This invention relates to an interconnectable panel that can be mechanically connected to other interconnectable panels. Such panels are used primarily as a floor covering (e.g., parquet or laminate flooring), but can alternatively be used as wall and ceiling coverings.
Individual panels that can be connected together to form a large, flat surface are known. Many such panels connect together mechanically without adhesives or separate mounting fasteners (e.g., screws or nails). This is advantageous because such panels can be installed more quickly and removed more easily.
These panels may be manufactured from laminate flooring panels made of a wood material. These panels may also be made of wood products in the form of parquet strips or panels or may alternatively be made of a plastic material.
Lateral (i.e., side edge) profile geometries of interconnectable panels having a tongue-and-groove connection for vertically interlocking panels are known. Lateral profile geometries of interconnectable panels having a pair of interlocking surfaces for horizontally interlocking panels are also known. These horizontal interlocking surfaces are usually obliquely aligned with respect to the top and side of the panels and usually engage one another via a “snap-action” or “snap-in” connection as the panels are interconnected.
The terms “snap-action” and “snap-in” connection refer to the manner in which the horizontal interlocking elements of a first panel lateral edge engage the complementary horizontal interlocking surfaces of a second panel lateral edge. Typically, this contact causes at least one element of the connection to bend or deflect during the interlocking process. Such connections, therefore, can only be made by overcoming a mechanical resistance, regardless of, whether the panels are pushed toward one another horizontally or connected via a pivoting motion.
Moreover, if the bent or deflected element remains bent or deflected after the connection is complete, that connection is referred to as “non-positive.” This means that the interlocking elements are at least partially bent or deflected in the connected state and consequently exert a reactive/contracting force.
Other panel connections are known to exhibit a “positive” connection. This means that the connecting elements are not bent or deflected after the panels are connected together. However, such connections may still result in the horizontal connection elements/surfaces contacting each other and being bent or deflected during the interconnection process.
A very precise fit between interconnection elements is very important, particularly with respect to the tongue and groove vertical interlock as well as the horizontal connection. However, this fit is typically impaired by forces resulting from the joining of known panels. These forces may, in particular, cause the connecting elements of the horizontal connection to deform, which can result in an inferior fit.
In view of the foregoing, it would be desirable to be able to provide an interconnectable panel in which the fitting accuracy of the vertical interlock and horizontal connection are improved.
It is an object of the invention to provide an interconnectable panel in which the fitting accuracy of the vertical interlock and horizontal connection are improved.
In accordance with the invention, an interconnectable panel that can be mechanically connected to another panel without adhesives or separate mounting fasteners (e.g., screws or nails) is provided with improved fit. Each panel (which may be, for example, square or rectangular) has a first lateral edge profile and preferably a complementary second lateral edge profile. The two profiles are complementary in that they can engage each another (when on respective panels) to produce a vertical interlock and horizontal connection. The complementary profile geometries are preferably arranged on the panel on opposite lateral edges and may also be arranged on each pair of opposite lateral edges. They may alternatively be arranged in other ways (e.g., complementary profiles may be arranged on adjacent, rather than opposite, lateral edges, or one profile may be arranged on all sides of one panel while the other profile may be arranged on all sides of another panel).
The first lateral edge profile has the following characteristics in accordance with the invention:
The first fitting surface and the second fitting surface form part of the vertical interlock on the first lateral edge, while the first contact surface and the second contact surface form part of the horizontal connection on the first lateral edge.
The second lateral edge profile has the following characteristics in accordance with the invention:
The third fitting surface and the fourth fitting surface form part of the vertical interlock on the second lateral edge, while the third contact surface and the fourth contact surface form part of the horizontal connection on the second lateral edge.
When two panels are connected to one another along two complementary lateral edges, the first and third contact surfaces, the second and fourth contact surfaces, the first and third fitting surfaces, and the second and fourth fitting surfaces adjoin one another.
Interconnected first and second lateral edge profiles have the following additional characteristics in accordance with the invention:
To connect two panels each having a respective one of the complementary lateral edges of the invention, a second panel having the second lateral edge is initially positioned at an incline with respect to a first panel, already installed, having the first lateral edge. The second lateral edge of the second panel is aligned along the first lateral edge of the first panel. From this position, the first panel and the second panel adjoin one another in the region of the upper corner of the lateral edges, while the front end of the fourth fitting surface on the tongue simultaneously adjoins the lower lip. The second panel is then pivoted downward relative to the first panel such that the fourth fitting surface slides along the second fitting surface (recall that they form a segment of a circle). The panels adjoin one another in the region of the center of the circle and are pivoted about this center. Consequently, no particular expenditure of force is required during this pivoting movement, and the second and fourth fitting surfaces are not pressed against one another with an excessively high force.
During this pivoting movement, the profile geometries of the invention ensure that the second contact surface and the fourth contact surface are spaced apart from one another. The second contact surface and the fourth contact surface have a contour. The distance from the center of the circle to the second and fourth contact surface contours continuously increases in the direction of the distal end of the lower lip. This ensures that no horizontal connection surfaces adjoin one another until the pivoting movement is substantially completed. The geometry is chosen such that the second contact surface and the fourth contact surface do not come in contact with one another until preferably the pivoting movement is completed (or alternatively, because of manufacturing tolerances, until at least shortly before completion of the pivoting movement).
The profile geometries of the invention distinguish between vertical interlocking and horizontal connection. The tongue-and-groove vertical interlock may not only result in a positive fit, but also a press fit. In other words, a very rigid vertical seat or interlock can be advantageously achieved. The horizontal connection, in contrast, intentionally represents a connection that results in a positive connection; that is, a connection that does not intentionally result in a press fit within the permissible range of manufacturing tolerances.
The above and other advantages of the invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
a–c are cross-sectional views of a fourth embodiment of first and second interconnectable panel edges according to the invention;
a–c are cross-sectional views of a fifth embodiment of first and second interconnectable panel edges according to the invention; and
a–c are cross-sectional views of a sixth embodiment of first and second interconnectable panel edges according to the invention.
The panel of the invention is preferably used as a flooring panel and can be manufactured from laminate flooring panels made of a wood material. Suitable wood materials include medium density fiber boards (MDF), high density fiber boards (HDF), particle boards, or oriented strand boards (OSB). The panels may also be made of wood products in the form of parquet strips or panels or may alternatively be made of a plastic material. While intended for use primarily as flooring, these panels may also be used in other applications, such as, for example, wall or ceiling coverings.
While the invention pertains primarily to an interconnectable panel preferably having two complementary lateral edges,
The connection of complementary lateral edges 4 and 6 (see
Second fitting surface 18 and fourth fitting surface 30 have a cross-sectional contour in the shape of a segment of a circle. The center M1 of the circle lies in the region of the upper sections of lateral edges 4 and 6. The circle has a radius r1 measured from center M1 to second and fourth fitting surfaces 18 and 30. In three-dimensions, second fitting surface 18 and fourth fitting surface 30 have the shape of a cylinder section.
Second contact surface 22 and fourth contact surface 32 are spaced away from center M1 by a distance a, which is greater than radius r1. Distance a (measured from center M1) increases in the direction of the distal end of lower lip 14. This is illustrated with distances a1, a, and a2. Distance a is greater than distance a1, and distance a2 is greater than distance a. In other words, the distance gradually increases outward from center M1 in the direction of the distal end of lower lip 14.
The broken auxiliary curve H in
The pivoting movement during the joining of two complementary lateral edges is now described in greater detail with respect to
a shows a first panel horizontally positioned on a surface (e.g., a floor) and a second panel brought in contact with the right side (first lateral edge 4) of the first panel. Both upper corners of lateral edges 4 and 6 contact one another, and the front region of fitting surface 30 adjoins fitting surface 18. In this position, contact surfaces 22 and 32 are spaced apart from one another as illustrated by the corresponding gap shown in
b shows the second panel in an intermediate pivot position (i.e., the pivoting movement is not yet completed). Fitting surfaces 30 and 18 adjoin one another along a longer section than in
c shows the completion of the pivoting movement, with the described pairs of fitting surfaces and contact surfaces adjoined. A positive fit (or, alternatively, if the dimensions of the elements are chosen accordingly, a press fit) is produced between groove 10 and tongue 26. In addition, a purely positive connection is produced in the region of contact surface pairs 8, 24 and 22, 32 (within the permissible range of manufacturing tolerances). A purely positive connection is one in which none of the elements involved in that connection is deflected or bent during the interconnection process.
The fitting surfaces and contact surfaces, which produce the connection, are consequently not subjected to excessively high forces during the joining process. This means that two panels can engage one another along the lateral edges without damaging the interlocking and connecting elements, thus providing an improved fit.
Returning to
As shown in
c show other embodiments of the invention. Identical reference symbols identify the same characteristics/features as those described above with respect to the first embodiment. Characteristics that differ from the first embodiment are identified by apostrophes and are described below.
c show a second embodiment of interconnectable panel 2 (or, alternatively, two different panels) in accordance with the invention. In contrast to the first embodiment, second contact surface 22″ and fourth contact surface 32″ have a straight cross-sectional contour that extends obliquely upward in the direction of the distal end of lower lip 14. However, despite this modification, the distance between contact surfaces 22″ and 32″ and center M1 also increases outwardly in the direction of the distal end of lower lip 14. This is illustrated in
The pivoting movement illustrated in
In other respects, the previous description of the first embodiment shown in
c show another embodiment of the invention that includes a combination of some of the characteristics of the first two embodiments. In this third embodiment, contact surfaces 22′″ and 32′″ respectively include (1) curved sections 22a′″ and 32a′″, which preferably have the shape of a segment of a circle, and (2) straight sections 22b′″ and 32b′″.
The embodiment shown in
a–c show another embodiment of first and second lateral edges of one or more interconnectable panels in accordance with the invention. The fitting surfaces and contact surfaces of this embodiment are again identical to those of the first embodiment. An elastic element 38 is additionally provided in the region of second contact surface 22. Elastic element 38 is made of an elastic material, which is preferably a plastic material such as PVC. Elastic element 38 is recessed into and protrudes slightly beyond contact surface 22. During the pivoting movement, shown in
Note that profiled strip 34 and elastic element 38 may be included in other embodiments of the invention.
Although panels of the invention can be mechanically connected to other panels without adhesives or separate mounting fasteners (e.g., screws or nails), an optional glue layer 42 may be applied within hollow space 40, as shown in
Thus it is seen that interconnectable panels with improved fit are provided. One skilled in the art will appreciate that the invention can be practiced by other than the described embodiments, which are presented for purposes of illustration and not of limitation, and the invention is limited only by the claims which follow.
Number | Date | Country | Kind |
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103 02 727 | Jan 2003 | DE | national |
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20040187423 A1 | Sep 2004 | US |