Floor panel and method of laying a floor panel

• US 20040128934A1
• Filed: 11/10/2003
• Published: 07/08/2004
• Est. Priority Date: 11/15/2002
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Kronotec AG
• Inventors: Hecht, Hendrik
• Granted Patent: US 7,484,337 B2
• Time in Patent Office: Days
• US Class Current: 52/578
• CPC Class Codes: E04F 15/02 Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: E04F 15/181 Insulating layers integrally formed with the flooring or the flooring elements
• CPC Class Codes: E04F 2201/0115 with snap action of the edge connectors
• CPC Class Codes: E04F 2201/0138 by moving the sheets, plates or panels perpendicular to the main plane
• CPC Class Codes: E04F 2201/023 with a continuous tongue or groove
• CPC Class Codes: E04F 2201/026 with rabbets, e.g. being stepped
• CPC Class Codes: E04F 2201/0523 Separate tongues; Interlocking keys, e.g. joining mouldings of circular, square or rectangular shape
• CPC Class Codes: E04F 2201/0529 the interlocking key acting as a dovetail-type key
• CPC Class Codes: E04F 2290/043 with a bottom layer for sound insulation

Abstract

Floor panel which is provided with means for releasably connecting at least two panels, it being the case that a tongue is formed to extend in the longitudinal direction of the side edge and corresponding recess is formed opposite it, that the recess comprises a top lip and a bottom lip, and the bottom lip forms a shoulder with a front shoulder side, said shoulder blocking the panels in the transverse direction (Q), that an undercut is adjoined by a recess, with a bearing region which corresponds to the shoulder, and a wall, which, with the front shoulder side in the installed state, is located opposite the latter, and that corresponding form-fitting elements are formed on the wall and the front shoulder side, said form-fitting elements, in the installed state, engaging one inside the other and bringing about locking in the vertical direction (V), and an underside of the tongue and a top side of the bottom lip runs parallel to the top side.

Claims

1. A floor panel which is bounded in a horizontal plane by a top side, provided with a decorative layer, and an underside, provided for resting on an underlying surface, and which is provided with means for releasably connecting at least two panels, a tongue is formed on at least one first side edge of a first panel, the tongue extending in the longitudinal direction of the side edge, and a recess which corresponds to the tongue is formed on the opposite, second side edge,

the recess comprises a top lip and a bottom lip, and the bottom lip forms a shoulder with a top shoulder side and a front shoulder side, said shoulder, with a corresponding undercut of the tongue, blocking the panels, in the transverse direction Q,

the undercut is adjoined by a recess, with a bearing region which corresponds to the top shoulder side, and a wall, which in the laid state is located opposite the front shoulder side,

and corresponding form-fitting elements are formed on the wall and the front shoulder side, said form-fitting elements, in the laid state, engaging one inside the other and bringing about locking in the vertical direction V, wherein an underside of the tongue and a top side of the bottom lip extends parallel to the top side.

2. The floor panel according to claim 1, wherein a protrusion is formed on the wall and a recess is formed on the front shoulder side.

3. The floor panel according to claim 1 wherein, in the installed state, a top side of the tongue butts against an underside of the top lip.

4. The floor panel according to claim 1, wherein the tongue is designed such that locking takes place by an introduction movement into the recess of the second panel and a pivoting-in movement about an axis parallel to the first side edge.

5. The floor panel according to claim 1, wherein the tongue and the recess have a wedge-shaped contour in cross section.

6. The floor panel according claim 1 wherein the tongue and the recess are designed such that, in the installed state, a gap is present between the front region of the tongue and that region of the recess which adjoins the top lip.

7. The floor panel according to claim 1, wherein the distal end of the tongue and the groove base is perpendicularly to the top side.

8. The floor panel according claim 1, wherein form-fitting elements for locking in the vertical direction V with a further panel are formed on a third side edge, which runs at an angle to the first side edge, the form-fitting elements being spaced apart from one another in the transverse direction Q and in the vertical direction V on two spaced-apart, essentially vertically oriented walls.

9. The floor panel according to claim 8, wherein a step-like milled relief which starts from the underside and has an inner wall and an outer wall is formed on the third side edge, in each case one form-fitting element which extends in the transverse direction Q being formed on the walls and in that formed on the fourth side edge which is located opposite the third side edge is a step-like milled relief which starts from the top side and has an inner wall and an outer wall, on which are formed undercuts which correspond with the form-fitting elements.

10. The floor panel according to claim 9, wherein the step-like milled relief which starts from the underside forms a shoulder which projects in the direction of the underside and has an essentially horizontally oriented head surface.

11. The floor panel according to claim 10, wherein the walls of the shoulder are oriented at an acute angle α

in relation to the head surface.

12. The floor panel according to claim 11, wherein the inner shoulder wall forms an undercut in relation to the head surface.

13. The floor panel according to claim 10, wherein the head surface has a transverse extent of 2 to 6 mm.

14. The floor panel according to claim 10, wherein the head surface has 0.25 to 0.4 times the overall transverse extent of the step-like milled relief.

15. The floor panel according to claim 8, wherein a form-fitting element of the third side edge projects horizontally beyond the termination edge of the top side.

16. The floor panel according to claim 15, wherein a recess, which undercuts the termination edge, is arranged between the top side and the projecting form-fitting element.

17. The floor panel according to claim 9, wherein the step-like milled relief, which starts from the top side, forms a shoulder which projects in the direction of the top side and has an essentially horizontally oriented head surface, the bottom region of the outer shoulder wall containing an undercut which corresponds with the form-fitting element of the inner wall of the milled relief of the opposite side edge.

18. The floor panel according to claim 17, wherein a horizontal base surface is formed between the inner shoulder wall and the inner wall of the milled relief, said base surface being designed such that, when the panels, have been laid, the head surface rests on the base surface and the top sides of the panels, are located in a single plane.

19. The floor panel according to claim 17, wherein the inner shoulder wall runs parallel to, or at a shallower angle than, the corresponding inner shoulder wall of the shoulder, which engages in the laid state.

20. The floor panel according to claim 17, wherein the inner shoulder wall forms an undercut in relation to the head surface.

21. The floor panel according to claim 17, wherein the upwardly projecting shoulder has not been formed, or has been removed, in at least one end region of the third side edge.

22. The floor panel according to claim 1, wherein at least one tongue is formed on a third side edge, which runs at an angle to the first side edge, and at least one groove with a first lip and a second lip is formed on an opposite, fourth side edge, in each case at least one recess which runs parallel to the top side being arranged on the tongue and at least on one of the lips and the recesses being arranged in relation to one another such that, when the panels, have been connected to one another, they form a channel for accommodating a separate locking element.

23. The floor panel according to claim 22, wherein the channel is of cylindrical, triangular or quadrilateral, polygonal, x-shaped or v-shaped design.

24. The floor panel according to claim 22, wherein the channel runs over the entire length of the groove and tongue.

25. The floor panel according to claim 22, wherein the channel runs beneath and parallel to a joint of the panels.

26. The floor panel according to claim 22, wherein the groove and the tongue are configured such that they bring about locking in the transverse direction Q.

27. The floor panel according to claim 1, wherein the first and second side edges are formed on the longitudinal side, and third and fourth side edges are formed on the transverse side, of the panel.

28. The floor panel according to claim 1, wherein third and fourth side edges are formed on the longitudinal side, and the first and second side edges are formed on the transverse side, of the panel.

29. The floor panel according to claim 1, wherein is the panels are made from HDF, MDF or an OSB material.

30. The floor panel according to claim 29, wherein no decorative layer is applied to the top side.

31. A method of laying a floor panel, comprising the steps:

a) connecting and locking a plurality of panels on third and fourth side edges for the purpose of setting down a first row on the floor of a room;

b) connecting and locking a further panel, by way of a first side edge, to a second side edge of at least one panel set down in the first row, in order to start a second row by introducing, and pivoting, a tongue into a groove;

c) arranging a new panel, by way of the third side edge, in direct abutment against the fourth side edge of the previously set-down, further panel, the tongue being introduced into the groove and the new panel being located at an angle to the first row of set-down panels;

d) pivoting the new panel, about an axis parallel to the first side edge, in the direction of the floor until form-fitting elements of the third side edge of the new panel butt against a corresponding milled relief of the further panel;

e) pushing the new panel downward until form-fitting locking has taken place over the entire third side edge.

32. The method according to claim 31, wherein the pushing-down action takes place by means of a hammer blow or using the ball of the thumb.

37. The method according to claim 31, wherein the tongue is formed on the second side edge and includes an undercut.

38. The method according to claim 31, further comprising a recess comprising a top lip and a bottom lip, and the bottom lip forms a shoulder with a top shoulder side and a front shoulder side, said shoulder, with a corresponding undercut of the tongue, blocks the panels in the transverse direction (Q), the undercut is adjoined by a recess, with a bearing region which corresponds to the top shoulder side, and a wall, which in the laid state is located opposite the front shoulder side.

39. The method according to claim 38, further comprising form-fitting elements formed on the wall and the front shoulder side, said form-fitting elements, in the laid state, engaging one inside the other and bringing about locking in the vertical direction (V) wherein an underside of the tongue and a top side of the bottom lip extends parallel to the top side.

40. The method according to claim 31, wherein the form-fitting elements lock in the vertical direction (V) with the further panel, formed on a third side edge, which runs at an angle to the first side edge, the form-fitting elements being spaced apart from one another in the transverse direction (Q) and in the vertical direction (V) on two spaced-apart, essentially vertically oriented walls.

33. A method of laying a floor panel, comprising the steps:

a) connecting and locking a plurality of panels on third and fourth side edges for the purpose of setting down a first row on the floor of a room;

b) connecting and locking a further panel, by way of a first side edge, to a second side edge of at least one panel set down in the first row, in order to start a second row by introducing, and pivoting, a tongue into a groove;

c) arranging a new panel, by way of its third side edge, at a distance from the fourth side edge of the previously set-down, further panel, the tongue not being introduced in the groove and the new panel being located at an angle to the first row of set-down panels;

d) pivoting the new panel, about an axis parallel to the first side edge, in the direction of the floor and displacing it along the first side edge until the tongue is accommodated in the groove, with a joint and a channel being formed in the process;

e) pushing a locking element into the channel.

41. The method according to claim 33, wherein the tongue is formed on the second side edge and includes an undercut.

42. The method according to claim 41, further comprising a recess comprising a top lip and a bottom lip, and the bottom lip forms a shoulder with a top shoulder side and a front shoulder side, said shoulder, with a corresponding undercut of the tongue, blocks the panels in the transverse direction (Q), the undercut is adjoined by a recess, with a bearing region which corresponds to the top shoulder side, and a wall, which in the laid state is located opposite the front shoulder side.

43. The method according to claim 41, further comprising form-fitting elements formed on the wall and the front shoulder side, said form-fitting elements, in the laid state, engaging one inside the other and bringing about locking in the vertical direction (V) wherein an underside of the tongue and a top side of the bottom lip extends parallel to the top side.

34. A method of laying a floor panel comprising the steps:

a) connecting and locking a plurality of panels on third and fourth side edges for the purpose of setting down a first row on the floor of a room;

b) connecting and locking a further panel, by way of a first side edge, to a second side edge of at least one panel set down in the first row, in order to start a second row by introducing, and pivoting, a tongue into a groove;

c) arranging a new panel, by way of the third side edge, in direct abutment against the fourth side edge of the previously set-down, further panel, the tongue being introduced into the groove and the new panel being located at an angle to the first row of set-down panels;

d) pivoting the new panel, about an axis parallel to the first side edge, in the direction of the floor until the tongue is accommodated in the groove, with a joint and a channel being formed in the process;

e) pushing a locking element into the channel.

44. The method according to claim 34, wherein the tongue is formed on the second side edge and includes an undercut the third and fourth side edges are formed on the longitudinal side, and the first and second side edges are formed on the transverse side, of the panel.

45. The method according to claim 44, further comprising a recess comprising a top lip and a bottom lip, and the bottom lip forms a shoulder with a top shoulder side and a front shoulder side, said shoulder, with a corresponding undercut of the tongue, blocks the panels in the transverse direction (Q), the undercut is adjoined by a recess, with a bearing region which corresponds to the top shoulder side, and a wall, which in the laid state is located opposite the front shoulder side.

46. The method according to claim 45, further comprising form-fitting elements formed on the wall and the front shoulder side, said form-fitting elements, in the laid state, engaging one inside the other and bringing about locking in the vertical direction (V) wherein an underside of the tongue and a top side of the bottom lip extends parallel to the top side.

35. A method of unlocking a floor panel comprising the steps:

a) pivoting about an axis parallel to a first side edge a plurality of panels which are connected on third and fourth side edges;

b) unlocking and removing the panels from a groove of a still laid row of panels;

c) pivoting about an axis parallel to the third side edge one panel of the panels which are connected on the third and fourth side edges, with the result that form-fitting elements of the panel disengage from the form-fitting elements of a corresponding milled relief of the other panel;

d) removing the first panel.

36. The method according to claim 35, in which, in step c), the pivoting takes place such that the angle between the underside of the panels is reduced.

47. The method according to claim 35, wherein the tongue is formed on the second side edge and includes an undercut.

48. The method according to claim 47, further comprising a recess comprising a top lip and a bottom lip, and the bottom lip forms a shoulder with a top shoulder side and a front shoulder side, said shoulder, with a corresponding undercut of the tongue, blocks the panels in the transverse direction (Q), the undercut is adjoined by a recess, with a bearing region which corresponds to the top shoulder side, and a wall, which in the laid state is located opposite the front shoulder side.

49. The method according to claim 48, further comprising the form-fitting elements is formed on the wall and the front shoulder side, said form-fitting elements, in the laid state, engaging one inside the other and bringing about locking in the vertical direction (V) wherein an underside of the tongue and a top side of the bottom lip extends parallel to the top side.

50. The method according to claim 35, wherein the form-fitting elements lock in the vertical direction (V) with the further panel, formed on a third side edge, which runs at an angle to the first side edge, the form-fitting elements being spaced apart from one another in the transverse direction (Q) and in the vertical direction (V) on two spaced-apart, essentially vertically oriented walls.