Flooring material

Abstract

A surface element designed to be assembled together with similar surface elements to form a unit of a plurality of joined surface elements; said surface elements comprising a core, a decorative upper surface and edges for joining, including a first and a second edges allowing joining by rotational movement, and a third and a fourth edge allowing joining by vertical movement, wherein two adjacent edges of the surface element at the same time, and concurrently with said rotational movement, is joined with a surface element adjacent to the first edge and a surface element adjacent to the third or fourth edge.

Claims

1. A surface element, wherein the surface element is configured to be assembled together with surface elements of a same configuration as the surface element to form a plurality of joined surface elements: the surface element comprising a decorative upper surface, an opposed general lower surface and at least four edges disposed between the upper surface and general lower surface, said general lower surface defining a plane; the four edges comprising a first edge and a second edge defining a first pair of opposite sides, and a third edge and a fourth edge defining a second pair of opposite sides; the four edges including upper edge portions, towards which the surface elements seen from the top visually extend in joined condition; wherein the first edge of the surface element comprises a first male joining member and the second edge comprises a first female joining member; the first male joining member comprising a distally extending tongue and the first female joining member comprising a groove which is bordered by an upper lip and a lower lip, said lower lip forming a lower cheek extending in distal direction further than said upper lip, wherein the distance by which the lower cheek extends beyond the upper lip defines a protruding cheek portion; the first male joining member and the first female joining member being configured such that the surface element can be coupled to a second surface element having a same configuration as the surface element and vertically as well as horizontally locked at their respective first and second edges; the vertical locking provided by the tongue fitting in the groove, said tongue and groove providing a positive vertical locking, said tongue thereto extending with a distal length underneath the upper lip, said length being such that joining of the tongue and groove by only a plane-parallel substantial vertical lowering of the surface element in respect to the second surface element having a same configuration as the surface element is made impossible; the tongue comprising a lower side, said lower side, seen in cross section, comprising a substantially flat portion, said flat portion substantially acting as a lowermost portion of the tongue; the horizontal locking provided by an upwardly directed lip at said lower cheek and a lower side groove at the edge comprising the tongue, said upwardly directed lip and said lower side groove having contact surfaces for realizing said horizontal locking; and wherein the third edge of the surface element comprises a second male joining member and the fourth edge comprises a second female joining member; said second male joining member and second female joining member of the surface element being configured such that the surface element and a third surface element having a same configuration as the surface element at their respective third edge and fourth edge can be interconnected by a downward motion of the third edge of the surface element with respect to the fourth edge of the third surface element having a same configuration as the surface element, to thereby result in a vertical as well as horizontal locking, wherein during said downward motion and viewed in a cross-sectional plane perpendicular to the lengthwise direction of said fourth edge, the surface element is configured to lower with its cross-section parallel to the cross-section of the third surface element having a same configuration as the surface elements and which is comprising the fourth edge, wherein the surface element can be joined with its first edge to a second surface element having a same configuration as the surface element and at a same time and in a same turning motion with its third edge to a third surface element having a same configuration as the surface element; said second male joining member being formed as an upper cheek protruding at said third edge and provided with a downward directed portion; said second female joining member being formed as a lower cheek protruding at said fourth edge and provided with an upward directed portion; said second male joining member comprising a male cheek surface at a lower side of said upper cheek and said second female joining member comprising a female cheek surface at an upper side of said lower cheek, the male and female cheek surfaces being arranged to interact with one another so that the surface element and the third surface element having a same configuration as the surface element become locked to each other in a horizontal direction; said second female joining member comprising said lower cheek configured as a seat which is open in an upward direction; said second male joining member comprising said downward directed portion that by a downward motion of the second male joining member with respect to the second female joining member is configured to insert into said seat of said second female joining member; and said third and fourth edges each comprising one or more locking surfaces for locking the third edge of the surface element coupled to the fourth edge of the third surface element against vertical separation.

2. The surface element of claim 1, wherein said lower cheek of the second edge is formed in one piece of a core material of the surface element.

3. The surface element of claim 1, wherein said flat portion is substantially horizontal.

4. The surface element of claim 3, wherein said upper edge of the first edge defines a theoretical vertical plane and wherein said flat portion in horizontal direction extends from a first location to a second location, said first location being located proximally from said vertical plane and said second location being located distally from said vertical plane.

5. The surface element of claim 3, wherein said lower side of the tongue comprises an inclined portion extending upwardly from said flat portion towards the tip of the tongue.

6. The surface element of claim 1, wherein the mean thickness of the portion of the tongue that in coupled condition is located underneath the upper lip is less than the mean thickness of the upper lip.

7. The surface element of claim 1, wherein said lower cheek of the first female joining member at its upper side defines a flat and substantially horizontal bottom portion proximally adjacent of the contact surface of the upwardly directed lip.

8. The surface element of claim 1, wherein the smallest thickness of the lower cheek of the second female joining member is smaller than the smallest thickness of the upper cheek of the second male joining member.

9. The surface element of claim 1, wherein the contact surface of the first female joining member is substantially planar and is upwardly directed from a proximal to a distal position.

10. The surface element of claim 1, wherein the joining members at the first, second, third and fourth edges are configured such that the joining motion that is required for joining the surface element with its first edge to a second edge of a similar adjacent second surface element, automatically results in the joining of the surface element with its third edge to a fourth edge of an adjacent third surface element.

11. The surface element of claim 1, wherein the second male joining member and the second female joining member are formed in one piece from said core material.

12. The surface element of claim 1, wherein said locking surfaces for locking said third and fourth edges of two such coupled surface elements against vertical separation provide a snap action, wherein the lower cheek is configured such that it will elastically bent to facilitate joining by said snap action.

13. A surface element, wherein the surface element is configured to be assembled together with surface elements of a same configuration as the surface element to form a plurality of joined surface elements: the surface element comprising a decorative upper surface, an opposed general lower surface and at least four edges disposed between the upper surface and general lower surface, said general lower surface defining a plane; the four edges comprising a first edge and a second edge defining a first pair of opposite sides, and a third edge and a fourth edge defining a second pair of opposite sides; the four edges including upper edge portions, towards which the surface elements seen from the top visually extend in joined condition; wherein the first edge of the surface element comprises a first male joining member and the second edge comprises a first female joining member; the first male joining member comprising a distally extending tongue and the first female joining member comprising a groove which is bordered by an upper lip and a lower lip, said lower lip forming a lower cheek extending in distal direction further than said upper lip, wherein the distance by which the lower cheek extends beyond the upper lip defines a protruding cheek portion; the first male joining member and the first female joining member being configured such that the surface element can be coupled to a second surface element having a same configuration as the surface element and vertically as well as horizontally locked at their respective first and second edges; the vertical locking provided by the tongue fitting in the groove, said tongue and groove providing a positive vertical locking, said tongue thereto extending with a distal length underneath the upper lip, said length being such that joining of the tongue and groove by only a plane-parallel substantial vertical lowering of the surface element in respect to the second surface element having a same configuration as the surface element is made impossible; the horizontal locking provided by an upwardly directed lip at said lower cheek and a lower side groove at the edge comprising the tongue, said upwardly directed lip and said lower side groove having contact surfaces for realizing said horizontal locking, said contact surfaces being substantially planar; and wherein the third edge of the surface element comprises a second male joining member and the fourth edge comprises a second female joining member; said second male joining member and second female joining member of the surface element being configured such that the surface element and a third surface element having a same configuration as the surface element at their respective third edge and fourth edge can be interconnected by a downward motion of the third edge of the surface element with respect to the fourth edge of the third surface element having a same configuration as the surface element, resulting in a vertical as well as a horizontal locking, wherein during said downward motion and viewed in a cross-sectional plane perpendicular to the lengthwise direction of said fourth edge, the surface element is configured to lower with its cross-section parallel to the cross-section of the third surface element having a same configuration as the surface elements and which is comprising the fourth edge, wherein the surface element can be joined with its first edge to a second surface element having a same configuration as the surface element and at a same time and in a same turning motion with its third edge to a third surface element having a same configuration as the surface element; said second male joining member being formed as an upper cheek protruding at said third edge and provided with a downward directed portion; said second female joining member being formed as a lower cheek protruding at said fourth edge and provided with an upward directed portion; said second male joining member comprising a male cheek surface at a lower side of said upper cheek and said second female joining member comprising a female cheek surface at an upper side of said lower cheek, the male and female cheek surfaces being arranged to interact with one another so that the surface element and the third surface element having a same configuration as the surface element become locked to each other in a horizontal direction; said second female joining member comprising said lower cheek configured as a seat which is open in an upward direction; said second male joining member comprising said downward directed portion that by a downward motion of the second male joining member with respect to the second female joining member is configured to insert into said seat of said second female joining member; said third and fourth edges each comprising one or more locking surfaces for locking the third edge of the surface element coupled to the fourth edge of the third surface element against vertical separation.

14. The surface element of claim 13, wherein the tongue comprises a lower side, said lower side, seen in cross section, comprising a substantially flat and substantially horizontal portion and wherein said lower side of the tongue also comprises an inclined portion extending upwardly from said flat portion towards the tip of the tongue.

15. The surface element of claim 13, wherein the contact surface of the first female joining member is upwardly directed from a proximal to a distal position.

16. The surface element of claim 13, wherein the joining members at the first, second, third and fourth edges are configured such that the joining motion that is required for joining the surface element with its first edge to a second edge of a similar adjacent second surface element, automatically results in the joining of the surface element with its third edge to a fourth edge of an adjacent third surface element.

17. The surface element of claim 13, wherein the second male joining member and the second female joining member are formed in one piece from said core material.

18. The surface element of claim 13, wherein said locking surfaces for locking said third and fourth edges of two such coupled surface elements against vertical separation provide a snap action, wherein the lower cheek is configured such that it will elastically bent to facilitate joining by said snap action.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention is described further in connection to enclosed figures showing different embodiments of a flooring material whereby,

(2) FIG. 1 shows, in cross-section, a first and a second edge 2.sup.I and 2.sup.II respectively, during joining.

(3) FIG. 2 shows, in cross-section, a second embodiment of a first and a second edge 2.sup.I and 2.sup.II respectively, during joining.

(4) FIG. 3 shows, in cross-section, a third embodiment of a first and a second edge 2.sup.I and 2.sup.II respectively, during joining.

(5) FIG. 4 shows, in cross-section, a fourth embodiment of a first and a second edge 2.sup.I and 2.sup.II respectively, during joining.

(6) FIG. 5 shows, in cross-section, a third and a fourth edge 2.sup.III and 2.sup.IV respectively, during joining.

(7) FIG. 6 shows, in cross-section, a second embodiment of a third and a fourth edge 2.sup.III and 2.sup.IV respectively, during joining.

(8) FIG. 7 shows, in cross-section, a third embodiment of a third and a fourth edge 2.sup.III and 2.sup.IV respectively, during joining.

(9) FIG. 8 shows, in cross-section, a fourth embodiment of a third and a fourth edge 2.sup.III and 2.sup.IV respectively and a vertical assembly joining profile 30, during joining.

DETAILED DESCRIPTION

(10) Accordingly FIG. 1 shows, in cross-section, a first and a second edge 2.sup.I and 2.sup.II respectively, during assembly. The figure shows parts of a flooring material comprising sheet-shaped floor elements 1 with a mainly square or rectangular shape. The floor elements 1 are provided with edges 2, a lower side 5 and an upper decorative layer 3. The floor elements 1 are intended to be joined by means of joining members 10. The floor elements 1 are provided with male joining members 10.sup.I on a first edge 2.sup.I while a second edge 2.sup.II of the floor elements 1 are provided with a female joining member 10.sup.II. The second edge 2.sup.II is arranged on a side opposite to the first edge 2.sup.I. The male joining member 10.sup.I is provided with a tongue 11 and a lower side 5 groove 12. The female joining member 10.sup.II is provided with a groove 13 and a cheek 14, the cheek 14 being provided with a lip 15. The floor elements 1 are intended to mainly be joined together by tilting the floor element 1 to be joined with an already installed floor element 1 or a row of already installed floor elements 1, with the male joining member 10.sup.I of the floor element 1 angled downwards and that the first edge 2.sup.I is allowed to be mainly parallel to the second edge 2.sup.II of the already installed floor element 1 or elements 1. The tongue 11 of the tilted floor element 1 is then inserted into the groove 13 of the female joining member 10.sup.II of the already installed floor element 1 or elements 1, whereby the tilted floor element 1 is turned downwards, with its lower edge as a pivot axis, so that the lip 15 eventually falls into the lower side 5 groove 12 where the decorative upper layer 3 of the floor elements 1 are mainly parallel.

(11) The embodiment shown in FIG. 2 corresponds mainly with the one shown in FIG. 1. The lip 15 and lower side 5 groove 12 are, however, provided with a cam 16 and a cam groove 17 which provides a snap action locking.

(12) The embodiment shown in FIG. 3 corresponds mainly with the one shown in FIGS. 1 and 2 above. The lip 15 and lower side 5 groove 12 are, however, provided with a cam 16 and a cam groove 17 which provides a snap action locking.

(13) The embodiment shown in FIG. 4 corresponds mainly with the one shown in FIG. 1 above. The lip 15 and cheek 14 is however shaped as a thin resilient section which provides a snap action locking.

(14) FIG. 5 shows, in cross-section, a third and a fourth edge 2.sup.II and 2.sup.II respectively, of a floor element 1 according to any of the FIGS. 1 to 4. The floor elements 1 are provided with a male vertical assembly joining member 10.sup.II on a third edge 2.sup.II while a fourth edge 2.sup.IV is provided with a female vertical assembly joining member 10.sup.IV. The fourth edge 2.sup.IV is placed on a side opposite to the third edge 2.sup.III. The male vertical assembly joining members 10.sup.III are provided with mainly vertical lower cheek surfaces 21 arranged parallel to the closest edge 2. The lower cheek surfaces 21 are intended to interact with mainly vertical upper cheek surfaces 22 arranged on the female vertical assembly joining members 10.sup.IV so that two joined adjacent floor elements 1 are locked against each other in a horizontal direction. The male vertical assembly joining members 10.sup.III are moreover provided with two snapping hooks 23 while the female vertical assembly joining members 10.sup.IV are provided with matching under cuts 24, which by being provided with mainly horizontal locking surfaces limits the vertical movement between two joined adjacent floor elements 1.

(15) The joint between a third and a fourth edge 2.sup.III and 2.sup.IV respectively of two joined floor elements 1 further comprises contact surfaces which are constituted by the horizontal locking surfaces of the under cuts 23 and hooks 24, the mainly vertical upper cheek surfaces 22 lower cheek surfaces as well as upper mating surfaces 25. The joint between two joined floor elements 1 also comprises cavities 6.

(16) Shown at 40, in both FIGS. 6 and 7, are mainly horizontal locking surfaces of undercut 24. Specifically, mainly horizontal locking surfaces 40 are designed to interact with snapping hook 23 to lock the respective floor elements 1 in place.

(17) The joint between a third and a fourth edge 2.sup.III and 2.sup.IV respectively of two joined floor elements 1 further comprises contact surfaces which are constituted by the horizontal locking surfaces of the under cuts 24 and hooks 23, the mainly vertical upper cheek surfaces 22 lower cheek surfaces as well as upper mating surfaces 25. The joint between two joined floor elements 1 also comprise cavities 6.

(18) The embodiment shown in FIG. 7 corresponds in the main with the one shown in FIG. 6. The snapping hook 23 on the male vertical assembly joining member 10.sup.III is, however, moved somewhat inwards in the floor element 1 whereby a guiding angle is formed above the undercut 24 of the female vertical joining member 10.sup.IV.

(19) The embodiment shown in FIG. 8 corresponds mainly with the one shown in FIG. 7. Both the third and the fourth edges 2.sup.III and 2.sup.IV respectively are, however, provided with male vertical assembly joining members 10.sup.III. A vertical assembly joining profile 30, provided with a female vertical assembly joining profile 10.sup.IV on both sides of a vertical symmetry line, is used for joining the two floor elements 1. The female vertical assembly joining members 10.sup.IV of the vertical assembly joining profile 30 are equipped similar to the female vertical assembly joining members 10.sup.IV in FIG. 7 above.

(20) Two adjacent edges 2 of a floor element 1 can at the same time, and in the same turning motion, be joined with a floor element 1 adjacent to the first edge 2.sup.I and a floor element 1 adjacent to the third or fourth edge 2.sup.III and 2.sup.IV respectively, when assembling floor elements 1 according to the above described embodiments.

(21) The floor elements 1 according to the present invention most often comprises a core. The core is most often comprised of particles or fibre of wood bonded with resin or glue. It is advantageous to coat the surface closest to the joint in cases where the floor will be exposed to high levels of moisture since the cellulose based material is sensitive to moisture. This coating may suitably incorporate resin, wax or some kind of lacquer. It is not necessary to coat the joint when it is to be glued since the glue itself will protect from moisture penetration. The upper decorative layer 3 is constituted of a decorative paper impregnated with melamine-formaldehyde resin. One or more so called overlay sheets of a-cellulose, impregnated with melamine-formaldehyde resin may possibly be placed on top of the decorative layer. The abrasion resistance may be improved by sprinkling one or more of the sheets with hard particles of for example a-aluminum oxide, silicon carbide or silicon oxide. The lower side 5 may suitably be coated with lacquer or a layer of paper and resin.

(22) The invention is not limited by the embodiments shown since they can be varied within the scope if the invention.

(23) According to a first particularly preferred embodiment, the invention relates to flooring material comprising sheet-shaped floor elements with a mainly square or rectangular shape, which floor elements are provided with edges, a lower side and an upper decorative layer, whereby the floor elements are joined by means of joining members, the edges being separated into a first and a second edge, which first and second edges are arranged on opposite sides, and a third and a fourth edge being adjacent to the first and the second edge and which third and fourth edges are arranged on sides opposite to one another, whereby the floor elements are provided with male joining members on the first edge, having a tongue and a lower side groove, and female joining members on the second edge, having a groove and a cheek, the cheek being provided with a lip, whereby the floor elements are joined together via the male and female joining members by tilting the floor element to be joined with an already installed floor element or a row of already installed floor elements, with the male joining member of the floor element angled downwards, that the first edge is positioned mainly parallel to the second edge of the already installed floor element or row of floor elements, whereupon the tongue of the titled floor element is inserted into the groove of the female joining member of the already installed floor element or row of floor elements, whereby the tilted floor element is turned downwards, with its lower edge as a pivot axis, so that the lip eventually snaps into the lower side groove where the decorative upper layer of the floor elements are mainly parallel, and that the third and fourth edges of the floor elements are joined by means of joining members selected from the group consisting of: a) wherein the floor elements, on the third edge, are provided with a male vertical assembly joining member while the fourth edge is provided with a female vertical assembly joining member, the fourth edge being arranged on a side opposite to the third edge, the male vertical assembly joining members being provided with mainly vertical lower cheek surfaces arranged parallel to the third edge, which lower cheek surfaces are arranged to interact with undercuts arranged on the female vertical assembly joining members so that two joined adjacent floor elements becomes locked to each other in a horizontal direction, that together the male and female vertical assembly joining members are provided with at least one snapping hook to interact with said undercuts which by being provided with a mainly horizontal locking surface limits the vertical movement between two joined adjacent floor elements, whereby the third edge and the fourth edge are joined with respective edges of adjacent floor elements through vertical motion, and b) wherein the floor elements on the third edge, are provided with a male vertical assembly joining member while the fourth edge also is provided with a male vertical assembly joining member, the fourth edge being arranged on a side opposite to the third edge, which adjacent male vertical assembly joining members are joined by means of a separate vertical assembly joining profile which vertical assembly profile is provided with female vertical assembly joining member, the male vertical assembly joining members being provided with mainly vertical lower cheek surfaces arranged parallel to either the third or the fourth the edge, which lower cheek surfaces are arranged to interact with mainly vertical upper cheek surfaces arranged on the female vertical assembly joining members so that two joined adjacent floor elements becomes locked to each other in a horizontal direction, that together the male and female vertical assembly joining members are provided with at least one snapping hook to interact with said undercut which by being provided with a mainly horizontal locking surface limits the vertical movement between two joined adjacent floor elements, whereby the third edge and the fourth edge are joined with respective edges of adjacent floor elements through vertical motion, whereby two adjacent edges of a floor element at the same time, and concurrently with the turning motion, is joined with a floor element adjacent to the first edge and a floor element adjacent to the third or fourth edge.

(24) In such particularly preferred embodiment, the force needed to overcome the static friction along the joint between two completely assembled male and female joining members is preferably larger than 10N per meter of joint length.

(25) In such particularly preferred embodiment, the floor elements are preferably provided with male vertical assembly joining members on a third edge and provided with female vertical assembly joining members on a fourth edge, the male vertical assembly joining members being provided with mainly vertical lower cheek surfaces arranged parallel to the third edge, which lower cheek surfaces are arranged to interact with mainly vertical upper cheek surfaces arranged on the female vertical assembly joining members so that two joined adjacent floor elements becomes locked to each other in a horizontal direction, that together the male and female vertical assembly joining members are provided with at least one snapping hook with matching undercut which by being provided with a mainly horizontal locking surface limits the vertical movement between two joined adjacent floor elements.

(26) Preferably, the joint between third and the fourth edge of two joined floor elements comprises contact surfaces which are constituted by the mainly horizontal locking surfaces of the undercuts and hooks, the mainly vertical upper cheek surfaces and lower cheek surfaces as well as upper mating surfaces.

(27) Preferably, the joint between two joined floor elements also comprises cavities.

(28) The said snapping hook can be constituted by a separate spring part placed in a cavity.

(29) Preferably such spring part is constituted by an extruded thermoplastic profile.

(30) Preferably, such spring part is constituted by a profile of a thermosetting resin.

(31) Alternatively, such spring part is constituted by an extruded metal profile.

(32) In such particularly preferred embodiment, the undercut may be constituted by a separate spring part which is placed in a cavity.

(33) Preferably, such spring part is constituted by an extruded thermoplastic profile.

(34) Alternatively, such spring part is constituted by a profile of a thermosetting resin.

(35) Further alternatively, such spring part may be constituted by an extruded metal profile.

(36) In such particularly preferred embodiment, the floor elements may be coated with twin-faced adhesive tape or glue.

(37) In such particularly preferred embodiment, the joining members may be coated with twin-faced adhesive tape or glue.

(38) In such particularly preferred embodiment, the force needed to overcome the static friction along the joint between two completely assembled male and female joining members is preferably larger than 100N per meter of joint length.

(39) According to a second particularly preferred embodiment, the invention relates to a surface element designed to be assembled together with similar surface elements to form a unit of a plurality of joined surface elements; said surface elements comprising a core, a decorative upper surface and edges for joining, at least one of said edges for joining comprising a cavity, and a separate spring part placed in said cavity.

(40) In such particularly preferred embodiment, the spring part is preferably formed of thermoplastic.

(41) Alternatively, such spring part is formed of thermosetting resin or of metal.

(42) Such spring part may comprise a snapping hook or an undercut.

(43) In such second particularly preferred embodiment, the decorative surface preferably comprises a laminate or a lacquer.

(44) The invention further relates to an assembled unit of a plurality of surface elements described herein above. Clearly, such assembled unit of surface elements preferably is characterized in that the edges for joining comprise a male joining element and female joining element on an opposite side edge, and third and fourth joining edges, the male and female joining elements capable of being joined by tilting the surface elements and relatively inserting the tongue into the groove and relatively turning downwards the surface elements towards one another and at least one of the third and fourth edges comprising the spring part.