BUILDING PANELS

Abstract

Flooring material comprising sheet-shaped floor elements with a mainly square or rectangular shape. The floor elements are provided with edges, a lower side and an upper decorative layer. The floor elements are intended to be joined by means of joining members. The floor elements are provided with male joining members on a first edge while a second edge of the floor elements are provided with a female joining member. The male joining member is provided with a tongue and a lower side groove while the female joining member is provided with a groove and a cheek. the cheek being provided with a lip. The floor elements are provided with a male vertical assembly joining member on a third edge while a fourth, opposite. edge is provided with female vertical assembly joining member.

Claims

1. A surface element designed to be assembled together with similar surface elements 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 two of such surface elements can be coupled 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 one surface element in respect to the other 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 configured for 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 two of such surface elements at their respective third edge and fourth edge can be interconnected by a downward motion of the third edge of one of said two surface elements with respect to the fourth edge of the other of said two surface elements, to thereby result in a vertical as well as horizontal locking; 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 two joined adjacent floor elements become locked to each other in a horizontal direction; said third and fourth edges each comprising one or more locking surfaces for locking the third edge and a fourth edge of two of such coupled surface elements against vertical separation; wherein said lower cheek of the second edge is formed in one piece of a core material of the surface element; and wherein said protruding cheek portion comprises a recess at its lower side, said recess extending along said lower side up to the distal end of the lower lip and said recess defining a lower side portion of said lower lip which is located at a level which is higher than the aforementioned plane.

2. The surface element of claim 1, wherein said lower side groove at a distal side thereof is bordered by a lower side protrusion at said tongue, said protrusion having a lowermost portion; and wherein said lowermost portion is located proximally from a vertical plane through the upper edge portion belonging to said first edge.

3. The surface element of claim 1, wherein said recess from the distal end of the lower lip towards the proximal end, extends at least completely underneath the upward directed portion.

4. The surface element of claim 3, 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.

5. The surface element of claim 2, wherein said recess from the distal end of the lower lip towards the proximal end, extends at least completely underneath the upward directed portion.

6. The surface element of claim 5, 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.

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

8. The surface element of claim 1, wherein the female cheek surface of the second female joining member is upwardly directed from a proximal to a distal position.

9. 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.

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

11. The surface element of claim 1, wherein said contact surfaces configured for said horizontal locking at the first pair of opposite sides are substantially planar.

12. The surface element of claim 1, wherein said contact surfaces configured for said horizontal locking at the first pair of opposite sides are curved.

13. 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.

14. 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 for 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

[0022] 5

[0023] The invention is described further in connection to enclosed figures showing different embodiments of a flooring material whereby,

[0024] FIG. 1 shows, in cross-section, a first and a second edge 2.sup.I and 2.sup.II respectively, during joining

[0025] 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.

[0026] 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.

[0027] 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.

[0028] FIG. 5 shows, in cross-section, a third and a fourth edge 2.sup.I and 2.sup.IV respectively, during joining.

[0029] 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.

[0030] 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.

[0031] 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.

[0032] FIG. 9 shows, in cross-section, a first and a second edge 2.sup.I and 2.sup.II respectively, during joining.

[0033] FIG. 10 shows, in cross-section, a second embodiment of a first and a second edge 2.sup.I and 2.sup.II respectively, during joining.

[0034] FIG. 11 shows, in cross-section, a third embodiment of a first and a second edge 2.sup.I and 2.sup.II respectively, during joining.

[0035] FIG. 12 shows, in cross-section, a fourth embodiment of a first and a second edge 2.sup.I and 2.sup.II respectively, during joining.

[0036] FIG. 13 shows, in cross-section, a third and a fourth edge 2.sup.III and 2.sup.IV respectively, during joining.

[0037] FIG. 14 shows, in cross-section, a second embodiment of a third and a fourth edge 2.sup.II and 2.sup.IV respectively, during joining.

[0038] FIG. 15 shows, in cross-section, a third embodiment of a third and a fourth edge 2.sup.II and 2.sup.IV respectively, during joining.

[0039] FIG. 16 shows, in cross-section, a fourth embodiment of a third and a fourth edge 2.sup.II and 2.sup.IV respectively and a vertical assembly joining profile 30, during joining.

DETAILED DESCRIPTION OF THE INVENTION

[0040] 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 pans 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. Such floors floor elements, for example, be constituted of solid wood, fibre board, such as medium density fibre board (MDF), particle board, chip board, or any other construction comprising pieces or particles of wood, including combinations of plastic elements and the particles or pieces of wood. The floor elements 1 are provided with male joining members 101 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 21 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.

[0041] The embodiment shown in FIG. 1 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.

[0042] 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.

[0043] 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.

[0044] FIG. 5 shows, in cross-section, a third and a fourth edge 2.sup.II and 2.sup.IV 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.II 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.II 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.

[0045] The joint between a third and a fourth edge 2.sup.II 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 comprises cavities 6.

[0046] The embodiment shown in FIG. 6 corresponds in the main with the one shown in FIG. 5. The male vertical assembly joining members 10.sup.II are, however, provided with only one snapping hook 23 while the female vertical assembly joining members 10.sup.IV are provided with a matching undercut 24, which by being provided with mainly horizontal locking surfaces limits vertical movement between to joined adjacent floor boards 1.

[0047] 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.II 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.

[0048] The embodiment shown in FIG. 8 corresponds mainly with the one shown in FIG. 7. Both the third and the fourth edges 2.sup.II 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.

[0049] 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 21 and a floor element 1 adjacent to the third or fourth edge 2.sup.II and 2.sup.IV respectively, when assembling floor elements 1 according to the above described embodiments.

[0050] 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 coal 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 melamineformaldehyde 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 panicles of for example a-aluminium oxide, silicon carbide or silicon oxide. The lower side 5 may suitably be coated with lacquer or a layer of paper and resin.

[0051] FIGS. 9-16 demonstrate the improvement of the radially projected dimension of the length (L) of the groove or undercut and the horizontal rotated radially projected height (L) of the lip or upper cheek surface of the boards of the invention. With respect to FIGS. 9-12, the radially projected dimension, indicated at a, corresponds to the length of the groove 13, while indicates the horizontal rotated length of lip 15. Additionally, indicates the length of the tongue 11, while is the horizontal rotated length of the locking groove 12. Because a is greater than , and is greater than , adjacent floor elements cannot be assembled horizontally. In other words, because tongue 11 (as well as groove 13) is greater than lip 15 (as well as locking groove 12), the floor elements depicted in these figures can only be assembled by rotating or turning one of the floor elements. Generally, in each of these figures, a is substantially equal to and is substantially equal to . This substantially equal relationship provides for a close fitting, while limiting movement of adjacent panels once assembled. For example, the difference in dimensions may be from 0.005-5%, or from 0.02-0.5 mm.

[0052] In contrast, the floor elements shown in FIGS. 13-16 may be assembled through horizontal motion. Specifically, is the length of the undercut 24, while corresponds to the horizontal rotated length of the upper cheek surface 22. Additionally, indicates the length of the snapping hooks 23, while the horizontal rotated length of the lower cheek surface 21 is specified by .

[0053] Because is less than and is less than , the floor elements can only be assembled through horizontal movement. That is to say, due to the particular dimensions of the undercuts 24, upper cheek surface 22, snapping hooks 23 and lower cheek surface 21, the floor panels of the invention may be joined through substantially vertical movement of one panel with respect to a second panel.

[0054] The dimensions and may also be related to the thickness of the floor element itself. For example, the ratio between and the thickness (or and the surface) may be in the range of about 0.025 to 0.2, typically, about 0.05 to about 0.1, and more typically, about 0.07 to 0.09. That is to say, when the thickness is 8 mm, as is common in conventional boards, or would be from 0.2 to 1.5 mm. Additionally, (or ) can be at least 2 times greater than (or ), while (or ) is at least 2 times (or ).

[0055] Moreover, all dimension lines of FIGS. 9-16 are intended to indicate the area taken up by the inserted pan as the recesses, such as, the groove 13 and need not be deeper than the tongue 11. Although in some cases, the recesses are deeper than the length of the tongue 11. With particular reference to FIG. 9, effectively is zero, meaning that there is no undercut when pivoting the panel.

[0056] Finally, the floor elements of this invention, preferably, comprise vertically-joined edges on at least two sides. For example, when the floor panel has a substantially rectangular shape, such vertically-joined edges may be found on two, three or all four sides. When the vertically-joined edges are located on less than all sides of the floor element, the remaining sides may include, for example, edges joined by rotating or horizontal movement or simple straight edges without a joining profile.

[0057] The invention is not limited by the embodiments shown since they can be varied within the scope if the invention.