Mechanical locking system for floor panels

Abstract

Building panels, especially floor panels are shown, which are provided with a locking system comprising several clips connected to a panel edge comprising a recess formed in a lower lip or in the tongue. Each clip may include an upwardly extending locking element, which is configured to cooperate with a locking groove for locking the two edges in a horizontal direction.

Claims

1. Building panels provided with a locking system comprising a tongue at a second edge of a second panel, the tongue being configured to cooperate with a tongue groove at a first edge of a first panel for locking in a vertical direction, the tongue groove comprising an upper lip and a lower lip, the locking system further comprising one or more clips attached to the first edge and a downwardly open locking groove formed at the second edge, each clip comprises an upwardly extending locking element, which is configured to cooperate with the locking groove for locking the first edge and the second edge in a horizontal direction, wherein: the clip comprises a clip body at a rear side of the first panel, said clip body is provided with an inner part, which extends inwardly from the first edge, and an outer part, which extends outwardly from said first edge, the inner part comprises a fixing element that cooperates with a downwardly open fixing groove, formed on the rear side of the first panel, for locking the clip to the first edge in a horizontal direction, the clip comprises a locking protrusion, which protrudes upwardly from the clip body, said locking protrusion is configured to lock the clip to the first edge in a vertical direction, the tongue comprises a recess, and the locking protrusion is in a locked position positioned in the recess.

2. The building panels according to claim 1, wherein a part of the locking protrusion is located in the tongue groove.

3. The building panels according to claim 1, wherein a part of the locking protrusion is located below the tongue.

4. The building panels according to claim 1, wherein the locking protrusion is spaced horizontally inwardly in the tongue groove beyond the outer tip of the tongue.

5. The building panels according to claim 1, wherein the locking protrusion comprises a first part that extends upwardly from the clip body and a second part that extends inwardly into the tongue groove.

6. The building panel according to claim 1, wherein the locking protrusion is located inwardly and spaced horizontally from the vertical plane.

7. The building panels according to claim 1, wherein the panel comprises a core of plastic material.

8. The building panels according to claim 1, wherein the panel comprises a surface of thermoplastic material.

9. The building panels according to claim 1, wherein the panel comprises a core with an upper core layer and a lower core layer, and wherein the locking protrusion protrudes vertically beyond the lower core layer.

10. The building panels according to claim 1, wherein the recess is formed in a lower part of the tongue.

11. The building panels according to claim 10, wherein the recess is configured to accommodate an outer part of the clip that extends beyond an upper edge of the panel.

12. The building panels according to claim 1, wherein the recess extends from the tongue to the locking groove.

13. The building panels according to claim 1, wherein the clip is an extruded section.

14. The building panels according to claim 13, wherein the extruded section is a plastic section or an aluminium section.

15. The building panels according to claim 1, wherein the recess includes a curved recessed surface extending from an outer tip of the tongue and along a lower surface of the tongue.

16. A flooring system comprising a first panel and a second panel being provided with a locking system comprising clips, said clips being arranged at a first edge of the first panel and at an opposite second edge of the second panel, wherein the locking system is configured to lock the first edge of the first panel to the second edge of the second panel in a horizontal direction and a vertical direction, wherein the first edge and the second edge each comprise a horizontal groove comprising a lower lip, wherein each clip respectively comprises a vertically extending locking protrusion with an upper part that is located essentially above the lower lip of only one of the first panel and the second panel, such that each clip respectively locks directly to only the one of the first panel and the second panel, wherein an entirety of the lower lip of the first edge is spaced horizontally and inwardly from an upper lateral surface of the first edge, and an entirety of the lower lip of the second edge is spaced horizontally and inwardly from an upper lateral surface of the second edge, and wherein, in a locked state of the first and second panels by each clip, the upper lateral surface of the first edge abuts against the upper lateral surface of the second edge in the horizontal direction, the upper lateral surface of the first edge being the outwardly-most surface of the first edge, and the upper lateral surface of the second edge being the outwardly-most surface of the second edge.

17. A method of locking a first building panel and a second building panel, the first and second panels being provided with a locking system comprising clips, said clips being arranged at a first edge of the first panel and at an opposite second edge of the second panels, the method comprising: locking the first edge of the first panel to the second edge of the second panel in a horizontal direction and a vertical direction, wherein the first edge and the second edge each comprise a horizontal groove comprising a lower lip, wherein each clip respectively comprises a vertically extending locking protrusion with an upper part that is located essentially above the lower lip of only one of the first panel and the second panel, such that each clip respectively locks directly to only the one of the first panel and the second panel, and wherein an entirety of the lower lip of the first edge is spaced horizontally and inwardly from an upper lateral surface of the first edge, and an entirety of the lower lip of the second edge is spaced horizontally and inwardly from an upper lateral surface of the second edge, such that the upper lateral surface of the first edge abuts against the upper lateral surface of the second edge in the horizontal direction, the upper lateral surface of the first edge being the outwardly-most surface of the first edge, and the upper lateral surface of the second edge being the outwardly-most surface of the second edge.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The disclosure will in the following be described in connection to exemplary embodiments and in greater detail with reference to the appended exemplary drawings, wherein:

(2) FIGS. 1a-f illustrates locking systems according to known technology.

(3) FIGS. 2a-f illustrate a clip that may be used to lock thin floor panels according to an embodiment of the invention.

(4) FIGS. 3a-h illustrate clips and a production methods to connect a clip to an edge according to embodiments of the invention.

(5) FIGS. 4a-c illustrate a locking system according to an embodiment of the invention.

(6) FIGS. 5a-d illustrate a locking system according to an embodiment of the invention.

(7) FIGS. 6a-c illustrate a locking system according to an embodiment of the invention.

(8) FIGS. 7a-d illustrate a locking system according to an embodiment of the invention.

(9) FIGS. 8a-c illustrate a locking system and a LVT floor panel with a core comprising several layers according to an embodiment of the invention.

(10) FIGS. 9a-b illustrate a panels with clips on long and short edges according to an embodiment of the invention.

(11) FIGS. 10a-10e illustrate A and B panels comprising clips on both adjacent edges.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

(12) FIGS. 1a-1f show known locking systems. FIG. 1a shows a conventional locking system formed in one piece with the core 5 and configured to lock with angling. The floor panel 1, 1 comprises a locking system that has a tongue 10 and a tongue groove 9 that lock vertically and a strip 5 with a locking element 8 that cooperates with a locking groove 14 and locks the edges horizontally.

(13) FIGS. 1b and 1c shows a locking system with a separate strip 5 that comprises a locking protrusion 17 connected to a lower lip 12 of the tongue groove 9 that protrudes beyond a vertical plane VP. The locking protrusion 17 is located under a horizontal plane HP that intersects the lower part of the tongue 10. Such locking system may not provide sufficient locking strength in thin and flexible core material since the lower lip 12 and the outer part of the strip 5 will bend downwards when the edges are exposed to pulling forces and the locking element 8 will slide out from the locking groove 14.

(14) FIGS. 1d-1f show similar locking systems comprising a plastic or metal clip 6 with a locking protrusion 17 connected to an upper part of the lower lip 12 which is located under the tongue 10 and under the cooperating locking surfaces between the tongue and the lower lip 12. The clip is connected to an outer part of a lower lip 12 that is positioned beyond the upper lip and beyond the vertical plane VP.

(15) To facilitate understanding of the described invention, several locking systems in the figures are shown schematically. It should be emphasised that improved or different functions can be achieved using combinations of the preferred embodiments.

(16) All embodiments may be used separately or in combinations. Angles, dimensions, rounded parts, spaces between surfaces etc. are only examples and may be adjusted within the basic principles of the invention.

(17) FIGS. 2a-2f show a first embodiment of the invention.

(18) FIG. 2a show a cross section of a first and second panel 1, 1 each provided with a surface layer 2 comprising a transparent wear layer 20 which may be coated by a UV cured PU lacquer. The first and the second panels 1, 1 are preferably LVT panels. A decorative plastic foil 21 is attached to a core 3 and under the transparent layer 20. The core 3 that preferably comprises a thermosetting plastic material with a filler may have several core layers, which may have different density and hardness. The locking system comprises a tongue 10 at the second edge of the second panel 1, a tongue groove 9 at a first edge of the first panel and a clip 6, that preferably is formed by punching a metal sheet, for example a 0.3-0.6 mm aluminium or steel sheet. The clip 6 comprises a clip body 7 at a rear side of a first panel 1. The clip body comprises an inner part IP that extends inwardly from a first edge of the first panel and an outer part OP that extends outwardly from the first edge of the first panel 1.

(19) The clip 6 comprises a fixing element 16 located in a fixing groove 15 in the first panel 1 and a locking element 8 located in a locking groove 14 formed in an adjacent second panel 1 that lock the panel edges horizontally and prevents horizontal separation. The clip 6 comprises a locking protrusion 17 formed on the strip body 7 between the locking element 8 and the fixing element 16. The locking protrusion 17 projects vertically upwardly from the strip body and is located in a recess 18 formed in the lower lip 12 of the tongue groove 9. The recess 18 extends vertically from an upper to a lower part of the lower lip 12. The locking protrusion 17 is in this embodiment located such that it is displaced inwardly from the vertical plane VP. A part of the locking protrusion 17 extends inwardly into the tongue groove 9 and beyond the outer part of the tongue 10. An upper part of the locking protrusion 17 is preferably located above a horizontal plane HP that intersects the lower part of the tongue 10 and the upper part of the lower lip 12. The locking protrusion 17 connects the clip 6 vertically to the first panel 1 edge and prevents downward bending of the clip 6 when the edges of the first 1 and the second 1 panels are exposed to separation forces. The locking protrusion 17 prevents a displacement of the clip 6 inwardly such that the clip 6 is accurately fixed and positioned in a pre-determined position by the locking protrusion 17 and the fixing element 16.

(20) An advantage is that the clip 6 may be connected to the core 3 in a horizontal plane HP that is located above the lower lip 12 and to an edge part that is more rigid than an outer part of the lower lip. The whole vertical extension of the lower lip 12 and tongue groove 9 may be used to accomplish a strong connection without any essential negative effect on the vertical tongue 10 and tongue groove 9 connection since only a small part of the lower lip 12 will be partially removed when the recess 18 is formed. The upper contact surfaces between the tongue 10 and the upper lip 11 are unchanged and may provide an unchanged sealing against moisture penetration into the joint. The locking protrusion may be connected to an edge part that comprises sufficient material to allow a strong connection even when the panels are thin for example 3-4 mm and comprise a core 3 of flexible material, such as thermoplastic material mixed with a filler, which is a material composition generally used in LVT floors.

(21) FIG. 2b is a top view of the clip 6. FIG. 2c shows a clip 6 that has a length direction L along the edge and a width direction W perpendicular to the length. A clip with a length of about 3 cm and a width of about 2 cm may provide a locking strength that corresponds to a pulling force of about 200 N. 10 clips/m are sufficient to provide a locking strength on a long edge of about 2000 N.

(22) FIG. 2d shows an edge section 1 that comprises a recess 18 formed in the lower lip 12. FIG. 2e shows the same edge section 1 with the surface layer 2 pointing downwards and the recess 18 formed in the lower lip 12.

(23) FIG. 2f shows a clip 6 connected to an edge section 1. The locking protrusion is located in a recess 18 formed in the lower lip 12.

(24) FIG. 3a shows that the locking system may be locked with angling. The lower lip 12 comprises preferably a sliding surface 19 that guides the tongue 10 into the tongue groove 9 during angling but also during horizontal snapping. The sliding surface 19 and a part of the lower lip 12 are located above the outer part OP of the clip body 7

(25) FIG. 3b shows that the clip 6 may be connected with angling and pressing of the fixing element 16 with a pressing tool P into the fixing groove 15. The recess 19 is preferably formed by a vertically rotating tool T that cuts the edge as a saw blade.

(26) FIGS. 3c, 3d and 3e show that the clip 6 may be connected by a horizontal displacement and pressing against the fixing element 16 such that a bending of the fixing element 16 takes place.

(27) FIG. 3f shows that the fixing element 16 may be pressed into the core 3 and the fixing groove 15 is formed by the fixing element 16. The fixing groove may be pre cut with a knife. Glue may also be used to connect the clip 6 to a panel edge. Glue may in some applications replace the fixing grove 15 and the fixing element 16.

(28) FIG. 3g shows that several clips 6a, 6b may be formed by punching a metal sheet and may be inserted after separation from a clip blank comprising several clips. FIG. 3h shows that the clip 6 may have several locking protrusions 17a, 17b.

(29) FIGS. 4a-4c show that the clip 6 may comprise guiding parts 22 having an upwardly extending sliding surface 19 that may facilitate the guiding of the tongue 10 into the tongue groove 9 during angling and/or horizontal snapping. The guiding part 22 may also be used to position the clip 6 horizontally against the lower lip 12.

(30) FIGS. 5a-5d show that the recess 18 may be formed in an upper surface of the lower lip 12 and extend along a part of the lower lip.

(31) FIGS. 6a-6c show that the recess 18 may be formed in a lower part of the tongue 10 as shown in FIG. 6c where the panel 1 is shown with the rear side pointing upwards. The locking protrusion 17 is in locked position connected into the tongue groove 9 and located in the recess 18 formed in the lower part of the tongue 10.

(32) FIGS. 7a and 7b show that the recess 18,18 may extend from the tongue 10 and to the locking groove 14 in order to accommodate the outer part OP of the clip 6 that extends beyond the upper edge of the panel 1. FIGS. 7a and 7b show that the clip 6 may be an extruded section, for example a plastic or aluminium section.

(33) FIGS. 8a and 8b show panels 1, 1 comprising a core 3 with an upper core layer 4a and a lower core layer 4b layer and wherein the locking protrusion 17 protrudes vertically beyond the lower layer 4b. FIG. 8c shows that the core 3 may comprise a glass fibre layer 4c and the upper part of the locking protrusion may be located above such glass fibre layer 4c.

(34) FIG. 9a shows a floor panel 1 comprising several clips 6 and recesses 18a on one of the long edges and several recesses 18b on the opposite long edge. The panel comprises a locking system on the short edges that is formed in one piece with the core. FIG. 9b shows a locking system comprising clips 6 on long and short edges.

(35) FIGS. 10a-10e show that all embodiment of this disclosure may be adapted such that a flooring system may comprise a first A panel and a second B panel comprising clips 6 on at least two opposite edges, a first edge 23a and a second edge 23b. The locking system is configured such that a first edge 23a of a first A panel may be locked to a second edge 23b and a first edge 23a of a second panel B.

(36) FIG. 1a shows a cross section C1-C1 of two adjacent edges 23a and 23b according to FIG. 10e. Both edges comprise a horizontal groove 9a and 9b and a lower lip 9a, 9b. The locking protrusion 17 is preferably located essentially above the lower lip 12a and the lower lip is preferably spaced horizontally from the vertical plane VP.

(37) FIG. 10b show the cross section C2-C2 in FIG. 10d and FIG. 10c shows the cross section C1-C1 in locked position.

(38) The clips are offset along the adjacent edges such that they may be inserted between each other.

(39) FIG. 10d shows that a first edge 23a of a first panel A may be locked to a second edge 23b of a second panel B. FIG. 10e shows that a first edge 23a of the first panel A may also be connected to a first edge 23a of the second panel B.

(40) The above-described locking system may be used to lock all types of floor panels. Ceramic tiles may be installed with a space between the upper edges. This allows that the outer part of the lower lip 12 may be located at the vertical plane VP or may even protrude horizontally beyond the vertical plane VP and the upper part of the edge.

EMBODIMENTS

(41) 1. Building panels provided with a locking system comprising a tongue (10) at a second edge of a second panel (1), the tongue being configured to cooperate with a tongue groove (9) at a first edge of a first panel (1) for locking in a vertical direction, the tongue groove (9) comprising an upper lip (11) and a lower lip (12), the locking system further comprising one or more clips (6) attached to the first edge and a downwardly open locking groove (14) formed at the second edge, each clip (6) comprises an upwardly extending locking element (8), which is configured to cooperate with the locking groove (14) for locking the first edge and the second edge in a horizontal direction characterised in: that the clip (6) comprises a clip body (7) at a rear side of the first panel (1), said clip body (7) is provided with an inner part (IP), which extends inwardly from the first edge, and an outer part (OP), which extends outwardly from said first edge,

(42) that the inner strip part (IP) comprises a fixing element (16) that cooperates with a downwardly open fixing groove (15), formed on the rear side of the first panel (1), for locking the clip (6) to the first edge in a horizontal direction,

(43) that the clip (6) comprises a locking protrusion (17), which protrudes upwardly from the clip body (7), said locking protrusion (17) is configured to lock the clip (6) to the first edge in a vertical direction,

(44) the lower lip (12) or the tongue (10) comprises a recess (18), and

(45) that the locking protrusion (17) is in a locked position positioned in the recess (18).

(46) 2. The building panels as in embodiment 1, wherein a part of the locking protrusion (17) is located in the tongue groove (9).

(47) 3. The building panels as in embodiment 1 or 2, wherein a part of the locking protrusion (17) is located below the tongue (10).

(48) 4. The building panels as in any one of the preceding embodiments 1-3, wherein said locking protrusion (17) is spaced horizontally inwardly in the tongue groove (9) beyond the outer tip of the tongue (10)

(49) 5. The building panels as in any one of the preceding embodiments 1-5, wherein the locking protrusion (17) comprises a first part (17a) that extends upwardly from the clip body (7) and a second part (17b) that extends inwardly into the tongue groove (9).

(50) 6. The building panel as in any one of the preceding embodiments 1-5 wherein the locking protrusion is located inwardly and spaced horizontally from the vertical plane

(51) 7. The building panels as in any one of the embodiments 1-6, wherein the panel comprises a core of plastic material

(52) 8. The building panels as in any one of the preceding embodiments 1-7, wherein the panel comprises a surface of thermoplastic material

(53) 9. The building panels as in any one of the preceding embodiments 1-8, wherein the panel comprises a core (3) with an upper core layer (4a) and a lower core layer (4b) and wherein the locking protrusion (17) protrudes vertically beyond the lower core layer (4b).

(54) 10. A flooring system comprising a first panel (A) and a second panel (B) being provided with a locking system comprising clips, said clips (6) being arranged at a first edge (23a) and at an opposite second edge (23b) of the first and the second panel (A,B), characterized in that the locking system is configured to lock the first edge (23a) of the first panel (A) to the second edge (23b) of the second panel (B) in a horizontal and a vertical direction.

(55) 11. The flooring system as in embodiment 10, wherein the first edge (23a) and the second edge (23b) each comprises a horizontal groove (9a, 9b) comprising a lower lip (12a,12b).

(56) 12. The flooring system as in embodiment 11, wherein each clip (6) comprises a vertically extending locking protrusion (17) with an upper part that is located essentially above the lower lip (12a, 12b) of the first and the second panel, respectively.

(57) 13. The flooring system as in embodiment 12, wherein each lower lip is spaced horizontally and inwardly from an upper part of the edge.