CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of Swedish application no. 2450019-1, filed on Jan. 10, 2024, and claims the benefit of Swedish application no. 2450309-6, filed on Mar. 20, 2024. The entire contents of each of Swedish application no. 2450019-1 and Swedish application no. 2450309-6 are hereby incorporated herein by reference in their entirety.
TECHNICAL FIELD
The disclosure generally relates to a set of panels comprising a locking device. More specifically, the locking device comprises a separate tongue configured to cooperate with a tongue groove for vertical locking of edge portions of the panels. The panels may be building panels, floor panels, ceiling panels, furniture components, or wall panels.
BACKGROUND
WO 2022/197234 A1 discloses panels comprising novel mechanical locking systems that allow for an easier disassembly of the panels. For example, the panels may be disassembled without using a tool and/or by applying a force to an edge of a panel with a tool. WO 2024/063687 A1 discloses further developments of this technical solution as well as various improvements of the disassembly of the panels.
However, there may be scenarios in which the panel edges are exposed to large forces during disassembly, thereby risking that the locking device becomes impaired or even broken.
SUMMARY
It is therefore an object of at least embodiments of the present disclosure to provide a set of panels comprising a locking device that may be disassembled in an improved manner, such as without using a tool interacting with the locking device. For example, the disassembly may involve manual operations only.
Another object of at least embodiments of the present disclosure is to provide a more controlled, such as smoother, disassembly or reassembly of a set of panels, especially when the disassembly involves manual operations only.
It is also an object of at least embodiments of the present disclosure to reduce the risk of damaging the panels during their disassembly or reassembly, such as by splintering or chipping.
Yet another object of at least embodiments of the present disclosure is to improve a strength of the locking device.
These and other objects and advantages that will be apparent from the description have been achieved by the various aspects, embodiments and examples described below.
In accordance with a first aspect of the disclosure, there is provided a set of panels, such as building panels, comprising a first panel and a second panel and a locking device for locking a first edge portion of the first panel to a second edge portion of the second panel. The panels comprise a front side and a rear side, wherein a normal of a main plane extending along the front and/or the rear side defines a vertical direction, preferably extending away from the front sides of the first and second panels. The locking device comprises a horizontal locking device and a vertical locking device. The vertical locking device comprises a separate tongue arranged in an insertion groove of the first edge portion, wherein a longitudinal extension of the separate tongue extends along the first edge portion, and a tongue groove provided in, and extending along, the second edge portion. In a vertically locked state of the first and second edge portions, an abutment member provided at a longitudinal end portion of the separate tongue cooperates with a stop surface of the second edge portion, and a locking portion of the separate tongue cooperates with the tongue groove at a locking surface. The locking surface is at least partially, such as entirely, arranged in a wood-based body layer of the second edge portion, wherein the body layer comprises wood fibres mainly oriented along a first fibre direction extending along the main plane and being parallel with a principal direction extending perpendicularly to a vertical plane provided in the vertically locked state along joining upper portions of the first and second edge portions.
In accordance with the first aspect, in the vertically locked state a transverse extension of the separate tongue from the insertion groove may be larger at the locking portion than at the longitudinal end portion. The edge portions may thereby be locally essentially vertically unlocked at the longitudinal end portion and the, preferably flexible, separate tongue may be gradually inserted into the tongue groove along the edge portions for providing their vertical locking.
Moreover, in accordance with the first aspect, the first and second panels may be disassembled by vertically displacing the first and second edge portions in a direction away from each other, preferably by means of a scissor or folding displacement, starting proximate to a location of the abutment member. For example, the edge portions may be vertically unlocked by a relative vertical displacement of the first and second edge portions away from each other, preferably essentially manually, optionally using a raising element under the second panel. During unlocking by means of the folding displacement, the separate tongue may be gradually displaced into the insertion groove along the first edge portion. In view of the above, it may be easier and/or less time consuming to disassemble or reassemble the panels. Particularly, a separate tool interacting with the locking device may not be needed during the disassembly, even though this is not excluded. As will be outlined elsewhere herein, the edge portions may in some embodiments be unlocked by repeatedly vertically displacing them away and towards each other.
Moreover, in accordance with the first aspect, a longitudinal extension of the separate tongue may extend essentially perpendicularly to the orientation of the wood fibres of the body layer. Thereby, the disassembly or reassembly of the first and second panels may become more controlled, such as smoother. Also, the risk of damaging the panels during their disassembly or reassembly, such as by splintering or chipping, may be reduced.
The stop surface may prevent a displacement of the separate tongue outwards from the insertion groove, preferably at least in a horizontal direction. The stop surface may further be a guiding surface, for example guiding the separate tongue during locking.
The stop surface may include an area of the second edge portion which cooperates with the separate tongue in the locked state, optionally also including an area which cooperates with the separate tongue during locking and/or unlocking.
Generally herein, cooperating surfaces may cooperate by direct engagement or indirect engagement. Examples of such cooperating surfaces include the stop surface and a surface of the abutment member. In any embodiment described herein, there may be a sealing agent, such as a wax or an adhesive, provided between the cooperating surfaces, thereby providing examples of an indirect engagement.
The second edge portion of the second panel may comprise a layered structure comprising the body layer and at least two wood-based joining layers comprising wood fibres mainly oriented along a second fibre direction, which is perpendicular to the first fibre direction. Optionally, the layered structure may further comprise at least one wood-based connection layer comprising wood fibres mainly oriented along the first fibre direction. Preferably, the layered structure is a plywood board, although other layered structures also are equally conceivable.
The body layer, and preferably a layered structure comprising the body layer, may extend between the second edge portion and an opposing edge portion of the second panel.
The body layer may be arranged in an edge piece, preferably comprising a layered structure, and the second panel may further comprise an inner core. Thereby, a simpler and/or more cost-effective core, including the edge piece and the inner core, may be provided, while maintaining the advantages of orienting the wood fibres of the body layer as described herein.
The vertical and/or horizontal locking device may be at least partially, such as entirely, formed in the edge piece. Thereby, the locking device may be formed in a stronger part of the core.
The inner core may comprise a wood-based board, such as a high-density fibreboard, HDF board or a particle board, or a plurality of core elements. A simpler and/or cheaper inner core may thereby be provided.
The second panel may further comprise a, preferably wood-based, top layer and/or bottom layer.
The tongue groove may comprise at least one bevel at least partially, such as entirely, arranged in the body layer. Preferably, the at least one bevel forms a guiding surface. By having the bevel in the body layer, the risk of damaging the panels during their disassembly, such as by splintering or chipping, may be further reduced.
At least 50%, such as at least 70%, of a vertical extension from an uppermost segment of the locking surface to a lower vertical end segment of the second edge portion positioned directly vertically below the uppermost segment may be arranged in the body layer and/or at least one wood-based connection layer comprising wood fibres mainly oriented along the first fibre direction. Thereby, a locking device which is stronger during assembly may be provided.
The abutment member may be provided in an outer and preferably in a lower portion of the separate tongue.
The abutment member may project downwards.
In some embodiments, opposing longitudinal end portions of the separate tongue may both comprise an abutment member. Hence, the abutment member may be one of at least two abutment members, and opposing longitudinal end portions of the separate tongue both comprise a respective one of the at least two abutment members. Thereby, the separate tongue may assume a curved, preferably essentially symmetrical, shape in the vertically locked state. Moreover, an unlocking of the edge portions may be initiated from either side thereof. Additionally, it may be suitable for use when several types of panels are included in the set for locking them to each other in a pattern, such as a herringbone pattern, e.g., including so-called A- and B-panels. Here, the separate tongue may include an abutment member facing a preferred part or side of the edge portion, such as a specific corner portion, regardless of the type of panel it is inserted into.
The first edge portion of the first panel and the second edge portion of the second panel may be short edge portions. In some embodiments, however, the edge portions may be long edge portions. Generally herein, the short edge portions may be shorter than the long edge portions.
The stop surface may be distinct from, preferably being spaced from, the locking surface. The stop surface may be disposed below the tongue groove.
The stop surface may be disposed outside an opening of the tongue groove.
The locking portion of the separate tongue may be spaced, such as horizontally and/or vertically, from the stop surface in the vertically locked state. Alternatively, or additionally, the locking portion of the separate tongue may generally be spaced, such as horizontally and/or vertically, from the abutment member, such as in the vertically locked state.
The stop surface may be planar and may extend essentially vertically, such as vertically. By extending essentially vertically, the stop surface may preferably form an angle of 0°-10°, such as 0°-5° or 0°-2°, with respect to the normal N. Thereby, the cooperation between the abutment member and the stop surface may provide little or even no vertical locking of the edge portions. Hence, a simpler assembly and/or disassembly of the panels may be provided.
In some embodiments, the stop surface may form an angle of 0°-30°, such as 0°-20°, preferably being inclined by exceeding 10° and not exceeding 30° or being 20°-30°, with respect to the normal N. By having an inclined stop surface an improved control of the unlocking of the edge portions may be provided. For example, an increased displacement of the separate tongue into the insertion groove during unlocking may be obtained.
The abutment member may be pretensioned against the stop surface in the vertically locked state. For example, the separate tongue may comprise flexible members. A pretensioning of the separate tongue may cause it to be biased outwards, such as by a spring force. By means of the abutment members, the separate tongue may assume a longitudinally curved or bent form such that its longitudinal end portion(s) cooperate(s) with the stop surface(s) of the second edge portion, and its locking portion cooperates with the tongue groove.
Preferably, the separate tongue is flexible.
The separate tongue may comprise flexible members configured to face an inner portion of the insertion groove when arranged therein. The flexible members may be configured to displace the separate tongue outwards during locking or unlocking.
During locking, the second edge portion, preferably a lower cooperating surface, may cooperate, preferably directly, with the locking portion for displacing the separate tongue into the insertion groove.
During locking, the locking portion may be configured to be gradually depressed towards or inserted into the insertion groove along the first edge portion in a first stage, and in a second subsequent stage the locking portion may be configured to be gradually inserted into the tongue groove along the second edge portion.
The abutment member and the locking portion of the separate tongue may be operatively coupled such that, during locking, the second edge portion pushing the locking portion in a direction toward an inner portion of the insertion groove causes the abutment member to move together with the locking portion in the direction toward the inner portion of the insertion groove.
The abutment member may comprise a straight portion extending in parallel with a longitudinal extension of the separate tongue and preferably being arranged longitudinally inside of a longitudinally curved section provided in the longitudinal end portion(s). By means of the straight portion, a larger contact surface with the second edge portion may be provided. Thereby, the risk of damaging the panels during locking and/or unlocking may become reduced.
The flexible members may each extend from a respective base portion of the separate tongue. Each flexible member may extend from and may be bendable around the respective base portion. In some embodiments, a flexible member extending from a base portion arranged at the longitudinal end portion may extend from and may be bendable around a longitudinal inner side of the base portion. Thereby, a smaller force may be needed for displacing the separate tongue at the longitudinal end portion, and hence an easier unlocking may be obtained.
The abutment member may be at least partially, such as entirely, arranged longitudinally outwards from the flexible members. Thereby, an outwardly directed pressure from the flexible members may become smaller at the location of the abutment member, and it may become easier to unlock the edge portions.
The separate tongue, preferably the locking portion of the separate tongue, may be longitudinally bent in the vertically locked state.
A tip portion of the separate tongue may be curved as seen in a cross-sectional side view, preferably by an angle in the interval of 0°≤σ≤35°, such as 0°≤σ≤30° or 10°≤σ≤30°. For example, the tip portion may be continuously curved, preferably such that no cooperating surface of the tip portion comprises a straight portion.
The horizontal locking device may comprise a locking element arranged on a strip extending horizontally outwards from a lower portion of the first edge portion and a locking groove provided in the second edge portion. The locking element and the locking groove may be configured to cooperate to provide a horizontally locked state of the first and the second edge portions.
The first and second edge portions may be configured to be vertically unlocked by a, preferably forced, relative vertical displacement of the first and second edge portions away from each other and/or by a repeated, preferably forced, relative vertical displacement of the first and second edge portions away and towards each other. The repeated relative vertical displacement may comprise a jerking displacement of the edge portions up and down. By means of the repeated displacement, preferably by means of a folding displacement, the unlocking of the edge portions may in some embodiments become more controlled. Indeed, a portion of the separate tongue may become jammed after a first relative vertical displacement of the edge portions away from each other, thereby obtaining partially unlocked edge portions, and a second relative vertical displacement of the edge portions towards each other may at least partially release the separate tongue from the jamming; thereafter, a third relative vertical displacement of the edge portions away from each other may follow, whereby the edge portions may become further unlocked. As a further advantage, by means of the relative vertical displacement a risk of damaging the edge portions, such as at their top layers, and/or the locking device may become reduced. Indeed, a too excessive force from a relative vertical displacement directed in a single direction only might damage the edge portions or the locking device.
In accordance with a second aspect of the disclosure, there is provided a set of panels in accordance with the second independent claim. The second edge portion may become reinforced by means of the body layer in accordance with the second aspect. Consequently, an improved strength of the vertical locking device, especially under a load of the panels, may increase (which is equally valid for the first aspect). Embodiments and examples of the second aspect are largely analogous to those of the first aspect, whereby reference is made thereto. In addition, the following embodiments are conceivable for the second aspect, as well as for the first and third aspects.
In the vertically locked state, a relative angle between a, preferably outermost, underside of a tip portion of the separate tongue and the locking surface may exceed 10°, such as exceeding 15° or exceeding 20°. Relative angles of these magnitudes could at least in some scenarios, such as when the panels comprise a wood-based core or a fragile and/or porous core, result in a deterioration of the locking surface, for example by crumbling. However, the orientation of the wood fibres of the body layer along the first fibre direction may provide a more robust locking surface and hence a more well-defined relative vertical positioning of the panels. Thereby, the risk of lippage or panel height difference may be reduced or sometimes even entirely avoided.
In accordance with a third aspect of the disclosure, there is provided a set of panels entirely in accordance with the first aspect, but without the locking surface necessarily being at least partially, such as entirely, arranged in the wood-based body layer of the second edge portion. Embodiments and examples of the third aspect are largely analogous to those of the first aspect, whereby reference is made thereto. In particular, the inclined stop surface disclosed in relation to the first aspect is also conceivable for the third aspect.
The first and second panels in accordance with the third aspect may comprise a wood-based core, such as an HDF board, a medium-density fibre board, MDF, a particle board, an oriented strand board, OSB, or a plywood board, or a polymer-based material, such as a thermoplastic material or a thermosetting material. Other conceivable material choices are disclosed in WO 2024/063687 A1 on page 6, lines 14-31, which content is expressly incorporated by reference.
Generally, all terms used herein, such as in the claims, are to be interpreted according to their ordinary meaning in the technical field, unless explicitly defined otherwise. All references to “a/an/the [element, member, device, component, means, step, etc.]” are to be interpreted openly as referring to at least one instance of said element, device, component, means, step, etc., unless explicitly stated otherwise. Reference to one or a plurality of “at least one element”, etc., may shortly be referred to as “the element(s)”.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosure will in the following be described in connection to exemplary embodiments and in greater detail with reference to the appended exemplary drawings, wherein:
FIGS. 1a-1e illustrate in top views embodiments of a panel (FIGS. 1a-1b) and embodiments of assembled panels (FIGS. 1c-1d), and in a perspective view an embodiment of panels during assembly or disassembly (FIG. 1e).
FIGS. 2a-2f illustrate an embodiment, e.g., of the panels in FIGS. 1c-1d, in a side view C1-C1 (FIG. 2a) and cross-sectional side views C2-C2 and C3-C3 (FIGS. 2c and 2e), and in a corresponding enlarged side view (FIG. 2b) and enlarged cross-sectional side views (FIGS. 2d and 2f) with an indicated schematic layered structure.
FIGS. 3a-3d illustrate an embodiment of a separate tongue in a perspective view (FIG. 3a), a corresponding enlarged perspective view (FIG. 3b), and cross-sectional side views along the sections A-A (FIG. 3c) and B-B (FIG. 3d) in FIG. 3a.
FIGS. 4a-4b illustrate in a top view (FIG. 4a) and a corresponding enlarged top view (FIG. 4b) an embodiment of a separate tongue in an unlocked state and in a locked state of the edge portions.
FIG. 4c illustrates in a cutaway perspective view an embodiment of a first panel and a separate tongue in a locked state of the edge portions.
FIGS. 4d-4e illustrate in a perspective view (FIG. 4d) and a corresponding enlarged perspective view (FIG. 4e) an embodiment of a separate tongue.
FIGS. 5a-5c illustrate in a perspective view (FIG. 5a), a side view (FIG. 5b), and a corresponding enlarged perspective view (FIG. 5c) an embodiment of a separate tongue.
FIGS. 5d-5e illustrate an embodiment of a set of panels in a side view (FIG. 5d) and a corresponding enlarged side view (FIG. 5e).
FIGS. 6a-6c illustrate in a perspective view (FIG. 6a), a side view (FIG. 6b), and a corresponding enlarged perspective view (FIG. 6c) an embodiment of a separate tongue and its cooperation with the second edge portion.
FIGS. 6d-6e illustrate in perspective views an embodiment of a separate tongue (FIG. 6d) and an embodiment of two such separate tongues arranged in an insertion groove (FIG. 6e).
FIGS. 7a-7f illustrate in side views (FIGS. 7a, 7c and 7e) and corresponding enlarged side views (FIGS. 7b, 7d and 7f) an embodiment of a first and a second edge portion during locking.
FIGS. 8a-8f illustrate in side views (FIGS. 8a, 8c and 8e) and corresponding enlarged side views (FIGS. 8b, 8d and 8f) an embodiment of a first and a second edge portion during locking or unlocking.
FIGS. 9a-9b illustrate in side views an embodiment of a first and a second edge portion during locking or unlocking.
FIGS. 9c-9f illustrate in side views (FIGS. 9c and 9e) and corresponding enlarged side views (FIGS. 9d and 9f) an embodiment of a first and a second edge portion during locking or unlocking.
FIGS. 10a-10c illustrate in cross-sectional side views embodiments of a first or a second panel comprising a layered structure extending between the opposing edge portions.
FIGS. 10d-10e schematically illustrate in top views an embodiment of a body layer or a connection layer (FIG. 10d) and an embodiment of a joining layer (FIG. 10d), including their fibre orientations.
FIGS. 11a-11b illustrate in cross-sectional side views embodiments of a first or a second panel comprising an edge piece.
FIGS. 11c-11e illustrate in side views an embodiment of a first and a second edge portion during locking or unlocking.
FIGS. 12a-12c illustrate in perspective views an embodiment of a set of panels during disassembly (FIGS. 12a-12b) and an embodiment of a raising element (FIG. 12c).
FIG. 12d illustrates in a side view an embodiment of interlocked third and fourth edge portions, such as those in, or obtainable, from FIG. 1e.
FIGS. 13a-13d illustrate in side views (FIGS. 13a-13b) an embodiment of a first and a second edge portion during unlocking using a separate tool, e.g., of the panels in FIGS. 1c-1d, in the cross-sectional side views C2-C2 (FIGS. 13a) and C3-C3 (FIG. 13b), and perspective views of an embodiment of such a separate tool (FIG. 13c) and its use (FIG. 13d).
FIGS. 14a-14b illustrate in top views different embodiments of a separate tongue in an unlocked state.
FIGS. 14c-14d illustrate an embodiment of a separate tongue in a perspective view (FIG. 14c) and in an enlarged perspective view (FIG. 14d) around its longitudinal end portion.
FIGS. 15a-15b illustrate in a side view (FIG. 15a) and an enlarged side view (FIG. 15b) an embodiment of locked edge portions in accordance with the second aspect.
FIG. 15c illustrates in a top view an embodiment of assembled panels, schematically indicating in a cutaway section a contact length and a contact area of a locking surface.
FIG. 15d illustrates in a cross-sectional side view and an enlarged cross-sectional side view C2-C2, for example in relation to the panels in FIGS. 1c-1d, an embodiment of locked edge portions, where the separate tongue has a curved tip portion.
DETAILED DESCRIPTION
In the following, various embodiments of the first, second and third aspects of the disclosure will be described with reference to the embodiments in, e.g., FIGS. 1a-1e, 2a-2f, 3a-3d, 4a-4e, 5a-5e, 6a-6e, 7a-7f, 8a-8f, 9a-9f, 10a-10e, 11a-11e, 12a-12d, 13a-13d, 14a-14d and 15a-15d.
The disclosure relates to a set of panels, such as building panels, comprising a first 1 and a second 2 panel comprising a first 1a and a second 2b edge portion, respectively, see, e.g., FIGS. 1a-1e and 2a-2f. Preferably, the panels herein are essentially identical. For example, the panels may be floor panels, but wall panels, as illustrated in, e.g., FIG. 11d of WO 2024/063687 A1, which figure is expressly incorporated by reference, or ceiling panels or furniture components are equally conceivable. The panels 1, 2 each comprise a front side 1e, 2e and a rear side 1f, 2f, preferably extending along a first X and a second Y perpendicular horizontal direction. For example, the first 1a and second 2b edge portions may extend along the first horizontal direction X. A normal N of a main plane M1, M2 extending along the front side 1e, 2e and/or the rear side 1f, 2f defines a vertical direction Z extending away from the front sides of the first 1 and second 2 panels.
The set of panels further comprises a locking device for locking the first 1a and second 2b edge portions to each other and obtaining a locked state. The locking device herein may be a mechanical locking device. Thereby, the first 1 and second 2 panels may be assembled to each other. The locking device comprises a horizontal locking device and a vertical locking device configured to define a horizontally and vertically locked state of the first 1a and second 2b edge portions, respectively. The locked state herein may include the vertically, and optionally the horizontally, locked state.
The panels 1, 2 herein may be rectangular, but may in some embodiments also be square. Preferably, the first 1a and second 2b edge portions where the locking device is provided are short edge portions. It is clear that the panels 1, 2 may comprise opposing short edge portions 1b, 2a as shown in, e.g., FIG. 1a. The panels 1, 2 may further comprise third 1c, 2c and fourth 1d, 2d opposing edge portions, which preferably are long edge portions. For example, the third and fourth edge portions may extend along the second horizontal direction Y. However, embodiments in which the opposing edge portions 1a, 1b, 2a, 2b are long edge portions and the opposing edge portions 1c, 1d, 2c, 2d are short edge portions are included herein mutatis mutandis.
The set may comprise additional panels, such as a plurality of panels. For example, and as illustrated in, e.g., FIGS. 1e, 12a and 12d, the set may comprise a third panel 1′ to which the panels 1, 2 may be assembled, such as along a third edge portion 1c′, a fourth 1d′ edge portion, and/or a first edge portion 1a′.
The panels 1, 2, such as floor panels, building panels, ceiling panels, furniture components, or wall panels, may be configured to be arranged on, or connected to, a substructure, such as a subfloor 20. In some embodiments, the panels 1, 2 are floor panels which may be arranged on and along a subfloor 20, preferably in a floating manner. The horizontal directions X, Y may extend in parallel with the substructure, such as the subfloor, and the vertical direction Z may extend perpendicularly thereto, cf. FIG. 1e. Consequently, in the case of wall panels the horizontal directions X, Y may extend along a visible wall surface 21 (see FIG. 11d of WO 2024/063687 A1), typically provided perpendicularly to a subfloor 20 in an environment in which the wall panels are assembled, and the vertical direction Z may extend perpendicularly to the subfloor.
As shown in, e.g., FIGS. 1a-1e, 2a-2f, 4c, 5d-5e, 6e, 7a-7f, 8a-8f, 9a-9f, 10a-10c, 11a-11e, 15a-15b and 15d, the vertical locking device comprises a separate tongue 3 arranged in an insertion groove 4 of the first edge portion 1a and a tongue groove 5 provided in the second edge portion 2b. The insertion groove, the separate tongue and the tongue groove may each have an elongated shape and may have a transverse extension and a, preferably larger, longitudinal extension. The longitudinal extensions of the insertion groove 4 and the separate tongue 3 may extend along the first edge portion 1a and the longitudinal extension of the tongue groove 5 may extend along the second edge portion 2b. For example, the edge portions 1a, 2b may extend along the first horizontal direction X. A cross-section of the locking device may be essentially constant along the edge portions 1a, 2b, except possibly in corner portions 8a, 8b, 8c, 8d of the panels 1, 2.
The separate tongue 3 may comprise a longitudinal end portion 3a and a locking portion 6. In some embodiments, and as shown in, e.g., FIGS. 1c, 3a, 4a, 4d, 5a, 6a and 14a-14d, the locking portion 6 may be a longitudinal inner portion of the separate tongue, preferably being provided between a pair of longitudinal end portions 3a. For example, the locking portion 6 may be a longitudinal central portion of the separate tongue. As shown in, e.g., FIGS. 1d and 6d, however, the locking portion 6 may in some embodiments extend to an opposing longitudinal end portion 3a, preferably without an inclusion of an abutment member 13. In accordance with the first or third aspect described herein, the separate tongue 3 thereby comprises an abutment member 13 provided at one or both longitudinal end portions 3a. Moreover, the second edge portion 2b comprises a stop surface 12. The locking portion 6 may generally be spaced, such as horizontally and/or vertically, from the abutment member 12, such as in the vertically locked state. The stop surface 12 and abutment member 13 are optional in the second aspect.
In the vertically locked state, the abutment member 13 cooperates, such as engages, with the stop surface 12 and the locking portion 6 cooperates, such as engages, with the tongue groove 5. For example, a tip portion 3i of the separate tongue 3 may cooperate with the tongue groove 5 at a locking surface 5g, cf. FIG. 2d. The locking surface 5g may form an angle & with respect to the main plane M2 (which for clarity is parallel transported downwards in FIGS. 2c-2d). Preferably 10°≤ε≤50°, more preferably 25°≤ε≤40° or 35°≤ε≤45°. Moreover, in the vertically locked state a, preferably outer portion of or outermost, underside 3j of the tip portion 3i may form an angle σ with respect to the main plane(s) M1 and/or M2. Preferably 0°≤σ≤30° or 0°≤σ≤25°, such as 10°≤σ≤30° or 0°≤σ≤10°, such as 3°≤σ≤7°. The underside 3j may include the locking portion 6. In a first example, at least a portion of the underside 3j, such as essentially the entire underside 3j, may be planar, preferably as seen in a cross-sectional side view. In a second example, at least a portion of the underside 3j, such as the entire outermost underside, may be curved, preferably such that the angle σ varies along the underside, see, e.g., FIG. 15d. The angle σ may vary along the second horizontal direction Y. For example, the tip portion 3i, preferably including the locking portion 6, may be curved, preferably as seen in a cross-sectional side view. The tip portion 3i may be curved by an angle in the interval of 0°≤σ≤35°, such as 0°≤σ≤30°, 10°≤σ≤30° or 3°≤σ≤7°. Alternatively, or additionally, the tip portion 3i may comprise a segment having a radius R, which may be 0.05-1.2 mm or 0.3-0.9 mm. For example, the tip portion 3i may be continuously curved, preferably such that no cooperating surface 3y of the tip portion comprises a straight portion. The cooperating surface 3y may be any, preferably outer and lower, surface of the tip portion 3i configured to cooperate with the locking surface 5g during locked and/or in the locked state. A relative angle θ between the, preferably outermost, underside 3j and the locking surface 5g may, for example, exceed 10°, such as exceeding 15° or exceeding 20°. For example, 10°<θ≤40°, such as 15°<θ≤35° or 20°<θ≤30°. Non-limiting examples of the inclinations of the locking surface 5g and the underside 3j and/or the tip portion 3i, in terms of the angles ε and σ, respectively, optionally being combinable with the relative angle θ, have been detailed in the previous paragraph, whereby reference is made thereto.
The second panel 2 comprises a wood-based body layer 31 comprising wood fibres 25 mainly oriented along a first fibre direction F1 and at least being arranged in the second edge portion 2b, see, e.g., FIGS. 2a-2f, 7a-7f, 8a-8f, 9a-9f, 10a-10e, 11a-11e and 15a-15d. The first fibre direction F1 extends along the main plane M1, M2 and is parallel with a principal direction 24 extending perpendicularly to a vertical plane VP provided in the vertically, and optionally the horizontally, locked state along joining upper portions 1g, 2g of the first 1a and second 2b edge portions. The principal direction 24 may be parallel with the second horizontal direction Y. The vertical direction Z may extend along the vertical plane VP. For example, when the first 1a and second 2b edge portions are short edge portions, the first fibre direction F1 may be parallel with the long edge portions of the second panel 2.
Preferably, the second edge portion 2b comprises a layered structure 30 comprising the body layer 31 and at least two wood-based joining layers 32a, 32b, 33a, 33b comprising wood fibres 26 mainly oriented along a second fibre direction F2, which is perpendicular to the first fibre direction F1. The second fibre direction F2 extends along the main plane M1, M2. The layered structure 30 may thereby form at least a part of a core 40 of the second panel 2. Optionally, the layered structure 30, and hence at least a part of the core 40, further comprises at least one wood-based connection layer 34a, 34b, 35a, 35b comprising wood fibres mainly oriented along the first fibre direction F1. Preferably, the number of layers in the layered structure 30 is odd, such as three, five, seven, or nine. Each joining layer 32a, 32b, 33a, 33b may be arranged between a pair of connection layers 34a, 34b, 35a, 35b or between the body layer 31 and a connection layer 34a, 35a. Thereby, the fibre orientations in adjacent layers may be arranged essentially perpendicularly to each other, whereby a cross-grained structure may be obtained. The layers in the layered structure 30 may be bonded to each other by an adhesive and may be pressed together.
A thickness T1 of the body layer 31, a thickness T2 of each individual joining layer 32a, 32b, 33a, 33b and/or a thickness T3 of each individual connection layer 34a, 34b, 35a, 35b may be essentially constant, at least horizontally inwardly of the locking device. Thereby, the layers may be substantially sheet-shaped layers.
In some embodiments, at least 20%, such as at least 50% or even at least 80%, of a vertical height TG of the tongue groove 5 may be arranged in the body layer 31, cf. FIG. 7d. For example, T1/TG≥0.2, such as T1/TG≥0.5 or T1/TG≥0.8. These bounds are conceivable for any number of layers in the layered structure 30, such as five, seven, or nine.
The body layer 31 may comprise a ply of natural wood, such as being a wood veneer layer. For example, the body layer 31 may comprise at least one continuous grain pattern, such as in a wood veneer layer. In fact, each layer 32a, 32b, 33a, 33b, 34a, 34b, 35a, 35b of the layered structure 30, including the body layer 31, may comprise a ply of natural wood, such as being a wood veneer layer. The first F1 and/or the second F2 fibre direction may correspond to a grain direction of the wood veneer layer. For example, a veneer thickness, such as a maximal thickness, of any or each layer of the layered structure 30, including the body layer 31, may be 0.5-2.5 mm. This bound may also hold generally for any of the thicknesses T1, T2, T3. Preferably, the layered structure 30 is a plywood board, although other layered structures also may be contemplated. In first example, each wood veneer layer of the layered structure 30 may comprise birch or spruce. In a second example, at least two wood veneer layers of the layered structure 30 may comprise birch and at least one wood veneer layer of the layered structure 30 may comprise a wood material other than birch, such as beech.
In the locked state, the locking surface 5g may include a contact area CA between the locking portion 6 and the tongue groove 5, see, e.g., FIG. 7d (before locking) and FIG. 15c (after locking). The contact area CA may at least include a contact length CL extending along the second horizontal direction Y, and optionally along the vertical direction Z, cf. FIGS. 9b and 15b. The contact area CA may be curved or planar and the contact length CL may be curved or linear. The contact area CA may further include a longitudinal contact length 48 along the first horizontal direction X, cf. FIGS. 1a and 15c. For example, the longitudinal contact length 48 may correspond to at least 50% or at least 70%, of a, preferably maximal, longitudinal length LT of the separate tongue 3. In non-limiting examples, the length may be 50 mm≤LT≤400 mm, such as 150 mm≤LT≤300 mm.
The locking surface 5g is at least partially arranged in the body layer 31 of the second edge portion 2b. For example, the locking surface 5g may be entirely arranged in the body layer 31.
The locking surface 5g may be arranged at any vertical position of the body layer 31. For example, in any embodiment herein, a preferably uppermost segment 46 of, the locking surface 5g may be arranged at a distance LS from an upper surface 31a of the body layer 31, wherein the distance LS is 20-80%, such as 30-70% or 40-60%, of a maximal thickness TB of the body layer 31, cf. FIG. 7f.
In preferred embodiments, at least 20%, such as at least 50%, of the contact length CL between the locking portion 6 and the locking surface 5g may be arranged in the body layer 31, cf. FIG. 15c. Optionally, the remaining part of the contact length CL may be arranged in an adjacent layer, such as the joining layer 32a, see, e.g., FIGS. 9a-9b and 15a-15b. In some embodiments, and as shown in, e.g., FIGS. 2a-2d, 5d-5e, 7e-7f, 8a-8b, 9c-9d and 11e, the entire contact length CL may be arranged in the body layer 31. Any of the contact lengths CL specified above may be valid in the longitudinal central portion of the separate tongue 3, and optionally also along the longitudinal contact length 48 around the longitudinal central portion, cf. FIGS. 1a and 15c. For example, the longitudinal contact length 48 may correspond to at least 20%, such as at least 50% or at least 70%, of the longitudinal length LT.
In some embodiments, and as shown in, e.g., FIGS. 10a-10c, the body layer 31 extends between the second edge portion 2b and the opposing edge portion 2a. Preferably, the entire layered structure 30 including the joining layers 32a, 32b, 33a, 33b and/or the connection layers 34a, 34b, 35a, 35b extends between the opposing edge portions 2a, 2b, such as to their horizontally outermost edges. The layered structure 30 may thereby form, or be part of, the core 40. The vertical and/or horizontal locking device may be entirely formed in the layered structure 30.
In some embodiments, and as shown in, e.g., FIGS. 11a-11b, the body layer 31 is arranged in an edge piece 41 and the second panel 2 comprises an inner core 42. Preferably, also the opposing edge portion 2a comprises an edge piece 41′, such that the inner core 42 is arranged between the edge pieces 41, 41′. The combination of the edge piece 41, the inner core 42, and optionally the edge piece 41′, may thereby form, or be part of, the core 40.
Preferably, the edge piece 41, 41′ comprises the layered structure 30 described above. For example, the layered structure 30 may be a plywood board. The vertical and/or horizontal locking device may be at least partially, such as entirely, formed in the edge piece 41, 41′. The inner core 42 may comprise a wood-based board, such as an HDF board or a particle board, see FIG. 11a. In some embodiments, the inner core 42 may comprise a plurality of core elements 43, as shown in FIG. 11b. The core elements 43 may be separate strips of wood-based material, e.g., so-called wood lamellas, being displaced by a distance 44 in relation to each other, preferably being less than 5 mm, and/or being in contact with each other. For example, the core elements 43 may comprise an HDF board, an MDF board, or solid wood, such as softwood, e.g., pine or spruce.
It is noted that the enlarged (cross-sectional) side views in FIGS. 2b, 2d and 2f are schematically illustrated and are conceivable for any number of layers, such as five, seven, or nine layers. For simplicity of the presentation, sometimes only the body layer 31 is explicitly shown in some of the figures herein, such as in FIGS. 2a, 2c and 2e. In particular, the embodiment in FIGS. 2a-2f may correspond to any of the embodiments in FIGS. 10a-10c and 11a-11b. Moreover, the body layer 31 is indicated schematically in FIGS. 5d-5e, 7a-7f, 8a-8f, 9a-9f, 11c-11e, 13a-13b and 15d, and in FIGS. 15a-15b in conjunction with a joining layer 32a, but it is clear to an artisan skilled in the art that any of these embodiments may comprise any of the layered structures 30 in, e.g., FIGS. 2a-2f, 10a-10e and 11a-11b, whereby reference is made thereto.
The second panel 2 herein, e.g., in any of FIGS. 10a-10e, 11a-11b and 15a-15b, may further comprise a top layer 50 and a bottom layer 51. The, preferably wood-based, top layer 50 may be a decorative layer, preferably comprising a wood veneer layer. A thickness of the top layer 50 may be at least 1.0 mm, preferably at least 2.5 mm. Moreover, the preferably wood-based, bottom layer 51 may comprise solid wood, such as softwood, e.g., pine or spruce. A thickness of the bottom layer 51 may be 1.0-2.5 mm, such as 1.0-1.5 mm. In FIGS. 11a-11b, the inner core 42, such as the core elements 43, and the edge pieces 41, 41′ may be bonded to the top 50 and/or bottom 51 layer by means of an adhesive. It is emphasized that the bottom layer 51 herein is optional. In addition, in some embodiments the panels 1, 2 may be configured to be attached to a subfloor by means of an adhesive.
The first panel 1 of the first and second aspects herein may be embodied identically to the second panel 2, see, e.g., FIGS. 10a-10e and 11a-11b.
The stop surface 12 may be at least partially arranged in the body layer 31 and/or at least partially arranged in a joining layer 33a disposed below the body layer 31. For example, the stop surface 12 may be entirely arranged in the body layer 31.
In some embodiments, and as illustrated in, e.g., FIGS. 10a-10c, 11a-11b and 15b, at least 50%, such as at least 70%, of a vertical extension 45 from the uppermost segment 46 of the locking surface 5g to a lower vertical end segment 49 of the second edge portion 2b positioned directly vertically below the uppermost segment 46 may be arranged in the body layer 31 and/or at least one connection layer 35a, 35b, cf. the reference numbers in FIG. 7f. By being positioned directly vertically below the uppermost segment 46, the uppermost segment 46 and the lower vertical end segment 49 may be located at the same horizontal positions along the second horizontal direction Y. For example, at least 50%, such as at least 70%, of a vertical extension 45′ from the uppermost segment 46 to a lowermost and outer segment 47 of the second edge portion 2b may be arranged in the body layer 31 and/or the connection layer(s) 35a, 35b. The vertical extension 45′ may be a maximal vertical extension between the uppermost segment 46 and a lowermost portion of the second edge portion 2b located horizontally outward of the locking groove 9 (see below). It is noted that in FIGS. 15a-15b the vertical extensions 45 and 45′ may be the same.
The contact area CA or contact length CL specified above may be determined in a locked state of the panels 1, 2 by a CT scanner, preferably in a plane P′ having a normal N′ extending from the locking surface 5g, cf. FIG. 7f. The vertical extension 45 or 45′ may be determined in the locked state by a CT scanner, preferably in a vertical plane arranged along the third edge portions 1c, 2c, for example corresponding to the cross-sectional side view in, e.g., FIG. 7f.
In the vertically locked state, and in accordance with the first or third aspect, a distance D2 from an inner portion 4a, such as an innermost portion, of the insertion groove 4, to the stop surface 12 may be smaller than a distance D1 from the inner portion 4a, such as the innermost portion, to the locking surface 5g with which the separate tongue 3, for example the outermost section of the tip portion 3i, cooperates. The distances D1 and D2 may be measured along the second horizontal direction Y. In non-limiting examples, the difference D1−D2 may be 0.1-3.0 mm, preferably 0.3-0.9 mm.
The locking portion 6 of the separate tongue 3 may be flexible. Indeed, it may be bent in the vertically locked state, such as an outermost surface 3m thereof being convex, as may be seen most clearly by the curves Q and Q′ in FIGS. 1c, 1d, 4a and 4c. For example, the outermost surface 3m may be specified in a top view of the first panel 1. By being longitudinally bent, a transverse length TL of the locking portion 6 from the insertion groove 4 along a transverse direction T of the separate tongue may be larger than a transverse length TE of the end portion(s) 3a from the insertion groove 4 and/or the vertical plane VP, see, e.g., FIG. 4c. For example, the difference TL−TE may essentially correspond to the difference D1−D2. Alternatively, or preferably additionally, by being longitudinally bent the separate tongue 3 may be curved around the normal N of the main plane M1 and/or around an axis AP extending perpendicularly to a groove plane GP arranged along an inner wall 4c of the insertion groove 4, cf. FIGS. 1c-1e, 2f, 4c and 5d. The longitudinal bending and/or the distances D1, D2 may be measured by a CT scanner, preferably in a central plane parallel to the main plane(s) M1 and/or M2.
As shown in, e.g., FIGS. 2a-2f, 3a-3d, 4c-4e, 5a-5e, 6a-6e, 7a-7f, 8a-8f, 9a-9f and 14a-14d, the abutment member 13 may be provided in a preferably transversely outer and lower portion of the separate tongue 3. The abutment member 13 may project downwards, such as from a tongue body portion 3c. In a first example, it may be formed essentially as a hook or a tooth 13b. In a second example, and as illustrated in FIGS. 6a-6c, it may comprise at least two, such as three, teeth 13b.
The tongue body portion 3c may comprise a continuous longitudinal outer section 3q, preferably extending along substantially the entire longitudinal extension L of the separate tongue 3, see, e.g., FIGS. 3a, 4a, 4d, 5a, 6a, 6d and 14a-14d.
Furthermore, in the locked state the abutment member 13 may in some embodiments be provided at or above the groove plane GP arranged along the inner wall 4c, see, e.g., FIGS. 2f and 5d. The inner wall 4c may be a vertically lower wall. The abutment member 13 may be at least partially, such as entirely, displaced into the insertion groove 4 during locking.
In some embodiments, and as shown in, e.g., FIGS. 2a-2f, 3a-3d, 4d-4e, 5a-5e, 6a-6e, 7a-7f, 8a-8f, 9c-9f, 10a-10c, 11a-11e, 14c-14d, 15a-15b and 15d, a, preferably transversely, outer portion of the separate tongue 3 may comprise a longitudinally extending cavity 3d. The cavity 3d may be disposed transversely behind the abutment member 13, when present, such as at the longitudinal end portion(s) 3a, and may face downwards when the separate tongue 3 is arranged in the insertion groove 4. By means of the cavity, a thickness, such as an outer thickness, TS of the separate tongue and hence the vertical height TG of the tongue groove 5 may be reduced. Also, a weight and/or cost of the separate tongue may potentially be reduced. The cavity 3d may extend along essentially the entire longitudinal length LT of the separate tongue 3, such as to one or both of the longitudinal end portions 3a or longitudinal distal ends thereof. In some embodiments, however, and as shown in, e.g., FIGS. 5a-5c, 10c and 14c-14d, the thickness TS, such as of the tongue body portion 3c, may be substantially constant at the longitudinal end portion(s) 3a, such as being absent of a cavity 3d. Such a separate tongue may be simpler to manufacture. Optionally, the locking portion 6 may comprise a cavity 3d, cf., FIGS. 5a-5c and 14c-14d. However, in some embodiments, the separate tongue 3 does not comprise any cavity 3d, especially not at the locking portion 6, see, e.g., FIG. 10c.
The abutment member 13 may be flexible along the transverse extension T of the separate tongue 3. For example, the flexibility may be achieved by means of the cavity 3d. Thereby, a simpler unlocking of the edge portions 1a, 2b may be obtained.
In some embodiments, opposing longitudinal end portions 3a of the separate tongue 3 both comprise an abutment member 13, see, e.g., FIGS. 1a-1c, 2a-2f, 3a-3d, 4a-4e, 5a-5c, 6a-6c, 7a-7f, 8a-8f, 9a-9f, 10a-10c, 11a-11e and 14a-14c. The edge portions 1a, 2b may thereby become unlocked from either side. In some embodiments, however, only a single longitudinal end portion 3a of the separate tongue 3 comprises an abutment member 13, see, e.g., FIGS. 1b, 1d, 6d-6e, 7a-7f, 8a-8f, 9a-9f, 10a-10c and 11a-11e. The edge portions 1a, 2b may thereby preferably become unlocked from one side. It is understood that any of these alternatives are equally conceivable herein.
By way of example, a longitudinal length LA of the abutment member 13, such as along the longitudinal extension L of the separate tongue 3, may be 1-20 mm, preferably 5-10 mm or 1-6 mm, more preferably 3-6 mm, cf., FIGS. 3a-3b, 4e and 5c. It is noted that a larger longitudinal length LA may imply a reduced vertical locking strength, but a simpler unlocking. Generally herein, the vertical locking strength must be sufficiently high for obtaining a functioning locking device along the edge portions; at the same time, the vertical locking strength has to be at least locally configured so that the edge portions may be unlocked.
The stop surface 12 may be distinct from, preferably being spaced from, the locking surface 5g. The stop surface 12 may be disposed vertically below the tongue groove 5, as shown, e.g., in FIGS. 2a-2b, 2e-2f, 5d-5e, 6b, 7a-7f, 8a-8f and 9a-9f. Additionally, or alternatively, the stop surface 12 may be disposed outside an opening 5a of the tongue groove 5. The opening 5a may extend horizontally from a vertical plane VS provided along the stop surface 12, such as an innermost portion thereof, optionally extending horizontally to the vertical plane VP. With respect to the second panel 2, the vertical plane VS may be provided horizontally inside of the vertical plane VP, see, e.g., FIG. 9b.
Optionally, the tongue groove 5, such as the opening 5a, may comprise at least one bevel 5b, cf., FIGS. 2b, 2d, 2f, 7b, 10a-10c and 11a-11b. Thereby, the stop surface 12 may be disposed, preferably horizontally, outside of the bevel. The bevel 5b may be positioned adjacent to the locking surface 5g and may form a guiding surface, such as during locking and/or unlocking. The at least one bevel 5b may be at least partially arranged in the body layer 31, see, e.g., FIG. 10b. Optionally, the remaining part of the bevel(s) 5b may be arranged in an adjacent layer, such as the joining layer 33a. In some embodiments, the at least one bevel 5b may be entirely arranged in the body layer 31, see, e.g., FIGS. 2d, 10a, 10c and 11a-11b. In yet some embodiments, the bevel(s) 5b may be entirely arranged in an adjacent layer, such as the joining layer 33a, cf. FIGS. 9a-9b together with the explicit layer configuration in any of FIGS. 2a-2f, 10a-10c and 11a-11b. Generally herein, the at least one bevel 5b may comprise a planar portion and/or a rounded portion, such as being planar or rounded. For example, an angle δ of the at least one bevel 5b with respect to the vertical plane VP may be 5°-45°, such as 10°-30°, cf. FIG. 8b. It is noted that the vertical height TG of the tongue groove 5 may include the at least one bevel 5b.
The stop surface 12 in any embodiment herein may be an edge surface and may extend along the second edge portion 2b, preferably with a constant cross-section there along, cf., FIGS. 1e and 12b. The locking portion 6 may be spaced, such as horizontally and/or vertically, from the stop surface 12 in the vertically locked state, see, e.g., FIGS. 2c-2d and 11e. There may be a horizontal distance 53 between the stop surface 12 and the locking portion 6 with which the locking surface 5g cooperates. For example, the horizontal distance 53 may be measured from an innermost portion 12a of the stop surface 12 (i.e., innermost with respect to the second panel 2) to, preferably the outermost section of, the tip portion 3i. The horizontal distance 53 may be measured along the second horizontal direction Y. For example, the horizontal distance 53 may essentially correspond to the difference D1−D2. In non-limiting examples, the horizontal distance 53 may be 0.1-3.0 mm, preferably 0.3-0.9 mm. The horizontal distance 53 may be measured by a CT scanner, preferably in a central plane parallel to the main plane(s) M1 and/or M2.
As shown in, e.g., FIGS. 2b, 2f, 5e 8b, 9b and 9d, at least a portion of, such as the entire, stop surface 12 may be planar, preferably extending essentially vertically, such as vertically. By extending essentially vertically, the stop surface 12 may form an angle τ of 0°-10°, such as 0°-5° or 0°-2°, with respect to the normal N, cf. FIG. 2a.
In some embodiments, and as may be seen most clearly in FIGS. 7a-7f, the stop surface 12 may form an angle τ of 0°-30°, such as 0°-20°, with respect to the normal N. Preferably, the stop surface 12 may be inclined such that the angle τ exceeds 10° but does not exceed 30°, such as exceeding 10° but not exceeding 20°, or being 20°-30°.
In some embodiments, and as schematically illustrated in, e.g., FIGS. 2b, 2f, 7f, 8f, 9b and 9d, the abutment member 13, such as an outer surface 13a thereof, may in the locked state extend essentially vertically, preferably with respect to the vertical direction Z. A simpler unlocking may thereby be provided, preferably together with an essentially vertical, such as vertical, stop surface 12.
In some embodiments, however, and as schematically illustrated in FIGS. 5e and 6b, the abutment member 13, such as the outer surface 13a, may in the locked state be inclined by an angle β, preferably with respect to the vertical direction Z. In a first example, and as shown in FIG. 6b, the angle may be negative, such that the outer surface 13a is inclined inwards, e.g., with a range of 0°<β≤10°, such as 1°≤β≤5°. In a second example, and as shown in FIG. 5e, the angle may be positive, such that the outer surface 13a is inclined outwards, e.g., with a range of 0°<β≤10°, such as 1°≤β≤5°.
Alternatively, or additionally, to an inclined abutment member 13, in some embodiments the stop surface 12 may be inclined. Generally herein, there may be a relative angle ϕ between the stop surface and the abutment member in the locked state, cf. FIGS. 5e and 6b. A non-zero relative angle ¢ may provide a simpler disassembly of the panels. For example, a negative relative angle may be −10°≤ϕ<0°, such as −5°≤ϕ≤−1°. A positive relative angle ϕ may additionally provide a larger bending of the separate tongue 3, whereby a smaller locking length of the separate tongue may be obtained and, for example, a simpler disassembly. For example, 0°<ϕ≤10°, such as 1°≤ϕ≤5°.
As shown in FIGS. 11c-11d, the abutment member 13 may in some embodiments be provided in a transversely outer and upper portion of the separate tongue 3. The stop surface 12 may be disposed vertically above the tongue groove 5 and/or outside the opening 5a.
In any of the first, second, and third aspects, a pair of oppositely arranged displacement surfaces 3g, 3h of the separate tongue 3 may vertically position the separate tongue in the insertion groove 4, preferably by cooperating with its inner walls 4c, 4d. Moreover, the displacement surfaces 3g, 3h may be configured to be displaced against the inner walls 4c, 4d during locking or unlocking, the displacement preferably being directed along the transverse extension T of the separate tongue and/or along the groove plane GP or GQ.
The separate tongue 3 in any of the first, second and third aspects may comprise flexible members 3b, such as flexible legs, configured to face the inner portion 4a of the insertion groove 4 when arranged therein. The flexible members 3b may be bendable (see arrow BE in FIGS. 4b and 14a-14b) between an inner 3k and an outer 3l position, preferably along a tongue insertion direction and/or tongue displacement direction of the insertion groove, which may be parallel with the transverse extension T of the separate tongue. Thereby, the separate tongue 3 may be displaceable between an inner and an outer position of the insertion groove. An inwardly directed pressure applied on the separate tongue 3 may displace it inwards toward the inner position during locking (see arrows B1) or unlocking (see arrows B2) and the flexible members 3b may be configured to displace it outwards during locking (see arrows B1′) or unlocking (see arrows B2′) toward its outer position, e.g., by virtue of a biasing force of the flexible members 3b. For example, the separate tongue may be compressed.
The separate tongue 3 may comprise a polymer-based material, such as thermoplastic material, e.g., PP, and optionally a reinforcing element, such as glass fibres. For example, the separate tongue may be formed by injection moulding. Optionally, it may comprise at least one friction element 3f for preventing it from being displaced out from the insertion groove 4. The friction element 3f may be shaped as a local protrusion which is arranged on one or several flexible members 3b, preferably extending perpendicularly outwards from any or both of the displacement surfaces 3g, 3h. The cooperation between the stop surface 12 and the abutment member 13 may prevent the separate tongue from being displaced into the tongue groove 5 at the longitudinal end portion(s) 3a. Preferably, the abutment member 13 is pretensioned against the stop surface 12 in the vertically locked state.
In some embodiments, and as illustrated in FIGS. 1b, 1d and 6e, at least two separate tongues 3, such as a plurality of separate tongues, may be arranged in the insertion groove 4. The separate tongues 3 may be arranged side-by-side along the first edge portion 1a, 2a, such as along the first horizontal direction X, and/or, as shown in FIG. 1b, along the third edge portion 1c, 2c. For example, the first edge portion 1a, 2a may be a short edge portion, but a long edge portion is equally conceivable. It is noted that the locking device on the third 1c, 2c and fourth 1d, 2d edge portions, e.g., in FIG. 1b, may be embodied similarly to the locking device on the first 1a, 2a and second 1b, 2b edge portions, such as in FIGS. 2a-2f.
The separate tongues 3 comprising an abutment member 13 at a single longitudinal end portion 3a may each be oriented in a similar manner in the insertion groove 4, such as having the abutment member 13 of each separate tongue located at the same longitudinal end portion 3a, cf., FIG. 6e. Thereby, each of the separate tongues may be properly displaced into and out of the insertion groove 4 along the entire length of the first edge portion 1a. Also, the edge portions 1a, 2b may become capable of being unlocked.
A skilled artisan will appreciate that in some embodiments at least two separate tongues 3, each comprising abutment members 13 at opposing longitudinal end portions 3a, may be arranged side-by-side in the insertion groove 4. For example, any of the separate tongues in FIGS. 2a-2f, 3a-3d, 4a-4e, 5a-5e, 6a-6c, 9a-9f, 10a-10c, 11a-11e and 14a-14d may be used.
Generally herein, such as in any of FIGS. 1a-1e, 2a-2f, 3a-3d, 4a-4e, 5a-5e, 6a-6e, 7a-7f, 8a-8f, 9a-9f, 10a-10c, 11a-11e, 12a-12b, 14a-14d and 15c-15d, an abutment member 13 of a separate tongue 3 may be arranged in an end section 11 of the first edge portion 1a, which may be provided adjacent to the third edge portions 1c, 2c, cf., FIGS. 1e, 6e and 12a-12b. The end section 11 may be configured to be locked during a final stage of the locking (see arrows A1) of the edge portions 1a, 2a and/or unlocked during an initial stage of the unlocking (see arrows A2) of the edge portions 1a, 2a, preferably by means of a folding displacement.
In FIG. 1b, the longitudinal end portion 3a of the separate tongues 3 in the short 1a, 2a and long 1c, 2c edge portions may comprise an abutment member 13 in one longitudinal end portion 3a. Preferably, the abutment member of the separate tongue in the long edge portion is adjacent to a corner portion 8a where strips 8, 18 of the long and short edge portions meet (see below). Thereby, a risk of an involuntary unlocking of the long edge portions, e.g., in a middle section thereof, may become reduced. Moreover, the abutment member of the separate tongue in the short edge portion preferably is adjacent to the corner portion 8a and/or provided in the end section 11. Optionally, the separate tongue 3 in the short edge portion 1a, 2a may also comprise an abutment member 13 in the opposing longitudinal end portion 3a (see leftmost reference number 13 in FIG. 1b).
Generally herein, the flexible members 3b may each extend from a respective base portion 3r of the separate tongue 3. Each flexible member may extend from and may be bendable around the respective base portion 3r. As shown in FIGS. 14a-14b, a flexible member 3b extending from a base portion 3r arranged at the longitudinal end portion 3a may extend from and may be bendable around a longitudinal inner side 3u of said base portion 3r. The inner side 3u may be a region of the base portion 3r facing away from a nearest longitudinally outermost edge 3v of the separate tongue. In other words, an end segment 3t of the flexible member 3b may be directed towards the longitudinal central portion of the separate tongue 3. Hence, an unlocking starting at this longitudinal end portion 3a is preferred.
As shown in FIG. 14a, the flexible members 3b may all be oriented in the same direction, e.g., such that they all extend from the same longitudinal side, such as inner side 3u or outer side 3w, of the base portion 3r. FIG. 14b illustrates that in some embodiments a flexible member 3b extending from a base portion 3r arranged at a respective longitudinal end portion 3a may extend from and may be bendable around a longitudinal inner side 3u of the base portion 3r. Hence, an unlocking from either longitudinal end portion 3a may be equally preferred. As shown in FIG. 14b, the flexible members 3b may be grouped into two sets S1, S2 that are oppositely oriented, e.g., such that they extend from opposite longitudinal sides of the base portions 3r of the respective set S1, S2, such as the inner sides 3u. For example, a distance DF from the longitudinally outermost edge(s) 3v to the flexible member 3b, such as to the end segment 3t, may be 5-30 mm, such as 10-20 mm.
The abutment member 13 may in some embodiments be at least partially arranged longitudinally outwards from the flexible members 3b, see, e.g., FIGS. 14c-14d. For example, the abutment member 13 may be entirely arranged longitudinally outwards from the flexible members 3b. The separate tongue 3 preferably comprises support members 3s arranged longitudinally outwards from the flexible members 3b. The support members 3s may cooperate with the inner portion 4a during locking.
In some embodiments, the first edge portion 1a may comprise an auxiliary groove 4b for housing at least a portion of the abutment member 13 during locking, see FIGS. 9a-9b. The auxiliary groove 4b may be located under an opening 4e of the insertion groove 4 and may extend along the first edge portion 1a, at least at the location of the abutment member 13, such as along an entirety of the first edge portion. In the locked state, the abutment member 13 may thereby be at least partly, such as entirely, provided below the groove plane GP, see, e.g., FIG. 9a. The insertion groove may be arranged above the groove plane GP. Thereby, the abutment member 13 may be displaced outside of the insertion groove 4 during locking.
In any of the embodiments herein, such as in FIGS. 1a-1e, 2a-2f, 4c, 5d-5e, 6e, 7a-7f, 8a-8f, 9a-9f, 10a-10c, 11a-11e, 12a-12b, 14a-14d and 15a-15d, the first edge portion 1a may comprise a strip 8 extending horizontally outwards from a lower portion thereof, such as along the second horizontal direction Y. The horizontal locking device may comprise a locking element 7 arranged on the strip 8, preferably extending upwards, and a locking groove 9 provided in the second edge portion 2b. The locking element 7 may be configured to cooperate, such as engage, with the locking groove 9 to provide a horizontally locked state of the first 1a and second 2b edge portions. For example, an inner portion 7a of the locking element 7 and an outer portion 9a of the locking groove 9 together with the joining upper portions 1g, 2g may lock the edge portions 1a, 2b in two opposite horizontal directions, such as along the second horizontal direction Y, cf., FIG. 2e.
In some embodiments, and as shown, e.g., in FIGS. 2a-2f, 7a-7f, 8a-8f, 9a-9f, 10a-10c and 11a-11e, the inner walls 4c, 4d of the insertion groove 4 may extend essentially horizontally, such as being essentially parallel with the main plane M1. This may be preferred for thicker panels, such as floor panels, for example having a thickness TP of at least 10 mm, preferably 10-25 mm, more preferably 12-16 mm. In some embodiments, the thickness TP may be 8-20 mm, such as 10-20 mm or 14-16 mm.
In some embodiments, and as shown in, e.g., FIGS. 5d-5e, 15a-15b and 15d, the insertion groove 4 may be inclined by an angle γ. The angle γ may be defined as an inclination of the groove plane GP with respect to the main plane M1 (which for clarity is parallel transported downwards in FIG. 5d). For example, the angle γ, may be less than 20°, preferably 5-15°, such as 10°. This may be preferred for thinner panels, such as laminate floor panels, for example having a thickness TP not exceeding 10 mm, such as 8-10 mm.
A skilled artisan will appreciate that the above embodiments are exemplary and that any of the embodiments of the insertion grooves in the previous two paragraphs with angles γ=0 and γ>0, respectively, may be interchanged.
As shown in, e.g., FIGS. 9c-9f, the second edge portion 2b may comprise a recess 5c for accommodating the abutment portion 13 in the locked state. The stop surface 12 may be provided as an inner 5d and/or a lower 5e recess surface. Preferably, the recess 5c is provided below the tongue groove 5. The second edge portion 2b may further comprise a protrusion 5f provided below the recess 5c. The recess and/or the protrusion may extend along essentially the entire second edge portion, preferably with a constant cross-section. By means of the recess and/or protrusion, a simpler disassembly of the panels may be provided. In particular, a quicker displacement of the separate tongue 3 into the insertion groove 4 may be provided. In addition, the displacement may be more controlled. Preferably, the inner 5d and/or the lower 5e recess surface(s) are/is planar. For example, the inner recess surface 5d may extend essentially vertically, such as 0°-10°, preferably 0°-5°. The lower recess surface 5e may extend at an angle α of 10°<α≤45°, preferably 10°≤α≤30°, with respect to the vertical direction Z.
In some embodiments, the joining upper portions 1g, 2g may horizontally overlap. As shown in FIGS. 5d-5e, the second edge portion 2b may extend above the first edge portion 1a. For example, the first 1a and 2b edge portions may comprise a ledge portion 1i and a lap portion 2i, respectively, which cooperate, such as engage, with each other in the locked state. The joining upper portions 1g, 2g of the edge portions 1a, 2b along which the vertical plane VP may extend may in the embodiment in FIGS. 5d-5e be disposed along a horizontally outermost surface of the upper portion 1g, such as of the ledge portion 1i.
The first 1a and second 2b edge portions in any of the first, second, and third aspects may be configured to be vertically locked to each other by a relative vertical displacement A1 of the first and second edge portions towards each other, such as displacing the second edge portion against the first edge portion. The relative vertical displacement A1 preferably comprises a folding displacement, or equivalently, scissor displacement (e.g., so-called fold down), whereby the second edge portion is gradually vertically displaced towards the first edge portion, see, e.g., FIGS. 1e, 7a-7f, 8a-8f, 9a-9f and 11c-11e (see arrows A1, starting with the lower figures in FIGS. 8a-8f and 9c-9f). By means of the folding displacement, the separate tongue 3, such as the locking portion 6, may in a first stage be gradually depressed towards or inserted into the insertion groove 4 along the first edge portion 1a and in a second subsequent stage gradually inserted into the tongue groove 5 along the second edge portion 2b. Clearly, the relative vertical displacement A1 may also lock the edge portions 1a, 2b horizontally, such as by means of the cooperating locking element 7 and locking groove 9.
During locking, the second edge portion 2b, preferably a lower cooperating surface 2j, may cooperate, preferably directly, with an outer cooperating surface 3e of the separate tongue 3 for displacing it into the insertion groove 4, see, e.g., FIGS. 7a-7f, 8a-8f, 9c-9f and 11c-11e (see arrows A1). For example, during locking, the second edge portion 2b, preferably the lower cooperating surface 2j, may cooperate, preferably directly, with the locking portion 6 for displacing separate tongue 3 into the insertion groove 4. The abutment member 13 and the locking portion 6 may be operatively coupled such that, during locking, the second edge portion 2b pushing the locking portion 6 in a direction toward the inner portion 4a causes the abutment member to move together with the locking portion in the direction toward the inner portion 4a. The lower 2j and outer 3e cooperating surfaces may be inclined, preferably with essentially corresponding inclinations. For example, the outer cooperating surface 3e may be arranged in the longitudinal outer section 3q. Moreover, the outer cooperating surface 3e preferably extends substantially along the entire longitudinal extension L. Optionally, the outer cooperating surface 3e may be chamfered at the longitudinal end portion(s) 3a by a chamfer 3p. Preferably, such a chamfer 3p may cooperate with the second edge portion 2b during locking for gradually inserting the separate tongue 3 into the insertion groove. The longitudinal end portion(s) 3a may comprise a longitudinally curved section 3x as seen from a top and/or bottom view of the separate tongue 3. The chamfer 3p may be arranged in the curved section 3x.
During locking, preferably during and/or between said first and second stages, at least one selected from the group of the stop surface 12, the bevel 5b, the inner 5d, the lower 5e recess surface and protrusion 5f, may cooperate with the separate tongue 3, such as with the tip portion 3i and/or the abutment member 13.
In any embodiment herein, the abutment member 13 may optionally comprise a straight portion 3n extending in parallel with the longitudinal extension L, optionally being entirely straight, see, e.g., FIGS. 3a-3b, 4a-4e, 5a-5c, 6a-6e and 14a-14d. Preferably, the straight portion 3n is arranged longitudinally inside of the longitudinally curved section 3x and/or the chamfer 3p.
During the relative vertical displacement A1, preferably folding displacement, a pair of third 1c, 1c′, 2c and fourth 1d, 2d edge portions may be configured to be locked to each other by a relative angling displacement of the third and fourth edge portions against each other, such as by angling the third edge portion against the fourth edge portion, cf., FIG. 1e. The edge portions 1c, 1c′, 2c, 1d, 2d may be vertically and horizontally locked to each other, for example by a locking device integrally formed with the core 40 of the panels 1, 1′, 2. For example, the edge portions may be interlocked by means of a cooperating tongue 14 and tongue groove 15 as well as a locking element 17 provided on a strip 18 cooperating with a locking groove 19, see, e.g., FIG. 12d. Alternatively, the edge portions may be interlocked analogously to the embodiments on the first 1a, 2a and second 1b, 2b edge portions described herein, such as in FIGS. 2a-2f, 5d-5e, 6e, 7a-7f, 8a-8f, 9a-9f and 11c-11e, whereby reference is made thereto. For example, a locking device on the third 1c, 2c and fourth 1d, 2d edge portions comprising one or several separate tongues 3, e.g., as in FIG. 1b, may be used. For other embodiments of the edge portions 1c, 1c′, 2c, 1d, 2d, we refer to, e.g., page 2, lines 13-22 and FIGS. 1a-1e and 2a-2e in WO 2021/206611 A1 whose contents hereby are explicitly incorporated by reference.
The first 1a and second 2b edge portions at least in accordance with the first and third aspects may be configured to be vertically unlocked by a relative vertical displacement A2 of the first and second edge portions away from each other, preferably by means of a folding displacement, see, e.g., FIGS. 1e, 8a-8f, 9e-9f and 12a-12b. Alternatively, or additionally, the first 1a and second 2b edge portions may be configured to be vertically unlocked by a repeated relative vertical displacement A2′ of the first and second edge portions away and towards each other, see, e.g., FIGS. 1e, 8a-8f, 9c-9f and 12a-12c (see arrows A2, A2′, starting with the upper figures in FIGS. 8a-8f and 9c-9f). By means of the folding displacement, the separate tongue 3, such as the locking portion 6, may be gradually displaced out from the tongue groove 5 along the second edge portion 2b and inserted into the insertion groove 4 along the first edge portion 1a. Thereby, the edge portions 1a, 2b may be gradually unlocked from each other. Analogously with the discussion above, the relative vertical displacement A2, A2′ may also unlock the edge portions 1a, 2b horizontally, such as by disengaging the locking element 7 from the locking groove 9. By unlocking the edge portions 1a, 2b, the first 1 and second 2 panels may be disassembled from each other.
During unlocking, the second edge portion 2b may cooperate with the separate tongue 3, such as the locking portion 6, for displacing it into the insertion groove 4, see, e.g., FIGS. 8a-8f and 9c-9f (see arrows A2). For example, at least one selected from the group of the stop surface 12, the bevel 5b, the inner 5d, the lower 5e recess surface and protrusion 5f, may cooperate with the separate tongue, such as with the tip portion 3i and/or the abutment member 13.
In some embodiments, and as shown in FIGS. 12a-12c, the unlocking may be accomplished by means of a raising element 16. The raising element 16 may comprise a wedge portion 16a and a, preferably inclined, support portion 16b, see FIG. 12c. This type of unlocking may be especially suitable when the panels 1, 2 are arranged on a subfloor 20, which preferably is substantially levelled or even. For example, the assembled first 1 and second 2 panels may be raised or angled together along the third edge portions 1c, 2c, e.g., by inserting the raising element 16 between the rear side 2f of the second panel 2 and the subfloor 20. For example, the raising element 16 may be gradually displaced under the rear side 2f and the assembled panels 1, 2 may be gradually raised vertically by means of the wedge portion 16a. When inserted, the rear side 2f may thereby rest on the support portion 16b. Thereafter, a force F may be applied to the front side 1e of the first panel 1, whereby the first 1a and second 2b edge portions may be relatively displaced vertically A2 away from each other and hence may become vertically unlocked, cf. FIG. 12b. By applying a larger force F, the unlocking may become more rapid.
In some embodiments, and as shown in 13a-13d, a separate tool 22, such as an elongated rod, may be used for unlocking the edge portions 1a, 2b, and hence disassembling the panels 1, 2. Such an unlocking is preferred for the embodiment in FIGS. 11c-11e, as indicated by the dashed line in FIG. 11e (see arrow A2 or A2′), and also for the embodiment in FIG. 15a-15b as described in WO 2020/145862 A1. Preferably, the separate tool 22 comprises a cylindrical end portion 23, for example having a cylindrical cross-section along its entire length direction, but other geometries are also possible. In non-limiting embodiments, a thickness TT of the separate tool may be 0.5-2.0 mm, preferably 0.8-1.5 mm, such as 1.1 mm. The separate tool 22 may be inserted into the tongue groove 5 (see arrow AW) such that the separate tongue 3, such as the locking portion 6, may be gradually displaced out from the tongue groove 5 along the second edge portion 2b and inserted into the insertion groove 4 along the first edge portion 1a. Thereby, the edge portions 1a, 2b may be gradually unlocked from each other.
Other ways of unlocking are equally conceivable, especially those described on page 18, line 22 to page 21, line 10 and FIGS. 13, 14a-14d, 15a-15b and 16a-16b in WO 2022/197234 A1, whose contents hereby are explicitly incorporated by reference.
During locking and/or unlocking, the separate tongue 3 may be at least partially, such as essentially entirely, straightened along its longitudinal extension, cf. FIG. 4a. For example, when it is displaced into the insertion groove 4, the outermost surface 3m of the separate tongue, preferably at least at the locking portion 6, may be straightened. Preferably, it is straightened from a convex shape (cf. curve Q) to a less convex shape (cf. curve Q′), such as being essentially straight, e.g., any local portion of the outermost surface 3m forming a maximal angle of 0°-10°, preferably 0°-5°, more preferably 0°-2°, with respect to the inner portion 4a, or completely straight (i.e., 0°) (see curve S). For example, the outermost surface 3m may be specified in a top view of the separate tongue 3 and/or first panel 1.
When at least one separate tongue 3 is provided along the short edge portion 1a, 2a, such as in FIG. 1a, the short edge portions may be locked or unlocked by folding and the long edge portions comprising an integrally formed locking device may be locked or unlocked by angling. When at least one separate tongue 3 is provided along the short edge portion 1a, 2a and at least one separate tongue 3 is provided along the long edge portion 1c, 2c, such as in FIG. 1b, the short or long edge portions may be locked or unlocked by angling and/or folding.
At least in some embodiments of the second aspect described herein, the separate tongue 3 does not comprise any abutment members 13, see, e.g., FIGS. 15a-15b. Apart from the positioning and characteristics of the layers of the first 1 and second 2 panels, some additional embodiments of the second aspect described herein are generally described, e.g., in claims 1-13 and FIGS. 4a-4b, 5a-5b, 6a-6b, 7a-7b, 8a-8d, 9b-9c, 10a-10b and 14a-14b of WO 2014/209213 A1 and, e.g., in claims 1-15 and FIGS. 2a-2b, 3a-3c and 4a-4c of WO 2020/145862 A1, whose contents are expressly incorporated by reference. In such embodiments, the separate tongue 3 does not comprise any abutment members 13 configured to cooperate with a stop surface 12, but comprises a cavity 3d, whose characteristics have been described above (in these embodiments, disregarding the abutment member 13). For example, the positioning and characteristics of the layers of the first 1 and second 2 panels with respect to the locking portion 6 may be embodied as in any of FIGS. 2a-2f, 5d-5e, 7a-7f, 8a-8f, 9a-9f, 10a-10e, 11a-11e and 15a-15b described herein, whereby reference is made thereto.
According to the second aspect, a cross-sectional view, such as any of those in FIGS. 2c-2d and 15a-15b, may thereby be applicable along substantially the entire longitudinal length LT.
Optionally herein, a coating 52, such as a wax, may be applied in the tongue groove 5, preferably including the locking surface 5g, cf. FIG. 8d. Thereby, the risk of damaging the panels 1, 2 during their disassembly or reassembly, such as by splintering or chipping, may be further reduced.
Any of the angles herein, for instance α, β, γ, ε, ϕ, θ, σ or τ, and the radius R may be measured by means of a profile projector, for example from Mitutoyo or Dravitec AB.
The disclosure has mainly been described above with reference to a few embodiments. However, as is readily appreciated by a person skilled in the art, other embodiments than the ones disclosed above are equally possible within the scope of the disclosure. For instance, it is clear that any of the embodiments in FIGS. 2a-2f, 4c, 5d-5e, 7a-7f, 8a-8f, 9a-9f, 10a-10c and 11a-11e may be embodied as in FIG. 1c or 1d in the locked state, with proper modifications depending on whether the separate tongue 3 comprises a single abutment member 13 or two of them at two opposing longitudinal end portions 3a. Also, it is appreciated that the edge portions 1a, 2b in FIGS. 15a-15b may be locked by a relative vertical displacement A1 as described elsewhere herein. Furthermore, it is emphasized that any of the panels 1, 2, 1′ herein may comprise any of the core 40 configurations, such as layer structures 30, and top 50 and/or bottom 51 layer configurations in, e.g., FIGS. 2a-2f, 10a-10e and 11a-11b, whereby reference is made thereto. Finally, it is clear that any folding displacement described herein, such as of the edge portions 1a, 2b, may be accomplished by angling of an adjacent edge portion, such as of a third edge portion 2c, cf. FIGS. 1e and 12a-12c.
Patent Application
20250223810
