This application is the national stage entry of PCT/EP2006/063154 filed Jun. 13, 2006.
The present invention relates in general to surface covering panels. It relates more particularly to “floating” flooring systems and in particular panels, commonly known as strips or boards, for producing such flooring systems.
Floating flooring systems have been increasing considerably in popularity in recent years. Unlike nailed or glued flooring systems, the laying of which is difficult and has to be left to specialists, a particular advantage of floating flooring systems is their ease of installation (on an existing floor covering of the carpet, ceramic tile or vinyl type or directly onto a stone floor).
As is known, flooring strips are conventionally provided on their edges with tongue and groove coupling elements which are intended to join two adjacent strips together by interlocking during assembly of the flooring system.
Among the various systems which have been proposed for interlocking flooring strips intended for the production of floating flooring, those which have met with the greatest success among consumers and have consequently become so prevalent that they will doubtless shortly displace all other systems, are those known as “angular interlocking” systems. In these angular interlocking systems, two flooring strips are joined together by engaging the strip to be assembled at a certain angle (generally 45°) relative to the strip which has already been laid and then imparting to this strip a rotational movement having an axis which approximately coincides with the edges, which are in contact, of the tops of the strips, to bring it into the assembly plane.
Such a system is described, for example, in U.S. Pat. No. 4,426,820 granted to Heinz Terbrack. The flooring strips are rectangular in shape and are designed to be assembled by interlocking their opposing lengthwise edges. In order to do this, one edge is provided with a first coupling element comprising a groove and the other with a second coupling element comprising a tongue which is intended to cooperate with the first coupling element of an identical flooring strip. Mechanical locking means are incorporated into said coupling elements so as, when two flooring strips are mated in the assembly plane, to prevent these flooring strips from moving apart from one another in a direction perpendicular to that of said edges and parallel to the assembly plane. According to the coupling profile presented in U.S. Pat. No. 4,426,820, the groove of the first coupling element is defined by an upper lip and a lower lip. The lower lip extends beyond the upper lip and comprises a projecting locking element. The second coupling means comprises, in addition to the tongue which engages in the groove of the first coupling means, a locking channel which cooperates with the projecting locking element in order to immobilise the strip in the transverse direction.
Many improvements have since been suggested by manufacturers, the most useful of which is commonly known as the “click” system. The “click” system describes partial immobilisation of the strips relative to one another after assembly which is intended to hold them firmly together by preventing rotation in the uncoupling direction: if an attempt is made to detach the most recently inserted strip, it will only be detached if a certain force is applied. This partial locking has 2 advantages:
This partial immobilisation effect is achieved by generating friction, and more specifically by exploiting the elasticity of the material at the end of rotation during assembly of the boards.
Such a click system is described, for example, in patent EP 1 026 341 B1 held by UNILIN. In this system, the coupling elements are equipped with means which, once inserted into one another in two adjacent flooring strips, exert a mutual tension force which forces the strips towards one another. This is achieved by a particular configuration of the locking channel and the locking projection, which, in the assembled state, brings about an elastic deformation of the lower lip of the first coupling element and so generates the desired tension force.
Thus, in known systems, the “click” effect is typically the result of loading the intrinsic elasticity of the constituent materials of the strips. Furthermore, the forces in play during the click action will place a greater or lesser load on the strip at the point where it is generally at its thinnest.
Finally, it should be noted, and this is quite obvious from the interest aroused by this system, that this effect is all the more worthwhile the more marked it is.
It may therefore readily be understood that, in the case of thin products, for example of the HDF type, it becomes tricky to reconcile the strength of the material with the intensity of the “click” effect. This is because, for such materials, the thickness of the strip may be less than one mm.
There is accordingly a need for flooring strips of the angular interlocking type which have a “click” effect which makes it possible to verify that the strips are firmly joined together during laying of flooring but which does not involve a risk of damaging the flooring strips.
According to the invention, this aim is achieved by a panel according to claim 1.
The panel according to the present invention makes use of coupling elements designed for angular interlocking essentially without elastic deformation which are comparable in this respect to those of the conventional Terbrack system. According to one important aspect of the invention, at least one of the coupling elements is provided with a repositionable adhesive in order to fasten together two identical panels joined by their respective coupling means. In this manner, angular interlocking with a “click” effect is obtained essentially without elastic deformation of the coupling elements and the panels, so enabling assembly/disassembly of the panels without jeopardising their integrity.
The term repositionable adhesive conventionally denotes adhesives having an adhesive strength, generally known as stickiness or tack, which is sufficient for immediate adhesion on loading. Such adhesives allow the bond to be made and broken many times, normally without any reduction in tack. A repositionable adhesive exhibits tack which is generally weaker than that of permanent glues and no increase in adhesive strength occurs after contact.
On interlocking, the repositionable adhesive makes it possible to fasten the panels together immediately, i.e. to immobilise them one relative to the other. The fact that the panels become fastened together is an indicator for the user of proper interlocking; the assembly may then be handled without risk of separation. If the user wishes to separate the assembled panels, he/she will have to overcome the adhesive strength of the glue. In practice, the user will feel a resistance to separation of the panels reminiscent of that of “click” systems involving elastic deformation.
The present invention accordingly relates to a panel for covering surfaces, the coupling elements of which are designed to enable use similar to known “click” systems. However, the panel according to the present invention is provided with a “chemical click” system which, unlike known “mechanical click” systems, is not based on elastic deformation of the coupling elements, but instead on locking (immobilisation of the respective coupling means one relative to the other) due to the physico-chemical properties of the materials in contact.
According to a preferred embodiment, the first coupling means comprises an upper lip and a lower lip defining the groove, the lower lip extending beyond the upper lip. Furthermore, the mechanical locking means comprise:
a projecting locking element towards the top of the lower lip, the locking element having a first locking surface; and
a second locking surface on the second coupling means, which surface is capable of cooperating with the first locking surface of a similar panel to prevent displacement perpendicular to the edges and parallel to the assembly plane.
In this variant, the locking element is preferably located on the lower lip beyond said upper lip in the direction perpendicular to the edge. The second locking surface is then defined by a locking channel in the second coupling means, behind the tongue.
The first locking surface, preferably planar, may have a locking angle of between 35 and 70° relative to the horizontal. The larger the angle, the better the transverse immobilisation.
Typically, for angular interlocking, the coupling means are designed such that the tongue of a first panel may be inserted, with a certain inclination, into the groove of a second panel, and that the stop of the second panel may be inserted into the locking channel of the first panel by a relative rotational movement between these panels about an axis of rotation corresponding to the tops of the edges in contact. Advantageously, the repositionable adhesive is provided on surfaces of the coupling means which are only placed under load at the end of the rotation during assembly, so immediately fastening the strips together and not hindering interlocking.
In order to disassemble two adjacent panels, the adhesive strength of the repositionable adhesive will have to be overcome. In the present document, “uncoupling moment” describes the moment which has to be overcome to initiate rotation of a panel in the disassembly direction. Preferably, this disassembly moment is of the order of 3 to 9 N·m/m, more preferably approximately 6 N·m/m. These values are of the order of magnitude of those observed with the “mechanical click” systems.
The “click” effect of the panels according to the invention may be adjusted in various ways. In particular, it is possible to act on the following parameters: tack of the adhesive; geometry/profile of the coupling means; shape of the adhesive deposit; number and position of adhesive deposits.
Tack is a function of the repositionable adhesive (glue) selected. In the light of the desired disassembly moment, repositionable adhesives with a predetermined tack of between 0.05 and 0.30 N/mm2, more preferably of the order of 0.15 N/mm2, are typically used. It goes without saying that tack here means the tack of the adhesive towards the panel which will come into contact with the adhesive during assembly and not the adhesive strength of the adhesive relative to the surface of the coupling means onto which it has been applied.
The repositionable adhesive selected preferably exhibits excellent adhesion to material constituting the panel (typically HDF, MDF or wood for producing flooring) during processing and thereafter retains a level of tack which will enable it to adhere partially to these same materials or to other materials of the polymer type (tack always remaining lower than adhesion during processing). The repositionable adhesive must, of course, exhibit immediate adhesion when placed under load and allow a large number of assembly/disassembly operations. A variety of repositionable glues is available and a selection may appropriately be made on the basis of the materials, the desired tack, the method of application, etc.
Hot-melt glues are particularly preferred, in particular due to their ease of processing. Application will be in the form of beads at desired points on the coupling means. Preferably, hot-melt glues will be selected which allow the formation, after cooling, of beads which exhibit hardness (and cohesion) sufficient to prevent the glue from flowing towards the other panel on disassembly.
Advantageously, the repositionable adhesive is provided on surfaces of the coupling means which are only placed under load at the end of interlocking (end of rotation) during assembly, so immediately fastening the panels together and not hindering interlocking.
Furthermore, the repositionable adhesive may be positioned on facing surfaces of the coupling means which are not in contact when the panel is coupled to an identical panel. It will therefore advantageously be possible to provide beads of glue on non-functional surfaces (which have neither an alignment nor locking function) of the coupling means, such as for example at the level of assembly clearances.
Such an assembly clearance is typically present behind the locking element which comprises surfaces facing the locking channel which are slightly spaced apart. These surfaces are not normally in contact with other surfaces during interlocking. The rear surface of this locking channel, which differs from the second locking surface, is therefore advantageously provided with one or more deposits of repositionable adhesive.
Positioning of the adhesive on the second coupling means, and in particular in the locking channel, enables restricted exposure of the adhesive deposits and so avoids degradation thereof (dust or other).
In order to prevent moisture rising up from beneath the panels, a deposit of repositionable adhesive will advantageously be provided in a lower part of the second coupling means. Such a deposit may also be provided in the upper part of the coupling means to prevent penetration of moisture from the upper face of the panels.
As indicated, the geometry of the profile has an influence on the click effect. In this context, it will be noted that a maximum disassembly moment may be obtained when the adhesive adheres to a surface of the locking element which is in a plane passing through the axis of rotation on decoupling. In general, the surfaces of the coupling means provided with a deposit of repositionable adhesive or which come into contact with the adhesive in the assembled state are preferably planar.
It will be noted that the adhesive deposits are preferably provided directly on the material constituting the panels, for example HDF or MDF, and that these deposit
It will also be noted that the surfaces of the coupling means which will come into contact with an adhesive deposit may be made from a material which differs from that of the remainder of the coupling means. These surfaces could, for example, be covered with a polymer. This may make it possible to avoid any accumulation of particles from the material constituting the panel on the adhesive on disassembly.
The panel according to the invention has been particularly developed for covering floors and in particular for producing flooring. It may therefore have the conventional shape (rectangular or square) of a flooring strip. Conventionally, the first coupling means will therefore be provided on a small and a large side, and the second coupling means will be provided on the other small and large sides. The deposits of repositionable adhesive are then advantageously provided on the coupling means of the small and large sides.
Depending on the particular application, the shape of the panels and the number of edges may vary (e.g. polygonal shape), and the coupling means will be distributed appropriately.
The panel according to the invention may be manufactured straightforwardly using conventional methods, whether from solid wood, laminate or multilayer material. The repositionable hot-melt glue may, for example, readily be applied by guns at the predefined points on the coupling means once the latter have been machined.
However, the panel according to the invention may be used for covering surfaces other than floors, such as walls or ceilings. The panels may therefore be made from various materials depending on the application.
In this context, it will be appreciated that the panel according to the invention makes it possible to achieve a “click” effect even with materials which, unlike wood, HDF or chipboard, do not have any real elasticity. Such materials, which may for certain applications prove to be serious competitors to HDF, are for example fibre cements or certain highly filled resins which can readily be machined (in order to produce an angular interlocking profile) but have no elasticity.
In many applications, the panel according to the invention may have a multilayer structure, generally of the type: upper layer/support layer/backing (if necessary). For flooring, the upper layer may be of solid wood glued onto the support or made from a melamine-impregnated decorative sheet (imitating wood or other materials such as stone, ceramics, etc.). The support layer may be a particle board (MDF, HDF, chipboard), or made from wooden battens. Depending on the application, the upper layer may be of ceramics or polymer. Furthermore, as mentioned above, the support may be of fibre cement or resin, or other readily machinable materials.
Other details and characteristics of the invention will emerge from the detailed description of an advantageous embodiment given below by way of illustration with reference to the appended drawings, in which:
The first coupling means 20 comprises a groove 24 and the second coupling means 22 is provided with a tongue 26. Conventionally, these coupling means 20 and 22 are designed so as to be able to cooperate together for assembling the panel 10 with other panels of this type.
The groove 24 of the first coupling means is defined by an upper lip 28 and a lower lip 30 which extends beyond the upper lip 28 in the direction perpendicular to the edge 16.
Mechanical locking means are incorporated into the coupling means 20 and 22, such that, when the panel 10 is coupled to another identical panel in the assembly plane, these locking means prevent the two panels from moving apart from one another in a direction perpendicular to that of the edges 16, 18 and parallel to the assembly plane. In the present variant, the locking means comprise a locking element or stop 32 projecting upwards on the lower lip 30, said stop 32 defining a first locking surface 34. The locking means furthermore comprise a locking channel 36 in the second coupling means 22, which channel comprises a second locking surface 38. As for the tongue 26 and the groove 24, the stop 32 and the channel 36 preferably extend over the entire length of the edges.
As shown in the figures, the stop 32 is located on the upper side of the lower lip 30, beyond the upper lip 28 and therefore outside the groove 24. The channel 36, on the other hand, faces downwards and is located behind the tongue 26. The stop 30 and channel 36 are designed such that, when coupled (
The coupling means are therefore designed so as to enable angular interlocking. Interlocking of two identical panels is shown in the
According to one important aspect of the present panel 10, the coupling means are advantageously designed such that during coupling and then once two adjacent panels are joined by their respective coupling means, there is essentially no elastic deformation.
Another important aspect is the presence of one or more deposits of repositionable adhesive on a surface portion of at least one of the coupling means 20 and 22. This enables immediate adhesion between the edges of two adjacent panels during assembly and so allows handling of the panels without their decoupling; however, the repositionable nature of the adhesive permits subsequent separation (decoupling) of two adjacent panels by applying a certain force. The panel according to the invention is therefore provided with a “chemical click” system obtained by this repositionable adhesive, which provides the same convenience of use as known “mechanical click” systems, while not giving rise to elastic deformation of the coupling means.
A repositionable adhesive (glue) is advantageously used which exhibits excellent adhesion to the material constituting the strip (generally HDF, MDF or wood) during processing thereof and which subsequently retains a residual adhesive power (tack) which will enable it to adhere partially to these same materials or to other materials of the polymer type, this residual bonding power always being lower than the adhesion during processing). This type of glue is sometimes known as “residual tack glue” or tacky adhesive. A variety of repositionable glues is available and selection may conveniently be made on the basis of the materials, the desired tack, application method, etc.
In the present variant, coupling is based on the conventional Terbrack profile as presented in U.S. Pat. No. 4,426,820 and which thus did not provide for elastic deformation of the coupling elements. As may be seen on
Once assembled, retention in the transverse direction is provided by the locking means and there are two other functional contact surfaces:
Making reference to
α≦180°−arctan(h/l)
In the present variant, this condition is satisfied since the angle α is tangent to the circle of radius AB at point B. A smaller angle α would thus meet the same requirement, but it is worthwhile to have the largest possible locking angle α in order to improve transverse locking.
As indicated above, the profile of the coupling means of the panel 10 comprises a certain number of functional contact zones. Outside these functional zones, there is no requirement for the coupling means to be in contact. This is for example the case in the rear part of the stop 32, where assembly clearance is preferably provided.
In the present variant, the repositionable adhesive is provided in this non-functional zone behind the stop 32, where it is applied in the form of beads which preferably extend over the entire length of the edge: a bead 39 or 39′ at the bottom of the channel 38 and a bead 40 or 40′, in the lower part of the second coupling element 22. The thickness of the bead corresponds to (or is slightly larger than) the clearance between the coupling means, such that on completion of assembly the beads 39, 40 are slightly crushed between the corresponding surfaces of the coupling means 20 and 22. This slight crushing of the bead improves the adhesion of this type of glue which generally exhibits a certain sensitivity to pressure.
It will also be noted that the adhesive deposits 39, 39′, 40, 40′ are preferably provided on planar surfaces of the channel 36, and that the surfaces of the stop 32 which will come into contact with the adhesive deposits are also planar. Furthermore, whereas in the present variant the adhesive deposits 39, 39′, 40, 40′ come directly into contact during assembly with the material constituting the stop 32, an appropriate polymeric coating could be provided on this stop 32 in order to prevent the bead from removing some particles from the stop during disassembly (something which could be of interest for certain materials).
It should be noted that immobilisation of the panels by the adhesive is achieved without effort, or only with a minimal effort ensuring close contact of the adhesive with the material facing it. It is the physico-chemical properties of the materials in contact which ensure the immobilisation of the panels, which are thus not subjected to any severe stresses likely to damage the coupling means or more generally the panel. The particular nature of repositionable glues allows a large number of coupling and decoupling operations without their effectiveness being degraded.
The desired “click” effect may be adjusted by acting on the following parameters: tack of the adhesive; geometry of the coupling profile; position of the adhesive bead(s); shape and dimensions of the adhesive bead; and number of beads. It will be understood that the important factor for the click effect is the tack relative to the surface which comes into contact with the adhesive deposit during interlocking and not the adhesive strength relative to the material onto which the adhesive deposit was applied.
Preferably, these various parameters will be acted upon in order to obtain a “click” effect on disassembly of the panels according to the invention which is similar to a mechanical “click” effect. A series of measurements carried out on various known “mechanical click” systems revealed that the average moment to be exerted to separate two neighbouring strips is of the order of 6 N·m for an edge length of 1 m (stated as 6 N·m/m)
The various parameters stated above will thus be acted upon to ensure that adhesion between two panels according to the invention is such that a moment (known as disassembly moment) of between 3 and 9 N·m/m, more preferably of the order of 6 N·m/m, is required for initiate rotation of a panel out of the assembly plane.
Such a disassembly moment may be achieved with repositionable glues having a tack of between 0.05 and 0.3 N/mm2, preferably of approximately 0.15 N/mm2.
It will be noted, by way of comparison, that if the panel 10, 10′ had not been provided with deposits of repositionable adhesive, the disassembly moment of this panel would solely be a function of its weight, since the coupling profile is not deformed during disassembly.
In the embodiment illustrated in
These hot-melt glues are generally based on polyolefins, polyurethane (PU), ethyl vinyl acetate (EVA), polyvinyl acetate (PVAC), polyvinyl butyral (PVB), etc. In the case of an application with HDF coupling means, it is possible to use the hot-melt glue known under the name INSTAWELD 6615 E (manufactured by NATIONAL Starch & Chemical).
It is alternatively possible to use glues which can be applied at ambient temperature (e.g. acrylic emulsions). These glues are for example deposited in film form by kiss contact against a cylinder of appropriate dimensions. This type of glue requires larger areas of contact.
It will be noted again that the important factor is that the glue used makes it possible to form an adhesive deposit exhibiting the behaviour of a repositionable adhesive towards the material which will come into contact therewith during interlocking. This type of deposit may possibly be obtained with glues which are not known (sold) as repositionable glues and which therefore also fall within the scope of the present invention.
As indicated above, the geometry of the coupling profile and the position of the beads of glue have an influence on the click effect perceived by the user.
In this configuration, the bonding surfaces are perpendicular to the disassembly direction of the panels, which makes it possible to maximise the disassembly moment required to separate the strips 110 and 110′ by rotation in the anticlockwise direction. Thus, for a bead having the same characteristics as is in
A larger area is also available for application of the bead.
Finally, the multilayer structure of the panel 10 will be noted which comprises (see
Depending on the application, the upper layer may be a melamine-impregnated decoration (multilayer material) or a ceramics material. The support may be of fibre cement or filled resin or other readily machinable materials. The backing is not always necessary.
Number | Date | Country | Kind |
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05291280 | Jun 2005 | EP | regional |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2006/063154 | 6/13/2006 | WO | 00 | 12/14/2007 |
Publishing Document | Publishing Date | Country | Kind |
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WO2006/134109 | 12/21/2006 | WO | A |
Number | Name | Date | Kind |
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3579941 | Tibbals | May 1971 | A |
6808777 | Andersson et al. | Oct 2004 | B2 |
20040031226 | Miller et al. | Feb 2004 | A1 |
Number | Date | Country |
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201 22 032 | Dec 2003 | DE |
2 377 457 | Jan 2003 | GB |
Number | Date | Country | |
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20080199676 A1 | Aug 2008 | US |