Panel joint and seal

• US 9,422,727 B2
• Filed: 09/14/2012
• Issued: 08/23/2016
• Est. Priority Date: 03/11/2003
• Status: Active Grant

• Current Assignee: Pergo Europe AB (Mohawk Industries Incorporated)
• Original Assignee: Pergo Europe AB (Mohawk Industries Incorporated)
• Inventors: Sjoberg, Ake, Wernersson, Hakan, Hansson, Krister, Nilsson, Magnus, Engstrom, Nils-Erik, Kornfalt, Sven
• Primary Examiner(s): Herring, Brent W
• Application Number:
  US13/620,136
• Publication Number:
  US 20130045043A1
• Time in Patent Office: 1,439 Days
• Field of Search: 525/921, 525/922, 525/924, 525/913, 525/911, 522/821, 525/81, 428/192, 156/304.5
• US Class Current: 1/1
• 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 15/02005 Construction of joints, e.g. dividing strips E04F15/024, E04F15/04, E04F15/06, E04F15/10 and E04F15/14 take precedence; separate provisional spacers E04F21/0092
• CPC Class Codes: E04F 15/02011 with joint fillings integrated in the flooring elements
• CPC Class Codes: E04F 15/02016 with sealing elements between flooring elements sealings of joints between building constructions in general E04B1/68
• 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 2201/0153 by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
• CPC Class Codes: E04F 2201/026 with rabbets, e.g. being stepped
• CPC Class Codes: E04F 2201/03 Undercut connections, e.g. using undercut tongues or grooves
• CPC Class Codes: E04F 2201/07 with connections using a special adhesive material
• CPC Class Codes: Y10T 403/472 including mechanical interlock
• CPC Class Codes: Y10T 428/24777 Edge feature

Abstract

A joint for panels, the panels comprising a core, a decorative upper surface and edges provided with joining means for positioning the panels towards one another. Predetermined portions of the edges are provided with a layer of polymer. The panels are joined to one another by use of the joining means where the polymer forms a seal in the joint preventing penetration of water into the joint wherein a highly water resistant unit of a plurality of panels is formed.

Claims

1. A panel comprising a rectangular oblong shape with at least a pair of long opposite edges and a pair of short opposite edges,

wherein the pair of short opposite edges consists of a male edge and a female edge for bringing the panel and an adjacent similar panel in an assembled condition by joining the male edge of the panel by vertical assembly motion with the female edge of the adjacent similar panel, the male edge and the female edge comprising:

a first vertical assembly joining member on the male edge and a second vertical assembly joining member on the female edge, wherein the first vertical assembly joining member comprises an upper cheek with an inclined lower cheek surface located at the lower side of the upper cheek, the second vertical assembly joining member comprises a lower cheek with an inclined upper cheek surface located at the upper side of the lower cheek, and the inclined lower cheek surface interacts with the inclined upper cheek surface of the adjacent similar panel in the assembled condition by a direct contact between the cheek surfaces such that the panel and the adjacent similar panel are locked against each other in a horizontal direction;

the upper cheek and lower cheek, including the lower cheek surface and the upper cheek surface, being made in one piece from the same material as the actual panel;

locking surfaces intended to interact with each other as an automatic result of the vertical assembly motion and limiting vertical movement between the panel and the adjacent similar panel; and

a polymer material situated on the female edge between an upper panel edge thereof and the lower cheek thereof;

wherein the pair of long opposite edges comprise a second male edge and a second female edge, comprising;

a tongue and a groove, wherein the groove is bordered by an upper lip and a lower lip which protrudes distally beyond the upper lip, wherein the groove cooperates with the tongue of an adjacent second similar panel in an assembled condition to limit vertical movement between the panel and the adjacent second similar panel, and wherein the upper lip and the lower lip are made in one piece from the same material; and

at least a web and a depression, wherein the web cooperates with the depression of the adjacent second similar panel in an assembled condition, such that the panel and the adjacent second similar panel are locked against each other in a horizontal direction;

wherein the tongue and groove at the long edges are configured such that they allow assembling two of such panels to each other at these edges by an angling movement;

wherein the joining members at the short edges allow the joining at the short edges simultaneously with the angling movement at the long edges;

wherein the polymer material is present at the location of the joint of the short edges in the assembled condition of a plurality of such panels at their long and short edges;

wherein the polymer material comprises a portion that is present at the female edge at a location protruding distally from the corresponding upper panel edge;

wherein said polymer is arranged at a proximal side of the female edge of the pair of short opposite edges, such that, at said proximal side, there is mainly one protrusion formed; and

wherein the inclined upper cheek surface is outwardly inclined in an upward direction.

2. The panel of claim 1, wherein the polymer material comprises a flexible insert located in a first recess.

3. The panel of claim 2, wherein the male edge further comprises a second recess leaving space for the flexible insert.

4. The panel of claim 3, wherein the flexible insert, the first recess, and the second recess allow a limited movement between two adjacent panels in the assembled condition.

5. The panel of claim 2, wherein the flexible insert is compressed in the assembled condition.

6. The panel of claim 1, wherein the portion of polymer material at a location protruding distally from the corresponding upper panel edge is formed as a protruding lip.

7. The panel of claim 1, wherein the locking surfaces are mainly horizontal.

8. The panel of claim 1, wherein the female edge and the male edge further comprise a male edge upper surface and a female edge upper surface, wherein the male edge upper surface and the female edge upper surface of the adjacent similar panel mate in the assembled condition.

9. The panel of claim 1, wherein the cheeks, inclusive of the cheek surfaces, are formed in the core material of the panel, and wherein the inclined lower cheek surface and the mainly vertical upper cheek surface lock against each other by the core material in a coupled condition of two of such panels.

10. The panel of claim 1, wherein the male and female edge allow for a limited movement of the panels towards each other or away from each other in the assembled condition.

11. The panel of claim 1, wherein cavities are present between the surfaces of the joint male edge and female edge in the assembled condition.

12. The panel of claim 1, wherein mating surfaces are present between the surfaces of the male edge and female edge of the joint and at least one of the mating surfaces contacts the polymer material in the assembled condition.

13. The panel of claim 1, wherein the panel comprises a core having an upper surface and a decorative surface layer atop the upper surface of the core, wherein the decorative surface layer covers the upper surface.

14. The panel of claim 1, wherein the polymer material is a thermoplastic material.

15. The panel of claim 1, wherein the polymer material is situated above an undercut.

16. The panel of claim 1, wherein the female edge comprises an inclined guiding surface which is positioned above the locking surfaces that limit the vertical movement in a coupled condition of two of such panels.

17. The panel of claim 1, wherein the short edges of the locking surfaces comprise a snapping hook and an undercut matching the snapping hook of an adjacent similar panel in the assembled condition.

18. The panel of claim 1, wherein the polymer is arranged at a proximal side of the female edge of the pair of short opposite edges, such that, in the assembled condition, it extends more inwardly with respect to the female edge than a protrusion present at a distal side of the male edge, said protrusion at the distal side of the male edge being made in one piece from the same material as the actual panel.

19. A panel comprising a rectangular oblong shape with at least a pair of long opposite edges and a pair of short opposite edges,

wherein the pair of short opposite edges consists of a male edge and a female edge for bringing the panel and an adjacent similar panel in an assembled condition by joining the male edge of the panel by vertical assembly motion with the female edge of the adjacent similar panel, the male edge and the female edge comprising:

a first vertical assembly joining member on the male edge and a second vertical assembly joining member on the female edge, wherein the first vertical assembly joining member comprises an upper cheek with a lower cheek surface located at the lower side of the upper cheek, the second vertical assembly joining member comprises a lower cheek with an upper cheek surface located at the upper side of the lower cheek, and the lower cheek surface interacts with the upper cheek surface of the adjacent similar panel in the assembled condition by a direct contact between the cheek surfaces such that the panel and the adjacent similar panel are locked against each other in a horizontal direction;

the upper cheek and lower cheek, including the lower cheek surface and the upper cheek surface, being made in one piece from the same material as the actual panel;

locking surfaces intended to interact with each other as an automatic result of the vertical assembly motion and limiting vertical movement between the panel and the adjacent similar panel; and

a polymer material situated on the female edge between an upper panel edge thereof and the lower cheek thereof;

wherein the pair of long opposite edges comprise a second male edge and a second female edge, comprising;

a tongue and a groove, wherein the groove is bordered by an upper lip and a lower lip which protrudes distally beyond the upper lip, wherein the groove cooperates with the tongue of an adjacent second similar panel in an assembled condition to limit vertical movement between the panel and the adjacent second similar panel, and wherein the upper lip and the lower lip are made in one piece from the same material; and

at least a web and a depression, wherein the web cooperates with the depression of the adjacent second similar panel in an assembled condition, such that the panel and the adjacent second similar panel are locked against each other in a horizontal direction;

wherein the tongue and groove at the long edges are configured such that they allow assembling two of such panels to each other at these edges by an angling movement;

wherein the joining members at the short edges allow the joining at the short edges simultaneously with the angling movement at the long edges;

wherein the polymer material is present at the location of the joint short edges in the assembled condition of a plurality of such panels at their long and short edges;

wherein the polymer material comprises a portion that is present at the female edge at a location protruding distally from the corresponding upper panel edge;

wherein said polymer is arranged at a proximal side of the female edge of the pair of short opposite edges, such that, at said proximal side, there is mainly one protrusion formed; and

wherein the upper cheek surface is outwardly inclined in an upward direction.

20. The panel of claim 19, wherein the polymer material comprises a flexible insert located in a first recess.

21. The panel of claim 20, wherein the male edge further comprises a second recess leaving space for the flexible insert.

22. The panel of claim 20, wherein the flexible insert is compressed in the assembled condition.

23. The panel of claim 19, wherein cavities are present between the surfaces of the joint male edge and female edge in the assembled condition.

24. The panel of claim 19, wherein the polymer is arranged at a proximal side of the female edge of the pair of short opposite edges, such that, in the assembled condition, it extends more inwardly with respect to the female edge than a protrusion present at a distal side of the male edge, said protrusion at the distal side of the male edge being made in one piece from the same material as the actual panel.