Mechanical locking system for floorboards

Abstract

Building panels, especially floor panels are shown, which are provided with a locking system that is configured to lock the adjacent edges by angling and that have a tongue and a strip on the same edge, and a method to divide a board and produce such building panels. A method for dividing a floor element, into a first floor panel and a second floor panel, said floor element including a core provided with a decorative surface layer and a balancing layer, wherein the method includes the step of forming, through the balancing layer or the decorative surface layer, a second groove by displacing the floor element past a fixed tool.

Claims

1. Building panels, comprising a surface and a core, provided with a locking system for vertical and horizontal locking of a first edge of a first building panel to an adjacent second edge of a second building panel, wherein upper parts of the first and the adjacent second edge in a locked position together define a vertical plane at which the upper parts contact each other, the vertical plane being perpendicular to a horizontal plane and parallel to the surface, said locking system being configured to lock the first edge of the first building panel and the adjacent second edge of the second building panel by angling the first and second building panels relative to each other, wherein the locking system comprises a tongue, made in one piece with said core, and a tongue groove configured to cooperate for vertical locking, and wherein the first edge comprises a strip, made in one piece with the core, which is provided with a locking element, which is configured to cooperate for horizontal locking with a downwardly open locking groove formed in the adjacent second edge, wherein: the tongue, which is provided in the first edge, is configured to cooperate with a lower lip of the tongue groove, which is provided at the adjacent second edge, at lower vertical locking surfaces, the locking element and the downwardly open locking groove are configured to cooperate at horizontal locking surfaces, the tongue protrudes outwardly beyond the vertical plane, the tongue groove comprises an upper lip, and a horizontal extension of the lower lip, in relation to the upper lip, is smaller than a horizontal extension of the tongue, the horizontal extension of the tongue being measured from the vertical plane.

2. The building panels as claimed in claim 1, wherein the horizontal locking surfaces lock the first edge and the adjacent second edge both horizontally and vertically with horizontal and vertical pretension between two of the horizontal locking surfaces.

3. The building panels as claimed in claim 1, wherein the tongue cooperates with the upper lip at upper vertical locking surfaces.

4. The building panels as claimed in claim 1, wherein the tongue and the tongue groove comprises upper and lower vertical locking surfaces that are parallel with the horizontal plane and offset horizontally such that a part of the upper vertical locking surfaces are horizontally closer to the locking element than the lower vertical locking surfaces.

5. The building panels as claimed claim 1, wherein the lower lip protrudes beyond the upper lip and the vertical plane.

6. The building panels as claimed in claim 1, wherein the horizontal extension of the tongue is at least about twice as large than the horizontal extension of the lower lip.

7. The building panels as claimed in claim 1, wherein the tongue and the tongue groove comprise guiding surfaces that are configured to be in contact with each other during the assembling by angling, when an edge part of the adjacent second edge is in contact with the strip and/or the locking element.

8. The building panels as claimed in claim 7, wherein the guiding surfaces are slanted relative the vertical plane and located on upper and/or lower parts of the tongue and the tongue groove.

9. The building panels as claimed in claim 1, wherein the horizontal locking surfaces are located below a horizontal strip plane that intersects an upper part of the strip, which is located vertically under an outer part of the tongue.

10. The building panels as claimed in claim 1, wherein the horizontal locking surfaces are located both below and above a horizontal strip plane that intersects an upper part of the strip, which is located vertically under an outer part of the tongue.

11. The building panels as claimed in claim 10, wherein the horizontal locking surfaces are located above a horizontal strip plane that intersects an upper part of the strip, which is located vertically under an outer part of the tongue.

12. The building panels as claimed in claim 1, wherein the locking system comprises a space between an upper part of the strip and an edge portion of the second panel located under the tongue.

13. The building panels as claimed in claim 1, wherein the upper vertical locking surfaces are offset horizontally in relation to the horizontal locking surfaces.

14. The building panels as claimed in claim 1, wherein the lower vertical locking surfaces and the horizontal locking surfaces are offset horizontally with a horizontal distance that is larger than the horizontal extension of the tongue.

15. The building panels as claimed in claim 1, wherein the core comprises HDF, particleboard, plastic or plywood material.

16. The building panels as claimed in claim 1, wherein the horizontal locking surfaces have a locking angle of about 40-60 degrees against the horizontal plane.

17. Building panels, comprising a surface and a core, provided with a locking system for vertical and horizontal locking of a first edge of a first building panel to an adjacent second edge of a second building panel, wherein upper parts of the first and the adjacent second edge in a locked position together define a vertical plane perpendicular to a horizontal plane, which is parallel to the surface, said locking system being configured to lock the first edge of the first building panel and the adjacent second edge of the second building panel by angling the first and second building panels relative to each other, wherein the locking system comprises a tongue, made in one piece with said core, and a tongue groove configured to cooperate for vertical locking, and wherein the first edge comprises a strip, made in one piece with the core, which is provided with a locking element, which is configured to cooperate for horizontal locking with a downwardly open locking groove formed in the adjacent second edge, wherein: the tongue, which is provided in the first edge, is configured to cooperate with a lower lip of the tongue groove, which is provided at the adjacent second edge, at lower vertical locking surfaces, the locking element and the downwardly open locking groove are configured to cooperate at horizontal locking surfaces, the tongue protrudes outwardly beyond the vertical plane, the tongue groove comprises an upper lip, a horizontal extension of the lower lip, in relation to the upper lip, is smaller than a horizontal extension of the tongue, and the horizontal extension of the lower lip, in relation to the upper lip, is smaller than a horizontal extension of the upper lip.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will by way of example be described in more detail with reference to the appended schematic drawings, which shows embodiments of the present invention.

(2) FIGS. 1a-e illustrate known technology.

(3) FIGS. 2a-d illustrate a locking system according to an embodiment of the invention.

(4) FIGS. 3a-f show alternative embodiments of the invention.

(5) FIGS. 4a-f show alternative embodiments of the invention.

(6) FIGS. 5a-b show a preferred embodiment of the locking system.

(7) FIGS. 6a-6g show separation of a board into several floor panels according to an embodiment of the invention.

(8) FIGS. 7a-b show separation with a band saw according to an embodiment of the invention.

(9) FIG. 7c shows a method to divide a board into two panels by a fixed tool(s), such as a carving or scraping tool, according to an embodiment of the invention.

(10) FIGS. 8a-e show a locking system and a method to divide the panels with carving tools according to embodiments of the invention.

(11) FIGS. 9a-f show how conventional locking systems may be adjusted and divided according to embodiments of the invention.

(12) FIGS. 10a-b show a carving tool according to an embodiment of the invention.

(13) FIGS. 11a-b show carving of horizontal and vertical grooves according to embodiments of the invention.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

(14) A first embodiment of floorboards 1, 1′ provided with a mechanical locking system according to the invention is shown in FIGS. 2a-2d.

(15) A building panel is shown that in this embodiment is a floorboard comprising a surface 2 attached to, or of, a core 3. The floorboard is provided with a locking system for vertical and horizontal locking of a first 1 and a second edge 1′ of adjacent panel edges. The upper parts of two edges 1,1′ of two joined floorboards together define a vertical plane VP. The vertical plane is perpendicular to a horizontal plane HP that is parallel to the panel surface. The locking system is configured to lock the edges 1, 1′ by angling two adjacent edges relative each other. The locking system comprises a tongue 10 made in one piece with said core 3 that cooperates with tongue groove 9 in the adjacent edge 1′ for vertical locking. The tongue groove 9 comprises a lower lip 9a and an upper lip 9b above the lower lip. The first edge 1 comprises a strip 6 made in one piece with the core 3 and provided with a locking element 8 which cooperates for horizontal locking with a downwardly open locking groove 14 formed in the second adjacent edge 1′. The tongue 10 is located on the first edge 1 above the strip 6 and protrudes outwardly beyond the vertical plane VP. FIG. 2b shows that the tongue 10 and the tongue groove 9 comprise upper 12 and lower 13 cooperating vertically locking surfaces. The locking element 8 and the locking groove 14 comprises cooperating horizontally locking surfaces 15 that lock horizontally and prevents a horizontal separation of the adjacent edges 1, 1′.

(16) The geometry of an angling locking system is limited in many respects by the rotating movement that is needed to accomplish a locking. The locking surfaces are, during the final stage of the angling motion, rotated along circles C1, C2, which have a centre point at the vertical plane in the upper part of the joint edges. A tangent line defines the “free angle” A that is the angle when the edges may be locked and separated without any locking surfaces that overlap each other and prevents such locking or disconnection. The free angle A increases when the locking element 8 is closer to the surface and/or more distant horizontally to the vertical plane VP. This means that a low locking angle makes it possible to design compact and cost efficient locking system. However this has a negative effect on the locking strength and the final guiding into a locked position. Over angling with locking angles LA higher than the free angle may be used if the locking surfaces are small and the material is partly compressible. Generally the horizontally locking surfaces 15 should comprise a locking angle of more than about 30 degrees in order to provide sufficient strength and guiding. Higher locking angles are even more preferable and a high quality locking system requires generally a locking angle of 45-60 degrees. Locking systems with higher locking angles that may be up to 90 degrees provides very strong locking. All such locking angles may be obtained with a locking system according to certain embodiments of the described invention.

(17) The tongue 10 and the tongue groove 9 should also be formed and adapted to the rotation during the final locking step. Rounded locking surfaces are optimal for a locking with angling but are in practice not suitable to use due to production tolerance. The ideal geometry is therefor essentially plane locking surfaces parallel with the surface that allow that the rotating tools may be displaced horizontally without any effect on the vertical position of the upper edges. The locking system has therefore in this embodiment preferably a lower lip 9a located under the tongue 10 that extends beyond the upper lip 9b and that allows forming of plane vertically locking surfaces 12, 13 that are essentially parallel with the horizontal plane HP. The tongue 10 and the tongue groove 9 comprises preferably upper 12 and lower 13 vertically locking surfaces that are essentially parallel with the horizontal plane HP and offset horizontally such that a part of the upper vertically locking surfaces 12 are closer to the locking element 8 than the lower vertically locking surfaces 13.

(18) The horizontal extension TE of the tongue 10 is larger than the horizontal extension LE of the lower lip 9a extending beyond the upper lip 9b. The locking system may also be formed with a lower lip 9b that is not extending beyond the upper lip 9b or even with an upper lip 9b that protrudes horizontally beyond the lower lip 9a. Having the eventual extension LE of the lower lip 9b as small as possible may limit the material waste. It is preferred that the extension of the lower lip 9a does not exceed more than about 0.5 times the extension TE of the tongue 10. A small extending lower lip 9b will not create additional waste since the saw blade must generally cut at a small distance from the edge in order to allow a final machining of the edges that removes chipping caused by the saw. This cutting distance to the final edge is also used to machine and form “banana shaped” edges into a straight edge. A small extension LE of about 1 mm will therefore not increase the material waste but may be used to form locking surfaces and/or guiding surfaces in the lower lip 9a. A strong vertical locking force may be obtained in a wood or HDF core with vertically locking surfaces 12, 13 that comprises a horizontal extension of about 1 mm and even less for example 0.5 mm may be sufficient in some applications.

(19) The locking system comprises preferably a space S between the upper part of the strip 6 and the second edge 1′. This may be used to eliminate the need for a precise positioning of the machining tools. The space S is preferably located vertically under the tongue 10.

(20) The locking system should be able to guide the edges into a correct position during installation. The floorboards are often somewhat curved or bended and the locking system should be able to straighten such bending and to guide the edges into a correct position.

(21) The tongue 10 and the groove 9 comprises preferably guiding surfaces 17a, 17b that are in contact with each other during angling when an edge portion EP of the second edge 1′ is in contact with the strip 6 and/or the locking element 8 as shown in FIG. 2c

(22) The guiding surfaces 17a, 17a′, 17b, 17b′ are preferably inclined relative the vertical plane VP and may be located on the upper and/or lower parts of the tongue 10 and the tongue groove 9. The guiding surfaces may also be rounded. At least two cooperating guiding surfaces 17a, 17b should preferably be in contact with each other when the second edge 1′ is position in an angle of about 10-20 degrees against the horizontal plane and with an edge portion EP in contact with the strip and/or the locking element as shown in FIG. 2c.

(23) The upper vertically locking surfaces 12 are preferably offset horizontally in relation to the lower horizontally locking surfaces 13 with a distance LD. It is preferred that this distance LD is larger than zero. LD is preferably larger than 20% of the horizontal extension TE of the tongue 10.

(24) The upper vertically locking surfaces 12 are preferably offset horizontally in relation to the lower horizontally locking surfaces 15 with a distance D. It is preferred that this distance D is larger than the horizontal extension TE of the tongue.

(25) In this preferred embodiment the horizontally locking surfaces 15 are located below a horizontal strip plane HPS that intersects an upper part 6a of the strip 6. This upper part is preferably located essentially vertically under the outer part of the tongue 10. Such geometry simplifies the forming of the edges since for example only vertically and horizontally rotating tools may be used. It allows maximum materials savings as described further below.

(26) FIGS. 3a-3f show that the locking system may more compact if the locking element 8 is moved towards the upper part of the floorboard.

(27) FIG. 3c shows that the horizontally locking surfaces 15 may be located both below and above the horizontal strip plane HPS.

(28) FIG. 3e shows that the horizontally locking surfaces 15 may also be located above the horizontal strip plane HPS. The locking angle LA is in this embodiment about 60 degrees. The free angle is about 50 degrees which means that this locking system comprises an over angling of about 10 degrees. The strip 6 comprises a rear side 6b, which is somewhat angled upwards and where the balancing layer and/or the core has been removed. This increases the flexibility of the strip and allows a small bending during locking and unlocking. It may also be used to create a pre-determined flexibility of the strip that may be used to create a pre tension inwardly and upwardly. This may be used to increase the angle of the horizontally locking surfaces and to eliminate some production tolerances. The floorboards may also be connected to the sub floor by nailing down and the tongue 10 provides a strong base for a nail 24. A nailing groove 26 may be formed on the rear side in order to prevent splitting of the rear side.

(29) The floorboards may have bevels 4 or a decorative groove 5 at the upper edges. It is preferred that the decorative groove 5 is formed on the second edge 1′ where chipping from the saw blade is most critical.

(30) FIGS. 4a-4f describe embodiments of the invention. FIG. 4a shows that the locking system may be formed without a protruding lower lip and without a space between the strip 6 and the lower part of the adjacent edge. FIG. 4c shows that vertical locking may be obtained with lower vertically locking surfaces 13 located on the lower part of the tongue 10 and on the upper part 16 of the strip 6 and the lower part of the second edge 1′.

(31) FIGS. 5a-b show that it is also possible to use only the lower vertically locking surfaces 13 and the horizontally locking surfaces 15 for the vertical locking. There may be a space S over the tongue 10 and between the upper part of the strip 6 and the lower part of the second edge 1′. The strip may be used to create a pre tension P inwardly P1 and upwardly P2 with the inclined locking surfaces 15 at the locking element 8. This pre tension may create a pressing force P3 that presses the lower locking surface 13 together. The strip is slightly bended downwards in locked position. This makes it possible to eliminate the need for tight production tolerances even further. Only the position of the lower locking surfaces 13 must be accurately controlled in order to produce a floor without so called “over wood” at the upper joint edges.

(32) A locking angle of about 40-60 degrees is preferable to create such horizontal and vertical pre tension. The vertical pre tension may also be created by an upper part of the locking element 8a that presses against an inner part of the locking groove 14a.

(33) FIG. 5b shows that essentially the same joint geometry may be used even if the floor thickness is increased. The lower part of the strip 6b may be such that the strip thickness is reduced. Alternatively a horizontal groove may be formed in the strip under the locking element in order to increase the flexibility.

(34) All described embodiments may be partly or completely combined into alternative embodiments. The locking systems may be used to lock long and/or short edges with an angling action. The locking system may also be adapted to be locked with horizontal snapping whereby the strip bends 6 backwards during the snapping action when lower guiding surfaces on the tongue and the lower lip cooperate with each other. This may for example be used to connect a long edge to a short edge or to snap long edges when angling is not possible.

(35) The locking system may also be connected by angling of the first edge 1 whereby the strip 6 is inserted under the lower lip.

(36) FIGS. 6a-6g show several production methods of dividing a board. The board may be a laminate board comprising a core 3, an upper surface 2, preferably comprising a decorative layer, and a lower surface, preferably comprising a balancing layer, into a first and a second panel, with first and second adjacent edges 1,1′. Two adjacent edges 1,1′ are formed comprising a locking system that locks vertically and horizontally. The first and the second panel may be e.g. building panels or floor panels.

(37) The methods may be used to divide the board into a first and a second panel. The first panel comprises a first edge 1 adjacent a second edge 1′ of the second panel. The first edge comprises an extension (10,6,8) that protrudes horizontally beyond an upper part of the first edge 1. A first and a second vertically open grooves 19, 18, are formed in the board by for example rotating saw blades 20. The grooves are horizontally offset.

(38) The second vertical open groove 18 comprises an opening towards the front side of the board and the first vertical groove 19 comprises an opening towards the rear side of the board. The board may be divided into several panels in various ways.

(39) FIG. 6b shows breaking or splitting that may be obtained by angling or pressing apart the edges 1, 1′. This method is very suitable when HDF is used as a core since the fibres are oriented horizontally and the crack is essentially horizontal. The same method may be used in a plywood core with different layer that may be design to create a controlled crack along one of the veneers. Preferably the fibre orientation is essentially oriented from one groove towards the other groove.

(40) The methods of dividing may also comprise the step of cutting by a fixed tool or fixed tools, such as a knife(s) 21, and/or scraping and/or carving tool(s) 22, as shown in FIG. 6c.

(41) A preferred embodiment comprises the step of forming a horizontally extending groove in the first vertical open groove and/or the second groove by the fixed tool (22). The horizontally extending groove extends from one of the first groove or the second vertically open groove toward the other of the first groove or the second vertically open groove. The horizontally extending groove extends under the front side of the board and/or above the rear side of board. FIG. 6C shows an embodiment comprising the step of forming a first horizontally extending groove, which extends from the first vertically open groove towards the second vertically open groove, and forming a second horizontally extending groove, which extends from the second vertically open groove towards the first vertically open groove. Embodiments may comprise the step of cutting a part of the first and/or the second vertically open groove by a saw blade before cutting a first and/or a second horizontally extending groove by a fixed tool.

(42) FIG. 6d shows that the first vertically open groove may be formed by a rotating saw blade 20 and the second vertically open groove may be formed by a scraping or carving tool 22. FIG. 6e shows that a knife 21 may be used to divide the first and second panel.

(43) FIGS. 6f and 6g shows an embodiment including forming of the first vertically open groove and of the second vertically open groove that overlap each other. The second vertically open groove may be formed by a sawblade and the first vertically groove by a scraping or carving tool 22. The step of splitting or forming of the horizontal groove is not required in this embodiment

(44) FIGS. 7a and 7b shows that the final separation may be made with a band saw 23 that cuts the core. Such a separation gives a very controlled cut and may be used in materials that are difficult to split, cut or carve.

(45) FIG. 7c shows an embodiment for dividing a board to a first panel (1) and a second panel 1′ by a by displacing the board past a fixed tool 22, such as a carving or scraping tool. The board may be provided with a balancing layer and/or a decorative layer and a fixed tool makes it possible to sort and dispose into separate containers chips from the core and the balancing layer and/or the decorative layer. The chips are preferably removed by several compressed air nozzles. Adjacent edges of the first and the second panel are preferably vertically overlapping and comprise a lower protruding part at a first edge of the first panel and a lower groove at a second edge of the second pane. A mechanical locking system, e.g. as described herein, may be formed at the adjacent edges by e.g. milling, carving or scraping. A locking element may be formed at the lower protruding part that is configured to cooperate with a locking groove, which may be formed at the lower groove. The vertically overlapping edges may reduce the waste of the board material relating to the dividing of the board and the forming the mechanical locking system. The method illustrated in FIG. 7c is preferably used for dividing MDF or HDF boards or boards comprising plastic, such as PVC.

(46) FIG. 8a show a preferred locking system with a tongue 10 on the strip side 1. FIG. 8b show that the edges 1, 1′ can obtain a relative position such that the upper surfaces 2 are positioned along the same horizontal plane HP and such that an edge part EP of one of the adjacent edges is located vertically above the upper part 8a of the locking element 8 and that there is a vertically extending space S of at least about 0.5 mm between the locking element 8 and the whole adjacent edge which is located above the locking element 8. The space S may be smaller but this makes the final separation much more costly and complicated.

(47) Such edge geometry as shown in FIG. 8b makes it possible to divide the board into floor panels with a carving tool, which may have sufficient size in order to divide the board in high speed and with a sufficient accuracy and tool lifetime. FIG. 8c show that the overlapping OL of the final machined edge portions may be even larger if the joint geometry is such that the necessary space S above the locking element 8b exists on and along the vertical plane VP. An even larger overlapping and cost saving may be reached if the space S exists when the edge part EP is located at the vertical plane VP and vertically above one of the horizontally locking surfaces 15a on the locking element 8.

(48) FIG. 8e show that the first 19 and/or the second 18 vertically open groove may be formed by a rotating saw blade 20 and/or a carving tool 22. In this preferred embodiment the second vertically groove 18 is formed by a rotating saw blade 20 and the first by a carving tool 22a.

(49) It is preferred that second groove 18 is made by sawing by the rotating saw blade 22, and that the first groove 19 is made before the cutting of the second groove 18.

(50) The panels are finally divided by an upper and a lower carving tool 22c, 22b that are inserted in the pre formed grooves and that forms essentially horizontal grooves.

(51) Such non-linear separation combined with overlapping edges OL may be used to decrease material waste W in all types of locking systems. The material waste W in a laminate floor may be less than the floor thickness T. It is possible to reduce the waste to about 5 mm and less in a laminate floor with a thickness of about 6-12 mm.

(52) The board may be arranged on a carrier, such as a conveyor belt/chain, preferably provided with a pushing device, such as a cam or ridge (not shown). The decorative surface of the board may be arranged against the carrier and facing downwards (not shown). The pushing device may be used to overcome the rather high cutting forces that have to be overcome in order to create a groove with non-rotating carving tools.

(53) FIG. 9a-9f show that considerable material waste W savings may be reached with a nonlinear panel separation and with overlapping edges OL even if the tongue 10 is formed on the second edge 1′ as in conventional locking systems as shown in FIGS. 9a-9b.

(54) FIG. 9b shows that the waste W may be decreased with two offset vertical grooves and with a small carving. FIG. 9c shows that it is possible to modify the locking system such that it may be compatible with the old locking system and that an increased overlapping of the edges may be obtained as shown in FIG. 9d. A part of the lower part of the tongue 10 and the upper outer part of the locking element 8 may be removed by a small rotating milling tool that may be angled or more preferably by a carving tool such that a space S may be created when the edges 1, 1′ are in an overlapped position as described above. It is preferred that the space S is larger above an outer part of the locking element than above the top of the locking element such that a strong and rather large carving tool edge 22b may be used to divide the panels. FIG. 9e-9f show that further cost savings and a larger overlapping may be reached if the tongue 10 is moved upwards.

(55) FIG. 10a shows a carving tool with four carving teeth 30a-30d. The teeth are connected to a tool body 31.

(56) Several methods may be used to increase the production capacity and flexibility.

(57) Each carving tooth may be fixed in an adjustable tool holder. Several carving teeth may be of the same length and the cutting depth may be adjusted by the adjustable tool holder.

(58) To make it possible to change the teeth quickly the tool holders may be attached to a tool body on a rotating disk or other tool cassette systems.

(59) FIG. 10b shows that the tool body may be slightly inclined such that each tooth carves a depth of for example 0.2 mm when the panel is displaced in the feeding direction against the fixed carving tool. Each tooth may be designed to carve a distance of for example 0.2-0.6 mm in a wood based core. HDF is especially suitable to be formed with carving.

(60) FIG. 11a shows how the first tooth 30a cuts the first cut under the backing laminate 11. The tooth edges comprise 3 cutting edges that formed the groove bottom 31a and two sidewalls 31b, 31c. It is preferred that the teeth have gradually smaller width along the feeding direction. Slightly V shaped teeth may be used to provide a more accurate cut with reduced chipping of the laminate. This reduces tool wear and the heat that may be created at high feeding speeds.

(61) FIG. 11b shows carving of an essentially horizontal groove that provides the final separation. The groove angle in the final groove may vary from zero to 45 degrees against the horizontal plane HP.

(62) The above-described locking systems have been especially design to allow a cost efficient separation of the boards in order to decrease the waste W. As may be seen from the drawings the waste may be reduced considerably. In most application a waste reduction of about 40-50% may be reached compared to conventional production methods.

(63) Embodiments of the invention are especially suitable to be used in solid wood floor where the material cost is high and where a protruding tongue creates a high waste cost. A floor comprising small individual rectangular small size parquet strips with width and length of 10*50 cm or smaller may be produced in a cost very efficient way with considerably lower waste.

(64) Embodiments of the invention may be used to form all types of locking systems on long and/or short edges that may be connected by various combinations of angling, and/or horizontal snapping and/or vertical folding.

(65) Embodiments of the invention are also suitable for panels, such as building panels and floor panels, with a digitally printed surface. The advantage is that it's not required to adjust the printed paper pattern on the board to the size of the panels, produced by the divided board, by an adjustment of the printing cylinder. The forming of the vertical grooves may be formed with thinner tools since the digitally printed surface layer is normally easy to cut. Panels, such as building panels and floor panels, may also be formed without a decorative surface. A decorative surface and a protective layer may be applied by for example digital printing after the locking system is already formed. This method reduces the surface waste to a minimum.

(66) Mechanical locking systems may be formed by rotating tools that generally have a diameter of about 20 cm or more. Rotating tool configurations are driven by tool motors which is a big cost of the total investment in a production line, they are also energy consuming, have a complicated electrical control system, and require a lot of maintenance. Rotating tools produce a lot of dust that have to be extracted. The dust comprises of a mixture of removed ships and dust. A disadvantage of even a sophisticated dust extraction system for rotating tool configurations, is that a fraction of dust and chips that goes in to the transport system and causes wear that effects the precision of the transport system in a negative way. All such problems may be reduced if rotating tools are replaced by carving tools.

(67) It is possible according to embodiments of the invention to separate the panels and to form the completed locking system with a tongue 10, a tongue groove 9, a strip 6, a locking element 8 and a locking groove 14, as shown in FIG. 8e by just using carving tools. Bevels or decorative grooves at the upper edges may also be formed by carving.

(68) Carving prior to the final separation may according to embodiments of the invention form several parts of the locking system or even the whole locking system. Scraping of the top edges with V shaped carving tools may provide a very precise and smooth edge.

(69) It is also possible to form, for example, the locking groove 14 prior to the separation of the panels. The locking groove may in a subsequent production step be used to guide the panels in correct position and this may be used to decrease the overlapping OL further and to save even more material.

EMBODIMENTS

(70) 1. A method for dividing a board into a first panel (1) and a second panel (1′), wherein the method comprises the step of displacing the board and dividing the board by a fixed tool (22), such as scraping or carving tool.

(71) 2. The method as in embodiment 1, wherein the method comprises the step of forming a first vertically open groove (19), through a rear side of the board and an offset second vertically open groove (19), through the front side of the board.

(72) 3. The method as in embodiment 2, wherein the first vertically open groove (18) is formed by a fixed tool or a saw blade.

(73) 4. The method as in any one of embodiments 2 or 3, wherein the second vertically open groove (19) is formed by a fixed tool or a saw blade.

(74) 5. The method as in any one of the embodiments 2-4, wherein the method comprises the step of forming, by a fixed tool (22b), a first horizontally extending groove that extends horizontally under the front side and/or the rear side of the board.

(75) 6. The method as in embodiment 5, wherein the first horizontally extending groove extends from the second groove (19) towards the first groove (18).

(76) 7. The method as in embodiment 5, wherein the first horizontally extending groove extends from the first groove (18) towards the second groove (19).

(77) 8. The method as in any one of the embodiments 5-7, wherein the first horizontally extending groove connects the first vertically open groove and the second vertically open groove.

(78) 9. The method as in embodiment 5, wherein the method comprises the step of forming, by a fixed tool (22b), a second horizontally extending groove that extends horizontally under the front side and/or rear side of the board, wherein the second horizontally extending groove extends from the second vertically open groove towards the first vertically open groove and the first horizontally extending groove extends from the first vertically open groove towards the second vertically open groove.

(79) 10. The method as in embodiment 9, wherein the first horizontally extending grooves is connected with the second horizontally extending grooves.

(80) 11. The method as in any one of the embodiments 2-10, wherein the forming of the second vertically open groove (18) is made by sawing by a rotating saw blade (22).

(81) 12. The method as in embodiment 11, wherein the forming of the first vertically groove (19) is made before the cutting of the second vertically open groove (18) and wherein the first vertically open groove is made by a fixed tool.

(82) 13. The method as in any one of the preceding embodiments, wherein the method comprises the step of arranging the board on a carrier, such as a conveyor belt/chain, preferably provided with a pushing device, such as a cam or ridge.

(83) 14. The method as in embodiment 7, comprising the step of arranging the front side of the board against the carrier and facing downwards.

(84) 15. The method as in any one of the preceding embodiments, wherein the fixed tool comprises several carving teeth, arranged for forming at different vertical and/or horizontal positions.

(85) 16. The method as in any one of the preceding embodiments, wherein the method comprises the step of removing the chips created by the fixed tool by compressed air, preferably by a compressed air nozzle, and preferably collected by a suction device.

(86) 17. The method as in any one of the preceding embodiments, wherein the board is a laminated board, such as a floor element (1b).

(87) 18. The method as in embodiment 17, wherein the laminated board comprises a core (3) provided with a decorative surface layer (2) and a balancing layer.

(88) 19. The method as in embodiment 18, comprising the step of removing the chips created by the forming, preferably by several compressed air nozzles, and preferably sorting and disposing into separate containers the chips from the core and the balancing layer and/or the decorative layer.

(89) 20. A method of forming a mechanical locking system for locking of a first and a second panel, wherein the method comprises the steps: dividing a board into a first and a second panel according to the method as in any one of the embodiments 1-19 and thereby forming a lower protruding part at a first edge of the first panel and a lower groove at a second edge of the second panel; forming a locking element (8) at the lower protruding part; and forming a locking groove (14) at the lower groove.

(90) 21. Building panels, each comprising an upper surface (2) and a core (3), provided with a locking system for vertical and horizontal locking of a first edge of a first building panel (1) to an adjacent second edge of a second building panel (1′), wherein upper parts of the first and the second edge in a locked position together define a vertical plane (VP), which is perpendicular to a horizontal plane (HP), which is parallel to the upper surface (2) of the first and the second building panel (1, 1′), said locking system is configured to enable assembling of the first and the second edge by angling the first and the second building panel (1, 1′) relative each other, the locking system comprises a tongue (10), made in one piece with said core (3), and a tongue groove (9) configured to cooperate for vertical locking, and a strip (6), made in one piece with the core, which is provided with a locking element (8) configured to cooperate for horizontal locking with a downwardly open locking groove (14) formed in the second edge (1′), the edges (1, 1′) can obtain a relative position with a distance between the first and the second edge, characterized in

(91) that in said position the upper surface (2) of the first and the second building panel (1, 1′), are in the same horizontal plane (HP),

(92) that an edge part (EP) of the second edges is located vertically above the upper part of the locking element (8), and

(93) that there is a vertically extending space S of at least about 0.5 mm between the locking element and all parts of the second which edge, which is located above the locking element.

(94) 22. The building panels as in embodiment 21, wherein the edge part (EP) is located at the vertical plane (VP).

(95) 23. The building panels as in embodiment 21 or 22, wherein the locking element (8) comprises a locking surface (15a) that cooperates with a locking surface at the locking groove (14) for horizontal locking and wherein the edge part (EP) is located vertically above the locking surface (15a) of the locking element.

(96) 24. The building panels as in any one of the preceding embodiments 21-23, wherein the space S is larger than 0.6 mm.

(97) 25. The building panels as any one of the preceding embodiments 21-25, wherein the space S is equal or larger above the outer part of the locking element than above the upper part of the locking element.

(98) 26. The building panels as in any one of the preceding embodiments 21-25, wherein the edge portion EP comprises a lower part that is inclined downwards and inwardly.

(99) 27. The building panels as in any one of the preceding embodiments 21-26, wherein the edge part comprises a lower part of the tongue (10)

(100) 28. The building panels as in in any one of the preceding embodiments 21-28 wherein the building panel is a floor board.

(101) 29. Building panels, comprising a surface (2) and a core (3), provided with a locking system for vertical and horizontal locking of a first edge of a first building panel (1) to an adjacent second edge of a second building panel (1′), wherein upper parts of the first and the second edge in a locked position together define a vertical plane (VP) perpendicular to a horizontal plane (HP), which is parallel to the surface (2), said locking system is configured to enable assembling of the first and the second edge by angling the first and the second building panel (1, 1′) relative each other, the locking system comprises a tongue (10), made in one piece with said core (3), and a tongue groove (9) configured to cooperate for vertical locking, the first edge (1) comprises a strip, made in one piece with the core, which is (6) provided with a locking element (8), which is configured to cooperate for horizontal locking with a downwardly open locking groove (14), which is formed in the second edge (1′), characterized in that:

(102) the tongue, which is provided on the first edge, cooperates with a lower lip (9a) of the tongue groove (9), which is provided at the second edge, at lower vertically locking surfaces (13),

(103) that the locking element (8) and the locking groove (14) cooperate at horizontally locking surfaces (15),

(104) that the tongue (10) protrudes outwardly beyond the vertical plane (VP),

(105) that the tongue groove (9) comprises an upper lip (9b), and

(106) that the horizontal extension (LE) of the lower lip (9a), in relation to the upper lip (9b), is smaller than the horizontal extension (TE) of the tongue (10).

(107) 30. The building panels as in embodiment 29, wherein the cooperating horizontally locking surfaces (15) lock the edges both horizontally and vertically with horizontal (P1) and vertical (P2) pre tension.

(108) 31. The building panels as in embodiment 29 or 30, wherein the tongue (10) cooperates with the upper lip (9b) at upper vertically locking surfaces (12).

(109) 32. The building panels as in any one of the preceding embodiments 35-37, wherein the tongue (10) and the tongue groove (9) comprises upper (12) and lower (13) vertically locking surfaces that are essentially parallel with the horizontal plane (HP) and offset horizontally such that a part of the upper vertically locking surfaces (12) are horizontally closer to the locking element (8) than the lower vertically locking surfaces (13).

(110) 33. The building panels as any one of the preceding embodiments 29-32, wherein the lower lip (9a) protrudes beyond the upper lip (9b) and the vertical plane (VP).

(111) 34. The building panels as in any one of the preceding embodiments 29-33, wherein the horizontal extension (TE) of the tongue (10) is at least about twice as large as the horizontal extension (LE) of the lower lip (9a).

(112) 35. The building panels as in any one of the preceding embodiments 29-34, wherein the tongue (10) and the tongue groove (9) comprise guiding surfaces (17a, 17b) that are configured to be in contact with each other, during the assembling by angling, when an edge part (EP) of the second edge (1′) is in contact with the strip (6) and/or the locking element (8).

(113) 36. The building panels as in any one of embodiments 29-35, wherein the guiding surfaces (17a 17b) are inclined relative the vertical plane (VP) and located on the upper and/or lower parts of the tongue (10) and the tongue groove (9)

(114) 37. The building panels as in any one of the preceding embodiments 29-35, wherein the horizontal locking surfaces are located below a horizontal strip plane (HPS) that intersects an upper part (6a) of the strip (6), which is located essentially vertically under the outer part of the tongue (10)

(115) 38. The building panels as in any one of the preceding embodiments 29-37, wherein the horizontal locking surfaces are located both below and above the horizontal strip plane.

(116) 39. The building panels as in any one of the preceding embodiments 29-38, wherein the horizontal locking surfaces are located above the horizontal strip plane.

(117) 40. The building panels as in any one of the preceding embodiments 29-39, wherein the locking system comprises a space (S) between the upper part of the strip (6) and an edge portion (EP) of the second panel (1′) located essentially under the tongue (10).

(118) 41. The building panels as in any one of the preceding embodiments 29-40, wherein the upper vertically locking surfaces are offset horizontally in relation to the horizontally locking surfaces.

(119) 42. The building panels as in any one of the preceding embodiments 29-42, wherein the vertically and horizontally locking surfaces are offset horizontally with a horizontal distance (D) that is larger than the horizontal extension (TE) of the tongue (10).

(120) 43. The building panels as in any one of the preceding embodiments 29-42, wherein the core comprises HDF, particle board, plastic or plywood material.

(121) 44. The building panels as in any one of the preceding embodiments 29-43, wherein the horizontally locking surfaces (15) have a locking angle of about 40-60 degrees against the horizontal plane (HP).