Joint of floor panels

Abstract

A floor panel system comprises a joint of floor panels wherein each of the floor panels is a rectangular plate with upper and lower surfaces, two long and two short edge side surfaces, and a longitudinal coupling element extending horizontally beyond the upper surface and includes a settling recess that couples with a downwardly extending projection of an adjacent panel, forming a horizontal retaining assembly, a bearing surface at the end of the coupling element which is away from a bearing surface of the adjacent panel, and a bearing projection between the bearing surfaces to form a second vertical retaining assembly and define a lower expansion joint. The panels are joined at the long and short edges using the first vertical retaining assembly and the second vertical retaining assembly via a bearing protrusion integrated into the panel and a having a height greater than the size of the lower dilation gap. Further, the longitudinal coupling element has an upwardly extending vertical projection placed in a settling seat below the guiding groove of the elastic insert.

Claims

1. A joint of floor panels (1, 1), including a floor panel and an adjacent floor panel, wherein each of the floor panels (1, 1) to be joined is in a form of a rectangular plate, comprising an upper surface (6) and a lower surface (25) parallel to the upper surface (6), intended to be laid on a substrate, two long edges (2, 2) of side surfaces (3, 3), two short edges (4, 4) of side surfaces (5, 5), a first vertical retaining assembly (10, 37) for the floor panels (1, 1) to be joined, in a form of an elastic insert (21) placed between the floor panels (1, 1) to be joined, a longitudinal coupling element (7, 8) shaped below one of the long edges (2) of the side surface (3), wherein the longitudinal coupling element (7, 8) is parallel to the upper surface (6) and extends horizontally beyond the upper surface (6), and furthermore, the longitudinal coupling element (7, 8) has a settling recess (12, 39) that couples with a downwardly extending projection (13, 40) of the adjacent floor panel (1) and forms with the adjacent floor panel a horizontal retaining assembly (9, 36) of the floor panels (1, 1) to be joined, wherein the longitudinal coupling element (7, 8) has a bearing surface (26, 46) at the end of longitudinal coupling element (7, 8), wherein the bearing surface (26, 46) is remote from a bearing surface (18, 42) of the adjacent floor panel (1), and furthermore, a bearing projection (27, 47) is placed between the bearing surfaces (26, 46; 18, 42) and forms a second vertical retaining assembly (10, 37), and defines a lower expansion joint (29, 29), wherein the floor panel (1) is joined by the respective long edge (2, 2) to the short edge (4, 4) of the adjacent floor panel (1) by means of the first vertical retaining assembly (10, 37) in the form of an elastic insert (21), placed via sliding in a guiding groove (22) between the floor panels (1, 1) to be joined and extending from the side surface (5, 5) below the short edge (4) and by means of a second vertical retaining assembly (10, 37), placed below the first vertical retaining assembly (10, 37), in a form of a bearing protrusion (27, 47) extending from the bearing surface (26, 46), where bearing surface (27, 47) is positioned partially in a groove (28, 48) formed in the bearing surface (18, 42) of the adjacent floor panel (1), the bearing protrusion (27, 47) being an integral part of the floor panel (1) and having a height (30, 30) greater than the size of the lower dilatation gap (29, 29), and furthermore, the longitudinal coupling element (7, 8) has an upwardly extending vertical projection (11, 38) placed in a settling seat (16, 41) below the guiding groove (22) of the elastic insert (21).

2. The joint of the floor panels (1, 1) according to claim 1, wherein the bearing projection (27, 47) is in a form of a cylindrical section, and the groove (28, 48) of the adjacent floor panel (1) is adapted in shape to receive a part of the bearing projection (27, 47).

3. The joint of the floor panels (1, 1) according to claim 1, wherein the groove (28) is formed in a downwardly extending tongue (19) of the adjacent floor panel (1).

4. The joint of the floor panels (1, 1) according to claim 3, wherein the bearing surface (18) of the downwardly extending tongue (19) of the adjacent floor panel (1) is inclined from the vertical by an angle (a) between 1 and 5.

5. The joint of the floor panels (1, 1) according to claim 1, wherein the downwardly extending projection (40) has two convex arched surfaces (R1, R2) matching two concave arched surfaces (r1, r2) of the settling recess (39).

6. The joint of the floor panels (1, 1) according to claim 5, wherein the two concave arched surfaces (r1, r2) form an elongated hump (49) at the contact point of the two concave arched surfaces (r1, r2) and the two convex arched surfaces (R1, R2) form a recess (50) at the contact point of the two convex arched surfaces (R1, R2), the elongated hump (49) being adapted in shape to the recess (50).

7. The joint of the floor panels (1, 1) according to claim 1, wherein the floor panel (1) has a slanted bearing surface (24, 43) above the settling recess (12, 44), intended for contacting the elastic insert (21), wherein the slanted bearing surface (24, 43) is positioned above a lower surface (32, 45) of the settling recess (12, 44) and a free space (FS, FS) is left between the lower side of the elastic insert (21) and the lower surface (32, 45) of the settling recess (12, 44).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The subject of the invention is shown in embodiments in the drawing, in which:

(2) FIG. 1 shows a floor panel in a top view;

(3) FIG. 2 floor panels laid in herringbone pattern in an axonometric view;

(4) FIG. 3 floor panels in a joined position, forming a joint between perpendicularly laid floor panels, where the long edge of the floor panel is joined to the short edge of the adjacent floor panel;

(5) FIG. 4 floor panels, intended to form the floor panel joint shown in FIG. 3, placed side by side;

(6) FIG. 5 floor panels from FIG. 4 in position during the joining operation;

(7) FIG. 6 floor panel joint as in FIG. 3, showing the orientation of the wood fibres;

(8) FIG. 7 another embodiment of the floor panel joint;

(9) FIG. 8 floor panel joint from FIG. 7 in a disjoined position;

(10) FIG. 9 floor panels from FIG. 8 in position during the joining operation;

(11) FIG. 10 floor panels in a joined position by coupling the longitudinal coupling elements together.

DETAILED DESCRIPTION OF THE DRAWINGS

(12) FIG. 1 illustrates a floor panel 1 having two long edges 2, 2, parallel to each other, of side surfaces 3, 3 and two short edges 4, 4, parallel to each other, of side surfaces 5, 5. The long edges 2, 2 and the short edges 4, 4 define a rectangular area of an upper surface 6 of the floor panel 1. Two longitudinal coupling elements 7, 8 project laterally beyond this upper surface 6 and are parallel to each other and parallel to the upper surface 6 of the floor panel 1.

(13) FIG. 2 shows three identical floor panels 1, 1 during a herringbone laying operation. The floor panels 1, 1 are joined by partial rotation and pressure.

(14) The floor panels 1 may join perpendicularly to each other to form a joint of the identical floor panels 1, 1. As shown in FIG. 3 and FIG. 4, such a joint of the floor panels 1, 1 constitutes a perpendicular arrangement in which the long edge 2 of the floor panel 1 is joined to the short edge 4 of the adjacent floor panel 1. The joining of these floor panels 1, 1 is carried out by a horizontal retaining assembly 9 and a first vertical retaining assembly 10, and a second vertical retaining assembly 10.

(15) The longitudinal coupling element 7 has in its lower part a convex arched surface R2 intended to be connected to the fasteners of the second longitudinal coupling element 8.

(16) The horizontal retaining assembly 9 is formed by an upwardly extending vertical projection 11 formed at the end of the longitudinal coupling element 7 of the floor panel 1. The vertical projection 11 forms a settling recess 12, located in the upper horizontal part of the longitudinal coupling element 7, adapted to receive a downwardly extending vertical projection 13 of the adjacent floor panel 1. The settling recess 12 is limited on one side by a vertical surface 14 and on the other side by a diagonal bearing surface 15 of the upwardly extending vertical projection 11. In turn, the downwardly extending vertical projection 13 of the adjacent floor panel 1 forms a settling seat 16 located between a diagonal bearing surface 17 and a vertical bearing surface 18 of a downwardly extending tongue 19.

(17) In the joined position of the floor panel 1 with the adjacent floor panel 1, the horizontal retaining assembly 9 makes it possible to obtain a predetermined size of an upper expansion joint 20 between the long edge 2 of the side surface 3 and the short edge 4 of the side surface 5.

(18) The first vertical retaining assembly 10 of the floor panels 1, 1 to be joined is formed in this embodiment by an elastic insert 21 placed via sliding in a guiding groove 22 from the side surface 5, the guiding groove 22 being located above the settling seat 16. Floor panels 1, 1 are joined by, essentially, vertically pressing the adjacent floor panel 1 in order to flush the upper surfaces 6 of the adjacent floor panels 1, 1. In the flush position, the upper part 23 of the resilient insert 21 extending from the guiding groove 22 remains in contact with the slanted bearing surface 24 formed between the vertical surface 14 and the side surface 3. In this position, lower surfaces 25 of the joined floor panels 1, 1 are also aligned in a single plane.

(19) The longitudinal coupling element 7 has a vertical retaining surface 26 from which a longitudinal bearing projection 27 in the shape of a cylindrical section protrudes, forming an integral part of the said longitudinal coupling element 7. In the joined position of the floor panel 1 with the adjacent floor panel 1, the longitudinal bearing projection 27 is located partially in a groove 28 formed in the vertical bearing surface 18 of the downwardly extending tongue 19 of the adjacent floor panel 1. A lower expansion joint 29 is provided between the bearing surfaces 18, 26, wherein the bearing projection 27 has a height 30 which is greater than the size of the lower expansion joint 29 because, in the joined position of the floor panels 1, 1, the end part of the bearing projection 27 is placed in the groove 28 of the adjacent floor panel 1 at a depth 31. This means that with the panels 1, 1 joined, the lower expansion joint 29 is smaller than the height 30 of the bearing protrusion 27 by the depth of the groove 28 of the adjacent floor panel 1.

(20) The longitudinal bearing protrusion 27 thus made, being an integral part of the longitudinal coupling element 7, intended to be placed in the groove 28 of the adjacent floor panel 1, constitutes the second vertical retaining assembly 10 of the floor panels 1, 1 to be joined. This configuration is also important for increasing the precision of joining the floor panels 1, 1.

(21) In the embodiment shown in FIG. 3 and FIG. 4, the distance between the bearing surface 24 and the lower surface 32 of the settling recess 12 is substantially greater than the thickness of the elastic insert 21. Placing the longitudinal bearing protrusion 27 in the groove 28 of the adjacent floor panel 1 and providing a free space FS between the elastic insert 21 and the lower surface 32 of the settling recess 12 allows a larger pressing force tolerance to be applied when joining the panels 1, 1. When a higher pressing force is applied, the elastic insert 21 does not engage in the guiding groove 22, nor does it deform due to contact with adjacent surfaces, and can move without increased frictional resistance to ensure proper vertical retention of the floor panels 1, 1 to be joined.

(22) During installation of the panels 1, 1, the bearing projection 27 is guided by the lower part of the vertical bearing surface 18, whereby, in such an installation position as shown in FIG. 5, the guidance of the elastic insert 21 is facilitated. This configuration of the bearing protrusion 27 and the vertical bearing surface 18 during installation protects the elastic insert 21 from damage. By guiding the bearing projection 27 into the groove 28 of the adjacent floor panel 1, the position shown in FIG. 3 is obtained, in which the upper part 23 of the elastic insert 21 is in contact with the slanted bearing surface 24. During installation, when the upper surfaces 6 of the side-by-side floor panels 1, 1 are made flush with each other and when the installer continues to press the adjacent floor panel 1, then the bearing protrusion 27 causes the longitudinal coupling element 7 to be displaced downwardly, and by such bending the pressure of the upwardly extending vertical projection 11 onto the settling seat 16 is released, which consequently prevents the elastic insert 21 from engaging in the guiding groove 22.

(23) FIG. 6 shows the orientation of the wood fibres in the individual layers of engineered wood floor panels 1, 1. As shown in the embodiment, the floor panel 1 has: an upper layer 33 with wood fibres arranged in a radial R, tangential T or intermediate R/T direction; a middle layer 34 with wood fibres arranged in a longitudinal direction L; and a lower layer 35 with wood fibres arranged in a radial R, tangential T or intermediate direction R/T direction. In the case of the adjacent floor panel 1, the wood fibres of the upper layer 33 are arranged in the longitudinal direction L; of the middle layer 34 in the radial R, tangential or intermediate R/T direction, and of the lower layer 35 in the longitudinal direction L. As shown in the embodiment, the bearing surface 18 of the downwardly directed tongue 19 of the adjacent floor panel 1 is preferably inclined from the vertical by an angle equal to 3, wherein equally good results in terms of facilitated guidance of the bearing protrusion 27 into the groove 28 of the adjacent floor panel 1 are obtained with an inclination of the bearing surface 18 within a range of 1 to 5.

(24) The use of the longitudinal bearing protrusion 27 placed partially in the groove 28 of the adjacent floor panel 1 is important in particular for floor panels 1, 1 made of wood and laid in herringbone or checkerboard patterns. In case of an increase in moisture, the forces acting between the joined floor panels 1, 1 are primarily transmitted through the lower layers 35, 35 and the middle layers 34, 34 and it is these layers that cause the greatest mutual pressure. In the solution according to the invention, the longitudinal bearing projection 27 placed partially in the groove 28 of the adjacent floor panel 1 bears the main part of the pressure forces and thus protects the upper surface 6 of the floor panels 1, 1 from damage.

(25) FIG. 7 and FIG. 8 show a joint of the floor panels 1, 1 laid perpendicularly in which the long edge 2 of the floor panel 1 is joined to the short edge 4 of the adjacent floor panel 1. The joining of these floor panels 1, 1 is carried out by the horizontal retaining assembly 36 and the first vertical retaining assembly 37.

(26) The horizontal retaining assembly 36 is formed by an upwardly extending vertical projection 38 formed at the end of the longitudinal coupling element 8 of the floor panel 1. The vertical projection 38 forms a settling recess 39, located in the upper part of the longitudinal coupling element 8, adapted to receive a downwardly extending vertical projection 40 of the adjacent floor panel 1. The settling recess 39 is limited by the upwardly extending vertical projection 38. In turn, the downwardly extending vertical projection 40 of the adjacent floor panel 1, located below the guiding groove 22 of the elastic insert 21, forms a settling seat 41 located between the vertical bearing surface 42 and the two convex arched surfaces R1, R2 of this adjacent panel 1.

(27) In the joined position of the floor panel 1 with the adjacent floor panel 1, as shown in FIG. 7, the horizontal retaining assembly 36 makes it possible to obtain a predetermined size of the upper expansion joint 20 between the long edge 2 of the side surface 3 and the short edge 4 of the side surface 5.

(28) The first vertical retaining assembly 37 of the floor panels 1, 1 to be joined is formed in this embodiment by the elastic insert 21 placed via sliding in the guiding groove 22 from the side surface 5. The joining of the floor panels 1, 1 is carried out essentially by half-rotation with vertical pressing of the adjacent floor panel 1 in order to render flush the upper surfaces 6 of the adjacent floor panels 1, 1. In the flush position, the upper part 23 of the elastic insert 21 extending from the guiding groove 22 remains in contact with a slanted bearing surface 43 located above a settling recess 44, with a free space FS remaining between the lower side of the elastic insert and a lower surface 45 of the settling recess 44. In this position, lower surfaces 25 of the joined floor panels 1, 1 are also aligned in a single plane.

(29) The longitudinal coupling element 8 has a vertical retaining surface 46 from which a longitudinal bearing projection 47 having a heigh 30 protrudes, forming an integral part of the longitudinal coupling element 8. In the joined position of the floor panel 1 with the adjacent floor panel 1, the longitudinal bearing projection 47 is located partially in a groove 48 formed in the vertical bearing surface 42 of the adjacent floor panel 1, at a depth 31, thus forming a second vertical retaining assembly 37. A lower expansion joint 29 is provided between the bearing surfaces 42, 46. In the joined position of the floor panels 1, 1, the lower expansion joint 29 is smaller than the height 30 of the longitudinal bearing protrusion 47, which is the result of placing the end part of the bearing protrusion 47 in the groove 48 of the adjacent floor panel 1.

(30) The longitudinal bearing protrusion 47 thus made, being an integral part of the longitudinal coupling element 8, intended to be settled in the groove 48 of the adjacent floor panel 1, constitutes the second vertical retaining assembly 37 of the floor panels 1, 1 to be joined. This configuration is also important for increasing the precision of joining of the floor panels 1, 1.

(31) In the embodiment shown in FIG. 7 and FIG. 8, the distance between the slanted bearing surface 43 and the lower surface 45 of the settling recess 44 is substantially greater than the thickness of the elastic insert 21, thereby creating a free space FS. Settling the longitudinal bearing protrusion 47 in the groove 48 of the adjacent floor panel 1 and providing a free space FS between the elastic insert 21 and the lower surface 45 of the settling recess 44 allows a larger pressing force tolerance to be applied when joining the panels 1, 1. When a higher pressing force is applied, the elastic insert 21 will not engage in the guiding groove 22, nor will it deform due to contact with adjacent surfaces. Such a design of the first vertical retaining assembly 37 ensures that increased frictional resistance of the elastic insert 21 does not develop in the guiding groove 22, allowing it to move and ensuring proper vertical retention of the floor panels 1, 1 to be joined.

(32) The horizontal retaining assembly 36 is formed by an upwardly extending vertical projection 38 formed at the end of the longitudinal coupling element 8 of the floor panel 1. The vertical projection 38 forms the settling recess 39, located in the upper part of the longitudinal coupling element 8, adapted to receive the downwardly extending vertical projection 40 of the adjacent floor panel 1. The settling recess 39 is limited by the upwardly extending vertical projection 38. In turn, the downwardly extending vertical projection 40 of the adjacent floor panel 1 forms a settling seat 41 located between the vertical bearing surface 42 and the two convex arched surfaces R1, R2 of this adjacent panel 1.

(33) The two convex arched surfaces R1, R2 of the downwardly extending projection 40 are adapted in shape to the two concave arched surfaces r1, r2 of the settling recess 39. An elongated hump 49 is formed at the contact point of the concave arched surfaces r1, r2, and a recess 50 is formed at the contact point of the convex arched surfaces R1, R2.

(34) As shown in FIG. 9, during installation of the panels 1, 1, the bearing projection 47 is guided by the lower part of the vertical bearing surface 42, whereby, in such an installation position, the guidance of the elastic insert 21 is facilitated. By guiding the bearing projection 47 into the groove 48 of the adjacent floor panel 1, the position shown in FIG. 7 is obtained in which the upper part 23 of the elastic insert 21 is in contact with the slanted bearing surface 43. In such a joined position, the elongated hump 49 enters the recess 50 which serves as an additional settling seat, causing additional stabilisation of the unambiguously made joint of the floor panels 1, 1.

(35) As shown in FIG. 10, the identical floor panels 1 are joined to each other by their long sides. In order to obtain such a joining, the longitudinal coupling element 7 of one long side of the floor panel 1 is joined to the second longitudinal coupling element 8 of the other side of the same floor panel 1. The vertical retention of such a joint is achieved by placing the end part of the longitudinal coupling element 7 in the settling recess 44, shown in FIG. 8. Additional vertical retention of such a joining is achieved by inserting the bearing projection 47 into a groove 51. The horizontal retention of the floor panels 1, between their long sides, is achieved by inserting the convex arched surface R2, of the longitudinal coupling element 7 into the concave arched surface r2 of this longitudinal coupling element 8, also with the use of the bearing projection 47 and the groove 51. Such a horizontal retention makes it possible to obtain a predetermined size of the upper dilatation gap 20 between the edges of the panels 1 to be joined.

(36) The chosen terminology used herein is for informational purposes only and does not in any way limit the scope of the present invention. For example, t terms such as: upper, lower, side, middle, vertical, horizontal or the like describe only the position shown in the Figures.

(37) As follows from the above, the upper surface refers to the surface visible after laying the floor panels on the substrate, regardless of whether the floor panels are laid on the floor, on the wall or on the ceiling. The lower surface refers to the surface that is not visible after installation, regardless of whether the floor panels are laid on the floor, on the wall or on the ceiling, and intended to come into contact with the substrate.

(38) Similar numbers on the Figures of the drawing refer to similar elements. The preferred embodiments disclosed in the Figures of the drawing and in the description, despite the use of specific terms, are only general in nature and should not be considered as limitations of the scope of the invention as defined in the following patent claims.

LIST OF REFERENCE NUMBERS

(39) 1, 1 Floor panel and identical adjacent floor panel; 2, 2 Long edge of the side surface of the floor panel; 3, 3 Side surface; 4, 4 Short edge; 5, 5 Side surface; 6 Upper surface of the floor panel; 7 Longitudinal coupling element; 8 Longitudinal coupling element; 9 Horizontal retaining assembly; 10 First vertical retaining assembly; 10 Second vertical retaining assembly; 11 Vertical projection; 12 Settling recess; 13 Vertical projection; 14 Vertical surface; 15 Slanted bearing surface; 16 Settling seat; 17 Slanted bearing surface; 18 Bearing surface; 19 Tongue; 20, 20, 20 Upper expansion joint; 21 Elastic insert; 22 Guiding groove; 23 Upper part of the guiding groove; 24 Bearing surface; 25 Lower surface of the floor panel; 26 Bearing surface; 27 Bearing projection; 28 Groove; 29 Lower dilatation gap; 30 Height of the bearing projection; FS, FS Free space between the elastic insert and the lower surface of the settling recess; 31, 31 Settling depth of the bearing projection; 32 Lower surface of the settling recess; 33, 33 Upper layer; R Radial direction of fibre arrangement; T Tangential direction of fibre arrangement; R/T Intermediate direction of fibre arrangement; 34, 34 Middle layer; 35, 35 Lower layer; Angle of inclination of the bearing surface; 36 Horizontal retaining assembly; 37 First vertical retaining assembly; 37 Second vertical retaining assembly; 38 Vertical projection; 39 Settling recess; 40 Vertical projection; 41 Settling seat; R1, R2 Convex arched surfaces; 42 Bearing surface; 43 Slanted bearing surface; 44 Settling recess; 45 Lower surface of the settling recess; 46 Bearing surface; 47 Bearing projection; 48 Groove; r1, r2 Concave arched surfaces; 49 Elongated hump; 50 Recess; 51 Groove; R2 Convex arched surface of the longitudinal coupling element.