U.S. patent application number 14/485893 was filed with the patent office on 2015-01-01 for covering, as well as panels and auxiliary pieces used therewith.
The applicant listed for this patent is FLOORING INDUSTRIES LIMITED, SARL. Invention is credited to Mark CAPPELLE, Pieter DEVOS.
Application Number | 20150000222 14/485893 |
Document ID | / |
Family ID | 43598112 |
Filed Date | 2015-01-01 |
United States Patent
Application |
20150000222 |
Kind Code |
A1 |
DEVOS; Pieter ; et
al. |
January 1, 2015 |
COVERING, AS WELL AS PANELS AND AUXILIARY PIECES USED THEREWITH
Abstract
A floor covering formed by a plurality of panels each having two
opposite edges arranged to couple adjacent panels to each other.
The coupling parts include a tongue and a groove, as well as
locking parts preventing the drifting apart of two such adjacent
panels. A separately manufactured insert is provided between at
least two of the coupled panels, and the tongue and groove. The
insert comprises at least two portions functioning as fixed spacing
elements with a first portion between the upper side of the tongue
and the lower side of the upper lip, and a second portion between
the locking parts.
Inventors: |
DEVOS; Pieter; (Koolskamp,
BE) ; CAPPELLE; Mark; (Staden, BE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FLOORING INDUSTRIES LIMITED, SARL |
Bertrange |
|
LU |
|
|
Family ID: |
43598112 |
Appl. No.: |
14/485893 |
Filed: |
September 15, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13810045 |
Jan 14, 2013 |
8833026 |
|
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PCT/IB2011/051523 |
Apr 8, 2011 |
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14485893 |
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61432021 |
Jan 12, 2011 |
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Current U.S.
Class: |
52/588.1 ;
52/582.2 |
Current CPC
Class: |
B32B 2307/414 20130101;
B44C 5/043 20130101; E04B 5/00 20130101; B32B 21/08 20130101; B32B
2307/412 20130101; E04C 2/20 20130101; B32B 7/02 20130101; B32B
2262/101 20130101; E04F 2201/049 20130101; Y10T 29/49789 20150115;
E04F 15/02038 20130101; B32B 27/32 20130101; B32B 2471/00 20130101;
B44C 5/0476 20130101; E04F 2201/0153 20130101; E04F 2201/0535
20130101; E04F 2201/0138 20130101; B32B 3/06 20130101; B32B 2307/51
20130101; E04C 2/38 20130101; E04C 2/30 20130101; E04F 2201/0146
20130101; Y10T 29/49826 20150115; B32B 27/304 20130101; B32B
2307/732 20130101; E04F 2201/0176 20130101; E04F 2201/0588
20130101; B32B 27/36 20130101; B32B 27/40 20130101; E04F 2201/0523
20130101; E04F 2201/0115 20130101; E04F 13/0894 20130101; B32B
2274/00 20130101 |
Class at
Publication: |
52/588.1 ;
52/582.2 |
International
Class: |
E04C 2/38 20060101
E04C002/38; E04F 15/02 20060101 E04F015/02; E04F 13/08 20060101
E04F013/08 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 15, 2010 |
BE |
2010/0441 |
Claims
1. Panel, wherein this panel, at least at two opposite edges, is
provided with coupling parts, which comprise hook-shaped parts and
which allow that two such panels can be coupled to each other by
means of a downward movement of one panel in respect to the other,
wherein these parts comprise locking surfaces, whereas in the
coupled condition of two of such panels, one hook-shaped part
defines a seat for the other one; wherein the panel is provided
with an associated, preferably pre-mounted, insert and comprises a
vertically active locking system with an elastically displaceable
locking part, which forms part of the insert, and which, in the
coupled condition, cooperates with an opposite locking part,
preferably in the form of a stop; wherein the locking part is
supported towards its back side; and wherein the elastic
displacement of the locking part during coupling is generated
mainly by the elastic compressibility of a first part of which the
locking part forms part.
2. The panel of claim 1, wherein said insert is clamped in the
panel in an elastic manner, such that the insert remains at its
place.
3. The panel of claim 1, wherein said first part has a bend-out
shape, wherein it is bent in the direction of the locking part.
4. The panel of claim 1, wherein said insert consists of a strip of
synthetic material.
5. The panel of claim 1, wherein said insert is provided at the
edge with the hook-shaped part defining the seat; wherein the
insert comprises said first part as well as a second part, said
second part situated at the bottom of said seat; and wherein said
first part adjoins to said second part.
6. The panel of claim 1, wherein the panel is oblong; wherein said
two opposite edges form the short sides of the panel; wherein the
panel, at the opposite edges forming the long sides of the panel,
is provided with coupling parts that allow that the panel is
coupled with one of its edges forming the long sides by means of a
downward turning movement to the edges forming the long sides of a
preceding row of similar panels; and wherein the coupling parts at
the edges forming the short sides allow that, simultaneously with
said downward turning movement, an engagement is realized between a
short side of the panel and a short side of a similar panel already
installed in the same row.
7. Panel, wherein this panel, at least at two opposite edges, is
provided with coupling parts, which comprise hook-shaped parts and
which allow that two such panels can be coupled to each other by
means of a downward movement of one panel in respect to the other,
wherein these parts comprise locking surfaces, whereas in the
coupled condition of two of such panels, one hook-shaped part
defines a seat for the other one; wherein the panel is provided
with an associated, preferably pre-mounted, insert and comprises a
vertically active locking system with an elastically displaceable
locking part, which forms part of the insert, and which, in the
coupled condition, cooperates with an opposite locking part,
preferably in the form of a stop; wherein, at the height of the
locking part, different material portions are applied, on the one
hand, a first material portion, of which the actual locking part is
formed, and a second material portion, which forms a back support
for the locking part, wherein the second material portion consists
of a material which can be compressed more supple than the material
of the first material portion.
8. The panel of claim 7, wherein the elastic displacement of the
locking part during coupling is generated at least partially and
preferably entirely by the elastic compressibility of the second
material portion.
9. The panel of claim 7, wherein said second material portion is
situated at least behind the portion of the locking part which
during coupling temporarily is pushed away laterally.
10. The panel of claim 7, wherein said insert is clamped in the
panel in an elastic manner, such that the insert remains at its
place.
11. The panel of claim 7, wherein at least said first and second
material portions are manufactured in one piece by means of
co-extrusion.
12. The panel of claim 7, wherein said insert is provided at the
edge with the hook-shaped part defining the seat; wherein the
insert comprises a first part of which the locking part forms part,
as well as a second part, said second part situated at the bottom
of said seat; and wherein said first part adjoins to said second
part.
13. The panel of claim 7, wherein the panel is oblong; wherein said
two opposite edges form the short sides of the panel; wherein the
panel, at the opposite edges forming the long sides of the panel,
is provided with coupling parts that allow that the panel is
coupled with one of its edges forming the long sides by means of a
downward turning movement to the edges forming the long sides of a
preceding row of similar panels; and wherein the coupling parts at
the edges forming the short sides allow that, simultaneously with
said downward turning movement, an engagement is realized between a
short side of the panel and a short side of a similar panel already
installed in the same row.
14. Panel, wherein this panel, at least at two opposite edges, is
provided with coupling parts, which comprise hook-shaped parts and
which allow that two such panels can be coupled to each other by
means of a downward movement of one panel in respect to the other,
wherein these parts comprise locking surfaces, whereas in the
coupled condition of two of such panels, one hook-shaped part
defines a seat for the other one; wherein the panel is provided
with an associated, preferably pre-mounted, insert and comprises a
vertically active locking system with an elastically displaceable
locking part, which forms part of the insert, and which, in the
coupled condition, cooperates with an opposite locking part,
preferably in the form of a stop; wherein the insert at least
comprises a first part which, on the one hand, on one side thereof
comprises the locking part and, on the other hand, at the other
side thereof, is bendable in its central part in respect to the
vertically displaced extremities thereof, more particular can be
pressed into a there behind situated space; and wherein the first
part has a bend-out shape in the direction of the locking part.
15. The panel of claim 14, wherein said insert is clamped in the
panel in an elastic manner, such that the insert remains at its
place.
16. The panel of claim 14, wherein said insert consists of a strip
of synthetic material.
17. The panel of claim 14, wherein said insert is provided at the
edge with the hook-shaped part defining the seat; wherein the
insert comprises said first part as well as a second part, said
second part situated at the bottom of said seat; and wherein said
first part adjoins to said second part.
18. The panel of claim 14, wherein the panel is oblong; wherein
said two opposite edges form the short sides of the panel; wherein
the panel, at the opposite edges forming the long sides of the
panel, is provided with coupling parts that allow that the panel is
coupled with one of its edges forming the long sides by means of a
downward turning movement to the edges forming the long sides of a
preceding row of similar panels; and wherein the coupling parts at
the edges forming the short sides allow that, simultaneously with
said downward turning movement, an engagement is realized between a
short side of the panel and a short side of a similar panel already
installed in the same row.
19. Panel, wherein this panel, at least at two opposite edges, is
provided with coupling parts, which comprise hook-shaped parts and
which allow that two such panels can be coupled to each other by
means of a downward movement of one panel in respect to the other,
wherein these parts comprise locking surfaces, whereas in the
coupled condition of two of such panels, one hook-shaped part
defines a seat for the other one; wherein the panel is provided
with an associated, preferably pre-mounted, insert and comprises a
vertically active locking system with an elastically displaceable
locking part, which forms part of the insert, and which, in the
coupled condition, cooperates with an opposite locking part,
preferably in the form of a stop; wherein the insert comprises a
first part which, on the one hand, on one side thereof comprises
the locking part and, on the other hand, at the other side thereof,
is bendable in its central part in respect to the vertically
displaced extremities thereof, this against the force of a material
portion functioning as an elastically compressible matter.
20. The panel of claim 19, wherein said first part has a bend-out
shape in the direction of the locking part.
21. The panel of claim 19, wherein said insert is clamped in the
panel in an elastic manner, such that the insert remains at its
place.
22. The panel of claim 19, wherein said material portion is made in
one piece, for example, by co-extrusion, with the remainder of the
insert.
23. The panel of claim 19, wherein said insert is provided at the
edge with the hook-shaped part defining the seat; wherein the
insert comprises said first part as well as a second part, said
second part situated at the bottom of said seat; and wherein said
first part adjoins to said second part.
24. The panel of claim 19, wherein the panel is oblong; wherein
said two opposite edges form the short sides of the panel; wherein
the panel, at the opposite edges forming the long sides of the
panel, is provided with coupling parts that allow that the panel is
coupled with one of its edges forming the long sides by means of a
downward turning movement to the edges forming the long sides of a
preceding row of similar panels; and wherein the coupling parts at
the edges forming the short sides allow that, simultaneously with
said downward turning movement, an engagement is realized between a
short side of the panel and a short side of a similar panel already
installed in the same row.
25. A panel substantially made from a panel material, wherein said
panel has coupling parts at least at two opposite edges and
arranged to couple adjacent panels to each other; wherein the
coupling parts include a tongue and a groove, and locking parts
preventing the drifting apart of two such adjacent panels, said
locking parts including a protrusion on a lower portion of the
tongue; wherein the groove is bordered by an upper lip and a lower
lip; wherein the upper lip, the lower lip and the tongue are formed
at least partially from the aforementioned panel material; wherein
in a coupled condition of two such adjacent panels, the tongue, at
least with a portion consisting of the panel material, reaches
underneath a portion of the upper lip consisting of the panel
material; wherein the panel includes at least one associated insert
arranged to be provided between the coupling parts of two such
adjacent panels; and wherein the coupling parts and the insert are
configured such that, in the coupled condition of two such adjacent
panels, the insert fits between the tongue and the groove of the
coupling parts, wherein the insert includes at least two portions
functioning as fixed spacing elements, a first portion between the
upper side of the tongue and the lower side of the upper lip, and a
second portion between the locking parts of the coupled panels,
respectively; and wherein, seen in cross-section, the length of
said insert is less than the length of the contour of the
edges.
26. The panel of claim 25, wherein said insert is provided with a
glue or a reactive product for effecting an adherence of the insert
to the respective edge of the panel.
Description
[0001] This application claims the benefit under 35 U.S.C. 119(e)
to the U.S. application Ser. No. 13/810,045 filed on Jan. 14, 2013,
which claims priority to U.S. provisional application No.
61/432,021 filed on Jan. 12, 2011.
FIELD OF THE DISCLOSURE
[0002] This invention relates to a covering, as well as panels and
auxiliary pieces, which are used therewith.
[0003] In particular, the invention is intended for floor
coverings, which are composed of floor panels mechanically coupled
together in a locking manner; however, more generally it can also
be applied with coverings for other purposes, such as wall and
ceiling coverings, which are composed of panels.
RELATED ART
[0004] More particularly, the invention relates to a covering,
which comprises a plurality of panels of a panel material; wherein
these panels, at least at two opposite edges, are provided with
coupling parts by which the panels are coupled to each other;
wherein these coupling parts comprise a tongue and a groove, as
well as locking parts preventing the drifting apart of two such
panels; wherein the groove is bordered by an upper lip and a lower
lip; wherein the upper lip, the lower lip and the tongue are formed
at least partially and preferably entirely from the aforementioned
panel material; and wherein in the coupled condition the tongue, at
least with the portion thereof which consists of the panel
material, reaches underneath that portion of the upper lip which
also consists of panel material. A covering, more particularly a
floor covering of this type, is known, amongst others, from the
patent document WO 97/47834.
[0005] Such coverings show the disadvantage that, in particular in
the case of panels where the panel material is wood or is based on
wood, and in particular with floor panels, too, creaking may occur
by tiny mutual movements of the panels. In particular with floor
panels, the risk is high that creaking noises will manifest
themselves, as, when the panels are walked on, they are pressed
somewhat into the mostly soft underlying layer underneath the
panels and the panels thereby perform a very small hinging movement
in the coupling parts, whereby, amongst others, the surfaces of the
locking parts shift along each other, which can be accompanied by
creaking noises.
[0006] A solution for this problem had already been suggested in EP
0 974 713, wherein a lubricating agent, such as, for example,
paraffin, or an elastic coating is provided on the coupling parts.
A disadvantage of such lubricating agent, however, is that it must
be applied relatively accurate, that it is not always efficient, as
mostly, it cannot be applied next to the edge of the decorative
surface of the panel, and that the mechanical application thereof
requires accurate and expensive equipment.
SUMMARY
[0007] The present invention aims at an alternative, whereby a
system, which is advantageous in many respects, for coupling panels
to each other is obtained and whereby, amongst others, the
disadvantage of creaking noises can be minimized, whereas one or
more disadvantages of the technique described in EP 0 974 713 are
excluded.
[0008] To this aim, the invention according to a first aspect
relates to a covering, which comprises a plurality of panels of a
panel material; wherein these panels, at least at two opposite
edges, are provided with coupling parts by which the panels are
coupled to each other; wherein these coupling parts comprise a
tongue and a groove, as well as locking parts preventing the
drifting apart of two such panels; wherein the groove is bordered
by an upper lip and a lower lip; wherein the upper lip, the lower
lip and the tongue are formed at least partially and preferably
entirely from the aforementioned panel material; and wherein in the
coupled condition the tongue, at least with the portion thereof
which consists of the panel material, reaches underneath that
portion of the upper lip which also consists of panel material;
characterized in that between at least two of the coupled panels,
between the aforementioned coupling parts, more particularly
between the aforementioned tongue and groove, at least one
separately manufactured insert is present, which insert comprises
at least two portions functioning as fixed spacing elements, a
first portion between the upper side of the tongue and the lower
side of the upper lip, and a second portion between the
aforementioned locking parts, respectively.
[0009] It is noted that by "fixed spacing elements", parts have to
be understood which, in the final condition, are present between
the adjoining sides of the coupling parts in a stable manner, and
which, for example, do not comprise any portions which can be
folded away laterally, as this is the case in fact with the inserts
known from FIG. 2b of document WO 00/47841 or of the corresponding
thereto US 2004/0068954 and FIG. 15 of DE 20 2009 004 530 U1. Such
inserts with portions which can be folded away, for example, in
order to allow a snap movement with a push-lock coupling, have the
disadvantage that a relatively large movability is possible, which
herein, however, is tried to be avoided.
[0010] However, this does not exclude that those portions of the
inserts of the invention, which are performed as fixed spacing
elements, can be somewhat elastically compressible or can be
provided with a profiled, for example, corrugated surface.
[0011] Further, it is noted that by a "panel material", the actual
material is meant from which the panel is made. In solid wooden
planks, this simply is the wood. In laminate panels, this often may
be MDF or HDF. Also, the panel material as such can be composed of
a plurality of materials, for example, in so-called "engineered
wood" panels.
[0012] By making use of one or more separately manufactured
inserts, the advantage is obtained that at the location of such
insert an element, which is clearly defined in respect to shape, is
inserted between the elements, which results in that one can always
be sure that such insert is present in a purposeful manner. Another
advantage is that it is easily applicable, for example, manually.
Thus, high-tech and/or difficult to adjust machinery for applying
and dosing lubricating agent are redundant.
[0013] However, the above does not exclude that the inserts can
also be applied by machine, over the tongue or in the groove.
[0014] It is clear that the invention is particularly beneficial
with floor panels which are attached to each other for forming a
floor covering, as creaking noises may occur in particular in floor
coverings, as a result of the forces exerted thereon when the floor
coverings are walked on.
[0015] It is also clear that the invention will show its advantages
in particular with panels where the panel material consists of
solid wood, in other words, with solid wooden planks, in particular
floor planks. In fact, solid wood is strongly subjected to tensions
and deformations, and therefore a purposeful solution against
creaking noises is advised.
[0016] According to a preferred embodiment, the covering is
characterized in that said insert, as well as the profiles with
which the aforementioned edges are realized, provide for that at
the edges concerned, seen in cross-section, there is no direct
contact between the actual panels. Due to the fact that there is no
contact, creaking noises as a result of contact between the actual
panels are completely excluded.
[0017] According to still another preferred characteristic, whether
or not in combination with the herein last-mentioned
characteristic, a visible gap will be present at least in the
proximity of the aforementioned edges of the panels, such by the
intermediary of the insert. Due to the insert, such gap can be
realized in a smooth manner. Hereby, in this manner a technical
solution is offered for imitating old floors having gaps between
the panels, whereas still a good coupling is guaranteed. Possibly,
the gap can be combined with the application of chamfers, whereby
acute edges at the entrance of the gap are avoided.
[0018] It is noted that the creation of such gap by means of an
insert is also useful for creating, for example, a visual distance
between the panels in wall and ceiling coverings, also for
applications where the problem of creaking noises is not
present.
[0019] According to a particular embodiment, in the case that such
gap is applied, means will be provided which hide the inserts from
view when someone looks into the gap.
[0020] These means can be of different kind. According to a first
possibility, overlapping parts are applied, which prevent that the
inserts can be observed via the gap. According to a second
possibility, the inserts can be made in a color which is chosen
such that they will be unobtrusive.
[0021] According to a particular embodiment, such gap is applied in
combination with an insert, the fixed parts of which, as
aforementioned, are somewhat elastically compressible. This allows
compensating expansion in the panels. For example, in the case of a
floor covering, it is a regular occurrence that it cannot expand or
expand only with difficulties, for example, when the covering rests
against the walls at two opposite edges or is weighed down by heavy
furniture. By now making use of somewhat compressible inserts, the
individual panels can expand slightly, wherein the expansion then
is taken up in the gap in that the aforementioned portions are
compressed further, whereby the gap will narrow.
[0022] Preferably, such insert is made as a wrapping or sock for
the tongue, wherein the insert then, over the majority of its
cross-section, adjoins closely or relatively close to the profiled
edge part, more particularly rests against the tongue over this
majority of the cross-section or is no further than 1 mm removed
therefrom. This has the advantage that a faulty assembly is
rendered almost impossible.
[0023] Preferably, such auxiliary piece or insert is substantially
or entirely made single-walled. On the one hand, this offers the
advantage that it is relatively stable and can deform little or not
at all when supporting and/or tensioning forces are exerted
crosswise on the wall thereof, whereas, on the other hand, the
thickness thereof remains limited and it can be smoothly provided
between the coupling parts. Also, this insert, for simplicity's
sake, preferably has a uniform wall thickness, although this is not
strictly necessary. By possibly applying different wall
thicknesses, in fact special properties can be created. For
example, then thickened parts can be integrated, which provide for
extra elasticity, for example, for elastically compensating
expansion in the panels or for forming an elastically deformable
locking part.
[0024] In a practical embodiment, the insert, viewed in
cross-section, and in the mounted condition, is formed at least of
a portion, which in height extends above the tongue, a portion
extending substantially parallel to the plane of the panels along
the upper side of the tongue, a portion extending around the tip of
the tongue, and a portion extending underneath the locking part
provided at the tongue. In this manner, so to speak, an encasing of
the entire tongue construction is obtained, such that the insert
can be smoothly positioned on the tongue or smoothly provided in
the groove.
[0025] The inserts can be provided in the longitudinal direction
locally and at a distance from each other, or continuously over the
major part of the length of an edge of a panel. In the first case,
the inserts have a short length in relation to the respective
length of the edge of the panels, with the advantage that the costs
of the inserts will remain limited. In the second case, the coupled
panels will be better supported in mutual respect over their entire
length, however, the costs for the material for the inserts will
rise.
[0026] In the case of oblong panels, the inserts preferably are
present at least on the long sides.
[0027] Preferably, the inserts are configured such that they can be
fixedly snapped over or in the respective edge portion. This allows
an assembly on the actual panels, without necessitating additional
attachment means, such as glue or the like. Herein, possibly an
insert can be applied which, in its free condition, is situated in
a somewhat deformed condition in comparison with the condition in
which it is after mounting, in such a manner that the insert after
mounting comes to sit in an elastically tensioned condition over or
in the edge concerned. When this is an insert which is intended for
being applied over a tongue, this thus originally will be somewhat
pressed closed, such that in mounted condition, it will be fitted
around the tongue in a somewhat elastically pushed-open condition
and will be tensioned around the tongue.
[0028] Attachments in other manners, however, are not excluded,
whether or not by means of glue.
[0029] Preferably, the panels fit into each other with a pretension
at least at the edges where the inserts are present, wherein the
pretension provides for that the panels are forced towards each
other. By means of the pretension, it is avoided that the panels
will be sitting loosely in each other and that undesired
deformations will manifest themselves in the floor covering.
[0030] It is clear that in the case where the panels fit into each
other with a pretension, a play between the coupled panels is
excluded. Even when the known as such "pretension principle" is not
applied, it is still preferred that the whole is constructed such
that, in the coupled condition of two such panels, no or almost no
play will be present.
[0031] Further, it is preferred that such insert in mounted
condition is clearly sitting free between the profiled parts at one
or more locations, such that these locations can function as
expansion zones, the advantage of which will become clear from the
description below.
[0032] The separately manufactured inserts preferably consist of
synthetic material, preferably a more or less soft synthetic
material, as such materials have good properties for avoiding
creaking noises. In the most preferred embodiment, a thermoplastic
elastomer (TPE) is applied. The synthetic material also may be
fiber-reinforced, for example, by glass fibers, as a consequence of
which the inserts practically cannot be torn.
[0033] According to a particular embodiment, the insert is
configured such that, with the mutual locking of two of these
panels, it can effect a snap effect. In this manner, an extra
function is given to the insert in an advantageous manner.
[0034] Although such insert, seen in cross-section, preferably is
manufactured in one piece from the same material, this does not
exclude to apply, according to a variant, an insert having, seen in
cross-section, two or more portions consisting of materials which,
as such, have different features and as such preferably also offer
different functionalities. Herein, this may relate, amongst others,
to synthetic materials with different properties, wherein these
preferably are connected to each other, preferably by means of
coextrusion. Such different functionalities may consist in, for
example, that a certain portion is intended for keeping the edges
of actual panels in a mutually correct and locked position, whereas
another portion is intended for supplying a pressing force for a
snap effect during the mutual locking of two panels.
[0035] According to a particular embodiment, the insert will
provide directly or indirectly for a sealing or gluing function,
directly via the nature of the material, which, for example, is
well adjoining, or indirectly, by providing the insert with a
sealing agent, a glue or a reactive product for avoiding or
restricting the penetration of water and/or for effecting an
adherence of the insert to the edge.
[0036] It is clear that when a sealing effect is desired, use shall
be made of inserts extending continuously over the respective
edge.
[0037] In order to provide for a good resistance against moisture
or water, it is preferred that the entire top side of such panel is
made water-proof or water-repellent, as well as the portion of the
lateral edges extending from the top side of the panel downward to
the insert.
[0038] When a sealing is intended via the inserts, this may be
performed on one pair of edges as well as on the other pair,
however, in the case of oblong panels, the sealing via the inserts
preferably is applied on the long sides, whereas on the short
sides, another technique is applied, either a technique providing
for a sealing, or a technique which makes the edges waterproof or
which provides for that the edges consist of a waterproof material.
To this aim, for example, an insertion piece of synthetic material,
from which the coupling parts are formed, can be applied on the
short edges, for example, such as known from WO 2007/141605.
[0039] It is noted that similar sealing techniques for realizing
seals on all sides can also be realized in combination with
applications according to the third and fourth aspects also
described herein below.
[0040] An important advantage of the invention consists in that by
using inserts according to the invention, also panels which are
somewhat deformed, which is a problem in particular with solid
wooden panels, still can be smoothly joined together, as such
deformations can be partially compensated in between the inserts
and/or by slightly impressing the inserts. Another advantage is
that for this reason, thinner planks than usual can be used, which
means enormous cost savings in respect to the wood. Preferably, the
covering according to the invention thus also shows the
characteristic that it is a floor covering with panels in the form
of solid wooden planks and that the thickness of these panels is
less than 15 mm and better is less than 14 mm and still better is
in the order of magnitude of 12 mm.
[0041] According to another preferred characteristic, the panels,
at the aforementioned edges, are provided with coupling parts,
which are configured such that the panels can be coupled to each
other by means of a turning movement. Such turning movement offers
the advantage that the panels can be smoothly joined together,
notwithstanding the presence of the inserts. In order to facilitate
this, it is preferred that use is made of a groove with a lower lip
extending beyond the upper lip, and wherein the locking part of the
lower lip is situated in that portion of the lip which is situated
beyond the upper lip.
[0042] It is noted that at the aforementioned edges, the tongue in
mounted condition preferably is sitting underneath the upper lip of
the groove in a pronounced manner, and this such that joining
together by means of a so-called push-lock action is impossible at
these edges.
[0043] In the case that oblong panels are used, the aforementioned
edges preferably form the long sides. At the short sides then
preferably coupling parts are applied which can be brought into
each other by means of a downward movement, more particularly by
means of the so-called "fold down" technique, which will be
explained herein below in more detail. Herein, on the short sides,
for example, a "drop-in" coupling without vertical locking can be
used, or a "push-lock" coupling with snap effect, or another
system, which makes use of displaceable locking elements, which,
for example, are of the type activated upon installation of a
subsequent row of panels.
[0044] It is clear that the invention also relates to panels for
realizing a covering according to the first aspect. Thus, it also
relates to a panel, which substantially is made of a panel
material, wherein this panel, at least at two opposite edges, is
provided with coupling parts by which such panels mutually can be
coupled to each other; wherein these coupling parts comprise a
tongue and a groove, as well as locking parts preventing the
drifting apart of two of such coupled panels; wherein the groove is
bordered by an upper lip and a lower lip; wherein the upper lip,
the lower lip and the tongue are formed at least partially and
preferably entirely from the aforementioned panel material; wherein
in the coupled condition of two of such panels, the tongue, at
least with the portion thereof which consists of the panel
material, reaches underneath that portion of the upper lip which
also consists of panel material; with the characteristic that it
comprises at least one associated, whether or not separately
provided, insert, which is intended for being provided between the
coupling parts of two such panels; and that the aforementioned
coupling parts and the insert are configured such that, in the
coupled condition of two such panels, the insert fits between the
coupling parts, more particularly between the aforementioned tongue
and groove, wherein such insert comprises at least two portions
functioning as fixed spacing elements, a first portion between the
upper side of the tongue and the lower side of the upper lip, and a
second portion between the aforementioned locking parts,
respectively.
[0045] According to a preferred embodiment, the inserts are
pre-mounted on one of the respective edges at the manufacturer's,
preferably on the edge comprising the tongue.
[0046] According to a first possibility, the inserts are fixedly
snapped on the respective edge. According to another possibility,
they are glued thereon, whether or not in combination with the fact
whether they are still fixedly snapped on the respective edge.
[0047] It is clear that such panel as such further may have all
properties which, in mounted condition, result in that a covering
is obtained having one or more of the aforementioned
subfeatures.
[0048] It is clear that herein in particular floor panels for
forming a floor covering are concerned. More particularly, this
relates to floor panels which are made as solid wooden planks,
wherein said coupling parts are formed in one piece from the wood,
whereas the inserts applied therewith consist of another material,
preferably synthetic material. It is noted that the term "panel"
thus must be interpreted in a broad manner and is not restricted to
an element made of a large board, but also relates to a "plank".
Such panel can be manufactured in a variety of dimensions and
thicknesses.
[0049] Of course, the invention also relates to auxiliary pieces,
more particularly inserts, which are specifically intended for
realizing a covering as aforementioned.
[0050] Such separate inserts preferably are formed by extrusion.
Preferably, they are made somewhat supple. The obtained extruded
strip then is cut off at desired lengths in order to obtain the
inserts concerned.
[0051] As aforementioned, the application of the separately
manufactured inserts may take place manually as well as by machine.
The inserts can be manually pre-mounted on the panels before the
latter are packaged, or, according to another possibility, they are
manually provided later on by the installing person realizing the
covering. According to the invention, application by machine
preferably is performed during or immediately after the production
of the panels. Herein, the inserts can be supplied from a roll and
systematically be cut to length shortly before or during the
application process, or can be supplied in a format already cut to
length in order to be mounted on the edge concerned. According to a
preferred aspect of the invention, the insert herein is elastically
deformed by means of a guiding element in order to bring it
smoothly in its position, for example, for pressing it over the
tongue or for pressing it into the groove, after which, by elastic
resiliency, it will automatically be positioned at its
location.
[0052] In the case that the invention, for the embodiments
described herein above as well as herein below, is applied with
floor panels, it is particularly suited for floatingly installed
floor coverings, as in particular with such embodiments the
disadvantage of undesired creaking noises may occur. However, this
does not exclude that floor panels according to the present
invention also can be connected with the underlying surface by
means of nails, screws or the like.
[0053] Further, the invention also relates to two deviating
embodiments, which also provide for a purposeful coupling between
panels, which are also useful for excluding the disadvantage of
possible creaking noises, and which herein after are defined as the
second and third aspects of the invention.
[0054] According to the second aspect, the invention relates to a
covering, which comprises a plurality of panels of a panel
material; wherein these panels, at least at two opposite edges, are
provided with coupling parts by which the panels are coupled to
each other; wherein these coupling parts comprise a tongue and a
groove, as well as locking parts preventing the drifting apart of
two such panels; wherein the groove is bordered by an upper lip and
a lower lip; wherein the upper lip, the lower lip and the tongue
are formed at least partially and preferably entirely from the
aforementioned panel material; and wherein in the coupled condition
the tongue, at least with the portion thereof which consists of the
panel material, reaches underneath that portion of the upper lip
which also consists of panel material; characterized in that on at
least one of the coupling parts, a covering layer is provided,
which is attached to the edge of the respective panel by hardening;
and that the coupling parts and the covering layer are performed
such that, viewed in cross-section, there is no contact between the
actual panels over the entire contour of the edges. An advantage of
the second aspect consists in that by the combination of such
covering layer and the fact that this is performed such that there
is no contact between the actual panels, a mutual contact among the
panel materials definitely is excluded. The covering layer,
however, is always present as from the production and, as it is
adhered, it cannot come loose when the panels are manipulated.
[0055] Preferably, for the covering layer of the second aspect, use
is made of hot-melt glue, the advantages of which will become clear
from the third aspect described herein below.
[0056] According to the third aspect, the invention relates to a
covering, which comprises a plurality of panels of a panel
material; wherein these panels, at least at two opposite edges, are
provided with coupling parts by which the panels are coupled to
each other; wherein these coupling parts comprise a tongue and a
groove, as well as locking parts preventing the drifting apart of
two such panels; wherein the groove is bordered by an upper lip and
a lower lip; wherein the upper lip, the lower lip and the tongue
are formed at least partially and preferably entirely from the
aforementioned panel material; and wherein in the coupled condition
the tongue, at least with the portion thereof which consists of the
panel material, reaches underneath that portion of the upper lip
which also consists of panel material; characterized in that on at
least one of the coupling parts, a covering layer is provided,
which is attached to the edge of the respective panel by hardening;
that this covering layer, at least at a number of locations,
functions as a spacing element between the coupled edges; and that
the covering layer is formed of hot-melt glue deposited and
hardened on the surface of the edge or edges concerned. In this
application, hot-melt glue offers the particular advantage that the
adherence is very efficient and that drying during application can
be performed very fast and in line. Another advantage is that
hot-melt glue has good properties in respect to avoiding creaking
noises.
[0057] It is clear that the invention also relates to panels which
are intended for realizing coverings according to the second and
third aspects, in other words, which are provided with a covering
layer as aforementioned.
[0058] Also according to the second and third aspects, in
particular floor panels of solid wood are concerned, wherein the
coupling parts at the aforementioned edges substantially are made
from the wood in one piece.
[0059] The aforementioned invention, when being realized, has also
led to particular coupling systems for panels, which also form the
basis for two broader independent inventive ideas, which herein
below are described as the fourth and fifth aspects of the
invention.
[0060] According to this fourth aspect of the invention, it relates
to a panel, which, at least at two opposite edges, is provided with
coupling parts, by which such panels mutually can be coupled to
each other, such that a locking is obtained according to a
direction perpendicular to the plane of the panels, as well as a
locking is obtained according to a direction perpendicular to the
coupled edges and in the plane of the panels, wherein the locking
according to a direction perpendicular to the coupled edges and in
the plane of the panels is performed by means of locking parts,
which prevent the drifting apart of two of such coupled panels, and
that these locking parts make use of a snap system, characterized
in that the snap system at least at one of the aforementioned
locking parts comprises at least two portions, which mutually are
manufactured of materials with different properties. By applying
materials with different properties, the advantage is obtained that
the snap system can be optimized, for example, as then each portion
can be provided with the properties most suitable for this
portion.
[0061] According to a preferred characteristic of the fourth
aspect, the materials both consist of synthetic materials and are
made as a whole by means of coextrusion. In a particular
embodiment, the aforementioned portions consist of an actual
locking part and a more elastic pressing part, which preferably
effects on the locking part as a pressing cushion. In this manner,
a particularly effective snap system is provided.
[0062] According to the fifth aspect of the invention, it relates
to a panel, which, at least at two opposite edges, is provided with
coupling parts, by which such panels mutually can be coupled to
each other, such that a locking is obtained according to a
direction perpendicular to the plane of the panels, as well as a
locking is obtained according to a direction perpendicular to the
coupled edges and in the plane of the panels, wherein the
aforementioned coupling parts allow that two such panels at the
aforementioned edges can be coupled to each other by means of a
downward movement of one panel in respect to the other, more
particularly according to the "push-lock" principle of the
"fold-down" principle, wherein the locking according to a direction
perpendicular to the plane of the panels is performed by means of
locking parts which make use of a snap system, characterized in
that the snap system at least at one of the aforementioned locking
parts comprises at least two portions, which mutually are
manufactured of materials with different properties, such by means
of coextrusion, wherein these portions consist of an actual locking
part and a more elastic pressing part, which preferably effects on
the locking part as a pressing cushion. In an embodiment according
to this fifth aspect, too, a very effective snap system is
obtained, which allows that the panels can be interconnected in a
smooth manner and at the same time gives a great certainty that the
locking will be performed indeed.
[0063] The fourth and fifth aspect are described for panels lying
down, however, they are not limited to floor panels and can also be
applied for wall panels, ceiling panels or other panels. It is
clear that the intended movements and directions then have to be
interpreted in a corresponding manner in function of the
application.
[0064] Further, the invention also relates to a number of further,
related independent aspects, as described herein below.
[0065] Thus, the invention also relates to a panel, preferably a
floor panel, wherein this panel, at least at two opposite edges, is
provided with coupling parts, which comprise hook-shaped parts and
which allow that two such panels can be coupled to each other by
means of a downward movement, wherein these parts comprise locking
surfaces, whereas in the coupled condition of two of such panels,
one hook-shaped part defines a seat for the other one; with the
characteristic that it is provided with an associated, preferably
pre-mounted, insert; that this insert comprises at least three
parts, which function as spacing elements, to with a first part
providing for that there is a gap between the actual panels, at
least based on nominal dimensions and still better effectively; a
second part at the bottom in the seat, and a third part, which, in
the coupled condition, is situated between the locking surfaces.
The coupling parts applied therein are particularly advantageous
for being employed at the short sides of panels, as a result of
which thus also on these sides a solution against creaking noises
can be offered in an effective manner. In a preferred embodiment,
this panel further is characterized in that the coupling parts are
of the push-lock type. According to still another preferred
characteristic, the coupling parts comprise a locking part which is
integrated into the insert.
[0066] Also, according to still another independent aspect, the
invention relates to a panel, wherein this panel, at least at two
opposite edges, is provided with coupling parts, which comprise
hook-shaped parts and which allow that two such panels can be
coupled to each other by means of a downward movement of one panel
in respect to the other, wherein these parts comprise locking
surfaces, whereas in the coupled condition of two of such panels,
one hook-shaped part defines a seat for the other one; with the
characteristic that it is provided with an associated, preferably
pre-mounted, insert and comprises a vertically active locking
system with an elastically displaceable locking part, which forms
part of the insert, wherein this locking system is realized
according to any of the following possibilities:
[0067] the locking part is supported towards its back side and the
elastic displacement thereof during coupling is generated at least
partially and preferably entirely by the elastic compressibility of
a part of which the locking part forms part;
[0068] at the height of the locking part, different material
portions are applied, on the one hand, a first material portion, of
which the actual locking part is formed, and a second material
portion, which forms a back support for the locking part, wherein
the second material portion consists of a material which can be
compressed more supple than the material of the first material
portion;
[0069] the insert comprises a part, which, on the one hand, on one
side thereof comprises the locking part and, on the other hand, at
the other side thereof, is bendable in its central part in respect
to the extremities thereof, more particular can be pressed into a
space situated therebehind;
[0070] the insert comprises a part, which, on the one hand, on one
side thereof comprises the locking part and, on the other hand, at
the other side thereof, is bendable in its central part in respect
to the extremities thereof, this against the force of a material
portion functioning as an elastically compressible matter, which
latter material portion is made in one piece, for example, by
coextrusion, with the remainder of the insert;
[0071] the insert comprises an upwardly directed part, which
comprises a locking part directly adjoining thereto, which latter
locking part is in the form of a downwardly directed lip, wherein
these parts are made in one piece and continuous from one and the
same material, with the same material characteristics.
[0072] These embodiments of locking systems offer the advantage
that constructively, they can be realized easily and at a low cost
and allow a smooth connection of panels according to the push-lock
principle.
[0073] Finally, the invention also relates to methods for
manufacturing panels.
[0074] More particularly, it relates to a method for manufacturing
panels, wherein these panels are provided with strip-shaped
insertion pieces, which are made as a spacing insert and/or as an
insert with a locking function, with the characteristic that the
insertion pieces are formed of a continuously produced strip,
however, are supplied to the panels in the form of pre-cut strips
from a magazine, such by means of an application device. This
method has the advantage that also strip-shaped insertion pieces
with a more complex cross-section can be provided smoothly at the
panels, which pieces, when they would be drawn off directly from a
roll, often would be difficult to present to the panels in a
correct manner. By forming strips of a certain length beforehand,
these are easy to handle.
[0075] Independently therefrom, it also relates to a method for
manufacturing panels, wherein these panels are provided with
strip-shaped insertion pieces, which are made as a spacing insert
and/or as an insert with a locking function, with the
characteristic that the insertion pieces are formed of a
continuously produced strip, however, are supplied to the panels in
the form of pre-cut strips from a magazine, which in their turn, by
means of a dividing device, are cut to further smaller strips,
which then form the actual insertion pieces and are provided on the
panels by means of an application device. This method also shows
the aforementioned advantage. Further, also the advantage is
obtained that the larger strips remain smooth to handle, whereas
the smaller strips then are formed only when being applied.
[0076] It is clear that these methods can be employed when applying
a variety of strip-shaped insertion pieces, which are made as a
spacing insert and/or as an insert with a locking function, and
thus are not limited to the application of the embodiments of
inserts described herein below by means of the figures.
[0077] It is clear that all aspects can be combined at choice,
inasmuch as they do not show any contradictory characteristics.
[0078] Further characteristics of the invention will become clear
from the following detailed description and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0079] With the intention of better showing the characteristics of
the invention, hereafter, as an example without any limitative
character, several preferred embodiments are described, with
reference to the accompanying drawings, wherein:
[0080] i. FIG. 1 in top plan view represents a panel, in this case
a floor panel, according to the invention;
[0081] ii. FIG. 2 in perspective represents a view according to
arrow F2 in FIG. 1;
[0082] iii. FIG. 3 at a larger scale represents a cross-section
according to line III-III in FIG. 1;
[0083] iv. FIG. 4 represents how two panels from FIG. 3 can be
coupled to each other;
[0084] v. FIG. 5 represents the panels from FIG. 4 in coupled
condition;
[0085] vi. FIG. 6 in cross-section represents an embodiment of
coupling parts, which can be applied on short sides of such
panels;
[0086] vii. FIG. 7 represents a variant of the embodiment of FIG.
6;
[0087] viii. FIG. 8 at a larger scale represents a view of the
portion indicated by F8 in FIG. 5, however, for a variant;
[0088] ix. FIGS. 9, 10 and 11 represent three variants of coupled
panels according to the invention, according to a view similar to
that of FIG. 5;
[0089] x. FIG. 12 represents a variant of the embodiment of FIG.
6;
[0090] xi. FIG. 13 represents another variant of the invention;
[0091] xii. FIG. 14 represents a portion of a floor covering,
wherein the second and third aspects of the invention are
applied;
[0092] xiii. FIG. 15 in cross-section represents another variant of
the invention, in a view similar to that of FIG. 5;
[0093] xiv. FIG. 16 in cross-section represents another
variant;
[0094] xv. FIG. 17 at a larger scale represents a variant of the
portion indicated by F17 in FIG. 16;
[0095] xvi. FIG. 18 represents a variant according to a view
similar to that of FIG. 12;
[0096] xvii. FIG. 19 at a larger scale represents a variant of the
portion indicated by F19 in FIG. 18;
[0097] xviii. FIG. 20 represents another particular embodiment of
the invention;
[0098] xix. FIG. 21 schematically represents a method according to
the invention, which can be applied when manufacturing panels
according to the invention;
[0099] xx. FIG. 22 at a larger scale schematically represents a
cross-section according to line XXII-XXII in FIG. 21;
[0100] xxi. FIG. 23 represents a panel according to the invention,
according to a view analogous to that of FIG. 1, however, for
another embodiment;
[0101] xxii. FIG. 24 represents an edge of a panel according to
still another variant;
[0102] xxiii. FIG. 25 in cross-section represents another variant
of the invention;
[0103] xxiv. FIG. 26 represents a view similar to that of FIG. 25
for a further variant;
[0104] xxv. FIG. 27 represents the insert from FIG. 26, however, in
the free condition thereof after manufacture;
[0105] xxvi. FIG. 28 schematically represents how the profiled
edges of the panel illustrated in FIG. 26 can be realized;
[0106] xxvii. FIG. 29 represents how the insert in the embodiment
of FIG. 26 is provided in the floor panel;
[0107] xxviii. FIGS. 30 and 31 schematically represent two methods
for providing inserts in floor panels;
[0108] xxix. FIGS. 32 to 36 represent different variants of the
portion indicated by F32 in FIG. 26.
DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS
[0109] In FIGS. 1 to 3, a panel 1, more particularly a floor panel,
according to the invention is represented, as well as a number of
auxiliary pieces applied therewith, in the form of inserts 2, in
such a manner that, as described in detail herein below, a floor
covering 3 can be formed therewith, as illustrated in FIGS. 4 to
6.
[0110] In the represented example, the panels as such consist of
solid wood, which latter thus also forms the panel material. In the
example, the panels are made as oblong wooden planks, with long
sides 4-5 and short sides 6-7.
[0111] The panels 1, at least at two opposite edges 8-9, in this
case the edges forming the long sides 4-5, are provided with
coupling parts 10-11, by which the panels 1 can be coupled to each
other. These coupling parts 10-11 comprise a tongue 12 and a groove
13, as well as locking parts 14-15 preventing the drifting apart of
two such panels 1. The groove 13 is bordered by an upper lip 16 and
a lower lip 17, wherein the upper lip 16, the lower lip 17 and the
tongue 12 in this represented example are formed entirely from the
aforementioned panel material. As can be seen in FIG. 5, the tongue
12, in the coupled condition, at least with the portion thereof
which consists of the panel material, reaches underneath that
portion of the upper lip 16 which also consists of panel
material.
[0112] The particularity of the invention consists in that between
at least two of the coupled panels 1, between the aforementioned
coupling parts 10-11, more particularly between the aforementioned
tongue 12 and groove 13, at least one separately manufactured
auxiliary piece as aforementioned, in particular an insert 2, is
present, which insert comprises at least two portions 18-19
functioning as fixed spacing elements, a first portion 18 between
the upper side 20 of the tongue 12 and the lower side 21 of the
upper lip 16, and a second portion 19 between the aforementioned
locking parts 14-15, respectively. As becomes clear from FIGS. 1
and 2, practically seen a plurality of such auxiliary pieces or
inserts 2 are applied along the edge of a panel concerned.
[0113] In the example of FIGS. 1 and 2, the inserts 2, in relation
to the respective edge length of the panels 1, have a short length
L1 and, as a result, are present along the respective edges on
local locations only and thus with interspaces in respect to each
other. Herein, the auxiliary pieces, in other words, the inserts 2,
do not all have to be of the same length. It is clear that instead
of a plurality of inserts on one edge, thus, in longitudinal
direction at a distance from each other, also only one insert can
be applied, which then preferably extends over the entire length or
almost entire length of the edge concerned.
[0114] In the embodiment of FIG. 5, the insert 2, as well as the
profiles with which the aforementioned edges 8-9 are made, are
configured such that, in the coupled condition, at the edges 8-9
concerned, viewed in cross-section, there is no direct contact
between the actual panels 1, in other words, that at the coupled
edges 8-9 there is no direct contact between the panel materials of
the one and the other panel 1. In the example, this is obtained, on
the one hand, by the presence of the inserts 2 which function as
spacing elements, and, on the other hand, an appropriate profile of
the edges 8-9. There, where the inserts 2 are situated, actually no
direct contact is possible. The profiled parts of the edges 8-9
preferably are straight-lined, such that, seen in longitudinal
direction, also the same distance is preserved over the interspaces
between the successive inserts 2 and consequently there is no
contact. Further, the profiles are such that, at least in the
example, seen according to the contour of the edges in
cross-section, openings, more particularly gaps 22-23, are
preserved above and underneath the inserts 2.
[0115] In the embodiments wherein a gap is desired on the upper
side, it preferably shows a restricted width B1, however,
preferably is visible to the naked eye. Practically seen, this
width is 0.05 to 0.2 mm, however, smaller or larger widths are not
excluded, either. It is clear that a very good visibility and
noticeability of the gap to the naked eye will occur at the upper
limit of said range only, as well as with larger values.
[0116] It is noted that in the example of FIG. 5, for clarity's
sake a gap is represented which is relatively wide in respect to
the remaining dimensions of the panel.
[0117] Further, it is preferred that at the upper sides of the
edges 8-9, chamfers 24-25 are formed, too.
[0118] As represented in the figures, the inserts 2 are performed,
so to speak, as a wrapping or sock, which wrapping or which sock
extends locally over the tongue 12 and/or is locally present in the
groove 13.
[0119] The represented embodiment of FIGS. 1 to 5 also shows that
such insert 2 preferably is single-walled. Further, it is preferred
that, as represented, the insert 2, seen in cross-section, in
mounted condition is at least formed by a portion 26 extending in
height above the tongue, a portion 27 extending substantially
parallel to the plane of the panels along the upper side of the
tongue, a portion 28 extending around the tip of the tongue, and a
portion 29 extending underneath the locking part 14 provided at the
tongue. Depending on the form of the coupling parts, however, other
forms are possible, of course.
[0120] As is represented in dashed line in FIG. 3, the inserts 2
are configured such that they can be fixedly snapped over the
tongue 12. Alternatively, such insert 2 also can be fixedly snapped
in the groove 13.
[0121] It is noted that it is preferred that the panels 1, at least
at the edges 8-9 where the inserts 2 are present, fit into each
other with a pretension, by which the panels are forced towards
each other. This is illustrated schematically in FIG. 5 by means of
the indicated tension forces T1-T2-T3-T4. By performing suitable
minor overlaps in the design, tension forces T1-T2 at the height of
the locking parts 14-15 may be obtained, which provide for that the
panels 1 also are forced together at the top, as a result of which,
as indicated by the tension forces T3 and T4, they press against
each other at the top by the intermediary of the portion 18. The
tension forces can be created in any manner, for example, by a
bending in the coupling parts or by elastic compression in the
materials of the panels and/or of the insert 2, or also by a
combination of these possibilities.
[0122] It is also noted that such insert 2 in mounted condition,
such as represented, preferably at a number of locations
P1-P2-P3-P4 is performed closely adjoining or rather closely
adjoining to the profiled parts, however, at a certain number of
locations P5-P6 also is clearly sitting freely between the profiled
parts. The last-mentioned locations P5-P6 then will function as
expansion zones in order to compensate deformations when such
insert 2 during the joining of the panels 1 on the closely
adjoining locations P1-P2-P3-P4 is pressed on its place, and/or in
order to compensate deformations as a result of tolerance
differences.
[0123] At the edge 8 comprising the tongue 12, as represented
preferably a stop 30 is formed, which can cooperate with the lower
end edge 31 of the inserts 2, which prevents that the inserts 2,
when the panels 1 are connected, are pressed away in downward
direction and/or would move downward by creepage.
[0124] As indicated by dashed line 31A in FIG. 5, the lower edge of
the insert 2 may end explicitly at a distance below the
thereabove-situated material of the panel concerned, such that
usually there will be a small space there above. This allows that,
when the insert settles during connecting two panels, the free
extremity 31A can move upward, by which it is excluded that such
settling can exert a disadvantageous influence on the locking.
[0125] As represented, such insert 2 can comprise a lip 32, which
facilitates the application thereof on a panel 1, at least when the
inserts 2 are provided manually. The lip 32 then forms a stop
against which pressure can be exerted with a finger in order to
press a loose insert 2 over the tongue 12 and the associated
locking part 14.
[0126] As aforementioned, the inserts 2 preferably consist of
synthetic material, preferably a thermoplastic elastomer (TPE).
[0127] In the represented example of FIGS. 1 to 5, the panels 1 are
provided at the edges 8-9 with coupling parts 10-11, which are
configured such that the panels 1 can be coupled to each other by
means of a turning movement, such as illustrated in FIG. 4. As
represented, it is preferred that the groove 13 herein is bordered
by a lower lip 17 extending to beyond the upper lip 16, wherein the
locking surfaces 33-34 formed a the locking parts 14-15 are
situated at the height of the portion of the lower lip 17 which
extends beyond the upper lip 16.
[0128] The panels 1 described above by means of FIGS. 1 to 5 can be
provided at the edges 35-36 of the short sides 6-7 with in
principle any type of coupling parts or may even be free from
coupling parts. Preferably, however, the panels 1 shall be of the
"fold-down type", which means that a panel is coupled with its edge
8 by means of a downward turning movement to the edges 9 of a
preceding row of panels and that simultaneously with this downward
turning movement, an engagement is realized between a short side of
this panel and the short side of a panel already installed in the
same row. In FIG. 6, a possible embodiment is represented, wherein
the coupling parts 37-38 formed at the edges 35-36 consist of
engaging behind each other hook-shaped parts, which, in the coupled
condition, exclusively provide for a locking in the plane of the
panels 1, however, do not provide for a locking perpendicular to
the plane of the panels. Systems making use of such coupling parts
37-38 are also called "drop-in" systems.
[0129] FIG. 7 represents a variant of the short sides, wherein use
is made of a so-called push-lock system, in this case according to
an embodiment which is known from document WO 2009/066153, wherein
then in the coupled condition, apart from a locking against the
drifting apart of the panels 1, also a locking perpendicular to the
plane of the panels 1 is obtained. Of course, other coupling parts
of the push-lock type are possible, too.
[0130] In FIG. 8, a variant is represented, which comprises means
in the form of overlapping parts 39-40, which prevent that the
inserts 2 are visibly observable through the gap 22. According to a
variant, such means also can consist in that the inserts, in
respect to color or tint, are adapted to the color or tint of the
upper side 20 of the tongue 12, whereby they practically are not
apparent when one looks between the gap 22.
[0131] In FIG. 9, a variant of the embodiment of FIG. 5 is
represented, wherein no gap 22 is present and the panels 1 on top
have directly contacting parts 41-42. The insert 2 applied in this
case does not comprise a portion 25 functioning as a spacing
element. It is clear that the coupling parts in this case, too, can
be designed such that the panels fit into each other with a
pretension, wherein said portions 41-42 then are forced towards
each other with a tension force T3, T4, respectively. This does not
exclude that also embodiments are possible which fit into each
other without any pretension. In consideration of the fact that the
panels 1, when being walked on, rather have the tendency to rotate
somewhat around each other, wherein the center of rotation is
situated next to the portions 41 and 42, there will be few
dislocations between the aforementioned portions 41 and 42 which
might cause creaking noises. On the locations where major
dislocations are possible indeed, the invention maintains its
advantages.
[0132] FIG. 10 shows another variant of the embodiment of FIG. 5,
wherein the coupling parts 10-11 fit into each other at least by
means of a shifting and snap movement M1. Apart therefrom, the
represented profile also allows an engagement by means of a turning
movement M2. In the represented example, the snap movement M1 is
possible as the lower lip 17 is made somewhat thinner and can bend
out in downward direction. By an opposed turning movement, coupled
panels 1 can be uncoupled again.
[0133] In FIG. 11, a variant of FIG. 5 is represented, wherein the
lip 32 is made somewhat more pronounced.
[0134] FIG. 12 represents a variant of the embodiment of FIG. 6,
which is intended for being applied at the short sides. Here, too,
use is made of an auxiliary piece in the form of an insert 43,
preferably of synthetic material, too, by which the risk of the
occurrence of creaking noises can be minimized. Herein, the whole,
as represented, can be designed such that, viewed in cross-section,
there is no direct contact between the actual panel material of the
coupling 1 along the entire contour, wherein on top then in fact a
gap is present between the panels 1. According to a not represented
variant, indeed a contact may exist on top, however, for the same
reasons as already described by means of FIG. 9, the risk is small
that this small contact will produce annoying creaking noises.
[0135] FIG. 13 represents a variant of the embodiment of FIG. 9,
with the particularity that the lips 16 and 17 are of the same
length or are of almost equal length.
[0136] Although it is preferred that at the short sides of the
panels 1 coupling parts are applied which allow being engaged by a
downward movement, more particularly according to the well-known
"fold-down" principle, either by means of coupling parts of the
"drop-in" type, or of the "push-lock" type, it is not excluded to
apply, according to variants, other coupling parts for the short
sides, which coupling parts require another installation technique.
For example, at the short sides also coupling parts, coupling
profiles, respectively, can be applied of the type wherein the
coupling is performed by means of a turning movement along the
respective edges and/or by a shifting and snap movement, wherein
these coupling parts are or are not equipped with one or more
inserts 2 in accordance with the invention. This means, amongst
others, that all embodiments represented in FIGS. 5, 9, 10, 11 and
13 can also be applied on the short sides.
[0137] FIG. 14 represents an embodiment, which meets the second and
third aspects of the invention. Here, a covering layer 44,
consisting of a material which is adhered on the panels by
hardening, is provided between the panels 1 and functions as an
insert. In the represented example, the covering layer 44 consists
of two parts 45 and 46, which both are deposited on the surface of
the tongue profile. Alternatively, as represented by dashed line
47, this may also be one continuous covering. In accordance with
the second aspect of the invention, the coupling parts and the
covering layer are made such that there is no contact between the
actual panels over the entire contour of the edges. In accordance
with the third aspect of the invention, the covering layer 44
consists of hot-melt glue deposited on the respective surfaces and
hardened.
[0138] It is noted that the covering layer 44 applied according to
the second and third aspects can be provided in any manner and does
not necessarily have to be a flat layer following the contour.
[0139] The material of the covering layer 44, more particularly the
hot-melt glue, is deposited on the surface concerned in liquid or
viscous condition. This may be performed, for example, by means of
one or more application nozzles, which either deposit a wide
continuous stream of material on the surface or provide this
material on the surface in the form of a pattern, such as a zigzag
pattern or dot pattern. Possibly, the thickness thereof can be
calibrated by means of a caliber, scraping system or the like.
[0140] The term "covering layer" has to be understood in a broad
sense and does not necessary have to mean a flat layer. The layer
may consist, for example, also of one or more local strips with a
round cross-section which extend in the longitudinal direction of
the edge.
[0141] It is noted that the covering layer preferably also is
present at least on the location between the upper side of the
tongue and the lower side of the upper lip, as well as on the
location between the locking parts, analogous to the aforementioned
inserts.
[0142] In FIG. 15, an embodiment of coupled panels 1 according to
the invention is represented, wherein the gap 22 is represented
with a small width B1, such in a realistic proportion to the
thickness of the panels. This figure makes clear that, when
applying a small width B1, it is almost impossible in practice to
still perceive the inserts from the outside, with the advantage
that these latter cannot effect an annoying effect in the
appearance of the covering.
[0143] According to a particular embodiment, the profiles of the
coupling parts 10 and 11 and the insert 2 are performed with such
dimensions that, in the mounted condition, the upside-situated
sides of the panels theoretically define a gap 22, however, in fact
the manufacturing tolerances are partially overlapping, such that
in practice mostly a gap will be present, however, such covering
may also comprise panels, or comprise portions of panels, where the
gap is closed. In this manner, on the one hand, gaps of small width
can be striven for, and, on the other hand, as the possible contact
which is present is of minor nature, large horizontal compression
forces at the upper edges by direct contact between the panel
materials will be avoided. In such case, the possible large forces
in horizontal direction then for the major part are transferred via
the portion 26, with as a consequence that the risk of the
occurrence of creaking noises is reduced.
[0144] As also indicated in FIG. 15, the insert 2 can comprise a
portion 48, which cooperates with a locking surface 49, behind
which the portion 48 is fitted in mounted condition. The locking
surface 49 as such does not necessarily have to be flat and may
also be curved. Preferably, the locking surface 49 is steeper than
the locking surface 33 or at last comprises a portion which is
steeper. Also, instead of a locking surface 49, a hollow portion or
the like can be applied, wherein at the interior side of the insert
2 then a protruding part is present, which can be fitted in the
hollow portion. It is clear that this characteristic in general can
be applied with all suitable inserts 2 of the invention. This
characteristic is, amongst others, also clearly visible in the
embodiment of FIG. 5.
[0145] In the embodiment of FIG. 15, as well as in most of the
other represented embodiments, the portion 26 in the mounted
condition is taken up in recesses 50 and 51, which are present on
the respective edges. According to a not represented embodiment,
only one recess 50 or 51 can be applied and this recess 50 or 51
can be made so deep that the portion 26 comes to sit in the recess
50 or 51 over its entire thickness, wherein then, for example, on
the location where no recess is present, a protrusion is formed,
which, in the mounted condition, comes into contact with the
portion 26. Instead of making use of such protrusion, a support
point in horizontal direction may also be created on another
location, for example, between the tip of the tongue and the bottom
of the groove, with the insert 2 therebetween.
[0146] In FIG. 16, a deviating variant of the invention is
represented, wherein the second portion 19, instead of as a fixed
spacing element, is realized as a movable spacing element and for
this purpose comprises a movable portion 52 allowing to lock two
such panels to each other by means of a snap effect. As
represented, herein the whole preferably is designed such that the
panels 1, by means of a movement M1 in the plane of the panels or
substantially in the plane of the panels, can be pushed towards
each other and thereby can be fixedly snapped into each other.
Herein, the locking surfaces 33 and 34 are not situated directly
opposite each other, however, they cooperate with each other by the
intermediary of the insert 2. More particularly, the locking
surface 33 cooperates with a support portion 53 of the insert 2,
whereas the locking surface 34 cooperates with a support portion
54, which is formed by the extremity of the movable portion 52.
[0147] In the embodiment according to FIG. 16, it is preferred that
the insert is mounted on the tongue at the manufacturer's, either
manually or automatically. Joining the represented panels then is
performed by shifting the left-hand panel according to arrow M1
towards the right-hand panel. Herein, the left-hand panel is
displaced over the lower lip of the right-hand panel. Herein, the
movable portion 52 is pushed elastically upward with its free
extremity until it springs back behind the locking surface 34, by
which the locked condition is effected. It is noted that the panels
1 in the represented embodiment can also be joined together by
means of a turning movement M2.
[0148] FIG. 17 represents a variant, wherein the movable portion 52
is tensioned by means of a pressing portion 55 in the form of a
compressible material portion, which cooperates with a side of the
movable portion 52. Herein, said pressing portion 55, so to speak,
forms an elastically compressible cushion. Preferably, the pressing
portion is made in one piece with the insert 2 and preferably is
formed by means of coextrusion.
[0149] The embodiments of FIGS. 16 and 17 can be applied on one
pair as well as on both pairs of sides of panels. In the case of
oblong panels, this embodiment in fact is particularly suitable for
the short sides, whereas on the long sides then, for example, an
embodiment as in FIG. 5 will be applied. Such combination allows
that newly to install panels can be coupled at their long sides to
a preceding row by means of a turning technique and at their short
sides by means of a push and snap technique.
[0150] It is clear that FIG. 17 also forms an example of the fourth
aspect of the invention.
[0151] In FIG. 18, a variant of FIG. 7 is represented, by which at
the second pair of sides, more particularly the short sides, a
push-lock coupling can be effected. Herein, use is made of an
element in the form of a strip or the like, which is provided at
one edge of the panel 1 and consists, for example, of synthetic
material, wherein this part comprises an elastically bendable or
elastically movable portion 56, which can engage behind an edge 57.
The strip-shaped element is attached to the edge concerned, for
example, by means of an attachment part 58. It is clear that the
panel represented at the right-hand side can be coupled to the one
at the left-hand side by means of a downward movement and that
therein, the movable portion first is pressed sideways to the right
in order to then engage behind the edge 57.
[0152] FIG. 19 represents a variant, wherein a pressing portion 59
is also present behind the elastically movable portion 56, in the
form of a compressible material part, which cooperates with a side
of the movable portion 52. Herein, this pressing portion 59, so to
speak, forms an elastically compressible cushion. The pressing
portion preferably is made in one piece with the strip and
preferably is formed together with it by means of coextrusion.
[0153] It is clear that FIG. 19 also forms an example of the fifth
aspect of the invention.
[0154] FIG. 20 represents another variant of FIG. 5, wherein one
insert 2 substantially is composed of two separate parts 18 and 19,
each formed by prefabricated strips, for example, of synthetic
material. In the example, these strips are mounted on the tongue 12
by means of attachment parts 60 and 61 in the form of ribs which
are fixedly clamped in recesses. Other manners of attachment are
not excluded. Also, according to a not represented variant, such
separate parts can be pre-mounted in the groove instead of on the
tongue. According to another not represented variant, one part, for
example, the part 19, is pre-mounted on the groove, whereas the
other part, in this case then the part 18, is mounted on the
tongue. It is clear that the designs and locations of the parts 18
and 19 are not limited to those of FIG. 20 and thus also other
embodiments of the herein above designed idea are possible. It is
also clear that also in the case of an embodiment with two separate
parts 18 and 19, these parts can extend continuously in the
longitudinal direction of the edge, and can as well consist of a
plurality of parts, which mutually are situated at a distance from
each other.
[0155] It is clear that the invention also relates to methods for
realizing such panels. According to one of these methods, first
panels are made and, at least on a number of edges, are provided
with the necessary profiled parts, after which the respective
inserts are provided on the edges concerned. Applying the inserts
may be performed after the panels themselves are formed completely,
however, before packaging them. According to a variant, however, it
is also possible to provide the inserts already during forming of
the actual panels, for example, by first milling the long sides,
then providing one or more inserts and only then milling the short
sides.
[0156] FIGS. 21 and 22 schematically represent an embodiment of a
technique which can be applied herein for providing an insert 2 on
a tongue 12. Herein, the insert 2 is supplied in the form of a
continuous strip by means of a supply 62. Herein, the strip can be
supplied from a not represented supply roll on which such strip is
wound up. Then, the strip is directed via the necessary guiding
means 63 into the direction of the panel 1. Herein, the strip is
guided along a cutting device 64, which is provided with a knife 65
in order to cut inserts with an appropriate length off the strip.
According to a particular aspect, the inserts are forced over a
guiding piece 66, which presses the inserts 2 open, such as
represented by the arrows in FIG. 22, after which said inserts, in
the somewhat pressed-open position, are provided over a tongue 12
of a passing panel.
[0157] The application is performed by means of an application
device 67, for example, in the form of a driven drive roll 68,
which carries the insert 2 along and transfers it onto the tongue
12.
[0158] It is noted that an applied insert 2 preferably is cut off
from the supply only after it is already partially sitting on the
tongue or, according to an alternative, is sitting in the
groove.
[0159] It is clear that in practice also additional drive
mechanisms may be provided and/or that other arrangements are
possible. For example, the knife 65 can be installed at the height
of or immediately after the guiding piece 66, such that the strip
is not interrupted before it is carried along by the drive roll 68.
Also, the drive roll 68 may possibly cooperate with a counter roll,
or the guiding piece 66 can be realized in the form of a counter
roll.
[0160] It is clear that an analogous system can be applied when
such insert has to be mounted in the groove of a panel 1 instead of
on a tongue.
[0161] In FIG. 23, for the sake of completeness, another panel as
in FIG. 1 is illustrated, with the difference that instead of a
plurality of separate inserts 2, now only one continuous insert 2
has been provided on the tongue.
[0162] FIG. 24 represents a particular variant of the embodiment of
FIG. 20, wherein the parts 18 and 19 are provided on the tongue
profile in the form of locally glued-in, preferably prefabricated
cord-shaped strips 69-70, wherein these strips effect a similar
spacer function as the inserts from FIG. 20. Possibly, apart
therefrom another additional strip 71 can be provided, if one wants
to avoid contact at the upper edges of the panels, which strip then
forms the aforementioned portion 26. As represented, these strips
can be deposited in recesses, for example, semi-circular recesses.
According to a variant, these strips can also be formed by
sprayed-on and hardening material, which then fulfills the second
aspect of the invention, in view of the fact that the local strips
then form local covering layers of a hardening material.
[0163] Instead of said two prefabricated parts or elements 18 and
19, according to a deviating embodiment also only one of the two
can be prefabricated, whereas the other is replaced by a covering
layer, which has been hardened on the edge.
[0164] In FIG. 25, a variant of the embodiment of FIG. 12 is
represented, with coupling parts 37-38, which are intended in
particular for the short sides of the panels, which comprise
hook-shaped parts 72-73, between which, in mounted condition, an
insert 74 is provided, which preferably has been provided on the
locking part 38 beforehand, more particularly already during
manufacture. In this example, the coupling parts provide
exclusively for a horizontal locking, such by means of the engaging
behind one another parts 72 and 73.
[0165] The hook-shaped part 73 consists of a lip 75 and an upwardly
directed locking part 76 with a locking surface 77. The hook-shaped
part 72 consists of a lip 78 and a downwardly directed locking part
79 with a locking surface 80.
[0166] The hook-shaped part 75 defines a seat 81, in which the
downwardly directed locking part 79 comes to sit when the panels
are coupled, such with the inclusion of the insert 74.
[0167] The insert 74 is a preferably separately manufactured
strip-shaped element and comprises at least three parts 82-83-84,
which function as spacing elements, to with a first part 82, which
is situated between the sides 85 and 86 directed towards each
other, a second part 83 at the bottom in the seat 81, and a third
part 84, which, in the coupled condition, is situated between the
locking surfaces 77 and 80, wherein the first part 82 provides for
that there is a gap 87 between the actual panels, at least based on
nominal dimensions and still better effectively, thus, with a
certain width B1.
[0168] In the preceding paragraph, by an "effective gap" it is
meant that such gap, how small the width B1 may be, really is
present. By a "gap based on nominal dimensions", it is meant that
at least the nominal dimensions during manufacture are chosen such
that a gap must be present in theory, however, due to overlapping
usual tolerances is not always effectively present. In the last
case, possible contacts between the basic materials of the coupled
panels thus are not excluded, however, as in such embodiments there
is not on all locations a contact, or in that the prevailing
pressure with which such panels are adjoining each other at their
upper edges then mostly is somewhat less than usual, still the
advantage aimed at hereby is obtained at least partially.
[0169] As represented, the hook-shaped parts 72-73 and the insert
74 preferably are realized such that the hook-shaped parts 72-73 in
the coupled condition cooperate with each other exclusively via the
insert 74 and that there is no direct contact, with the advantage
that creaking noises as a result of direct contact between the
actual material of the panels 1 are excluded, which is particularly
useful for solid wooden panels.
[0170] It is noted that the whole preferably is configured such
that the insert 74 is fixedly sitting in the seat 81 due to its
shape and thus cannot drop out of it.
[0171] As represented, for this purpose it is preferred that the
part 82, at least in the proximity of its free upper edge, is
countersunk into the side 86 and thereby cooperates with a
downwardly directed collar 88.
[0172] Further, the part 82 can be somewhat buckled or bent, in de
direction as illustrated, and more particularly can be provided
with a buckle 89. This design contributes to that the insert 74 by
itself will remain better in the seat 81 as soon as it has been
provided therein.
[0173] In the example of FIG. 25, the insert 74 also comprises an
additional part 90, which engages over the edge of the hook-shaped
portion.
[0174] In FIG. 26, a variant of the embodiment of FIG. 25 is
represented, wherein instead of the aforementioned part 90 now a
single flange 91 is provided, by which the insert 74 is more simple
and also is easier to apply.
[0175] The insert 74 preferably consists of an at least somewhat
elastically deformable strip, preferably of synthetic material. In
FIG. 27, the strip of the embodiment of FIG. 26 is represented in
free condition. As illustrated, the shape thereof then is somewhat
wider, such that this strip, when being applied in the seat 81, is
clamped in a somewhat elastic manner, such that it will remain
better at its place.
[0176] It is clear that the second part 83 is intended for
providing a vertical support. According to a not represented
alternative of FIGS. 26 and 27, the spacing portion 83 can also be
replaced by a spacing portion at the location of the flange 91,
wherein the locking part 79 then at the bottom preferably does not
make any more contact with the insert. All other characteristics
then will remain applicable.
[0177] In FIG. 28, it is schematically represented how the
hook-shaped parts can be provided on the panels 1 in different
steps S1 to S4, which each comprise specific cutting operations.
Usually, herein the panels are placed with their decorative side
downward.
[0178] In step S1, by means of cutting tools 92-93 cuts 94-95 are
formed at a short distance from the flanks to be formed. This
treatment is in particular of importance when the hook-shaped parts
must be provided on the small sides of solid wooden planks, thus,
on so-called cross grain wood. By forming such cuts 94-95 by means
of this pre-treatment, a splitting of the wood during subsequent
operations is excluded. The cutting tools 92-93 preferably are
slitting saws.
[0179] Subsequently, in different steps S2, S3 and S4 the desired
profile shapes are provided at the panels by means of cutting tools
96-97-98-99-100, more particularly milling cutters.
[0180] FIG. 29 represents how the strip-shaped insert 74 can be
rolled by means of a roll 101 into the seat 81.
[0181] As aforementioned, the invention also relates to a number of
special techniques for applying strip-shaped insertion pieces in a
panel. In FIGS. 30 and 31, two applications thereof are represented
schematically.
[0182] FIG. 30 schematically illustrates a technique for providing
inserts 2 on the long edges of the panels 1. The particularity
therein is that the inserts 2 originate from a continuously
produced strip, however, are supplied to the panels in the form of
pre-cut strips 102 from a magazine 103, such by means of a feeding
device 104, which is only schematically indicated in the form of a
roll 105. The use of such pre-cut strips offers the advantage that
these are easy to handle and to orientate, such contrary to a
continuous strip coming from a roll, which strip sometimes tends to
position itself not in the right direction.
[0183] FIG. 31 schematically represents a technique for applying
inserts 74 on the short edges of the panels 1. The particularity
therein is that the inserts 74 originate from a continuously
produced strip, however, are supplied in the form of pre-cut larger
strips 106 from a magazine 107, which strips in their turn, by
means of a dividing device 108, are cut to further smaller strips
109, which then form the actual inserts 74 and are provided on the
panels 1 by means of an application device 110. This technique is
also useful for providing inserts on one panel, at a distance from
each other, also, for example, on the long edge.
[0184] It is noted that the application devices 104 and 110 are
represented only very schematically, as the practical realization
thereof can be performed in a variety of ways and is within the
range of knowledge of the person skilled in the art.
[0185] In FIGS. 32 to 36 respectively a part is represented similar
to the part indicated by F32 in FIG. 26, however, for different
variants, with the particularity that in these embodiments
respectively a vertically active locking system 111 is integrated,
which provides for a vertical locking between the hook-shaped parts
72-73 and allows that the hook-shaped part 72 can be locked in the
part 73 by means of a downward movement.
[0186] A first particularity consist in that, as represented, the
insert 74 combines two functions, namely a vertical locking,
preferably as a coupling of the "push-lock" type, and the
application of a gap 87.
[0187] A second particularity consists in that herein, specific
embodiments of vertically active locking systems 111 are applied,
which, as will be explained herein below, are of a particular
construction and which also are generally applicable in so-called
"push-lock" connections, and/or in "fold-down" systems,
irrespective whether those are applications with or without a gap
87, and irrespective how the insert is realized for the rest, as
well as irrespective of the fact whether the insert has or has no
other functions than vertical locking.
[0188] The locking systems 111 represented in FIGS. 32 to 36 all
have a locking part 112 formed at an insert 74, which locking part
can displace itself elastically during coupling and which, in the
coupled condition, cooperates with an opposite locking part 113,
preferably in the form of a stop. As represented, the locking part
113 preferably is formed in one piece from the associated
hook-shaped part.
[0189] In the embodiment of FIG. 32, a particular property consists
that the locking part 112 is supported towards its back side and
that the elastic displacement thereof during coupling is generated
at least partially and preferably entirely by the elastic
compressibility in the part 82, more particularly in the portion
thereof of which the locking part 112 forms part.
[0190] In the embodiment of FIG. 33, a particularity consists in
that at the height of the locking part 12 different material
portions are applied, on the one hand, a first material portion
114, of which the actual locking part is formed, and a second
material portion 115, which forms a back support for the locking
part 112, wherein the second material portion consists of a
material which can be compressed more supple than the material of
the first material portion. The material portion 114, which
preferably is relatively stiff and still better is very stiff,
extends at least over the entire height between the locking part
113 with which it cooperates and the collar 88 for offering in this
manner a stable locking by means of a relatively rigid support. The
material portion 115 is situated at least behind the locking part
112, anyway at least behind the portion thereof which during
coupling temporarily must be pushed away laterally. In the example,
with the exception of the material portion 114 the entire insert is
made as a material portion 115.
[0191] In the embodiment of FIG. 34, a particularity consists in
that the locking system 111 comprises an insert 74 with a part 82,
wherein this part 82, on the one hand, on one side thereof
comprises the locking part 112 and, on the other hand, in its
central part is bendable in respect to the extremities thereof,
more particularly can be pressed into a there behind situated space
116. Herein, the part 82 preferably has a bend-out shape in the
direction of the locking part 112. Also, the part 82 preferably is
supported in both distal directions, in this case in upward
direction by means of the collar 88, and in downward direction by
the bottom of the seat 81.
[0192] FIG. 35 represents a variant of the embodiment of FIG. 34,
wherein the aforementioned central part of the part 82 can be
compressed towards the rear against the force of a material portion
117 functioning as an elastically compressible matter, which is
made in one piece, for example, by coextrusion, with the remainder
of the insert 74.
[0193] In the embodiment of FIG. 36, an insert 74 is applied with
an upwardly directed part 82, which comprises a locking part 112
directly adjoining thereto, in the form of a downwardly directed
lip 118, wherein the portions 82 and 118 are manufactured in one
piece and continuously from the same material, with the same
material characteristics.
[0194] All inserts represented in the figures preferably consist of
synthetic material, thus also in the embodiments of the FIGS. 32 to
36, and preferably consist of continuously extending profiles,
which are obtained by means of extrusion.
[0195] In general, it is noted that the coupling parts 10-11 as
such, in other words, the tongue, the groove, as well as the
locking parts, preferably are manufactured in one piece from the
panel material, as in such case the invention shows its advantages
in an optimum manner. The same is valid for the hook-shaped parts
72 and 73. In the case of a solid wooden plank, this means thus in
one piece of one and the same wood. In the case of a panel which as
such is made of a plurality of parts, which, for example, are glued
to each other, it is clear that coupling parts made in one piece
from the panel material as such can comprise a plurality of
materials. Examples of such panels are so-called panels of
prefabricated parquet, more particularly of the type also called
"engineered wood" in English, or "Fertigparkett" in German, and
which are composed, for example, of a top layer of a hard wood
species, a bottom layer of a soft wood species, and a central layer
glued between the aforementioned layers, for example, of a board
material or of softwood laths, possibly with strips of a more
stable material provided on one or more edges of the panel.
[0196] However, the above does not exclude that in a particular
embodiment, the invention may also comprise coupling parts, wherein
certain portions of the latter, for which reasons whatsoever,
consist of another material than the panel material.
[0197] It is noted that everything mentioned above also applies for
wall and ceiling panels. In such case, the terms applied therefor,
which specifically refer to floor panels, have to be interpreted in
a conform manner. For example, with a covering for a wall and
ceiling, the "upper lip" has to be considered the lip which is
situated closest to the decorative side, whereas the "lower lip"
then is the lip which is situated closest to the opposite side.
Interconnecting by means of a downward movement then, for example,
with ceiling panels, must be interpreted as an upward movement. The
terminology of the claims has to be interpreted within the same
context.
[0198] The present invention is in no way limited to the
embodiments described by way of example and represented in the
figures; on the contrary may such covering, more particular floor
covering, and the panels and auxiliary pieces applied therewith, be
realized according to various variants, without leaving the scope
of the invention. For example, such panels 1 can also be produced
without a chamfer 24 and, as already mentioned, such insert or such
covering layer can be provided with a spacer function, either at
the tongue or at the groove, or even partially at the tongue and
partially at the groove. Also, all embodiments described herein
above may be realized as strips extending continuously over the
major part of the edge on which they are applied, as well as
shorter lengths of such strips, which then are situated at a
distance from each other. Strips extending over the entire or
almost entire length are preferred, as then the intended effects
are guaranteed over the entire or almost entire length with
certainty.
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