Patent Application
20250122731
The present application claims the benefit of Swedish Application No. 2351187-6, filed on Oct. 13, 2023, of Swedish Application No. 2351376-5, filed on Nov. 30, 2023, and of Swedish Application No. 2351308-8, filed on Nov. 16, 2023. The entire contents of each of Swedish Application No. 2351187-6, Swedish Application No. 2351376-5, and Swedish Application No. 2351308-8 are hereby incorporated herein by reference in their entirety.
The present application relates to the field of building panels, such as floor panels, wall panels, furniture components, or similar. More specifically, the present application relates to the field of mechanical locking devices for such building panels.
Building panels, such as floor panels, may typically comprise a mechanical locking device for assembling the building panel with similar or essentially identical building panels such that said building panels are locked together in the assembled position. The mechanical locking device may lock adjacent building panels in a horizontal and/or vertical direction. The building panels may, e.g., be assembled by a folding or pivoting motion.
For certain applications or material choices, such as for a Luxury Vinyl Tile (LVT tile), a Stone Plastic (Polymer) Composite panel or Solid Polymer Core panel (SPC panel), or an Expanded Polymer Core panel (EPC panel), also known as Water Proof Core panel or Wood Plastic Composite panel (WPC panel), it may be advantageous to utilize a mechanical locking device which is formed in one piece with the floor panel. Such locking systems are described in the disclosure WO 2021/20661 or WO 2023/106988 and may provide strong locking of the panels and a fast and easy installation of them.
It has been found that a mechanical locking device used for this type of installation and for this type of building panels may be improved when it comes to, e.g., withstanding vertical pressure. Accordingly, there is room for improvement in the technical field.
US20170254096 A1 discloses a panel having a long edge locking system forming a slide lock system on the long edges. The three set of cooperative locking surface are configured to provide a strong press fit between the locking element and the locking groove. Thereby, the panels can be tightly secured to each other such that displacement along the long edges is prevented.
US20170067261A1 discloses a panel having a complementary locking means of a second pair of edges which are to be joined to each other by a downward, vertical movement. The locking means comprises in one example a lower latching means comprising a female latching element and a male latching element.
An object of embodiments of the present invention is to provide improvements over known art.
In a first aspect of the present invention there is provided a set of building panels, such as floor panels, comprising similar or essentially identical building panels wherein each building panel comprises a first mechanical locking device configured to horizontally and vertically lock a first edge of a building panel to a second edge of an adjacent building panel, wherein the first edge and the second edge preferably are the long edges of said building panels, and a second mechanical locking device configured to horizontally and vertically lock a third edge of a building panel to a fourth edge of an adjacent building panel, wherein the third edge and the fourth edge preferably are the short edges of said building panels. The first mechanical locking device and/or the second mechanical locking device comprises, at one of the first edge or second edge, and/or at one of the third edge or fourth edge, a locking strip extending from respective edge in a direction away from said edge. The locking strip comprises, at its outermost portion, a locking element extending in a direction perpendicular to the extension of the locking strip. Further, the locking element is configured to cooperate with a locking groove arranged in the other of the first edge or second edge, and/or in the other of the third edge or fourth edge, such that adjacent building panels are locked in a horizontal direction in an assembled position. The locking element comprises an impact surface extending from an outer surface of the locking element in a direction towards a back surface of the building panel, at an acute angle in relation to the horizontal plane. Further, the locking groove comprises an impact surface extending from an inner surface of the locking groove in a direction towards the back surface of the building panel, at an acute angle in relation to the horizontal plane and configured to cooperate with the impact surface of the locking element in an assembled position, when a force, acting, at least partially, in a vertical direction, is applied to at least one of the building panels.
The force acting, at least partially in the vertical direction, may be a force resulting from a load applied on the building panel in the assembled position. The force may act on the at least one building panel in the assembled position during conventional use, for example when being installed in a room.
The force may be applied on a front surface of at least one the building panels, opposite the back surface of at least one of the building panels.
In an embodiment only the first mechanical locking device comprises a locking strip and a locking groove respectively having an impact surface.
In another embodiment only the second mechanical locking device comprises a locking strip and a locking groove respectively having an impact surface.
In yet another embodiment the first mechanical locking device is essentially the same as the second mechanical locking device, each comprising a locking strip and a locking groove respectively having an impact surface.
At least the cooperating impact surfaces of respective locking element and locking groove are beneficial as they improve the stability and strength of the mechanical locking device, such as the vertical locking strength of the mechanical locking device.
The impact surfaces may also be referred to as support surfaces in the entirety of the present disclosure.
The impact surfaces, or support surfaces, are configured to cooperate with a corresponding impact surface, or support surface, when a force, acting, at least partially, in a vertical direction, is applied to at least one of the building panels. The impact surfaces, or support surfaces, may be configured to provide support during an impact, i.e., a force, acting, at least partially, in a vertical direction, applied to at least one of the building panels. The two impact surfaces may be configured to cooperate with each other, such as being in contact with each other, and support each other, when a force, acting, at least partially, in a vertical direction, is applied to any one of the building panels in the assembled position.
In one embodiment in a play is arranged between the impact surface of the locking element and the impact surface of the locking groove in the assembled position.
The play may be arranged between the impact surface of the locking element and the impact surface of the locking groove in the assembled position when no force, acting at least partially, in the vertical direction, applied to at least one of the building panels.
In one embodiment the first edge and the second edge of the building panels are assembled with the first mechanical locking device by means of a pivoting motion or a snapping motion.
Further, the impact surface of the locking element may be arranged at the acute angle of between 40° and 70° in relation to the horizontal plane.
Yet further, the impact surface of the locking groove may be arranged at the acute angle of between 40° and 70° in relation to the horizontal plane.
In an embodiment the impact surface of the locking element is essentially parallel to the impact surface of the locking groove.
In another embodiment the impact surface of the locking element is non-parallel to the impact surface of the locking groove.
For example, the impact surface of the locking element may be arranged at an angle relative to the impact surface of the locking groove, such as 1-20°, such as 1-10°, for example, 1-5°.
Further, the first edge and the second edge of the building panels may be assembled with the first mechanical locking device by means of a pivoting motion or a snapping motion.
The snapping motion, or snapping assembly, may be achieved by a more horizontal displacement of the building panels being assembled, compared to a pivoting assembly.
The snapping motion, or snapping assembly, may be achieved by an essentially horizontal displacement of the building panel being assembled to an adjacent building panel.
The first edge and the second edge of the building panels may be assembled by a pivoting motion pivoting about an upper portion of one of the first edge or the second edge.
In an embodiment the third edge and the fourth edge of the building panels may be assembled with the second mechanical locking device by means of a vertical displacement.
The building panel may further have a thickness of between 3 and 8 mm.
In an embodiment building panel has a thickness of between 3 and 4.5 mm and the impact surface of the locking element is arranged at the acute angle of between 40° and 60° in relation to the horizontal plane.
In another embodiment the building panel has a thickness of between 4.5 and 8 mm and the impact surface of the locking element is arranged at the acute angle of between 40° and 70° in relation to the horizontal plane.
Further, the locking element may further comprise a locking surface configured to cooperate with a locking surface of the locking groove in which the locking element is arranged in an assembled position.
In an embodiment the locking surface of the locking element and the locking surface of the locking groove are essentially parallel.
In another embodiment the locking surface of the locking element is arranged at an acute angle of between 40° and 60°, preferably about 50°, in relation to the horizontal plane.
The locking groove may further comprise a chamfer arranged below the impact surface.
In an embodiment the chamfer comprises a tilted surface extending in a direction down and in towards the rest of the building panel in which it is arranged. In another embodiment the chamfer comprises a surface extending in an essentially vertical direction.
The mechanical locking device may further comprise, at one of the first edge or second edge, and/or at one of the third edge or fourth edge, an upper locking tongue extending from respective edge in a direction away from said edge, and configured to be received in and cooperate with an upper tongue groove arranged in the other of the first edge or second edge, and in the other of the third edge or fourth edge.
In an embodiment the height of the upper locking tongue is greater than the height of the upper tongue groove in order to create a tight seal between the adjacent building panels.
The difference between the height of the locking tongue and the height of the tongue groove may be in the range of 0.01 to 0.2 mm, or in the range of 0.01 to 0.1 mm, or in the range of 0.01 or 0.05 mm.
Further, at least a substrate of the building panel may comprise a thermoplastic material, preferably the substrate comprises 10-50 wt. %, or preferably 20-40 wt. %, of the thermoplastic material.
Yet further, each building panel may comprise a single layered substrate, wherein the impact surface of the locking element and the impact surface of the locking groove are arranged in said substrate.
In one embodiment, the building panels may be provided with a pre-attached foam layer attached to the back surface of the building panel.
Embodiments of the invention will be described in the following: reference being made to the appended drawings which illustrate non-limiting embodiments of how the inventive concept can be reduced into practice.
Specific embodiments of the invention will now be described with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The terminology used in the detailed description of the embodiments illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, like numbers refer to like elements. Generally, in this disclosure, terms like “below” or “lower” typically implies closer to the back surface of the panel or a plane thereof, whereas “above” or “upper” implies closer to the front surface or a plane thereof. Further, the thickness direction of the panel is defined as the vertical direction when the panel lays flat on a surface. The horizontal and vertical directions are applicable definition when the building panel is laid flat on, e.g., a floor. Instead of horizontal and vertical directions, the description will also refer to a direction parallel with extension of the front surface of the building panel and a direction perpendicular to the extension of the front surface of the building panel. When a building panel is lays flat on, e.g., a floor, the horizontal direction is the same as the direction parallel with the extension of the front surface of the building panel and the vertical direction is the same as the direction perpendicular to the extension of the front surface of the building panel.
By “horizontal plane” is meant a plane, which extends parallel to the outer main surface of the surface layer, or in examples wherein no surface layer is provided, a plane, which extends parallel to an upper surface of the substrate. Immediately juxta-posed upper parts of two adjacent joint edges of two joined building panels together define a “vertical plane”, perpendicular to the horizontal plane.
With reference to the drawings, a building panel 1 is illustrated in
The building panel 1 includes four edges 2a-2d, a front surface 7a and a back surface 7b. The building panel 1, as illustrated, further includes a substrate 8 and a surface layer 9 arranged on one side of the substrate 8. The surface layer 9 may preferably be a decorative surface layer. The surface layer 9 is configured to face a user in an installed position. The surface layer 9 is an optional layer 9. If no surface layer 9 is present it is possible, if desirable, to provide the substrate 8 with a decorative feature, e.g., a print or the like.
In an embodiment the surface layer 9 may comprise a decorative layer. The decorative layer may be a colored powder layer, a paper sheet, a polymer-based sheet, a wood-based sheet, a wood veneer, a cork-based sheet or a fabric, woven or non-woven. Such layer may further be printed.
In other embodiments the decorative layer 9 may be a printed sheet, or a printed sheet in combination with a primer, e.g., a paper sheet. The decorative layer may further be a printed decor which is printed directly on the substrate.
In other embodiments the decorative layer may be the surface layer, e.g., when the surface layer is a wood based layer, such as a wood veneer of varying thicknesses, or an impregnated or unimpregnated paper sheet with or without a decorative print. Further, the surface layer 9 may comprise a wear layer, such as a wear resistant foil, a wear layer having wear resistant particles and/or a lacquered layer and/or coating layer.
The substrate 8 may be a single-layer substrate or a multi-layer substrate. A multi-layer substrate may include different layers to fulfil different features of the building panel, for example, layers with the purpose of providing the building panel with the desirable strength, hardness and/or balancing properties to name a few.
The substrate 8 may be a polymer-based substrate, comprising one of several polymer-based materials and optionally a filler and/or other additives.
The substrate 8 of, preferably, all building panels in the set, may comprise a thermoplastic material and a filler. For example, the thermoplastic material may be chosen from a group comprising polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), polyethylene (PE), polystyrene (PS), polypropylene (PP), polycarbonate (PC), polyvinyl acetate (PVAc), ethylene-vinyl acetate (EVA), polyacrylate methacrylate, polymethylmethacrylate (PMMA), acrylonitrile butadiene styrene (ABS), thermoplastic polyurethane (TPU), and/or a combination thereof. The filler may be an organic filler or inorganic filler. An organic filler may be fibres of wood, coconut or bamboo and rice husks. An inorganic filler may be calcium carbonate (CaCO3), barium sulphate (BaSO4), limestone, talc, fly ash, MgO, stone material and/or a combination thereof.
In preferred embodiments, the substrate 8 may comprise 10-40 wt. %, or 15-35 wt. %, of the thermoplastic material, such as PVC, and 50-80 wt. % of an inorganic filler.
A degree of plasticizer in the substrate 8 may be less than 5 wt. %, preferably less than 3 wt. % or less than 1 wt. % and may be in the range of 0.1-5 wt. %, 0.5-5 wt. %, or 0.5-3 wt. %. Generally herein, the substrate 8 may be dense or, alternatively, foamed.
In any embodiment herein, the substrate 8 and/or the building panel 1 per se, may have a modulus of elasticity of 2-12 GPa, such as 4-9 GPa or 3-7 GPa.
In alternative embodiments, the substrate 8 may be a polymer-based substrate, comprising one of several polymer-based materials, a wood-based substrate, such as HDF, MDF, particle board or plywood board, or a mineral-based substrate, e.g., MgO. The substrate 8 may further comprise one or several fillers and/or other additives.
In other alternative embodiments the substrate may instead comprise a polyurethane, PUR, thermoset and, optionally, MgO.
The building panel 1 preferably has a thickness between 2 and 20 mm, or between 3 and 10 mm, or between 3 and 8 mm, or between 3 and 5 mm. In an embodiment the building panel 1 has a thickness of between 3.5 mm and 5 mm.
As illustrated in
In order to lock adjacent building panels 1, 1′, 1″ together each building panel 1 includes a first mechanical locking device 10 arranged along the first edge 2a and the opposite second edge 2b, where the first and second edge 2a, 2b preferably are the long edges of the building panel 1, and a second mechanical locking device 10′ arranged along the third edge 2c and the fourth edge 2d, where the third and fourth edge 2c, 2d preferably are the short edges of the building panel 1. However, it may be possible to instead provide the third edge 2c and the fourth edge 4d, preferably the short edges, with the first mechanical locking device 10 and the first edge 2a and the second edge 2b, preferably the long edges, with the second mechanical locking device 10′.
Each mechanical locking device 10, 10′ is configured for horizontal and vertical locking of similar or essentially identical building panels in an assembled position. The assembled position may be achieved by means of a pivoting motion, also called pivoting assembly, of one or several building panels 1, 1′, 1″, a snapping motion, also called snapping assembly, of one or several building panels 1, 1′, 1″ and/or vertical displacement, also called vertical assembly, of one of several building panels 1, 1′, 1″.
The first mechanical locking device 10 includes at the first edge 2a connecting means 12a and at the second edge 2b connecting means 12b which are compatible with the connecting means 12a at the first edge 2a. The same goes for the second mechanical locking device 10′ which includes at the third edge 2c connecting means 12c which are compatible with connecting means 12d at the fourth edge 2d.
Illustrated in
The assembly of the first edge 2a of the first building panel 1 to the second edge 2b of the adjacent second building panel 1′ is defined as a pivoting assembly. The assembly of the third edge 2c of the first building panel 1 to the fourth edge 2d of the adjacent third building panel 1″ is defined as a vertical assembly but may also be called a fold down assembly.
The pivoting assembly of the first edge 2a of the first building panel 1 to the second edge 2b of the adjacent second building panel 1′ by a pivoting motion may pivot around an upper portion of the second edge 2b of the adjacent second building panel 1′.
The first mechanical locking device 10 may be configured for pivoting assembly. The second mechanical locking device 10′ may be configured for vertical assembly. The first mechanical locking device 10 may be of the type described below with reference to any of
In alternative embodiments, the first mechanical locking device 10 may be configured for a snapping assembly and/or pivoting assembly. The second mechanical locking device 10′ may be configured for vertical assembly. The first mechanical locking device 10 may be of the type described below with reference to any of
Illustrated in
However, in a first step of the assembly method illustrated in
The pivoting motion may pivot around an upper portion of the fourth edge 2d of the second building panel 1′.
In a second step, the first and second building panel 1, 1′ are assembled to the third building panel 1″, by means of the first edge 2a of the first and second building panel 1, 1′ and the second edge 2b of the third building panel 1″, i.e., the long edges in the illustrated example. This is achieved by lifting the second edge 2b of the first and second building panel 1, 1′ and arranging the connecting means 12a of the opposite first edge 2a in the connecting means 12b of the second edge 2b of the third building panel 1″, such that the two connecting means 12a, 12b are able to cooperate to lock the adjacent building panels 1, 1′, 1″. The second edge 2b of the first and second building panel 1, 1″ is then lowered down such that a pivoting motion around the cooperating connecting means 12a, 12b of the first and second edge 2c, 2d is achieved. During the pivoting motion and into the assembled position, where the building panels 1, 1′, 1″ are arranged flush with each other, the cooperating connecting means 12a, 12b of each edge 2a, 2b locks the two adjacent edges 2a, 2b of the building panels 1, 1′, 1″ together. The pivoting motion may also be referred to as a pivoting assembly PA. In the assembled position of the long edges, the connecting means 12a of the first mechanical locking device 10 arranged in the first edge 2a of the first and second building panel 1, 1′ is locked to the connecting means 12b of the first mechanical locking device 10 arranged in the second edge 2b of the third building panel 1″, the uppermost part of the first edge 2a of the first and second building panel 1, 1′ are juxtaposed creating a seal S, preferably a tight seal, with the uppermost part of the second edge 2b of the third building panel 1″, and the adjacent building panels 1, 1′, 1″ are locked in at least a horizontal direction.
The pivoting motion may pivot around an upper portion of the second edge 2b of the third building panel 1″.
A more detailed view of the pivoting assembly PA is illustrated in
In the embodiment illustrated in
In an alternative installation (not shown) the first building panel may be simultaneously assembled to the second and third building panel, in which the pivoting assembly in the short edges are achieved simultaneously with the pivoting assembly in the long edges.
The first mechanical locking device 10 may be provided along either the opposite first edge 2a and second edge 2b or the opposite third edge 3c and fourth edge 4d of the building panel 1. However, for the detailed description of embodiments below the first mechanical locking device 10 is described as being provided along the opposite first edge 2a and second edge 2b of the building panel.
Further, the second mechanical locking device 10′ may be provided along either the opposite first edge 2a and second edge 2b or the opposite third edge 3c and fourth edge 4d of the building panel 1. However, for the detailed description of embodiments below the second mechanical locking device 10′ is described as being provided along the opposite third edge 2c and fourth edge 2d of the building panel.
The first mechanical locking device 10 in
The locking strip 15 has an elongated shape and includes, at the outermost end of the locking strip 15, a locking element 16. The locking element 16 extends in a direction perpendicular to the extension of the locking strip 15, at least partially in a direction towards the front surface 7a of the building panel 1.
The outermost end may be a most distal end of the locking strip 15, as seen from the vertical plane. The vertical plane is formed in the assembled state by a locking surface 30 of an upper edge portion 4b, configured to cooperate with a corresponding opposite upper locking surface 45 of the upper edge portion 3b of the adjacent building panel, illustrated as an essentially vertical surface forming the vertical plane. In the non-assembled position as in
The locking element 16 is configured to be received in a locking groove 32 arranged in the edge 2a of an adjacent building panel 1 during the assembly of two building panels 1. The locking element 16 and the locking groove 32 are together configured to lock the adjacent building panels 1 in at least the horizontal direction.
The locking element 16 comprises a locking surface 18 which is configured to cooperate, and preferably be in contact, with a corresponding locking surface 34 arranged in the locking groove 32. The two locking surfaces 18, 34 are together configured to lock the adjacent building panels 1 in at least the horizontal direction. The locking surface 18 of the locking element 16 is arranged with an acute angle α in relation to the plane extending parallel to the front surface 7a of the building panel 1, in the illustrated examples parallel to the horizontal plane. The acute angle α is preferably between 40° and 60°, even more preferably about 50°. The corresponding locking surface 34 in the locking groove 32 is preferably substantially parallel to the locking surface 18 of the locking element 16.
The locking surface 18 of the locking element 16 is located in an upper portion of the locking element 16. It is further arranged to face towards the edge 2b and the rest of the building panel 1. The locking surface 18 of the locking element 16 may extend between an upper surface 19a of the elongated part 19 of the locking strip 15 and an upper surface 20a, preferably an uppermost surface, of the locking element 16.
The locking element 16 further comprises an impact surface 22 which is configured to cooperate with a corresponding impact surface 38 arranged in the locking groove 32. The two impact surfaces 22, 38 are together configured to cooperate with each other, preferably be in contact with each other, and support each other, when a force, acting, at least partially, in a vertical direction, is applied to any one of the building panels 1, in the assembled position.
The force acting, at least partially in the vertical direction, may be a force resulting from a load applied on the building panel 1 in the assembled position. The force may act on the at least one building panel 1 in the assembled position during conventional use, for example when being installed in a room.
The force may be applied on the front surface 6a of at least one the building panels 1, opposite the back surface of at least one of the building panels 1.
The load, and the resulting force, may applied by footsteps, loads from furniture and the like, loads from objects being transported, loads form objects falling on the top surface, etc., on the building panel 1 in the assembled position, for example, when installed to form a flooring in a room. The force may originate from dynamic loads and/or static loads. The force may be such forces conventionally occurring during normal use, for example when installed as a flooring in a room. The force may originate from a permanent or temporary load on the building panel 1 in the assembled position.
Such force and/or load may be referred to as an impact impacting on the mechanical locking devices. Such impact may activate the impact surfaces 22, 38 of the mechanical locking device, such that the impact surfaces 22, 38 cooperate with each other, such as contact each other.
The impact surface 22 and the impact surface 38 may also be referred to as a support surface 22 and a support surface 38, respectively, in the present disclosure.
The impact surface 22 of the locking element 16 is located in a lower portion of the locking element 16. It is further arranged to face away from the edge 2b and the rest of the building panel 1. The impact surface 22 of the locking element 16 may extend between a lower surface 19b of the elongated part 19 of the locking strip 15 and an outer surface 20b, preferably an outermost surface, of the locking element 16 . . . . The impact surface 22 may extend from the outer surface 20b of the locking element 16 in a direction towards the back surface 7b of the building panel 1, and preferably in a direction towards the building panel in which the impact surface 22 is arranged.
The outer surface 20b may be a distal surface of the locking element 16, such as a most distal surface of the locking element 16, as seen from the vertical plane. In the non-assembled position as in
For building panels arranged on a sub-floor, the impact surface 22 of the locking element 16 is arranged to face the sub-floor.
The impact surface 22 of the locking element 16 is arranged with an acute angle β in relation to the plane extending parallel to the front surface 7a of the building panel 1, or to the horizontal plane. The acute angle β is preferably between 40° and 70°. Depending on the thickness of the building panel 1 the acute angle β may vary. In an embodiment, when the building panel has a thickness of between 3 and 4.5 mm the impact surface 22 of the locking element 16 may be arranged at the acute angle β of between 40° and 60° in relation to the horizontal plane. In an alternative embodiment, when the building panel 1 has a thickness of 4.5 mm or more, e.g., 5 mm or 8 mm, the impact surface 22 of the locking element 16 may be arranged at the acute angle β of between 40° and 70° in relation to the horizontal plane.
The impact surface 22 of the locking element 16 is in the illustrated example a continuous surface but may in other embodiments have two or more sections arranged at different angles, see e.g.
The elongated part 19 of the locking strip 15 may be able to flex in a direction perpendicular to the extension of the elongated part 19, or in the vertical direction. A flexible locking strip 15 may be configured to create a pretension in the locking surfaces 18, 34 of the first mechanical locking device 10 such that the edges 2a, 2b of two adjacent building panels 1 are in contact with each other, in the assembled position. The pretension may be created by the two locking surfaces 18, 34 of respective locking element 16 and locking groove 32, which are in the assembled position in contact with each other.
A pretension, in the assembled position, between the two locking surfaces 18, 34 of respective locking element 16 and locking groove 32, may also be created without a flexible locking strip 15, e.g., by having a flexible layer arranged under the building panel during installation.
At an inner portion of the locking strip 15 and above the locking strip 15 there is arranged a tongue groove 24. The tongue groove 24 is configured to cooperate with a locking tongue 40 arranged in the edge 2a of the adjacent building panel 1. The tongue groove 24 and the locking tongue 40 are together configured to lock the adjacent building panels 1 in at least the vertical direction.
The tongue groove 24 comprises an upper surface 25 which is configured to cooperate with a corresponding upper surface 41 of the locking tongue 40. The two upper surfaces 25, 41 are together configured to lock the adjacent building panels 1 in at least the vertical direction.
Arranged above the tongue groove 24 is an upper locking tongue 27. The upper locking tongue 27 is preferably integrally formed in the edge 2b of the building panel 1 and extends out from the edge 2b of the building panel 1. The upper locking tongue 27 is configured and shaped to be received in an upper tongue groove 42 arranged in the edge 2b of the adjacent building panel 1. The upper locking tongue 27 and the upper tongue groove 42 are together configured to lock the adjacent building panels in at least the vertical direction. The upper locking tongue 27 and the upper tongue groove 42 are together further configured to create a tight seal TS such that any liquid, e.g., water, is prevented, or at least obstructed, from penetrating further into the building panel 1. In order to create the desirable tight seal TS it is preferred that the height H1 of the upper locking tongue 27 is greater than, or at least the same as, the height H2 of the upper tongue groove 42. The difference between the height H1 of the upper locking tongue 27 and the height H2 of the upper tongue groove 42 is in the range of 0.01 to 0.2 mm, preferably 0.01 to 0.1 mm, even more preferably 0.01 or 0.05 mm. The height H1 of the upper locking tongue 27 is preferably between 0.2 and 2.0 mm, or between 0.2 and 1.0 mm.
The upper locking tongue 27 comprises an upper surface 28 which is configured to cooperate with an upper surface 43 the upper tongue groove 42. The upper surface 28 of the upper locking tongue 27 and the upper surface 43 of the upper tongue groove 42 are together configured to create the tight seal TS and lock the adjacent building panels 1 at least in the vertical direction.
The upper locking tongue 27 and the corresponding upper tongue groove 42 are optional features, and embodiments without these features are illustrated in
In the upper edge portion 4b, above the upper locking tongue 28, there is provided an upper locking surface 30, illustrated as an essentially vertical surface. The locking surface 30 is configured to cooperate with a corresponding opposite upper locking surface 45, illustrated as an essentially vertical surface, arranged in the upper edge portion 3b of the adjacent building panel 1′. The two locking surfaces 30, 45 are configured to cooperate and preferably be in contact with each other in the assembled position. The upper locking surface 30 of the first building panel 1 and the upper locking surface 45 of the adjacent building panel 1′ are configured to create the seal S, as illustrated in
The essentially vertical surface may form the vertical plane in the assembled position.
The first mechanical locking device 10 in
The locking groove 32 and the locking element 16 are together configured to lock the adjacent building panels 1 in at least the horizontal direction.
The locking groove 32 comprises a locking surface 34 which is configured to cooperate, and preferably be in contact, with the corresponding locking surface 18 of the locking element 16. The two locking surfaces 18, 34 are together configured to lock the adjacent building panels 1 in at least the horizontal direction. The locking surface 34 of the locking groove is preferably essentially parallel to the locking surface 18 of the locking element 16. Thus, the locking surface of the locking groove may be arranged with an acute angle δ in relation to the plane extending parallel to the front surface 7a of the building panel 1, or to the horizontal plane. The acute angle δ is preferably between 40° and 60°, even more preferably about 50°.
The locking surface 34 of the locking groove 32 is located in an upper portion of the locking groove 32. It is further arranged to face in towards the rest of the building panel 1. The locking surface 34 of the locking groove 32 may extend between an upper surface 35 of a lower part of the locking groove 32, which is opposite the upper surface 19a of the elongated part 19 of the locking strip 15 of the adjacent building panel 1 in the assembled position, and an upper surface 36a, preferably an uppermost surface, of an upper part of the locking groove 32, which is opposite the upper surface 20a of the locking element 16 of the adjacent building panel 1 in the assembled position.
The locking groove 32 further comprises an impact surface 38 which is configured to cooperate with the corresponding impact surface 22 of the locking element 16. The two impact surfaces 22, 38 are together configured to cooperate with each other, be in contact with and support each other, when a force, acting, at least partially, in a vertical direction, is applied to any one of the building panels 1, in the assembled position.
The impact surface 38 and the impact surface 22 may be referred to as a support surface 38 and a support surface 22 in the present disclosure.
The impact surface 38 of the locking groove 32 may be parallel to the impact surface 22 of the locking element 16, alternatively the impact surface 38 of the locking groove 32 may be non-parallel to the impact surface 22 of the locking element 16.
The impact surface 38 of the locking groove 32 is located in a lower portion of the locking groove 32. It is further arranged to face away from the rest of the building panel 1. The impact surface 38 may extend from an inner surface 36b, preferably an innermost surface, of the locking groove 32 in a direction towards, and in some embodiments all the way to, the back surface 7b of the building panel 1, and preferably in a direction away from the building panel 1.
The inner surface 36b may be a distal surface of the locking groove 32, such as a most distal surface of the locking grove 32, as seen from the vertical plane. In the non-assembled position as in
The impact surface 38 may be arranged with an acute angle ϕ in relation to the plane extending parallel to the front surface 7a of the building panel 1, or to the horizontal plane. The acute angle ϕ is preferably between 40° and 70°. Depending on the thickness of the building panel 1 the acute angle ϕ may vary. In an embodiment, when the building panel has a thickness of between 3 and 4.5 mm the impact surface 38 of the locking groove 32 may be arranged at the acute angle β of between 40° and 60° in relation to the horizontal plane. In an alternative embodiment, when the building panel 1 has a thickness of 4.5 mm or more, e.g., 5 mm or 8 mm, the impact surface 38 of the locking groove 32 may be arranged at the acute angle ϕ of between 40° and 70° in relation to the horizontal plane.
The impact surface 38 of the locking groove 32 is in the illustrated example a continuous surface but may in other embodiments, see e.g.,
At a lowermost end of the impact surface 38 of the locking groove 32 there may be provided a chamfer 39, preferably a vertical chamfer, extending from the impact surface 38 to the back surface 7b of the building panel 1. This chamfer 39 is an optional feature but may be beneficial to have for installation properties. For example, if it is desirable to design the impact surfaces 38 with an acute angle β, ϕ of between 40° and 45° and parallel to each other, it may be beneficial to remove material, shorten the impact surface 38 of the locking groove 32, and have the chamfer 39 in order to decrease the risk that the features of the first mechanical locking device 10 arranged in the first or third edge 2a, 2c to abut features of the first mechanical locking device 10 arranged in the second or fourth edge 2b respectively during the assembly of building panels 1. The height H3 of the chamfer 39 may vary depending on the acute angle β, ϕ, the thickness of the building panel 1 and possibly other features of the first mechanical locking device 10, see e.g.,
Opposite the locking groove 32, in the horizontal direction, a locking tongue 40 is arranged, which is preferably integrally formed in the edge 2a of the building panel 1 and which extends out from the edge 2a. The locking tongue 40 is configured and designed to be received in the tongue groove 24 arranged in the edge 2b of the adjacent building panel 1. The tongue groove 24 and the locking tongue 40 are together configured to lock the adjacent building panels 1 in at least the vertical direction.
The locking tongue 40 comprises an upper surface 41 which is configured to cooperate with the corresponding upper surface 25 of the tongue groove 24. The two upper surfaces 25, 40 are together configured to lock the adjacent building panels 1 in at least the vertical direction.
Arranged above the locking tongue 40 is an upper tongue groove 42. The upper tongue groove 42 extends into the edge 2a of the building panel, preferably as a continuation of the upper surface 40 of the locking tongue 40. The tongue groove 42 is configured to receive the upper locking tongue 27 arranged in the edge 2b of the adjacent building panel 1. The upper tongue groove 42 and the upper locking tongue 27 are together configured to lock the adjacent building panels in at least the vertical direction. The upper tongue groove 42 and the upper locking tongue 27 are together further configured to create the tight seal TS such that any liquid, e.g., water, is prevented, or at least obstructed, from penetrating further into the building panel 1. In order to create the desirable tight seal TS it is preferred that the height H1 of the upper locking tongue 27 is greater than, or at least the same as, the height H2 of the upper tongue groove 42. The difference between the height H1 of the upper locking tongue 27 and the height H2 of the upper tongue groove 42 is in the range of 0.01 to 0.2 mm, preferably 0.01 to 0.1 mm, even more preferably 0.01 or 0.05 mm.
The upper tongue groove 42 comprises an upper surface 43 which is configured to cooperate with the upper surface 28 of the upper locking tongue 27. The upper surface 43 of the upper tongue groove 42 and the upper surface 28 of the upper locking tongue 27 are together configured to create the tight seal TS and lock the adjacent building panels 1 at least in the vertical direction.
The upper locking tongue 27 and the corresponding upper tongue groove 42 are optional features, and embodiments without these features are illustrated in
In the upper edge portion 3b, above the upper tongue groove 42, there is provided an essentially upper locking surface 45. The locking surface 45 is configured to cooperate with the corresponding opposite essentially upper locking surface 30 arranged in the upper edge portion 4b of the adjacent building panel 1. The two locking surfaces 30, 45 are configured to cooperate and preferably be in contact with each other in the assembled position. The upper locking surface 30 of the first building panel 1 and the upper locking surface 45 of the adjacent building panel 1′ are configured to create the seal S, as illustrated in
As seen in
In the assembled position the locking element 16 of the second building panel 1′ is arranged in the locking groove 32 of the first building panel 1. The locking strip 15 of the second building panel 1′ extends below the first edge 2a of the first building panel 1, more specifically, the elongated part 19 of the locking strip 15 is arranged below a portion of the first edge 2a between the locking tongue 40 and the locking groove 32.
Further, the locking tongue 40 of the first building panel 1 is arranged in the tongue groove 24 of the second building panel 1′ and the upper locking tongue 27 of the second building panel 1 is arranged in the upper tongue groove 42.
The two adjacent building panels 1, 1′ are in the assembled position locked in both the vertical direction, by means of at least the locking tongue 40 in the tongue groove 24 and the upper locking tongue 27 in the upper tongue groove 42, and in the horizontal direction, by means of the at least the locking element 16 in the locking groove 32. Further, the two adjacent building panel 1, 1′ are, in the assembled position, arranged such that the two essentially upper locking surfaces 30, 45 of respective building panel 1, 1′, cooperate and create a seal S in the upper edge portions 4b, 3b of the building panels 1, 1′. Yet further, the upper locking tongue 27 and the upper tongue groove 42 are, in the assembled position, are configured to create the tight seal TS between respective upper surface 28, 43.
The seal S may extend in the vertical plane.
Taking a closer look at the locking element 16 arranged in the locking groove 32, this embodiment comprises locking surfaces 18, 34 of respective locking element 16 and locking groove 32, that are essentially parallel to each other. In alternative embodiments (not shown) the two locking surfaces may be non-parallel to each other.
As described above, the locking surface 18 of the locking element 16, and preferably also the locking surface 34 of the locking groove 32, are arranged with the acute angles α, δ in relation to the horizontal plane. The acute angles α, δ are preferably between 40° and 60°, even more preferably about 50°.
The impact surfaces 22, 38 of respective locking element 16 and locking groove 32, are essentially parallel to each other in this embodiment. In alternative embodiments, see
As described above, the impact surface 22 of the locking element 16, and preferably also the impact surface 38 of the locking groove 32, are arranged with the acute angles β, ϕ in relation to the horizontal plane. The acute angles β, ϕ are preferably between 40° and 70°. Depending on the thickness of the building panel 1 the acute angles β, ϕ may vary. In an embodiment, when the building panel has a thickness of between 3 and 4.5 mm the impact surface 22 of the locking element 16 may be arranged at the acute angle β of between 40° and 60° in relation to the horizontal plane. In an alternative embodiment, when the building panel 1 has a thickness of 4.5 mm or more, e.g., 5 mm or 8 mm, the impact surface 22 of the locking element 16 may be arranged at the acute angle β of between 40° and 70° in relation to the horizontal plane. In an embodiment, when the building panel has a thickness of between 3 and 4.5 mm the impact surface 38 of the locking groove 32 may be arranged at the acute angle ϕ of between 40° and 60° in relation to the horizontal plane. In an alternative embodiment, when the building panel 1 has a thickness of 4.5 mm or more, e.g., 5 mm or 8 mm, the impact surface 38 of the locking groove 32 may be arranged at the acute angle ϕ of between 40° and 70° in relation to the horizontal plane. The impact surface 38 of the locking groove 32 may or may not be parallel to the impact surface 22 of the locking element 16.
Further, there may be a play P1 arranged between the impact surface 22 of the locking element 16 and the impact surface 38 of the locking groove 32 in the assembled position. The play P1 may be between 0 mm and 0.2 mm or between 0.02 and 0.1 mm, or about 0.05 mm.
The play P1 arranged between the impact surface 22 of the locking element 16 and the impact surface 38 of the locking groove 32 may be present in the assembled position at least when no force, acting at least partially, in the vertical direction, applied to at least one of the building panels. The play P1 is measured in the assembled position, when the upper vertical surfaces 30, 45 are in contact. The play P1 may be measured by a feeler gauge.
The building panels may be configured to have the play P1 in an assembled position, prior to application of a force, acting, at least partially, in a vertical direction, is applied to at least one of the building panels 1, 1′, 1″. Thereafter, the force may reduce the play P1 and cause the impact surface 38 of the locking groove 32 to cooperate with the impact surface 22 of the locking element 16.
In one example, as illustrated in
In an embodiment, the play P1 is present, while the second play P2 is not present. In an embodiment, the second play P2 is present, while the play P1 is not present. In another embodiment, both the play P1 and the second play P2 are present.
As explained above the building panel in
Whereas
In the first illustration,
In the first illustration,
In the second illustration,
Further, the first mechanical locking device 10 illustrated in
Yet two other possible embodiments are illustrated in
In order to facilitate pushing down the locking strip 15 the locking element 16 includes a tilted guiding surface 17 arranged in a front portion of the locking element 16. The guiding surface 17 of the locking element 16 is configured to cooperate with a corresponding guiding surface 34 arranged in the lower edge portion, below the locking tongue 40, of the first edge 2a of the building panel 1 being assembled. The two guiding surfaces 17, 34 are configured to guide the locking element 16 and in turn the locking strip 15 downwards when they are in contact with each other, i.e., in the moment after
In order to facilitate the right position of the building panel 1 being assembled there is provided corresponding upper guiding surfaces 26, 44. The first upper guiding surface 26 is arranged in the upper portion of the tongue groove 24 and may preferably extend between the upper surface 25 of the tongue groove 24 and the upper locking surface 30. The second upper guiding surface 44 is arranged in the upper portion of the locking tongue 40 and may preferably extend between the upper surface 41 of the locking tongue 40 and the frontmost surface of the locking tongue 40. The two guiding surfaces 26, 44 are configured to guiding the locking tongue 40 into the correct position in the tongue groove 24 and in turn guide the edge 2a of the building panel 1 being assembled into the right position in relation to the edge 2b of the adjacent building panel 1′. As the locking tongue 40 is guided into the tongue groove 24 the locking strip 15 is pushed further down, see
Further, in the embodiment shown in
The mechanical locking device 10 illustrated in
The second mechanical locking device 10′ is configured to be assembled preferably by the vertical assembly, as illustrated in
Vertical assembly may include displacement of the first building panel 1 in an essentially vertical direction.
The second mechanical locking device 10′ comprises a locking strip 50, preferably integrally formed in the fourth edge 2d of the building panel 1′. The locking strip 50 is arranged in a lower edge portion 6a of the edge 2d, projecting outwards from the lower edge portion 6a in a direction substantially parallel to the front surface 7a of the building panel 1.
The locking strip 50 has an elongated shape and includes, at the outermost end of the locking strip 50, a locking element 51. The locking element 51 extends in a direction perpendicular to the extension of the locking strip 50, at least partially in a direction towards the front surface 7a of the building panel 1.
The outermost end may be a most distal end of the locking strip 50, as seen from the vertical plane. The vertical plane is formed in the assembled state by a locking surface 80 of an upper edge portion 5b, configured to cooperate with a corresponding opposite upper locking surface 64 of the upper edge portion 6b of the adjacent building panel, illustrated as an essentially vertical surface forming the vertical plane. In the non-assembled position as in
The locking element 51 is configured to be received in a locking groove 67 arranged in the third edge 2c of an adjacent building panel 1, during the assembly of two building panels 1, 1′. The locking element 51 and the locking groove 67 are together configured to lock the adjacent building panels 1 in at least the horizontal direction, but preferably in both the horizontal and vertical direction.
The locking element 51 comprises a locking surface 53 which is configured to cooperate, and preferably be in contact, with a corresponding locking surface 69 arranged in the locking groove 67. The two locking surfaces 53, 69 are together configured to lock the adjacent building panels 1, 1′ in at least the horizontal direction. The locking surface 53 of the locking element 51 is arranged with an angle θ in relation to the plane extending parallel to the front surface 7a of the building panel 1, in the illustrated examples parallel to the horizontal plane. The angle θ may be between 60° and 90°, between about 70° and 90°, or about 80°. The corresponding locking surface 69 in the locking groove 67 is preferably substantially parallel to the locking surface 53 of the locking element 51.
The locking surface 53 of the locking element 51 is located in an upper portion of the locking element 51. It is further arranged to face towards the edge 2d and the rest of the building panel 1′. The locking surface 53 of the locking element 51 may extend between an upper surface 54a of an elongated part 54 of the locking strip 50 and an upper surface 55, preferably an uppermost surface, of the locking element 51.
The elongated part 54 of the locking strip 50 may be able to flex in a direction perpendicular to the extension of the elongated part 54, or in the vertical direction. A flexible locking strip 50 may be configured to create a pretension in the locking surfaces 53, 69 of the second mechanical locking device 10′ such that the edges 2c, 2d of two adjacent building panels 1, 1′ are in contact with each other, in the assembled position. The pretension may be created by the two locking surfaces 53, 69 of respective locking element 51 and locking groove 67, which are in the assembled position in contact with each other.
A pretension, in the assembled position, between the two locking surfaces 53, 69 of respective locking element 51 and locking groove 67, may also be created without a flexible locking strip 50, e.g., by having a flexible layer arranged under the building panel during installation.
At an inner portion of the locking strip 50 and above the locking strip 50 there is arranged a displaceable tongue groove 57. The displaceable tongue groove 57 is configured to receive a displaceable locking tongue 59. The displaceable locking tongue 59 is in turn configured to cooperate with a tongue groove 70, arranged in the edge 2c of the building panel 1 being installed. The displaceable locking tongue 59 is also configured to at least partly be received in the tongue groove 70. The displaceable tongue groove 57, the displaceable locking tongue 59 and the tongue groove 70 are configured to together lock the assembled building panels 1, 1′ in at least the vertical direction.
An embodiment of a suitable displaceable locking tongue is illustrated in
In the resting position, as illustrated in
Before assembling the adjacent building panels 1, 1′, 1″ the displaceable locking tongue 59 is arranged in the displaceable tongue groove 57 in the fourth edge 2d, with its bendable parts 84 facing into the displaceable tongue groove 57 and the longitudinal base portion 82 arranged just outside the displaceable tongue groove 57, facing the building panel 1 to be assembled, see
The second mechanical locking device 10′ comprises, arranged in the third edge 2c, the locking groove 67 which is configured to receive the locking strip 50 with the locking element 51 of the adjacent building panel 1′, as described above. The locking groove 67 is arranged in a lower edge portion 5a of the edge 2c, extending inwards, in a direction substantially parallel to the front surface 7a of the building panel 1, into the building panel 1. The locking groove 67 further extends, at an innermost end of the locking groove 67, up towards the front surface 7a of the building panel 1, in which space the locking element 51 is to be received.
The locking groove 67 and the locking element 51 are together configured to lock the adjacent building panels 1, 1′, 1″ in at least the horizontal direction.
The locking groove 67 comprises a locking surface 69 which is configured to cooperate, and preferably be in contact, with the corresponding locking surface 53 of the locking element 51. The two locking surfaces 53, 69 are, as described above, together configured to lock the adjacent building panels 1, 1′, 1″ in at least the horizontal direction. The locking surface 69 of the locking groove 67 is preferably essentially parallel to the locking surface 53 of the locking element 51.
The locking surface 69 of the locking groove 67 is located in an upper portion of the locking groove 67. It is further arranged to face in towards the rest of the building panel 1. The locking surface 69 of the locking groove 67 may extend between an upper surface 67a of a lower part of the locking groove 67, which is opposite the upper surface 54a of the elongated part 54 of the locking strip 50 of the adjacent building panel 1′ in the assembled position, and an upper surface 67b, preferably an uppermost surface, of an upper part of the locking groove 67, which is opposite the upper surface 55 of the locking element 51 of the adjacent building panel 1′ in the assembled position.
The embodiment of the second mechanical locking device 10′ illustrated in
The ledge 61 and the protruding upper part 72 are optional features.
Instead of an arrangement with a displaceable locking tongue, as illustrated in
The first chamfer 75 is arranged in an outer surface, preferably an outermost surface of the upper edge portion 6b of the edge 2d in which the first chamfer 75 is provided. The tilted surface of the first locking chamfer 75 is preferably tilted down and in towards the rest of the building panel 1′.
The second chamfer 76 is arranged in an outer surface, preferably and outermost surface, of the upper edge portion 5b of the edge 2c in which the second chamfer 76 is provided, or even arranged in an outermost surface of the edge 2c in which it is provided. The tilted surface of the second locking chamfer 76 is preferably tilted down and out from the rest of the building panel 1.
The two locking chamfers 75, 76 are configured to cooperate in the assembled position between the two adjacent building panels 1, 1′, and preferably also be in contact with each other during the assembled position in order to create a tight locking of the two adjacent building panels 1, 1′.
In the embodiment illustrated in
Further, the locking surface 53 of the locking element 51, which is configured to cooperate, and preferably be in contact, with the corresponding locking surface 69 arranged in the locking groove 67 are arranged at a different angle compared to previously described embodiments. The locking surface 53 of the locking element 51 is arranged with an angle θ in relation to the plane extending parallel to the front surface 7a of the building panel 1, in the illustrated examples parallel to the horizontal plane. The angle θ may be between 90° and 105° or between about 90° and 100°. The corresponding locking surface 69 in the locking groove 67 is preferably substantially parallel to the locking surface 53 of the locking element 51.
The two locking surfaces 53, 69 are together configured to lock the adjacent building panels 1, 1′ in at least the horizontal direction.
In order to facilitate the assembly of such mechanical locking device 10′ it may be preferred that the elongated part 54 of the locking strip 50 is able to flex in a direction perpendicular to the extension of the elongated part 54, or in the vertical direction. A flexible locking strip 50 facilitates the assembly as the building panel 1 is pushed down in the vertical direction once the building panel 1 being assembled reaches the position illustrated in
The embodiment of the second mechanical locking device 10′ illustrated in
The ledge 61 and the protruding upper part 72 are optional features.
In the following examples tests have been made to establish the technical effect of the presence and cooperation of the impact surface in the locking element and the corresponding impact surface of the locking groove.
The building panels are manufactured from a SPC panel with a PVC-base. The building panels further have a 0.2 mm wear layer. For the tested building panels the modulus of elasticity is about 7000 MPa, and the density is about 2000 kg/m3.
In Test 1, two building panels 1, 1′ having a polymer-based substrate, such as a thermoplastic-based substrate, were assembled by means of a mechanical locking device 10 as described above. Subsequently a pressure F was applied, close to the mechanical locking device 10, to one of the building panels. See
For reference, two assembled building panels, having a polymer-based substrate, such as a thermoplastic-based substrate, with a mechanical locking device having no impact surfaces on respective locking element and locking groove, were tested with the above method. A reference was made for each building panel thickness.
Test 1 was then performed on two assembled building panels of the same material composition as the reference, i.e., having a polymer-based substrate, such as a thermoplastic-based substrate, having different thicknesses. The building panels had a mechanical locking device with impact surfaces on respective locking element and locking groove, tested with varying angles β, ϕ, according to the present inventive concept. Some tests were performed on building panels having a mechanical locking device including upper locking tongue and upper tongue groove. The results were compared to the relevant reference which are presented in the Table 1-5. In the tables below the specimens with the impact surfaces are named IS.
The thicknesses tested are 3.5 mm (see Table 1 and 2), 5.0 mm (see Table 3), 7.0 mm (see Table 4) and 8.0 mm (see Table 5).
The reference specimens for every thickness are provided with locking surfaces, α, δ, arranged at 65°. The IS specimens for every thickness are provided with locking surfaces, α, δ, arranged at 50°. Having the locking surfaces arranged at 50° enables a variety of angles, β, ϕ, at which the impact surfaces are arranged, especially when it comes to enabling the assembly of two adjacent building panels.
Conclusion: For building panels having a thickness of 3.5 mm, Test 1a shows that the maximum load capacity of the mechanical locking device, in the vertical direction, increases, or at least are about the same, compared to the reference, when the mechanical locking device comprises impact surfaces of the locking element respective locking groove, arranged with an angle β, ϕ below 60°.
For building panels having a thickness of 3.5 mm, Test 1b shows that the maximum load capacity of the mechanical locking device, in the vertical direction, increases when the mechanical locking device comprises impact surfaces of the locking element respective locking groove, compared to the reference with no impact surfaces.
For building panels having a thickness of 5 mm, Test 1c shows that the maximum load capacity of the mechanical locking device, in the vertical direction, increases when the mechanical locking device comprises impact surfaces of the locking element respective locking groove, compared to the reference with no impact surfaces. Here the angle β, ϕ with which the impact surfaces are arranged matter less than when the building panel has a inner thickness, e.g., 3.5 mm.
For building panels having a thickness of 7 mm, Test 1d shows that the maximum load capacity of the mechanical locking device, in the vertical direction, increases compared to the reference.
For building panels having a thickness of 8 mm, Test 1e shows that the maximum load capacity of the mechanical locking device, in the vertical direction, increases compared to the reference.
In Test 2, several building panels were assembled together by means of mechanical locking devices. Subsequently a Castor Chair test according to ISO 4918:2016 with wheel type W, EN 425:2002, and a foam Dongguan Hongzhida 0610 was performed on the assembled building panels.
Test 2 were performed on building panels having a polymer-based substrate, such as a thermoplastic-based substrate and a thickness of 4.5 mm. Each building panel is provided with a first mechanical locking device along its long sides, i.e., the first edge and second edge, and a second mechanical locking device along its short sides, i.e., the third and fourth edge. The first mechanical locking device corresponds to the embodiment illustrated in
The Castor Chair test ran either until the layers of the building panels delaminated, until a gap between the edges of two adjacent building panels exceeded a predetermined value, e.g., at least 0.2 mm, or until it reached the maximum revolutions of 25000 revs.
The set of building panels were, after the Castor Chair test, examined in order to detect gaps between the building panels or cracks in the building panels. The results of Test 2 are presented in Table 6 below and in
Conclusion: Test 2 shows great improvements of the set of building panels when the mechanical locking device comprises the impact surfaces of the locking element respective locking groove, arranged at an angle β, ϕ of 50°, i.e., specimens 2a and 2b. As can be seen in Table 6, the value of maximum applied revolutions increased, from 16687 revs. to at least 25000 revs, compared to the Reference, see specimen IS 2b. Further, there were no visual gaps between the building panels of specimen IS 2b, compared to the Reference which had gaps of 0.3 mm between the short sides of the building panels. Yet further, the total length of cracks in the specimen IS 2b was less than the Reference even if it was exposed to more than 8000 revs. more than the Reference. This means that the total length of cracks in the specimen, having a first mechanical locking devices with impact surfaces, were about 23% less even if that mechanical locking device was exposed of more than 8000 revs. more than the mechanical locking device without impact surfaces.
Further, looking at the specimen IS 2a, which was stopped at the same revolution as the Reference performed, we can clearly see the improvement. There was no visible gap between the building panels of specimen IS 2a, compared to the Reference which had gaps of 0.3 mm between the short sides of the building panels. Further, the total length of cracks in the specimen IS 2a was significantly less than the Reference as the total length of the cracks in specimen IS 2a was 320 mm, compared to the total length of cracks in the Reference which was 800 mm. This means that the total length of cracks in the specimen, having a first mechanical locking devices with impact surfaces, were about 150% less compared to the mechanical locking device without impact surfaces.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2351187-6 | Oct 2023 | SE | national |
| 2351308-8 | Nov 2023 | SE | national |
| 2351376-5 | Nov 2023 | SE | national |
