Note: Descriptions are shown in the official language in which they were submitted.
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LOCKING SYSTEM COMPRISING A COMBINATION LOCK FOR PANELS
Area of Invention
The invention generally relates to the field of floor
panels with mechanical locking systems with a flexible and
displaceable tongue.
Background of the Invention
In particular, yet not rdstrictive manner, the invention
concerns a locking system a floor panel and a set of floor
panels mechanically joined to preferably a floating floor.
However, the invention is as well applicable to building
panels in general. More particularly invention relates to
the type of mechanically locking systems comprising a
flexible or partly flexible tongue and/or displaceable
tongue, in order to facilitate the installation of
building panels
A floor panel of this type is presented in
W02006/043893, which discloses a floor panel with a
locking system comprising a locking element cooperating
with a locking groove, for horizontal locking, and a
flexible tongue cooperating with a tongue groove, for
locking in a vertical direction. The flexible tongue bends
in the horizontal plane during connection of the floor
panels and makes it possible to install the panels by
vertical folding or solely by vertical movement. By
"vertical folding" is meant a connection of three panels
where a first and second panel are in a connected state
and where a single angling action connects two
perpendicular edges of a new panel, at the same time, to
the first and second panel. Such a connection takes place
for example when a long side of the first panel in a first
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row is already connected to a long side of a second panel
in a second row. The third panel is then connected by
angling to the long side of the first panel in the first
row. This specific type of angling action, which also
connects the short side of the new panel and second panel,
is referred to as "vertical folding". It is also possible
to connect two panels by lowering a whole panel solely by
vertical movement against another panel.
Definition of Some Terms
In the following text, the visible surface of the
installed floor panel is called "front face", while the
opposite side of the floor panel, facing the sub floor, is
called "rear face". The edge between the front and rear
face is called "joint edge". By "horizontal plane" is
meant a plane, which extends parallel to the outer part of
the surface layer. Immediately juxtaposed upper parts of
two adjacent joint edges of two joined floor panels
together define a "vertical plane" perpendicular to the
horizontal plane.
By "joint" or "locking system" are meant co acting
connecting means, which connect the floor panels
vertically and/or horizontally. By "mechanical locking
system" is meant that joining can take place without glue.
Mechanical locking systems can in many cases also be
combined with gluing. By "integrated with" means formed in
one piece with the panel or factory connected to the
panel.
By a "flexible tongue" is meant a separate tongue which
has a length direction along the joint edges and which is
forming a part of the vertical locking system and could be
displaced horizontally during locking. The tongue could
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for example be bendable or have a flexible and resilient
part in such a way that it can bend along its length and
spring back to its initial position.
By "angling" is meant a connection that occurs by a
turning motion, during which an angular change occurs
between two parts that are being connected, or
disconnected. When angling relates to connection of two
floor panels, the angular motion takes place with the
upper parts of joint edges at least partly being in
contact with each other, during at least part of the
motion.
Summary of the Invention
The present invention is directed to a
locking system and a set of floor panels or a floating
flooring, which provides for new embodiments according to
different aspects offering respective advantages. Useful
areas for the invention are floor panels of any shape and
material e.g. laminate, wood, HDF, veneer or stone.
According to a first embodiment, the invention provides for
locking system for a floor panel comprising a first
connecting device. The first connecting device comprises a
combination lock configured to lock horizontally and
vertically to a second and third connecting devices of a
second and third connecting device, respectively. The
combination lock comprises a locking element for
cooperating with a locking grove of the second and third
connecting _device, for the horizontal locking. Further
more, the combination lock comprises a flexible tongue and
displacement groove, configured to cooperate with a
flexible tongue groove of the second floor panel and a
tongue of a third floor panel.
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As th locking system for a floor panel according to the
first embodiment of the invention is provided with a flexible
and displaceable tongue, displaceable in a displacement
groove and configured to cooperate with a flexible tongue
groove as well as with a tongue, this offers several
advantages. A first advantage is that it is possible to
connect one side of a floor panel with a first connecting
device to two different connecting devices. A second
advantage is that a strong joint is provided and a third
that the height position between the floor panels, in the
short edge to long edge joint is improved.
A locking system for a floor panel of this type is known
from W02006/043893, as mentioned above, and discloses a
bow shaped flexible tongue bendable in the length
direction. The drawback of this locking system is that if
it is used on a joint between a long and short side it
weakens the joint. The first panel has a long edge of an
angling type (see fig 10a), comprising a locking element
and a tongue groove. To facilitate the connection to a
short side of a second panel, the short side is provided
with a flexible tongue and a displacement groove. This
results in a very thin section between the bottom of the
displacement groove and the locking groove. The thin
section makes the joint weak and it's likely that this
thin section will crack when the joint is put under load.
Advantageously, the length of the displacement groove is
at least equal to the sum of the width of the flexible
tongue and the tongue.
Advantageously, the width of the entrance E of the
displacement groove is at least equal to the thickness TT
of the tongue.
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Preferably, the flexible tongue is displaceable via the
tongue.
Preferably, the panels joined are of A and B type, with
mirror inverted connecting devices.
5 Preferably, the flexible tongue has a straight outer edge
and an inner edge with bendable protrusions.
According to a second embodiment, the invention provides for
a set of floor panels comprising the combination lock above at
two of the edges of a first panel, configured to cooperate with
the second connecting device of a second panel and with a third
connecting device of a third panel. The set of floor panels has
the same advantage as mentioned above and it provides for easy
installation of advanced patterns.
According to one embodiment of the present invention, there
is provided a locking system for a floor panel comprising a
first connecting device comprising an integrated combination
lock at a first edge of a first floor panel, the combination
lock is configured to connect the first floor panel to another
floor panel, so that upper joint edges of the floor panels in
the connected state define a vertical plane, wherein the
combination lock comprises an upwardly directed locking element
configured to cooperate with a locking groove, of a second
connecting device to an edge of a second floor panel, for
connecting the first floor panel with said second floor panel
in a horizontal direction perpendicular to said vertical plane,
wherein the combination lock comprises a flexible tongue, in a
displacement groove, the flexible tongue is configured to
cooperate with a tongue groove of the second connecting device
for connecting the first and the second floor panel together in
a vertical direction parallel to the vertical lane, wherein the
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displacement groove and the flexible tongue of the combination
lock is configured to cooperate with a tongue of =a third
connecting device at an edge of a third panel, for connecting
the first panel and the third panel in the vertical direction
parallel to the vertical plane and wherein the flexible tongue
is displaceable via the tongue of the third panel and
positioned, in a connected position of the first and the third
panel, via the tongue inside the joint edge of the first panel
and inside the displacement groove.
According to another embodiment of the present invention,
there is provided a set of floor panels, comprising a first, a
second and a third floor panel, the first floor panel
comprising a first connecting device comprising an integrated
combination lock at a first and a second adjacent edge of the
first floor panel, the combination lock is configured to
connect the first floor panel to the second and the third floor
panel, so that upper joint edges of the floor panels in the
connected state define a vertical plane, wherein the
combination lock comprising an upwardly directed locking
element configured to cooperate with a locking groove of an
adjacent second connecting device at a first edge of the second
floor panel and of an adjacent third connecting device at a
first edge of the third floor panel for connecting the first
and second edge of the first floor panel with said second and
third floor panel in a horizontal direction perpendicular to
said vertical plane, wherein the combination lock comprising a
flexible tongue, in a displacement groove, the flexible tongue
is configured to cooperate with a tongue groove of the second
connecting device for connecting the first edge of the first
panel and the first edge of the second floor panel together in
a vertical direction parallel to the vertical plane, wherein
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the displacement groove and the displaceable tongue of the
combination lock at the second edge of the first panel is
configured to cooperate with a tongue of the third connecting
device at the first edge of the third panel, for connecting the
second edge of the first panel and first edge of the third
panel in the vertical direction parallel to the vertical plane
and wherein the flexible tongue is displaceable via the tongue
of the third panel and positioned, in a connected position of
the first and the third panel, via the tongue inside the second
edge of the first panel and inside the displacement groove.
All references to "a/an/the [element, device,
component, means, step, etc]" are to be interpreted openly as
referring to at least one instance of said element, device,
component, means, step, etc., unless explicitly stated
otherwise.
Brief Description of the Drawings
Figs. la-b illustrate a locking system according to an
embodiment of the invention.
Fig. 2 shows an installation of two panels according to an
embodiment of the invention, a tongue side of a panel is
connecting a tongue side of an adjacent panel.
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Fig 3 shows an installation of two panels according to
an embodiment of the invention, a tongue side of a panel
is connecting a groove side of an adjacent panel.
Figs 4a-b show short sides of two floor panels,
according to prior art, with a locking system adapted for
vertical folding.
Figs 5a-b show locking of short sides of two floor
panels, according to prior art, with a locking system
adapted for vertical folding.
Fig 6a shows locking with vertical folding in a 3D-view.
Fig 7a-e show displaceable tongues in embodiments
according to the invention.
Fig 8a-e show embodiments of applicable installation
patterns.
Fig 9a-d show embodiments of the locking system of the
invention applied to rectangular and square A and B
panels.
Fig 10a shows a prior art locking system.
Figs 10b-d show embodiments of the locking system
according to the invention.
Fig 11 shows an installation of panels in a pattern,
comprising A, B and square panels for which the locking
system of the invention is applicable.
Fig 12a-b shows an embodiment of a combination of
locking system, comprising rectangular and quadratic A and
B panels for which the locking system of the invention is
applicable.
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Description of Embodiments of the Invention
As represented in figures 1-3, 7-12 the invention
relates to a locking system and a set of floor panels with
a displaceable tongue.
Figure la-b show an embodiment of a locking system
according to the invention. Figure lb, .shows the locking
system in a state wherein a first connecting device , a
combination lock C, of a first panel 1, is connected to a
second connecting device FG of a second panel 11. The
combination loc comprises a locking strip 6 and an
upwardly projected locking element 8 cooperating with a
locking groove 14 of the second connecting device for
horizontal locking. Further more, the combination lock
comprises a flexible and displaceable tongue 15,
displaceable in a displacement groove 40, cooperating with
a flexible tongue groove 20, of the second connecting
device for locking in the vertical direction.
Henceforward, the second connecting device will be
referred to as a FG-lock. Figure la, shows the locking
system in a state wherein the "combination lock is
connected to a third connecting device T of a third panel
3. The third connecting device comprising a locking groove
14 cooperating with the locking element of the combination
lock for horizontal locking. Further, the third connecting
device comprises a tongue, pushing the flexible tongue of
the combination lock into the displacement groove, and
cooperating with the displacement groove for locking in
the vertical direction. Henceforward, the third connecting
device will be referred to as a T-lock
Figure la-b show an embodiment with a depth D of the
displacement groove 40 equal to the width of the flexible
tongue F and the tongue S. A deeper displacement groove
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is possible, and also a shallower is possible if the
properties of the tongue allow compression and/or foiling.
Figure 2 shows in four steps a preferred connection
method of the first panel with the combination lock C to
the third panel with the T-lock. The panels are connected
by angling and the flexible tongue is pushed into the
displacement groove. The panels are preferable provided .
with guiding surfaces 22 which facilitate overcoming the
displacement resistance of the flexible tongue. The width
of the entrance E of the displacement groove is preferably
at least equal to the thickness TT of the tongue. The
entrance of the displacement groove is in this
relationship defined to start at the joint plane.
Figure 3 shows in four steps a preferred connection
method of the first panel with the combination lock C to
the second panel with the FG-lock. The panels are
connected by folding or solely by vertical movement of the
whole panel and the flexible tongue is during the
connection pushed into the displacement groove and springs
then back into the flexible tongue groove. The panels are
preferable provided with guiding surfaces 22 which
facilitate overcoming the displacement resistance of the
flexible tongue.
A prior art floor panel 1, l' provided with a mechanical
locking system and a displaceable tongue is described with
reference to Figs 4 and 5. The mechanical locking system
provides locking of the panels relative to each other in
the vertical direction D1 as well as the horizontal
direction D2.
To provide joining of the two joint edges in the Dl and
D2 directions, the edges of the floor panel have in a
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manner known per se a locking strip 6 with a locking
element 8 in one joint edge, hereafter referred to as the
"strip panel" which cooperates with a locking groove 14 in
the other joint edge, hereafter referred to as the "fold
panel", and provides the horizontal locking.
The prior art mechanical locking system comprises a
separate flexible tongue 15 fixed into a displacement
groove 40 formed in one of the joint edges. The flexible
tongue 15 has a groove portion P1, which is located in the
displacement groove 40 and a projecting portion 22
projecting outside the displacement groove 40. The
projecting portion P2 of the flexible tongue 15 in one of
the joint edges cooperates with a tongue groove formed in
the other joint edge.
The flexible, tongue 15 has a protruding part P2 with a
rounded outer part 31 and a sliding surface 32, which in
this embodiment if formed like a bevel. It has upper 33
and lower 35 tongue displacement surfaces and an inner
part 34.
The displacement groove 40 has an upper 42 and a lower
46 opening, which in this embodiment are rounded, a bottom
44 and upper 43 and lower 45 groove displacement surfaces,
which preferably are essentially parallel with the
horizontal plane HP.
The tongue groove 20 has a tongue-locking surface,
which cooperates with the flexible tongue 15 and locks the
joint edges in a vertical direction Dl. The fold panel
has a vertical locking surface 21, which is closer to the
rear face 62 than the tongue groove 20. The vertical
locking surface 21 cooperates with the strip 6 and locks
the joint edges in another vertical direction. The fold
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panel has in this embodiment a sliding surface 23 which
cooperated during locking with the sliding surface 32 of
the tongue.
Figure 4a shows a cross section A-A of a panel according
5 to figure 4b seen from above. The flexible tongue 15 has a
length L along the joint edge, a width W parallel to the
horizontal plane and perpendicular to the length L and a
thickness A in the vertical direction Dl. The sum of the
largest groove portion P1 and the largest protruding part
10 P2 is the total width TW. The flexible tongue has also in
this embodiment a middle section MS and two edge sections
ES adjacent to the middle section. The size of the
protruding part P2 and the groove portion 21 varies in
this embodiment along the length L and the tongue is
spaced from the two corner sections 9a and 9b. The
flexible tongue 15 has on one of the edge sections a
friction connection 36 which could be shaped for instance
as a local small vertical protrusion. This friction
connection keeps the flexible tongue in the displacement
groove 40 during installation, or during production,
packaging and transport, if the flexible tongue is
integrated with the floor panel at the factory.
Figure 5a and 5b shows the position of the flexible
tongue 15 after the first displacement, during the
installation, towards the bottom 44 of the displacement
groove 40. The displacement is caused essentially by
bending of the flexible tongue 15 in its length direction
L parallel to the width W. This feature is essential for
this prior art.
Figure 6a shows one embodiment of a vertical folding. An
initial panel 1" in a first row is connected to a first
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panel 1 in a second row. The second panel 1' is connected
with its long side 5a to the long side 5b of the initial
panel 1" with angling. This angling action also connects the
short side 4b of the second panel 1' with the short side 4a
'
of the first panel 1. The second panel l' is locked to the
first panel 1 with a combined vertical and turning motion
along the vertical plane. VP. The protruding part P2 has. a
rounded and or angled folding part P2' which during folding
cooperates with the sliding surface 23 of the second panel
1'. The combined effect of a folding part P2', and a sliding '
'surface 32 of the tongue which during the folding cooperates
with the sliding surface 23 of the second panel l'
=
facilitates the first displacement of. the flexible tongue 15.
An essential feature of this embodiment is the position of
the projecting portion P2, which is spaced from the corner
section 9a and 9b. The spacing is at least 10% of the length
of .the joint edge, in this case the visible short side 4a.
. Figure 7a-e shows emboaments of the displaceable tongue
15, which are applicable according to the invention,
besides the bow shaped tongue shown in figure .4 and 5.
,Tongues are preferably made of moulded plastic. Any 'type
of polymer materials could be used such as PA (nylon),
POM, PC, PP, PET or PE or similar having the properties
described above in the different embodiments. These
plastic materials could be-when.injection moulding is used
be reinforced with ,for instance glass fibre, Kevlar fibre,
carbon fibre or talk or chalk: A preferred material is
glass fibre, preferably, extra long, reinforced PP or POM.
jigure 7a shows an embodiment with a first long edge Li
and a second long edge L2. The first long edge has
protrusions extending in a plane-parillel to the topside
=
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64 of the tongue 15 and with an angle relative the
longitudinal direction of the tongue.
Figure 7a-b show the embodiment, in top and in a side
view, with a first long edge Li and a second long edge L2.
The first long edge has protrusions 61 extending in a
plane parallel to the topside, an upper displacement
surface, and rear side, a lower displacement surface,
of the tongue and with an angle relative the longitudinal
direction of the tongue. The protrusions are preferably
bow shaped and, in a particular preferred embodiment, the
tongue is provided with a recess 62 at each protrusion 61.
The recess is preferably adapted to the size and shape of
the protrusion.
The protrusions are preferably provided with a friction
connection 63, most preferably close to or at the tip of
the protrusion, which could be shaped for instance as a
local small vertical protrusion. This friction connection
keeps the flexible tongue in the displacement groove 40
during installation, or during production, packaging and
transport, if the displaceable tongue is integrated with
the floor panel at the factory.
Figure 7d shows one embodiment of the locking system
according to the invention illustrating the tongue 15 in
the cross section B-B in figure 7c and positioned in the
displacement groove 40 of a first panel 1 with a
combination lock C. The upper and lower displacement
surface of the tongue is configured to cooperate with an
upper 43 and a lower 45 groove displacement surfaces. The
panel comprising a locking strip 6 and z locking element 8
for horizontal locking. The panel 1 is configured to be
connected to a second panel 1' in a similar way as the
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shown in figure 2 or 3. The upper displacement surface
(64) and/or the lower displacement surface (65) of the
tongue is in one preferred embodiment provided with a
bevelled edge, presenting a sliding surface (32, 31) and
an inclined locking surface (66), respectively. The
inclined locking surface cooperates preferably with an
inclined tongue-locking surface in the tongue groove
20. The combination lock C, may be connected to a second
panel l' provided with the FG-lock or to a third panel
provided with the T-Lock.
In the embodiments according to fig.7d, the displacement
groove (40) is formed in one piece with the core of the
panel, but other alternatives are possible. The
= Displacement groove may be formed in a separate material,
for example HDF, which is connected to a wood core in a
parquet floor. The displacement groove may be formed of U-
shaped plastic or metal sections, which are connected to
the panel with for example a snap connection, glue or
friction. These alternatives could be used to reduce
friction and to facilitate horizontal displacement of the
tongue in the displacement grove. The displacement groove
may also be treated with a friction reducing agent. These
principles may also be applied to the tongue groove.
The figure 7e show a casting gate 71 which is cut'of
before insertion into the displacement groove.
Figure 8a-e show different installation pattern, which
are possible to install with the locking system and set of
floor panels according to the invention. The shown system
comprises two different types of floorboard A and B
respectively, the connecting devices of one type of
floorboard Asalong one pair of opposite edge portions
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being arranged in a mirror-inverted manner relative to the
corresponding connecting devices along the same pair of
opposite edge portions of the other type of floorboard B.
Figure 8a shows a pattern with three floor panels
connected at the short edges to a long edge of a panel
with mirror inverted connecting devices, A and B-panels,
which is explained below and in figure 9a-e. The pattern
consists of a group of three panels in first direction,
surrounded by groups of three panels in a perpendicular
direction. Figure 8b show a quadratic panel connected at
all edges to a long edge of a rectangular. Figure Sc shows
a pattern in which a panel in a first direction is
connected at an edge to three panels in a second
perpendicular direction, which is connected to a first
long edge of a fourth panel in the first direction, whose
opposite edge is connected to three panels in the second
direction, continued in a repeating manner. Figure 8d
shows a pattern comprising a group of four connected
quadratic panels surrounded and connected to the long
edges of rectangular panels. Figure 8e shows a traditional
herringbone pattern. All these installation patterns
involve connecting of a short side to a long side. The
invention provides a solution, which make it possible to
install the patterns with a vertical folding method,
connecting the panels with a strong joint in the vertical
and the horizontal direction. The pattern involves joining
of e.g (cf. fig 9,12):
+a short edge provided with a combination lock C to a
long edge provided with the T-lock
.1
=
*a short edge provided with the FG-lock to a long edge
provided with the combination lock C
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=a long edge provided with the combination lock C to a
long edge with the T-lock
*a short edge provided with the FG-lock to a short edge
provided with the combination lock C
5 *an edge of a quadratic panel provided with a
combination lock C to another edge of a quadratic panel
provided with the T-lock
'an edge of a quadratic panel provided with a
combination lock C to another edge of a quadratic panel
10 provided with the FG-lock
*an edge of a quadratic panel provided with a
combination lock C to a long edge provided with the FG-
lock
*an edge of a quadratic panel provided with a
15 combination lock C to a long edge provided with the T-
lock
*an edge of a quadratic panel provided with a FG-lock to
a long edge provided with the combination lock C
*an edge of a quadratic panel provided with a T-lock to
a long edge,provided with the combination lock C
The short edge of an A-panel are preferably joined to
the long edge of a B-panel, as is common for
installation with A and B-panels.
One way to enable connecting of a short side to a long
side is to provide A-panels and B-panels with mirror
inverted connecting devices, as is shown in figure 9a-d.
Two adjacent edges of the panels are provided with the
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combination lock C, one edge with the FG-Lock and one edge
provided with the T-lock. The three types of connecting
devices C, FG, T are distributed mirror inverted on the A
and on the B panel. Figure 9a shows a rectangular A-panel
with long and short edges. Figure 9b shows a rectangular
B-panel with long and short edges. Figure 9a shows a
quadratic A-panel and 9b shows a quadratic B-panel.
Figure 10a shows an embodiment wherein a displaceable
flexible tongue 15 and a displacement groove 40 is
provided on fourth connecting device on a fourth panel 4
comprising a locking groove 14. This makes it possible to
connect a short side, with the fourth connecting device,
of a floor panel 4 to a long side of fifth panel 5
comprising a standard connecting device, comprising
locking element 8 and tongue groove 11 for connection by
angling, with vertical folding. The problem is that this
solution creates a thin section between the bottom of the
displacement groove 40 and the locking groove 14,
resulting in a weak joint.
Figure 10b shows an embodiment wherein the flexible
tongue is removed and the joint is only locking in the
horizontal direction.
Figures 10o-d show how the principles of the inventibn
may be applied to tongue-groove joint, without any
horizontally locking. Figure 10c illustrates a panel with
a flexible tongue 15 and a displacement groove 40
cooperating with a tongue 10 of a tongue panel. Figure 10d
illustrates a groove panel with a flexible tongue groove
20 cooperating with the flexible tongue 15. The groove
panel may be connected also to a tongue panel with a
tongue cooperating with the groove 11.
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Figure 11 shows in 10 steps a preferred connection
method of A and B-panels, quadratic and with long and
short edges in an advanced pattern. Short edges are joined
to long edges and the quadratic panels are at all edges
joined with long edges.
Figure 12a shows an enlarged part of the pattern in
figure 11 and how the combination loc is distributed to
generate the A and B-panels and to enable the pattern.
Figure 12b shows how the combination loc is distributed
to generate the quadratic A and B-panels. The panels are
connected in manner avoiding a row with several CFG-
joints, which is a joint between a combination loc against
to a FG-lock, in a line. This is an advantage, since a CT-
joint, which is a joint between the combination loc C to a
Ti-lock, offers a stronger connection in the vertical
direction. Consequently it is preferred that every second
joint in a line is a CFG-joint and provided there between
is a CT¨joint. The figure also shows an embodiment of the
distribution of the connecting devices to provide, which
make it possible to connect several quadratic panels to a
long edges of a rectangular panel. Several edges of the
quadratic panels with the combination lock may be
connected to a long edge with the T-lock. Quadratic
panels, with edges in a line having the FG-lock and the T-
lock, may be connected to a long edge with the combination
lock C.
A disadvantage with the CT-joint is that the flexible
tongue pushes the panels apart and possible causing a gap
between the panels. One solution to avoid this is to adapt
the stiffness of the flexible tongue, so that the force
pushing the panels apart is reduced, but this also
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=
influence the final position in a CFG-joint. A second '
solution is that the flexible tongue is configured to be
cracked or destroyed when the tongue pushes it into the
displacement groove. A third solution is a strong locking
element with guiding surfaces, facilitating the
installation. A fourth solution is to dissolve or remove
the tongue. It is also possible to provide the joint edges
with bevels or decorative grooves, which hidden the gap.
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