CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 13/640,814 filed Oct. 12, 2012, published as U.S. 2013/0025231A1 on Jan. 31, 2013, which is a Section 371 National Stage Application of International Application PCT/EP2010/054992 filed Apr. 15, 2010 and published as WO/2011/127981 A1 in English, all of which are incorporated herein by reference in their entirety.
The discussion below is merely provided for general background information and is not intended to be used as an aid in determining the scope of the claimed subject matter.
Aspects of the invention relate to a floor panel assembly comprising sheet-shaped floor panels, which floor panels are provided with edges, a lower side and an upper side. The floor panels are intended to be joined by means of joining members. Particularly, each floor panel is provided on at least a first edge with a first joining member and, on an opposite second edge, with a second joining member. The first and second joining members are adapted to be joined by a movement of two panels with their first and second panel edges towards to each other such that in the joined position the panels meet each other near their upper side along a seam. The first and second joining members locking the panels at the adjacent edges at least in a direction perpendicular to the upper side and in a direction parallel to the upper side but perpendicular to the adjacent first and second edges in their joined position. The first and second joining members are provided with at least one locking element which is deformable and/or movable, during said joining, from a first position allowing the first and second joining members to be joined, to a second position in which it locks the first and second joining members to each other. The locking element is provided on one of the first and second joining members and comprises a first locking surface adapted to co-operate with a second locking surface on the other of said first and second joining members.
This Summary and the Abstract herein are provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary and the Abstract are not intended to identify key features or essential features of the claimed subject matter, nor are they intended to be used as an aid in determining the scope of the claimed subject matter. The claimed subject matter is not limited to implementations that solve any or all disadvantages noted in the Background.
An aspect of the invention is a locking element that has a locking portion on one end bearing said first locking surface and a control portion near the other end as well as a connecting portion between them. The connecting portion is slidably accommodated in a channel having two open ends, and is pushed at least partly out of a first end of the channel when the locking element is moved and/or deformed from the first to the second position by means of the control portion extending from an opposite end of the channel for cooperation with the other of said first and second joining members.
In this manner, the locking element is guided in a reliable manner and has a control portion on one side of the channel and the locking surface on the other. The channel may be formed by a hole, groove, slit or the like.
An end of the control portion is movable and is guided by a wall of the joining member during movement of the control portion from the curved to the more straight shape. In this way the movement of the end of the control portion will mainly control the movement of the locking element.
In a further alternative, the control portion of the locking element has a control surface that is inclined with respect to the direction of movement of the locking portion and with respect to the direction of movement of the panel edges, such that it can co-operate with a control surface of the other of said first and second joining members to move the locking portion of the locking element from the first to the second position. All kinds of other shapes and guiding ways can be used to cause the movement of the locking element.
In a particular embodiment, the first and second joining members are configured as a male and female joining member, the locking element being attached to the male joining member, although it is also conceivable to attach the locking element to the female joining member. If the edges of the panels are moved with respect to each other in a vertical sense, the female joining member will normally be on the lower edge and the male joining member will be on the upper edge.
In a further development, the male joining member is provided with a protrusion extending away from the upper side of the panel, the channel extending through said protrusion, particularly substantially parallel to the upper side of the respective panel.
The female joining member may then comprise a control portion for cooperation with the control portion of the locking element to move the locking element when the panel edges move towards each other.
Also, the female joining member may comprise a lip protruding substantially parallel to and from the lower side of the panel at the first edge, said lip having a depression to accommodate the protrusion of the male joining member, said depression having an upright projection near the free end of the lip forming the control portion of the female joining member.
The locking portion of the locking element may extend a part of the length of the respective panel edge and may be accommodated in a groove extending preferably along the length of the panel edge, the locking element being further provided with a plurality of connection and control portions accommodated in a plurality of channels.
In this manner, the groove can easily be made, for example by grinding the whole edge of the panel, while the locking portion may be of a shorter length allowing easy engagement of the locking surfaces, also if the panel edges are not moved towards each other in a parallel fashion.
It is very convenient if the connecting portion includes a spring-like part to absorb the movement of the control portion and to transfer it to the locking portion as soon as the first and second locking surfaces are allowed to engage.
This enables the control portion of the locking element to be actuated before the locking surfaces can enter into engagement with each other. The movement of the panel edges is accumulated as spring energy which is release at a desired time. As a result it is not required to allow the locking surfaces to engage gradually in synchronisation with the movement of the panel edges, although this is also encompassed by the invention. The locking surfaces may now engage instantaneous under influence of the spring force on the locking portion.
Nonetheless, the first and second locking surfaces may be inclined to facilitate their engagement.
An aspect of the invention also includes a floor panel for use in the above-described floor panel assembly, as well as a locking element for use in such floor panel.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details and advantages of aspects of the invention follow from the below description of the invention with reference to the drawings showing embodiments of the invention by way of example only.
FIG. 1 is a perspective view of a plurality of panels of a panel assembly in a stage of laying the panels.
FIG. 2 is an enlarged cross sectional view according to the line II-II in FIG. 1 showing partly two panels with their third and fourth edges on the long sides of the panels.
FIG. 3 and FIGS. 4a, 4b and 4c are views showing an embodiment of the invention.
FIGS. 5a and 5b are views corresponding to those of FIG. 3, but showing another embodiment of the invention.
FIGS. 6a, 6b, 6c are views corresponding to those of FIGS. 4a, 4b, 4c, but showing the embodiment of FIGS. 5a and 5b.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
The drawings and in first instance FIGS. 1 and 2 thereof, show a number of panels of an embodiment of the panel assembly. In particular, FIG. 1 shows a first panel 1, a second panel 2, a third panel 3 and a fourth panel 4. These panels are substantially rectangular and may both be square or elongated. The four panels shown are elongated having a first edge 5 and an opposite second edge 6 that are the short edges, and a third edge 7 and an opposite fourth edge 8 that form the long edges.
In principle the panel assembly is intended to form a floor covering, but the panels may also be used as wall panels, ceiling panels or panels for covering other surfaces. These surfaces may be indoor or outdoor surfaces.
In a particular embodiment, the panels may be constructed as laminate panels for forming a laminate flooring which is well known in the art. These panels are used to imitate planks or tiles of natural material, such as wood, stone or any other material. Generally these laminate panels comprise a core of relatively cheap material, in particular a wood based material such as material including wood particles or fibres such as MDF/HDF, a wood plastic composite (WPC), other composites including plastics, or plastics. The core of these panels may be covered by a decorative layer formed for example from transfer foil or a laminate of paper layers immersed with resin. The decor may also be formed in a different way, for example by printing directly and/or digitally on the core, or by finishing the core by embossing, chafing or the like. An upper surface 9 on the upper side of the panels is formed thereby. A lower surface 10 on the lower side of the panels may be formed by another layer, for example a water-proof coating or sheet. However, the invention is also applicable for panels made of wood, plastic or other material with or without separate upper and/or lower layers.
The edges 5-8 of each panel 1-4 are provided with joining members to join the panels to each other to obtain a floor covering in which the panels are coupled to each other substantially without the formation of a gap. For this purpose, the first edge 5 of each panel is provided with a first or male vertical joining member 11, the second edge 6 with a second or female vertical joining member 12, whereas the third edge 7 is provided with a first or male horizontal joining member 13 and the fourth edge 8 with a second or female horizontal joining member 14.
The third and fourth edges 7, 8 with the first and second joining members 13, 14 are shown in FIG. 2 and may be configured in a well known manner. These joining members 13, 14 are such that they allow a joining of the third and fourth edges 7, 8 of two panels by bringing the male joining member 13 in contact with the female joining member 14 of a panel or of two panels which are already installed on the surface. In FIG. 1, panel 1 is brought in engagement with panels 3 and 4. The first male joining member 13 is brought in engagement with the second female joining member 14 while the panel 1 is held in a relatively inclined position, where after panel 1 with the male joining member 13 is rotated with respect to the other panels 3 and 4 so as to bring the upper surfaces 9 of the panels substantially in alignment with each other. This method is also known as the “angling in” joining method. In principle, it would also be possible to angle in a female joining member onto a male joining member of a panel already installed.
In the embodiment shown in FIG. 2 the joining members comprise locking element(s) which prevent the panels from drifting apart in a direction parallel to their surfaces 9, 10 and perpendicularly to their edges 7, 8. These locking element(s) are configured such that they exert a force urging the panels towards each other (i.e. perpendicular to their edges) while the panels are in their joined condition. This force counteracts the formation of gaps between the panels, in particular at the position near the upper surface 9 where the panels meet each other. This position may be exactly at the upper surface, but in case the upper edges of the panels are machined for example to form a V-groove (see FIGS. 4a-4c), U-groove or other lowered area between the panels, the panel edges will meet at a distance from the upper surface 9.
FIG. 2 also shows that the first male joining member 13 includes locking portion herein a tongue 15, while the second female joining member 14 includes a groove 16 which is able to receive at least a portion of the tongue 15 therein so as to lock the panels with respect to each other in a direction perpendicularly to surfaces 9, 10, i.e. in a vertical direction. The shape of the tongue and groove 15, 16 may have all kinds of configurations and orientations as long as they include surfaces that restrict movements in a direction perpendicularly to the surfaces 9, 10.
The horizontal lock of the panels away from each other is accomplished by means of a lip 17 below the groove 16 projecting from the panel 2 and carrying near its free edge an upper protrusion 18 engaging into a lower groove 19 positioned behind the tongue 15 of the panel 3.
It is shown in the drawings that the first joining member 11 of the first panel 1 is provided with a separate locking element 20 which is connected to the first joining member 11, and has sufficient freedom of movement to move or deform in order to cooperate with the second joining member 11 in order to couple the joining members 11, 12 to each other such that it locks the first and second joining members 11, 12 to each other in both a direction perpendicular to the upper surface 9 and in a direction parallel to the upper sur-surface 9 but perpendicular to the adjacent first and second edges 5, 6 in their joined position. For this purpose, the locking element 20 is in a first position, allowing first and second joining members 11, 12 to be joined (FIG. 4a), to a second position in which it locks the first and second joining members 11, 12 to each other (FIGS. 4c).
In the embodiment shown, the locking element 20—when viewed in a direction parallel to the respective edge 5—is provided with a locking portion 33 on one of its ends, a control portion 36 on its other end and with a connecting portion 35 in between. The locking element 20, and in particular the locking portion 33 thereof, may extend along the whole length of the first edge 5, but preferably there are provided a plurality of short locking elements 20 distributed along the length of the edge 5, or even only one short locking element 20 substantially in the middle of the second edge 6. The length and placement of the locking element 20 depends on various factors, in particular the length of the edges 5, 6, the material of the panels and the particular use of the panel assembly. The use of one or more narrow locking elements 20 facilitate a connection between two panel edges when the edges are moved towards each other in a non-parallel orientation, for example, if one panel is folded down as is disclosed here. Also the locking effect is better when there is a high local load because if one locking element is disengaged due to the high local load, the other locking elements will remain locked and keep the edges together.
The operation of the joining members 11, 12 is illustrated with reference to FIGS. 4a- 4c. The function of the locking element 20 is described with reference to one control and connecting portion 36, 35, but it should be kept in mind that this embodiment has two control and connecting portions 36, 35, while even a larger number is conceivable.
The second or female joining member 12 comprises a groove 21 extending at a distance below the upper side of the panel 2 and parallel to the respective panel edge 6. The panel portion below the groove 21 is extended into a protruding lip 22 including in its upper surface a depression 23 adjacent to groove 21. In the embodiment shown, the depression 23 has a flat bottom parallel to the edge 6. On its free end the lip is provided with an upper projection 24 having an upright wall 25 bordering the depression 23 and an upper surface 26. On the free end of the lip 22 remains a free space 27 to the first edge 5 of the other panel in order to ensure that the seam between vertical wall surfaces 28, 29 near the upper surface 9 of the panels 1, 2 can be closed.
The first or male vertical joining member 11 comprises a downward protrusion 30 having in this case a substantially flat lower surface extending parallel to the first edge 5. The shape and dimension of this downward protrusion 30 is such that it will fit into the depression 23 of the female joining member 12 when the first and second joining members 11 and 12 are in their coupled condition. The lower surface of the protrusion 30 forms the lowest point of the first joining member 11 where the distance from the upper surface 9 of the panel is at a maximum. On the lower side of the first edge 5 is a recess 31 which is sufficiently large to take up the upward projection 24 on the lip 22 of the female joining member 12 and allow it to activate and lock the locking element 20 at the first joining member 11 in the coupled condition of the joining members 11, 12.
The protrusion 30 has on its side adjacent the vertical wall surface 28 and at a distance from the lower surface of the protrusion 30 a groove 32 preferably extending the whole length of the edge 5 and adapted to slidingly accommodate a locking portion 33 of the locking element 20. Furthermore, the protrusion 30 comprises at least one, here two channels 34 extending substantially perpendicularly to the groove 32 and connecting the groove 32 with the recess 31 of the first joining member 11. The channels 34, which are here formed as holes with two open ends, are adapted to guide a connecting portion 35 of each locking element 20 which can thus transfer a movement of a control portion 36 of the locking element 20 to the locking portion 33 thereof. The height of the channel 34 may be greater than that of the groove 32 so that the channel 34 also extends in the portion of the protrusion 30 below the groove 32, having there the form of an upwardly open groove.
As is clearly shown in FIGS. 3 and 4a-4c, the locking portion 33 of the locking element 20 is here in the form of a tongue 33. The tongue 33 is sized to be fully accommodated in the groove 32 in the first joining member 11 when it is in its first position, and to engage into the groove 21 of the second joining member 12 when it is in its second, locking position. For this locking function the tongue 33 is provided on its upper surface with a locking surface 37 co-operating with a locking surface 38 at the upper wall of the groove 21 in the second joining member 12. The locking surfaces 37 and 38 are inclined with respect to the upper surface 9 and the vertical wall surface 29. The angle may vary with respect to the upper surface 9 of the panel, but generally the locking surfaces 37 and 38 will be parallel to each other when engaged. The inclination of the locking surfaces allow them to gradually engage when the joining members 11, 12 are being coupled to each other.
In the embodiment illustrated, the control portion 36 of the locking element 20 has a control surface 46 that is inclined with respect to the direction of movement of the tongue 33 and with respect to the direction of movement of the panel edges 5, 6 during joining, such that it can co-operate with an also inclined control surface 47 of the female joining member 12 (in this case it is formed by a part of the upright wall 25) to move the tongue 33 of the locking element 20 from the first to the second position. A spring 41 of the connecting portion 35 takes up the displacement before it is transferred to the tongue 33 as soon as it has arrived in front of the groove 21. Of course it would be sufficient if only one of the surfaces 46, 47 is inclined to be able to move the tongue 33.
In another embodiment of FIGS. 5a, 5b, 6a and 6b, the control portion 36 has another configuration such that it has a flexible portion 44 extending along a curved guide 44 in the recess 31 so that the free end of the control portion 36 is at an angle to the tongue 33 and groove 32 and has at least a component perpendicular to the upper surface 9 of the respective panel, and in this embodiment is perpendicular to the upper surface 9. A lowered portion 45 of the upper surface 26 of the projection 24 of the second joining member 12 can come into engagement with the free end of the control portion 36 and can move it upwardly with respect to the first panel 1. As a result, the curved guide 44 of the first joining member 11 transfers the vertical movement of the free end of the control portion 36 into a horizontal movement of the opposite end of the control portion adjacent to the connecting portion 35. This horizontal movement or movement parallel to the upper surface 9 of the panel 1 moves the tongue 33 directly or through the spring action of the connecting portion 35 into the groove 21 of the second joining member 12.
It is noted that aspects of the various embodiments as shown and described may be used in different combinations. The invention is not limited to the embodiments shown in the drawing and described above, which may be varied in different ways within the scope of the invention. For example, it would be possible to provide the locking element in the second or female joining member. This would be more or less the upside down version of the embodiments shown in the drawings. The locking element may also be substantially rigid, while other parts of the panels may be deformable or the locking element and the joining members may have a shape allowing a gradual movement of the locking element. For example an upper entry wall of the groove on the other panel receiving the tongue may be inclined to directly take up the tongue as soon as it is moved by the control portion. Furthermore, it is conceivable to use the invention with panels that have vertical joining members on all four sides and that can thus be laid by moving the panels vertically with respect to one, two or more panels already installed. Although the locking element has been described before as an element that is separate from the panels, it could be integrated in one of the panels, especially if the panels are made from plastic material. It is also possible that each of the first and second joining members has its own locking element co-operating with the other one. The tongue of the locking elements may be more or less pin shaped such that the tongue and the control element have substantially the same width and thus each tongue has only a single control element. The panels may have a different configuration than substantially rectangular, in particular triangular or hexagonal. The panel edges should be configured such that adjacent panel edges have matching joining member.