Patent Grant
11486147
The invention generally relates to the field of sets of panels for covering floors, ceilings or walls, in particular sets of panels comprising a plurality of panels to be joined at their adjacent edges.
Building panels and in particular floorings used in highly frequented and heavy load environments necessarily need strong locking to prevent opening of the locked edges between two adjacent panels. It is known for such floorings to provide a locking system comprising a locking profile provided to one of the panels along the adjacent edges, wherein said locking profile is manufactured in either plastic materials or a metal material such as aluminum.
To date and as disclosed in WO98/24994 and WO98/24995, such locking profiles and in particular the metallic locking profiles are manufactured starting from metal sheets punched into a desired shape that is subsequently fixed to a panel along an edge thereof.
A first drawback of the method and locking mechanism disclosed in the prior art is that mechanically fixing the locking profiles to panels is a very slow process slowing down the entire production process of the panels. Another drawback is that the punching of metal sheets is a slow process providing only very limited design options and requiring large capex for each variation in the design of the locking profiles. Further improvements of this locking system have therefore been rare.
It is however an object of the present invention to further improve this locking system.
In a first aspect, the present invention relates to a set of panels (1,2), each panel comprising:
In contrast to the general assumptions in the business of flooring (cf. WO94/26999) Applicant has now surprisingly discovered that by providing a continuous second rim, far greater control of the design of the locking profile and far greater freedom of design of the locking profile can be obtained allowing further improving the locking strength of the locked panels, while at the same time drastically improving production time of the locking profiles and the speed at which the locking profiles can be fixed to the panels.
In particular, the Applicant has discovered that by manufacturing the locking profile with a continuous second rim, the angles of the rims of the locking profile interacting with the panels can be designed such as to strongly increase the locking strength when compared to locking profiles made of punched metal sheets and that, apart from the increased strength, the locking between adjacent panels with the locking profile according to the invention provides an improved stability of the lock.
As illustrated in
The preferred method of manufacturing the locking profile of the set of panels according to the present invention is by extrusion.
In a second aspect, the present invention relates to method of manufacturing a set of panels (1, 2), the method comprising:
In a third aspect, the present invention relates to locking profile (3) for locking two adjacent panels of a set of panels (1, 2), said locking profile (3) comprising a base (16) and at least protruding rims (17, 18, 19) extending parallel to one another in the longitudinal direction of the locking profile (3), whereby a first rim (17) and a second rim (18) situated between the first and third rims (17, 19) define a clamp allowing clamping a section of a panel therebetween and whereby the second rim (18) is continuous over the entire length of the locking profile (3).
In a fourth aspect, the present invention relates to an assembly of panels comprising a set of panels (1, 2) as defined in any of claims 1-12.
The present invention concerns a set of panels, typically for covering floors, ceilings or walls.
In the embodiment represented in
At its side most proximate to the first edge (6) of the panel, the first groove (10) is partially delimited by a sidewall or abutment surface (12) that preferably at least partially extends slanting in view of the direction normal to the bottom surface (4) such that this sidewall inclines towards the first edge of the panel in a direction from the bottom surface (4) towards the top surface (5) of the panel and as such defines a wedge shaped section (13) in the panel between this sidewall (12) and the first edge (6). In the embodiment represented in
Preferably, the first panel (1) further comprises a recess (14) provided in the first edge (6) that in this case is delimited by a sidewall (15) comprising a first part (15.1), most proximate to the bottom surface (4) of the panel extending substantially parallel to the direction normal to the bottom surface (4) and a second wall part (15.2) slanting in view of the first wall part inclined towards the second edge (7) of the panel in a direction from the bottom surface (4) towards the top surface (5) of the panel and as such defines the wedge shaped section (13) in the panel between the first edge (6) and the first groove (10).
As shown in
According to the present invention, the second rim (18) is continuous and extends over the entire length of the locking profile (3). Preferably also the first and third rims (17, 19) are continuous and extend over the entire length of the locking profile (3).
As represented in
The third rim (19) of the locking profile (3) preferably comprises two parts: a first part (19.1), most proximate to the base (16) of the locking profile (3); and a second part (19.2), most distant from the base (16). The first part (19.1) is inclined away from the second rim (18) over an angle γ with the base (16) of the locking profile (3) of at least 75°, preferably between 80°-90°, most preferably between 80°-86°.
Alternative to the two part designs of the first, second and third rims (17, 18, 19), any or all can be designed as a rim extending in a same direction over its entire height, in which case this direction is preferably inclined at angles α, β and γ respectively as described hereinabove.
Preferably, the locking profile (3) is an extruded profile manufactured in a plastic material (e.g. a glass-fiber reinforced plastic material, such as polystyrene) or preferably, in a metal material such as aluminum.
In order to assemble the set of panels (1, 2) and as represented in
The strength of the horizontal lock, defined as the force needed to tear both panels apart in the direction perpendicular to the first and second edges (6, 7) of the first and second panels (1, 2) in the plane of the bottom surfaces (4) of both panels (1, 2), is apart from material failure of the panels, dependent on the strength of the locking profile.
When manufacturing the locking profile in aluminum and with a base having a thickness of at least 0.4 mm, for example 0.6 mm, a locking strength FMAX of at least 3 kN/m can be achieved when measured according to ISO24334 (2006), more preferably at least 4 kN/m.
The thickness of the base (16) and the rims (17, 18, 19) preferably ranges between 0.4 mm and 1.2 mm, preferably between 0.5 mm and 0.8 mm. In some embodiments of the locking profile as explained further, the first and/or second rim may deviate from these ranges.
In addition hereto it is mentioned that the thickness of the base (16) of the locking profile (3) may vary between a first section (16.1) extending between the first rim (17) and the second rim (18) and a second section (16.2) extending between the second rim (18) and third rim (19).
For the second section (16.2) the thickness is preferably chosen to allow elastic bending of the locking profile (3) as shown in
As mentioned supra the locking profiles (3) are preferably manufactured by extrusion. Once extruded, the locking profiles (3) are cut to a desired length, whereafter the cutted profiles (3) are stacked by positioning a plurality of locking profiles in a first orientation parallel to one another to create a first layer of locking profiles (3) and subsequently positioning a plurality of locking profiles in a second orientation parallel to one another and perpendicular to the first orientation to create a second layer of locking profiles (3) on top of the first layer of locking profiles. A third layer of locking profiles (3) positioned in the first orientation can subsequently be placed on the second layer of locking profiles and so on, thereby obtaining a cross-stack (21) of locking profiles (3) shown in
As schematically represented in
Subsequently, as represented in
It is preferred that the first rim (17) of the locking profile (3), when extruded, is configured to allow bending the first rim (17) towards the second rim (18), for clamping said locking profile (3) on a panel (1), while still providing sufficient resistance against bending the first rim (17) backwards such that the tensile strength of the locking profile (3), measured in the plane of the base (16) of the locking profile (3) is at least 3 kN/m measured in accordance with ISO24334(2006), preferably at least 4 kN/m.
According to a preferred embodiment, the first rim (17) is permanently deformed by the bending operation. In case the locking profile is manufactured in a plastic material, heat may be applied to the first rim (17) just before, during or after bending the first rim (17) to make the deformation of the first rim permanent thereby ensuring clamping of the locking profile (3) on a panel (1).
The locking profile (3) shown in
The locking profile shown in
The first wing (25) is inclined towards the first rim (17) of the locking profile (3) and has the same function of clamping the locking profile (3) on the first panel (1) as the inclined second part (18.2) of the second rim (18) of the locking profile described with reference to
The locking profile (3) shown in
In this case both spaced apart rims (181 and 182) comprise a wing. The first spaced apart rim (181), situated most proximate to the first rim (17), comprises a wing (25) that is inclined towards the first rim (17) of the locking profile (3). This rim (181) has the same function as the second rim (18) of the locking profile described with reference to
In
In the represented embodiment, the tongue is provided on the first edge (6) of the first panel (1), while the groove is provided in the second edge (7) of the second panel (2), yet clearly it is also possible to provide the tongue on the second edge (7) of the second panel (2) and to provide the groove in the first edge (6) of the first panel (1).
Further it is mentioned that the thickness of the base (16) of the locking profile may vary between a first section (16.1) extending between the first rim (17) and second rim (18) and a second section (16.2) extending between the second rim (18) and the third rim (19).
For the second section (16.2) the thickness is preferably chosen to allow elastic bending of the locking profile (3) as shown in
With respect to the detailed description of the invention here above, the facing edges of two adjacent panels have been addressed by the first and second edges (6 and 7), without limitation to the shape of the panels and without specifying, in case the panels are rectangular, whether the concerned first and second edges are longitudinal edges (long edges) or transversal edges (short edges). It is therefore clear that for the above description, no limitation to position or length of the pair of parallel edges was intended.
Now, in some cases it is desirable to provide locking profiles on more than one pair of facing edges of adjacent panels. As represented in
In such a configuration, overlapping locking profiles are to be prevented. Therefore it is preferred that the locking profile disposed at a long side of the panel is allowed to extend into the corner region defined by the first and third edges of the panel, whereas the locking profile disposed at the short edge of the panel does not extend into that corner portion or vice versa.
Further, according to the present invention there is no real limit on the minimum and maximum length of the locking profile disposed along a single side of a panel and lengths varying from 5 cm up to several meters can be envisaged. However, in order to obtain a rigid lock with sufficient FMAX locking strength, it is preferred that in case the locking profile has a length that is a multitude smaller than the length of the side on which it is disposed, a plurality of locking profiles is disposed on that same edge of the panel, with the sum of the lengths of the locking profiles disposed on that edge being equal to or larger than at least 80% of the total length of the concerned side edge.
For all the above described embodiments, the panels can be be made from many different materials or combinations of materials as long as it is feasible to make the retaining profiles as described hereinbefore, on their edges.
The panels may be wood-based (e.g. solid wood, a fiberboard (MDF, HDF), or a particle board). The panels may also be made of, or at least comprising a layer of, synthetic material. The term “synthetic material” as used in the context of the current invention can be a single polymer or a blend of two or more polymers. The synthetic material can be, for example, a thermoplastic polymer, a thermosetting polymer, a rubber (elastomer), or any combinations thereof. In one particular example, the polymeric material is a thermoplastic polymer that includes vinyl containing thermoplastics such as polyvinyl chloride, polyvinyl acetate, polyvinyl alcohol, and other vinyl and vinylidene resins and copolymers thereof; polyethylenes such as low density polyethylenes and high density polyethylenes and copolymers thereof; styrenes such as ABS, SAN, and polystyrenes and copolymers thereof, polypropylene and copolymers thereof; saturated and unsaturated polyesters; acrylics; polyamides such as nylon containing types; engineering plastics such as polycarbonate, polyimide, polysulfone, and polyphenylene oxide and sulfide resins and the like. The synthetic material compound used to form the panel or a layer thereof can be a PVC powder compound that has good impact strength, ease of processing, high extrusion rate, good surface properties, excellent dimensional stability, and indentation resistance.
The panels may also comprise composite materials, or one or more layers thereof, such as wood-plastic composites (WPC), referring to a composite structure comprising a wood-based material and a synthetic material. The panel may comprise multiple layers which can be identical or different with respect to composition and/or physical properties.
| Number | Date | Country | Kind |
|---|---|---|---|
| 16151625 | Jan 2016 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2017/050669 | 1/13/2017 | WO |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2017/121851 | 7/20/2017 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 6339908 | Chuang | Jan 2002 | B1 |
| 6449918 | Nelson | Sep 2002 | B1 |
| 7051486 | Pervan | May 2006 | B2 |
| 7171790 | Mei | Feb 2007 | B2 |
| 7805903 | Liu | Oct 2010 | B2 |
| 8276343 | Yang | Oct 2012 | B2 |
| 8763340 | Pervan | Jul 2014 | B2 |
| 9856658 | Yang | Jan 2018 | B2 |
| 10060139 | Pervan | Aug 2018 | B2 |
| 20020095894 | Pervan | Jul 2002 | A1 |
| 20050160694 | Pervan | Jul 2005 | A1 |
| 20080028707 | Pervan | Feb 2008 | A1 |
| 20090107076 | Kim | Apr 2009 | A1 |
| 20090151290 | Liu | Jun 2009 | A1 |
| 20140026513 | Bishop | Jan 2014 | A1 |
| 20150040508 | Zhang | Feb 2015 | A1 |
| 20160060880 | Stover | Mar 2016 | A1 |
| 20160194885 | Whispell | Jul 2016 | A1 |
| 20160237695 | Pervan | Aug 2016 | A1 |
| Number | Date | Country |
|---|---|---|
| 2 492 416 | Aug 2012 | EP |
| WO 9426999 | Nov 1994 | WO |
| WO 9824994 | Jun 1998 | WO |
| WO 9824995 | Jun 1998 | WO |
| WO 0020706 | Apr 2000 | WO |
| WO 2012159162 | Nov 2012 | WO |
| WO 2015005860 | Jan 2015 | WO |
| Entry |
|---|
| International Standard ISO 24334 (1st ed. 2006), “Laminate floor coverings—Determination of locking strength for mechanically assembled panels” (excerpt). |
| Number | Date | Country | |
|---|---|---|---|
| 20180355618 A1 | Dec 2018 | US |
