0085] To facilitate understanding, several locking systems in the
figures are shown schematically. It should be emphasised that
improved or different functions may be achieved using combinations
of the preferred embodiments.
[0086] The inventor has tested all known and especially all
commercially used locking systems on the market that are installed
with vertical folding in all type of floor panels, especially
laminate and wood floorings and the conclusion is that at least all
these known locking systems which have one or more locking elements
cooperating with locking grooves may be adjusted to a system with a
slide lock on the long edges which prevents displacement along the
adjacent edges and with fold down locking system on short edges
that only locks vertically.
[0087] The most preferable embodiments are however based on
floorboards with a surface layer of laminate, powder based paper
free surfaces or wood surfaces, a core of HDF or wood and a locking
system on the long edge with a strip extending beyond the upper
edge which allows locking by angling combined with a tongue and
groove joint on the short edges comprising a separate tongue which
preferably only locks vertically.
[0088] All embodiments may be used separately or in combinations.
Angles, dimensions, rounded parts, spaces between surfaces etc. are
only examples and may be adjusted within the basic principles of
the invention.
[0089] FIGS. 2a -2e show a first preferred embodiment of a short
edge locking system provided with a flexible and displaceable
tongue 30 in a first edge 1 inserted in a fixation groove 40 that
cooperated with a tongue groove 20 in an adjacent second panel 1'
and locks the panels in a first vertical direction according to
known technology. The first panel 1 (strip panel) comprises a
protruding strip 6 that extends outwardly beyond a vertical plane
VP. The second panel 1' comprises a locking cavity 7 that
cooperates with the locking strip 6 and locks the panels in a
second vertical direction. FIG. 2e show that the panels are only
locked vertically and that they may be released or connected
horizontally in essentially the same plane since there is no
locking element on the strip and no hook connections in the locking
system that prevents such horizontal displacement.
[0090] FIGS. 3a and 3b show a slide lock system according to one
preferred embodiment comprising a tongue 10 and a tongue groove 9,
a locking strip 6, a locking element 8 and a locking groove 14. A
flexible and compressible material 16 such as synthetic or natural
rubber or plastic foam is applied in the upper part of the locking
groove 14 as a layer or in local spots. The upper part of the
locking element 8 is formed such that preferably two horizontally
opposite edges press against the compressible material 16a, 16b. In
a wood floor with a lamella core the locking element and the
locking groove will be formed across the fibre orientation. The
swelling and shrinking in the horizontal direction along the wood
fibres is extremely small and will not cause any dimensional
changes of the fitting tolerances between the locking element 8 and
the locking groove 14. The counter pressure will not have any
effect on the locking tolerances and swelling and shrinking of this
part of the locking system will easily be compensated by the
flexibility of the compressible material even in other wood based
materials such as HDF. It is preferred that the upper part of the
locking element is wedge formed and that it cooperates with a
complementary groove 14. It is preferred that the inner part of the
groove 14 is smaller than the groove opening. This design may be
used to create a friction connection even without compressible
material.
[0091] FIGS. 3c and 3d show a locking system with at least three
sets of cooperative locking surfaces between the locking element 8
and the locking groove 14. The first 11,12 and the second 21,22
sets are located in the upper part of the locking element wherein
the first set is closer to the upper edges 4,5 than the second set.
The third set 23,24 is located on the lower and outer part of the
strip 6. The locking surfaces are essentially flat but they may
also be curved. The locking surfaces are preferably inclined.
Preferably the angle Al against a horizontal plane of the first set
of cooperated surfaces should be slightly smaller than the angle A3
of the third set. This geometry may be used to accomplish a strong
press fit between the locking element 8 and the locking groove 14
and the panels will be tightly secured to each other such that
displacement along the long edges and perpendicular to the short
edges will be prevented. Such a locking system with a press fit may
be made much stronger than conventional locking systems with hooks
at the short edges. A horizontally extending groove 35 may be
formed in a wall or the locking groove 14 in order to increase the
flexibility of one of the locking surfaces 23 in the third set of
locking surfaces.
[0092] The locking element and the locking groove may be formed in
a very precise manner if high precision profiling is used where
several tools are positioned at the same tool station such that the
upper edge 4 and the locking element are formed at the same time in
order to eliminate turning of the panels during machining. The
locking groove and the upper edge 5 may be formed in the same
way.
[0093] FIG. 4a-4c show that the separate tongue may be attached to
the fold panel 1'.
[0094] FIGS. 5a-5d show that all known tongues may be used in the
short edge locking system. FIG. 5a shows a bow shaped tongue and
FIG. 5b shows a bristle tongue. Such tongues are bended in length
direction during locking. FIG. 5c shows a wedge tongue that is
displaced with a side push action from the long edge such that it
is displaced both along and perpendicular to the edge into the
tongue groove 20. FIG. 5d shows as side push rigid tongue that is
only displaced along the edge such that the protrusions on the
tongue overlap the protrusions formed in the tongue groove 20.
[0095] FIGS. 6a-6f show that all known fold down systems may be
adapted to a locking system according to the invention by removing
a part the locking element and preferably a part of the strip 6.
This will provide cost savings due to less waste and a stronger
joint. It is also possible to form a fold down system in very thin
floorboards for example with a thickness of 4-6 mm. FIG. 6d shows a
side push system with a wedge shaped tongue and FIG. 6e shows a
side push system with a tongue comprising protrusions. Even
one-piece systems with a machined tongue as shown in FIG. 6f may be
used. A short strip provides a much easier machining of the
undercut groove 41.
[0096] FIGS. 7a-7b show preferred embodiments. The long side
locking system comprises a friction element 15, which in this
embodiment is located on the upper part of the locking element 8,
and that cooperates with a friction groove 17. The advantage is
that no compressible material 16 is applied in the active locking
surfaces 9a,9b,10a,10b,3,4,11,12 that lock the panels vertically
and horizontally.
[0097] FIG. 7c shows that the friction may be improved if friction
cavities 18 are formed on the upper part of the locking element 8
or in the friction element 15. Such cavities form expansion spaces
for the flexible material 16 that may be applied with lower
requirements on production tolerances. The cavities are preferably
formed with a screw cutter as describe in WO2010087752. Friction
cavities 18' may also be formed on other parts of the locking
system for example the outer part of the strip 6.
[0098] FIGS. 8a and 8b show that present locking systems, as shown
in FIG. 8a may easily be converted to a locking system according to
the invention, as shown in FIG. 8b, and that the new locking system
may be compatible with the old locking system. Friction cavities 18
are formed in the upper part of the locking element with a screw
cutter, compressible material 16 is preferably inserted essentially
in the groove along the whole long edge or in parts thereof and the
locking element on the short edges is removed.
[0099] The panels are installed such that a long edge 2'' of a new
panel in a second row is put at an angle against a long edge 2 of a
first panel installed in a previous row and displaced until its
short edge 1' is in contact with a short edge 1 of a second panel
installed in the second row. The new panel is angled down whereby
the flexible tongue locks 30 the short edges 1,1' vertically. The
long edges comprise a locking system with a friction connection
that prevents displacement of the panels along the long edges 2,
2', 2''.
[0100] FIG. 9a shows that several friction elements 15, 15' and
friction grooves 17,17' with compressible material 16,16, may be
provided.
[0101] FIG. 9b shows that the strip 6 may be replaced by
overlapping upper edges 32, 33 above the separate tongue 30. It is
of course possible to use both overlapping edges and a locking
strip 6 cooperating with a locking cavity 7.
[0102] FIG. 9c shows that flexible and compressible material 16 may
be applied on the friction element 15.
[0103] The long edge locking along the edge may be accomplished
with a tight fit, with high friction or with all known methods to
prevent displacement along the joint.
[0104] Wood floor with a lamella core that generally has a rough
surface may be formed with a locking system with tight fit and with
rather large cooperating locking surfaces. No flexible materials
are needed to obtain sufficient friction. Such long side locking
system is extremely difficult to displace, especially when the
floor boards are long, for example 1.8-2.4 m and the friction force
is generally sufficient to accomplish a locking which keeps the
short edges together during the lifetime of the floor.
[0105] The locking strength of the slide lock may be increased
considerably with a locking strip that is slightly bended and that
causes a permanent vertical pressure as shown in FIG. 9d.
Sufficient friction may be created even in HDF material that
generally is formed with rather smooth surfaces. A strip 6 that in
locked position is bended backwards will press the locking element
8 into the locking groove 14 when people walk on the floor or when
furniture is applied on the surface. This will increase the locking
strength of the second horizontal connection along the long edges.
The locking strength may be increased further if for example a
pressing protrusion 23 is formed on the lower part of the strip,
preferably under the locking element. Such pressing protrusion 23
may be applied as a separate material on essentially the whole
strip 6 or on separate parts along the edge.
[0106] Wedge shaped locking elements 8 that are pressed into a
cooperating locking groove 14 as shown in FIG. 9d may create a
sufficient friction even without a compressible friction material.
FIG. 9d shows embodiment that comprises a locking element 8 and
locking groove with two sets of cooperating locking surfaces. A
first set 11,12 is located closer to the vertical plane than a
second set 21,22. The locking surfaces are preferably inclined such
that a lower part of the locking element is larger than an upper
part. The locking surfaces may be essentially plane or curved. It
is preferred that there is a space S between the upper part of the
locking element and the locking groove. Such a space S may be used
to give more production tolerances. The angle A1,A2 of the
cooperating surfaces, or tangent line in case the surfaces are
curved, should preferably be larger than about 45 degrees.
[0107] Preferably the vertical extension of the second set 21,22 of
locking surfaces is essentially the same or larger than the
vertical extension of the first set 11,12 of locking surfaces. The
second set should preferably extend downwards to a level, which is
below the first set.
[0108] A flexing groove 34, 34' may be formed in the locking
element 8 and/or behind the locking groove 14 in order to increase
the flexibility of the walls of the locking element 8 or the
locking groove 14. Such flexing groove may also be filled with a
flexible material that increases the flexibility further.
[0109] A wedge shaped locking element as described above may be
used to position the upper edges with a small play of for example
of about 0.01-0.10 mm. Such a play will allow the top edges to
swell and damages on the upper edges or squeaking sound will be
eliminated. Such locking system is also very suitable to use in
glue down floor installations or in combination with bevels between
the upper joint edges.
[0110] The above-described embodiment may of course be combined
with friction cavities 18 and flexible material 16 may be inserted
between the locking element and the locking groove.
[0111] The locking system may be formed with two or more sets of
locking elements and locking grooves in order to increase the
friction. Small friction grooves 23 parallel with the joint edge
may also increase the friction.
[0112] Glue or wax that cures after some time is also possible to
use and may eliminate problems with shrinking and swelling of a pre
tensioned locking system. Wax mixed with aluminium oxide particles,
which are applied in the locking system, increases the friction
considerably.
[0113] The long edge locking system may be used with all known
vertical folding systems that lock the short edges vertically and
horizontally.
[0114] The separate tongues are generally factory connected into an
edge. Separate lose tongues that are inserted prior to folding or
when two short edges are laying flat on the sub floor are not
excluded.
[0115] The long edge locking system may be formed such that it is
displaceable in an angle of 3-5 degrees. This facilitates
installation around doors and similar.
* * * * *