US20050144881A1

US20050144881A1 - Molding and flooring material

Info

Publication number: US20050144881A1
Application number: US11/015,741
Authority: US
Inventors: Diane Tate; Sven Kornfalt; Nils-Erik Engstrom
Original assignee: Pergo Europe AB
Current assignee: Unilin Nordic AB
Priority date: 2003-12-18
Filing date: 2004-12-20
Publication date: 2005-07-07

Abstract

A molding (1) for use together with floor panels (2). The molding (1) is provided with a first and a second distal edge (3 ^Iand 3 ^II, respectively), the distal edges (3 ^Iand 3 ^II, respectively) being provided with means for locking a first distal edge (3 ^I) of a first molding (1) to the second distal edge (3 ^II) of a second molding (1). A joint (101) constituted for mechanical locking between panels, the joint (101) having a first edge (101 ^I) and a second edge (101 ^II). The panel have an upper side (103) and a lower side (104), the first edge (101 ^I) having a lower cheek (102). The lower cheek (102) has an outermost portion (102 ^I) and an innermost portion (102 ^II). At least one groove (105) is present on the lower side (104) of the panel, the groove (105) being arranged in a position between the innermost portion (102 ^II) and the outermost portion (102 ^I). A base portion (105 ^I) of the groove (105) is located at a predetermined distance (L) from the upper side (103).

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention related to a molding such as a floor strip such, a dilatation profile, a transition profile or a finishing profile.
The present invention also relates to a flooring material comprising board shaped floor elements which are joined vertically by means of separate assembly profiles.
2. Description of Related Art
It is previously known to produce different types of molding such as floor strips, metal strips, wood veneer coated strips and strips of homogeneous wood. There is a strong desire to bring about a floor strip with the same pattern as on a floor of thermosetting laminate. During the last years, these floors have become very usual. For instance, they are made with wood pattern, marble pattern and fantasy pattern. Possibly, you can use a homogeneous wood strip or a wood veneer coated strip for a few of the wood patterned floors. Previously known strips do not go well together with all the other floor patterns. The moldings most often comprise a thin decorative thermosetting laminate or a thermoplastic foil and a carrier which consist of a fibre board or a particle board. One problem with these moldings is that they do absorb moisture and, therefore, will expand, contract and warp with changes in moisture content. Joints between such moldings are inevitable and it is in these joints the effects of the expansion, contraction and warping is most noted.
Prefabricated floor panels which are provided with tongue and groove at the edges are well known today. As these are rather easy to install, this can be achieved by the average handy man. Such panels can be made of solid wood, particle board or fibre board. These floor panels are most often provided with a top surface, such as lacquer or some kind of laminate. The panels are often joined by being glued together via their tongue and groove. A version of this tongue and groove type of joint for panels is where the joint is provided with snap action which allows it to be joined without using glue. One such joint is known from WO 97/47834. In this publication the joint is constituted of an upper and lower cheek on the groove portion of the joint and a tongue on the tongue portion of the groove. The tongue is provided with a protrusion on the lower side and the groove is provided with a recess matching the position of the protrusion. The lower cheek is bent downwards during the insertion of the tongue and snaps back once the tongue and groove are in correct position. It is here essential that the force needed to bend the lower cheek is kept within predetermined parameters as great differences would either result in a mechanical lock which is too weak or that a too great amount is needed when joining the panels. This is normally not a problem when producing the panels from the same batch of panel core material. However when using panel core material from several different suppliers small deviations in panel thickness may occur. Such a deviation will inevitably result in problems with locking force and/or the force needed to assemble the panels.

SUMMARY OF THE INVENTION

The above mentioned problems have been solved through the present invention whereby a joint between moldings which are intended to be used as a floor strip, a dilatation profile, a transition profile or a finishing profile. Accordingly, the invention relates to a molding wherein the molding is provided with a first and a second distal edge. The invention is characterized in that the distal edges are provided with means for locking a first distal edge of a first molding to the second distal edge of a second molding.
The first edge is according to one embodiment of the invention provided with a protruding tongue having a bulging section and that the second edge is provided with a groove having an undercut. The tongue with bulging section is designed to match the groove with undercut.
According to another embodiment of the invention, the first edge is provided with at least one recess and that the second edge is provided with at least one recess. The moldings are connected to one another by means of a joining plate having protrusions matchings position of the recesses of the first and second edges. The recesses are suitably holes and are arranged on a rear side of the molding or a bottom side of the molding. The joining plate is suitably further provided with means for being attached to a wall. It will hereby be possible to use the joining plate for attaching the molding to said wall. The means for attaching the joining plate to the wall is suitably constituted of at least one hole. The at least one hole is so arranged that one molding can be attached to one end of the joining plate while still allowing an installer to access at least one of the at least one holes. The protrusions are suitably provided with hooks. These hooks are formed so that they grip into the walls of the recesses.
It has, through the present invention been possible to solve the above mentioned problems, whereby an improved joint with mechanical locking where the locking force and assembly force is kept within predetermined parameters. Accordingly the invention relates to a joint constituted for mechanical locking between panels. The joint have a first edge and a second edge. The panel further have an upper side and a lower side. The first edge has a lower cheek. The invention is characterised in that the lower cheek has an outermost portion and an innermost portion whereby at least one groove is present on the lower side of the panel. The groove is arranged in a position between the innermost portion and the outermost portion. A base portion of the groove is located at a predetermined distance from the upper side.
The core material of the panel may be constituted of a multitude of different materials known today. However materials like medium density fibre board, high density fibre board, particle board and oriented strand board are considered as suitable. It is however also possible to utilise materials like thermoplastic composite board and thermosetting composite board.
According to one embodiment of the invention the joint further comprises a tongue on the second edge and that the first edge further comprises a panel groove and an upper cheek. The lower cheek suitably further comprises an upper face recess and that the tongue is provided with a protrusion on its lower face. The position of the upper face recess and the protrusion is on matching positions.
According to one alternative the upper cheek comprises a lower face recess while the tongue is provided with a protrusion on its upper face. The position of the lower face recess and the protrusion is on matching positions. It is of course possible to arrange more than one protrusion with matching recesses on either side, or both sides, of the tongue and groove respectively. This type of joint is joined by turning the tongue into the groove or by sliding the tongue horizontally into the groove.
According to a second embodiment of the invention the joint further comprises a snapping heel and a lower side groove on the second edge and that the first edge further comprises a panel undercut and a cheek protrusion.
A joint according to the present invention is suited for installations without use of glue. It is of course possible to use glue or double-faced adhesive tape in order to make the installation completely permanent. The glue or tape is then suitably applied in, or in connection to, possible cavities in the joint before the assembly. This glue may be a standard wet glue or a dry glue which is activated before the assembly.

RELATED DISCLOSURES

The invention as described herein can be use in conjunction with, made by, or otherwise is associated with one or more disclosures made in a foreign application identified below and herein incorporated in its entirety, by reference including the abstract, specifications, claims and drawings as though fully set forth herein.



Swedish Application No.	Filing Date	Inventors

SE 0303020-2	Nov. 13, 2003	Krister Hansson
SE 0303021-0	Nov. 13, 2003	Krister Hansson
SE 0303080-6	Nov. 20, 2003	Hakan Wernersson and
		Ake Sjoberg
SE 0303074-9	Nov. 20, 2003	Ola Olofsson
SE 0303343-8	Dec. 11, 2003	Nils Erik Engstrom and
		Fredrik Schlyter
SE 0303381-8	Dec. 16, 2003	Nils Erik Engstrom and
		Sven Kornfalt
SE 0303382-6	Dec. 16, 2003	Magnus N. Nilsson, Ake
		Sjoberg and Sven Kornfalt
SE 0303380-0	Dec. 16, 2003	Mona Caroline Green
SE 0303422	Dec. 18, 2003	Nils Erik Engstrom

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is explained further together with enclosed drawings showing different embodiments of the invention whereby,
FIG. 1 shows, in perspective view, a joint between two adjacent moldings 1 according to a first embodiment of the invention.
FIG. 2 shows, in perspective view, a joint between two adjacent moldings 1 according to a second embodiment of the invention.
FIG. 3 a-3 b shows, in perspective view, a special embodiment of joining plates 40 ^Iand 40 ^II, respectively, according to the invention.
FIG. 4 shows, in cross-section, a molding 1 and a joining plate 40 according to an embodiment of the invention.
FIG. 5 a-5 b shows, in cross-section, a joint 101 constituted for locking between panels according to one embodiment of the invention.
FIG. 6 shows, in cross-section, a joint 101 for locking between panels according to a second embodiment of the invention.

DETAILED DESCRIPTION OF THE EMBODIMENT EXAMPLES

Accordingly, FIG. 1 shows, in perspective view, a molding 1 which is provided with a first and a second distal edge 3 ^Iand 3 ^IIrespectively. The distal edges 3 ^Iand 3 ^II, respectively, are provided with means for locking a first distal edge 3 ^Iof a first molding 1 to the second distal edge 3 ^IIof a second molding 1. The first edge 3 ^Iis provided with a protruding tongue 30 having a bulging section 31. The second edge 3 ^IIis provided with a groove 32 having an undercut 33. The tongue 30 with bulging section 31 is designed to match the groove 32 with undercut 33.
FIG. 2 shows, in perspective view, a molding 1 which is provided with a first and a second distal edge 3 ^Iand 3 ^II, respectively. The distal edges 3 ^Iand 3 ^II, respectively, are provided with means for locking a first distal edge 3 ^Iof a first molding 1 to the second distal edge 3 ^IIof a second molding 1. The first edge 3 ^Iis provided with one recess 34 while the second edge 3 ^IIis also provided with at least one recess 34. The moldings 1 are connected to each other by means of a joining plate 40 having protrusions 41 matching the position of the recesses 34 of the first and second edges 3 ^Iand 3 ^II, respectively. The recesses 34 are holes which are arranged on the rear side of the molding. The joining plate 40 is provided with holes for being attached to a wall. The joining plate 40 can hereby be used for attaching, at least the ends of the molding 1 to said wall. The holes are so arranged that one molding 1 can be attached to one end of the joining plate 40 while still allowing an installer to access one of the holes.
The protrusions 41 may be provided with hooks which are gripping walls of the recesses 34.
The rear side of the molding 1 is, according to the present invention, suitably provided with a longitudinal groove 35 which allows room for the joining plate 40. Edges 35 ^Iof the groove 35 may further be provided with an undercut 36 (See, FIG. 4), while the joining plate 40 is provided with snapping edges 42 (See, FIG. 4).
According to the present invention, the interaction between the protrusions 41 and the recesses 34 will secure the distal edges 3 ^Iand 3 ^II, respectively, of two adjacent moldings so that undesired gaps do not form between said moldings 1. The joining plate 40 is further designed to interact with the edges 35 so that the upper and lower surface of adjacent moldings 1 are flush when assembled. Finally, the interaction between the snapping edges 42 and the undercut 36 will ensure that the front face of adjacent moldings 1 are flush when assembled.
It is, according to the present invention, also possible to provide the joining plate 40 in the form of an angled joining plate for inner corners 40 ^I(See, FIG. 3 a) and an angled joining plate for outer corners 40 ^II(See, FIG. 3 b). The folding line may further be made so it is easy for the installer to adjust the angle in case the corner is not at straight angle. The protrusions 41 for the angled plate for inner corners 40 ^Iare either angled or resilient to make assembly possible.
It is known that moldings 1, like the ones described in the invention, have to be cut at some point or another. It is also known that such moldings have to be proved with a mitre at corners. It will, in these cases, be necessary for the installer to drill new recesses 34. It is, therefore, suitable to use a template or a jig to ensure that these new recesses are correctly placed. Such templates or jigs may be delivered together with, or as an accessory to, the molding 1 and joining plate 40 system. It is also possible to design the joining plate 40 in such a way that it may double as a drilling template by arranging holes and/or providing it with guiding notches.
Accordingly, FIG. 5 a-5 b shows in cross-section a joint 101 constituted for locking between panels according to a first embodiment of the invention. FIG. 5 a shows the joint 101 where a first type of panel material has been used. FIG. 5 b shows the joint 101 when a second panel material has been used. The thickness of the panels deviates as they are manufactured by different suppliers. The joint 101 is constituted for mechanical locking between panels where the panels are joined by turning or by horizontally pushing the panels together. The joint 101 have a first edge 101 ^Iand a second edge 101 ^II. The panel have an upper side 103 and a lower side 104. The first edge 101 ^Ihave a lower cheek 102 which lower cheek 102 has an outermost portion 102 ^Iand an innermost portion 102 ^II. A groove 105 is present on the lower side 104 of the panel. The groove 105 is arranged in a position between the innermost portion 102 ^IIand the outermost portion 102 ^I. The innermost position 102 ^IIis the area where at least some flexing of the lower cheek 102 will occur. The groove 105 or portions of the groove 105 may therefore be arranged on a position further from outermost portion 102 ^Iof the lower cheek 102 than the innermost face of a panel groove 120. A base portion 105 ^Iof the groove 105 is located at a predetermined distance L from the upper side 103. The core material of the panel is made of medium density fibre board. The joint 101 further comprises a tongue 110 on the second edge 101 ^IIwhile the first edge 101 ^Ifurther comprises a panel groove 120 and an upper cheek 122. The lower cheek 102 also comprises an upper face recess 102 ^Uwhile the tongue 110 is provided with a protrusion 111 on its lower face. The position of the upper face recess 102 ^Uand the protrusion 111 are arranged on matching positions.
The panels includes a core which is covered with an upper decorative surface layer. The core is most often constituted of saw dust, fibre or particles of wood which are bonded together with glue or resin. Since the cellulose based material in the core is sensitive to moisture, it is advantageous to coat the surface closest to the joint if the floor will be exposed to moisture. This surface treatment may include wax, resin or some kind of lacquer. It is not necessary to coat the joint when the floor boards are to be glued together since the glue itself will protect from penetration of moisture. The upper decorative surface may be constituted by a decorative paper impregnated with melamine-formaldehyde resin. One or more layers of so-called overlay paper made of α-cellulose which are impregnated with melamine-formaldehyde resin are advantageously placed on top of the decorative paper. One or more of the layers may be sprinkled with hard particles, of for example, aluminium oxide, silicon oxide or silicon carbide in connection to the impregnation in order to improve the abrasion resistance. It is also possible to provide the upper surface with a decor which is protected by a layer of UV curing lacquer which may comprise hard particles for further abrasion resistance. The lower side may be surface treated with lacquer or a surface layer of paper and resin.
FIG. 6 shows in cross-section a joint 101 constituted for locking between panels according to a first embodiment of the invention. The joint 101 is constituted for mechanical locking between panels where the panels are joined through vertical motion. The joint 101 have a first edge 101 ^Iand a second edge 101 ^II. The panel have an upper side 103 and a lower side 104. The first edge 101 ^Ihave a lower cheek 102 which has an outermost portion 102 ^Iand an innermost portion 102 ^II. At least one groove 105 is present on the lower side 104 of the panel. The groove 105 is arranged in a position between the innermost portion 102 ^IIand the outermost portion 102 ^I. A base portion 105 ^Iof the groove 105 is located at a predetermined distance L from the upper side 103. A core material of the panel comprises high density fibre board. The joint further comprises a snapping heel 113 and a lower side groove 114 on the second edge 101 ^IIwhile the first edge 101 ^Ifurther comprises a panel undercut 123 and a cheek protrusion 124.

Claims

1. A molding (1) which is provided with a first and a second distal edge (3 ^Iand 3 ^II, respectively), wherein the distal edges (3 ^Iand 3 ^II, respectively) being provided with means for locking a first distal edge (3 ^I) of a first molding (1) to the second distal edge (3 ^II) of a second molding (1).

2. A molding (1) according to claim 1, wherein the first edge (3 ^I) is provided with a protruding tongue (3) having a bulging section (31) and that the second edge (3 ^II) is provided with a groove (32) having an undercut (33), that the tongue (30) with bulging section (31) is designed to match the groove (32) with undercut (33).

3. A molding (1) according to claim 1, wherein the first edge (3 ^I) is provided with at least one recess (34) and that the second edge (3 ^II) is provided with at least one recess (34) and that the moldings (1) are connected to each other by means of a joining plate (40) having protrusions (41) matching position of the recesses (34) of the first and second edges (3 ^Iand 3 ^II, respectively).

4. A molding (1) according to claim 3, wherein the recesses (41) are holes.

5. A molding (1) according to claim 3, wherein the recesses (41) are arranged on a rear side of the molding (1).

6. A molding (1) according to claim 3, wherein the recesses (41) are arranged on the bottom side of the molding (1).

7. A molding (1) according to claim 3, wherein the joining plate (40) is provided with means for being attached to a wall and that the joining plate (40) is used for attaching the molding (1) to said wall.

8. A molding (1) according to claim 7, wherein the means for attaching the joining plate (40) to the wall is present in the form of at least one hole and that the at least one hole is so arranged that one molding (1) can be attached to one end of the joining plate while still allowing an installer to access at least one of the at least one holes.

9. A molding (1) according to claim 3, wherein the protrusions (41) are provided with hooks, the hooks gripping walls of the recesses (34).

10. A joint (101) constituted for mechanical locking between panels, the joint (101) having a first edge (101 ^I) and a second edge (101 ^II), the panel having an upper side (103) and a lower side (104), the first edge (101 ^I) having a lower cheek (102) wherein the lower cheek (102) has an outermost portion (102 ^I) and an innermost portion (102 ^II) whereby at least one groove (105) is present on the lower side (104) of the panel, the groove (105) being arranged in a position between the innermost portion (102 ^II) and the outermost portion (102 ^I), that a base portion (105 ^I) of the groove (105) is located at a predetermined distance (L) from the upper side (103).

11. A joint (101) according to claim 10, wherein a core material of the panel comprises medium density fibre board.

12. A joint (101) according to claim 10, wherein a core material of the panel comprises high density fibre board.

13. A joint (101) according to claim 10, wherein a core material of the panel comprises particle board.

14. A joint (101) according to claim 10, wherein a core material of the panel comprises oriented strand board.

15. A joint (101) according to claim 10, wherein a core material of the panel comprises thermoplastic composite board.

16. A joint (101) according to claim 10, wherein a core material of the panel comprises thermosetting composite board.

17. A joint (101) according to claim 10, wherein the joint (101) further comprises a tongue (110) on the second edge (101 ^II) and that the first edge (101 ^I) further comprises a panel groove (120) and an upper cheek (122).

18. A joint (101) according to claim 17, wherein the lower cheek (102) further comprises an upper face recess (102 ^U) and that the tongue (110) is provided with a protrusion (111) on its lower face, the position of the upper face recess (102 ^U) and the protrusion (111) being on matching positions.

19. A joint (101) according to claim 17, wherein the upper cheek (122) further comprises a lower face recess and that the tongue (110) is provided with a protrusion on its upper face, the position of the lower face recess and the protrusion being on matching positions.

20. A joint (101) according to claim 10, wherein the joint further comprises a snapping heel (113) and a lower side groove (114) on the second edge (101 ^II) and that the first edge (101 ^I) further comprises a panel undercut (123) and a cheek protrusion (124).