Floorboard for floating floors, has mechanical locking system comprising machined locking strip that is joined with floorboard and is used to connect floorboard with identical floorboard by least angling

SWEDEN (12) PATENTS (η) C2 ¢ 11) 526 443 (19) SE (51) International class ⁷

E04F 15/04

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(21)

PATENT AND REGISTRATION (45) (41) (22) (24) (62) (86) (86)

Patent filed Application widely available The patent application was submitted on expiration date

Tribal application number

2005-09-13

2004-08-01

2003-01-31

2003-01-31

Patent Application Number () 300271-4

Application received as:

(83)

International filing day

Filing date for European patent application Deposit of microorganism (30) Priority information Swedish patent application completed international patent application with number □ converted European patent application with number (73) (72) (74) (54) (56)

Assignee

INVENTOR

AGENT

NAME

Välinge Innovation AB, Darko Pervan, Viken SE Välinge Innovation AB Locking system for mechanical to achieve a liquid

CALLED PUBLICATIONS:

WO Al 0 020 705, DE Al US A 6 203 653

Apelvägen 2 260 40 Viken SE joining of floorboards to floor covering

601 322, FR Al 2 810 060, (57)

SUMMARY: „,.

Flooring boards with mechanical locking system, consisting of a separately machined strip which is mechanically joined to the floorboard.

1·

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The numbers in parentheses indicate the INID code.

526 443 • ··· · · ·· · ·« ·· ·· ···· ····· ···· · · · · ··· ·· ··· · · · · ···· ······ · • · ♦· ··· ··· · · • · · »· · «· ···· ···· ··«

SUMMARY

Flooring boards with mechanical locking system, 5 separately machined strip, which is the mechanical floorboard.

which consists of a merged with

526 443 ·· ··«· ···· «··

Technical area

The invention relates generally to the field of mechanical locking systems for floorboards. The invention relates partly to floorboards provided with such locking systems, partly to substances for such locking systems and partly to methods for making floorboards with such locking systems. The invention is particularly suitable for use in mechanical locking systems of, for example, the type described and disclosed in WO9426999, WO9966151, WO9966152, SE 0100100-7 and SE0100101-5 (held by Välinge Aluminum AB) but is also useful in any mechanical locking system which can be used. used for joining floors.

More specifically, the invention relates primarily to floors of the type having a core and a decorative surface layer on the top of the core.

Field of application of the invention

The present invention is particularly suitable for use in liquid flooring formed by floorboards, which are mechanically joined together with a locking system integrated with the floorboard ie factory mounted, and partly made up of one or more top layers of veneer, decorative laminate or decorative plastic material. an intermediate core of wood fiber-based material or plastic material and preferably a lower balance layer on the back of the core; and partly produced by cutting large panel blanks to floor panels. The following description of the prior art, problems of known systems and the objects and features of the invention will therefore, as non-limiting examples, be directed primarily to this field of application and then mainly laminate floors designed as rectangular floor boards, intended to be mechanically joined on both long and short sides. . It should

5⁹6 443 can be used in optional where the floorboards can be pointed out, however, that the invention can be floorboards with optional locking systems, joined together with a mechanical locking system in the horizontal and vertical direction. Thus, the invention can also be applied to, for example, homogeneous wooden floors, parquet floors with a core of wood or wood fiber-based material and the like, which are manufactured as separate floor panels, floors with a printed and preferably also varnished surface and the like. The invention can also be used for joining, for example, wall panels.

Background of the invention

Laminate flooring usually consists of a frame of a 6-11 mm thick wood fiber board, a 0.2-0.8 mm thick upper decorative surface layer of laminate and a 0.1-0.6 mm thick lower balance layer of laminate, plastic, paper or similar. The surface layer creates the appearance and durability of the floorboards. The body provides stability, and the balance layer keeps the disc flat as the relative humidity (RH) varies throughout the year. The floorboards are laid floating, ie without glue, on an existing subfloor. Traditional hard floorboards in floating floors of this type are usually joined by glued groove / spring joints (ie joints with a tongue on a floorboard and a tongue groove on adjacent floorboard) on the long and short sides. In laying, the discs are joined horizontally, whereby a protruding tongue along the joint edge of a disc is inserted into a tongue groove along the joint edge of the adjacent disc. The same method is used on both long and short sides.

In addition to such traditional floors, which are joined together by glued tongue / tongue groove joints, in recent years, floorboards have been developed that do not require the use of glue, but instead are mechanically joined by means of so-called mechanical locking systems. These systems contain locking means which lock the discs horizontally and vertically.

The mechanical locking systems are usually formed by machining the core of the disc. Alternatively, parts of • ···· ·

• ···

A / 1 • · «· · · ·» · · • · · · ··· ··· • · ·· The locking system is formed of a separate material, for example, aluminum which is integrated with the floorboard, ie joined with the floorboard already in connection with the manufacture of this.

The main advantages of floating floors with mechanical locking systems are that they can be laid easily and quickly through various combinations of angling, snap-in and insertion. They can also be easily picked up again and reused in another place. A further advantage of the mechanical locking systems is that the edge parts of the floorboards can be formed in materials that do not have good bonding properties. The most common core material is high density wood fiber board and good stability commonly referred to as HDF - high density fiber board. Sometimes MDF - medium density fiberboard - is also used as the core.

Laminate flooring and also many other floors with a surface layer of plastic, wood, wood veneer, cork and the like are made by applying surface layer and balance layer to a core material. This application can be done by gluing an already manufactured decorative layer, for example when the wood fiber board is provided with a decorative high-pressure laminate, produced in a separate operation where several impregnated sheets of paper are compressed under high pressure and high temperature. However, the most common method used today in the manufacture of laminate flooring is direct laminating, which is based on a more modern principle where both the manufacture of the decorative laminate layer and the fixing to the wood fiber board take place in the same manufacturing step. Impregnated sheets of paper are applied directly to the board and pressed together under pressure and heat without any bonding.

In addition to these two methods, a variety of other methods are used to provide the core with a surface layer. A decorative pattern can be printed on the surface of the core, which is then painted, for example, with a wear layer. The core can also be provided with wood, veneer, decorative paper or plastic foil, and these materials can then be coated with a wear layer. The core can also be provided with a soft wear layer,

526 443 for example needle felt. Such a floor has good

1j outdoor features.

As a rule, the above-mentioned methods result in a panel blank in the form of a large sheet which is then sawn into, for example, about 10 floor panels, which are then processed into floor boards. The above mentioned methods can in some cases result in finished floor panels and termination is not necessary before the processing to the finished floorboard is carried out. The manufacture of individual floor panels is most common when the panels have a surface layer of wood or wood veneer.

The above floor panels are in each case individually machined to floor boards. Edge machining is done in advanced milling machines, where the floor panel is precisely positioned between one or more ball bearing chains and strips, so that it can be passed with a high speed and precision past a number of milling motors equipped with diamond tools or metal tools, which process the edge of the floor panel. Using multiple milling motors operating at different angles, advanced joint geometries can be formed at speeds in excess of 100 m / min and with an accuracy of ± 0.02 mm.

Definition of certain terms

In the following text, the visible surface of the pre-assembled floorboard is referred to as the front, while the opposite side of the floorboard, facing the subfloor, is referred to as the back side. The disc-shaped starting material used is called the core. When the core is coated with a surface layer closest to the front and preferably also a balance layer closest to the back, it forms a semi-finished product called a floor panel or panel blank in the event that the semi-finished product, in a subsequent operation, is divided into a plurality of the aforementioned floor panels. When the floor panels are edged to obtain their final shape with the locking system, they are referred to as floor boards. By surface layer is meant all layers that are applied to the core closest to the front and preferably cover the entire front of the core.

526 ^ 43 floorboard. By decorative surface layer is meant layers which are mainly intended to give the floor its decorative appearance. By wear layer is meant layers which are primarily intended to improve the wear resistance of the front. In laminate floors, this layer usually consists of a transparent paper with admixture of alumina impregnated with melamine resin. By reinforcing layers is meant layers which are primarily intended to improve the surface layer's ability to withstand impact and pressure and in some cases also compensate the corrugations of the core so that they do not become visible at the surface. In high-pressure laminates, this reinforcing layer usually consists of a brown kraft paper impregnated with phenolic resin. By horizontal plane is meant a plane which is parallel to the outer part of the surface layer. Immediately adjacent to the upper parts of two adjacent joint edges of two joined floorboards together define a vertical plane perpendicular to the horizontal.

The outer parts of the floorboard at the edge of the floorboard between the front and the back are called joints. The joint edge usually has several joint surfaces which can be vertical, horizontal, angled, rounded, chamfered, etc. These joint surfaces are available on different materials, for example laminates, wood fiber boards, wood, plastic, metal (especially aluminum) or sealing material. By joint edge portion is meant the joint edge of the floorboard as well as part of the parts of the floorboard closest to the joint edge.

By joint or locking system is meant cooperative coupling means which connect the floorboards vertically and / or horizontally. By mechanical locking system is meant that joining can be done without glue. In many cases, mechanical locking systems can also be joined with glue.

With the above techniques one can make laminate floors which are very natural copies of wood flooring, stone, clinker and the like and which are very easy to install with mechanical locking systems. The length and width of the floorboards are usually 1.2 * 0.2 meters. Recently, laminate flooring with other formats has also started to be marketed.

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However, the techniques used to manufacture such floorboards with mechanical locking systems are still relatively costly, since the machining of the joint parts to form the mechanical locking system gives rise to considerable spillage, especially as the width of the floorboards is increased so that the length of the joint parts per square meter of floor area increases. New formats could be manufactured and the market for these types of flooring could increase substantially if the mechanical locking systems could be manufactured in a simpler and cheaper way and with better function.

Known technology and problems with this

In order to facilitate the understanding and description of the present invention and the insight into the problems underlying the invention, reference will now be made with reference to Figures 1-8 of the accompanying drawings, a description of both basic construction and function of floorboards according to WO 9426999 and the manufacturing principles for the manufacture of laminate flooring and mechanical locking system in general. Where applicable, the following description of the prior art also applies to embodiments of the present invention described below.

Figures 3a and 3b show a floorboard 1 according to WO94 26999 from above and from below, respectively. The disc 1 is rectangular with an upper side 2, an underside 3, two opposite long sides with joint edge portions 4a and 4b, and two opposite short sides with joint edge portions 5a and 5b, respectively.

Both longitudinal joint edges 4a, 4b and short edge joint portions 5a, 5b can be mechanically bonded together without glue in a direction D2 in Fig. 1c, so that they meet in a vertical plane VP (marked in Fig. 2c) and so that they have their upper sides in a common horizontal plane HP (highlighted in Figure 2c).

In the illustrated embodiment, which is an example of floorboards according to WO 9426999 (Figs. 1-3 of the accompanying drawings), the disc 1 has a factory-mounted flat strip 6, · ··· • · • · ···· ···

526 which runs along the entire long side 4a and is made of a flexible, resilient aluminum sheet. The strip 6 extends outwardly past the vertical plane VP at the joint edge portion 4a.

The strip 6 may be fixed mechanically according to the embodiment shown or also with adhesive or otherwise. As stated in the aforementioned writings, as a material for a molding that is attached to the floorboard at the factory, other molding materials, such as sheets of other metal, aluminum or plastic profiles, can also be used. As also stated in WO 9426999, the strip 6 may instead be formed integrally with the disc 1, for example by suitable machining of the frame of the disc 1.

The present invention is primarily useful for improving floorboards where the strip 6, or at least a portion thereof, is integrally formed with the body, and the invention solves particular problems encountered with such floorboards and their manufacture. The body of the floorboard does not need but is preferably formed of a uniform material. The strip 6 is always integrated with the disc 1, ie it must have been designed on the disc or be factory fitted.

A similar fixed shorter strip 6 'is arranged along one short side 5a of the disc 1. The projecting portion of the strip 6 past the vertical plane VP is formed with a locking element 8, which extends along the entire strip 6. The locking element 8 has in the lower part an active locking surface 10 facing the vertical plane with a height of, for example, 0.5 mm. In laying, this locking surface 10 cooperates with a locking groove 14, which is received in the underside 3 of the joint edge portion 4b of the opposite long side of an adjacent disc 1 '. The strip 6 'along the short side is provided with a corresponding locking element 8', and the joint edge portion 5b of the opposite short side has a corresponding locking groove 14 '. The edge of the locking grooves 14, 14 'away from the vertical plane VP forms an active locking surface 10' for interaction with the active locking surface 10 of the locking element.

For mechanical joining of both long sides and short sides even in vertical direction (direction D1 in Fig. 1c),

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van 1 further along one long side (joint edge portion 4a) and one short side (joint edge portion 5a) formed with a laterally open recess or groove 16. This is delimited upward by an upper lip at the joint edge portion 4a, 5a and downward by respective strips 6, 6 '. At the opposite edge portions 4b and 5b there is an upper cutout 18 which defines a locking tongue 20 cooperating with the recess or groove 16 (see Fig. 2a).

Figures 1a-1c show how two long sides 4a, 4b of two such disks 1, 1 'on a support U can be joined by angling by pivoting about a center C near the intersection of the horizontal plane HP and the vertical plane VP, while keeping the disks substantially in contact together.

Figures 2a-2c show how the short sides 5a, 5b of the disks 1, 1 'can be joined by snap-in. The long sides 4a, 4b can be joined by either method, while the joining of the short sides 5a, 5b - after laying the first row of floorboards - is normally joined only by snapping, since the long sides 4a, 4b are first joined.

When a new sheet 1 'and a previously laid sheet 1 are to be joined along its long side edge portions 4a, 4b of FIGS. 1a-1c, the long side edge portion 4b of the new sheet 1' is pressed against the long side edge portion 4a of FIG. 20 is inserted into the recess or groove 16. The disc 1 'is then angled down to the sub-floor U according to Fig. 1b. In this case, the locking tongue 20 goes fully into the recess or the groove 16 at the same time as the locking elements 8 of the strip 6 snap into the locking groove 14. During this downward angle, the upper portion 9 of the locking element 8 may be operable and provide a steering of the new disk 1 'towards the previously placed disk 1.

While in the joined position of Fig. 1c, the disks 1, 1 'are locked in both the D1 and D2 directions along their long side edge portions 4a, 4b, but the disks 1, 1' can be displaced relative to each other in the longitudinal direction of the joint along the long sides (i.e., the direction D3 ).

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Figures 2a-2c show how the short side edge portions 5a and 5b of the disks 1, 1 'can be mechanically joined together in both the Dloch D2 direction by displacing the new disk 1' substantially horizontally against the previously placed disk 1. In particular, this can be done since the new the long side of the disk 1 'by angling according to FIGS. 1a-c is joined to a previously placed disk 1 in an adjacent row. In the first step of FIG. 2a, chamfered surfaces cooperate at recess 16 and locking tongue 20, respectively, so that the strip 6 'is forced downwards as a direct result of the joining of the short side edge portions 5a, 5b. During the final assembly, the latch 6 'snaps up as the locking element 8' enters the locking groove 14 ', so that the active locking surfaces 10, 10' on the locking element 8 'and in the locking groove 14' engage with each other.

By repeating the steps shown in Figures 1a-c and 2a-c, the entire flooring can be laid without glue and along all the joint edges. Thus, known floorboards of the aforementioned type are mechanically joined together by usually first angling them down the long side and by shortening the short sides, when the long side is locked, by horizontal displacement of the new sheet 1 'along the long side of the already laid sheet 1 (the direction). D3). The disks 1, 1 'can, without damaging the joint, be taken up again in reverse order as they have been laid and then re-laid. Parts of these laying principles are also applicable to the present invention.

The locking system allows displacement along the joint edge in the locked position after an optional side is joined. Laying can therefore be done in a number of different ways, all of which are variants of the three basic methods&gt; Long side angling and short side snap.

&gt; Long side snapping - short side snapping&gt; Short side angle, displacement of the new disc along the previous side's short side edge, and finally two angles. These laying methods can also be combined with insertion along the joint edge

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The most common and safest laying method is that the long side is first angled down and locked against another floorboard. Thereafter, a displacement is made in the locked position against the short side of a third floor slab so that the short side can be snap in. Laying can also be done by snapping one side, long or short side, with another disc. Thereafter, an offset occurs in the locked position until the other side snaps together with a third disc. Both of these methods require at least one page snippet. However, laying can also be done without wrapping. The third alternative is that the short side of a first disc is first angled towards the short side of a second disc, which is already joined on its long side towards a third disc. After this joining, the first and second discs are usually angled up slightly. The first disc is moved in an angled position along its short side until the upper joint edges of the first and third disc are in contact with each other, after which both discs are jointly angled down.

The above-described floorboard and its locking system have gained great success in the market. A number of variants of this locking system are found on the market mainly in connection with laminate flooring but also thin wooden floors with veneer and parquet flooring.

Recording can take place in several ways. However, all methods require that the long sides can be angled up. The short sides can then be angled up or pulled out along the joint edge. An exception is small floorboards with a size corresponding to a parquet bar which, for example, is laid in fishbone patterns. These small floorboards can be released by extending along the long side so that the short sides snap out. The ability to angle mainly long sides is of great importance for a well functioning locking system. Pick-up is usually started with the first or last row of the laid floor.

Figures 5a-5e show the preparation of a laminate floor. Figure 5a shows the production of high pressure laminates. One

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wear layer 34 of a transparent material of high wear resistance is impregnated with melamine with admixture of alumina. Under this layer 34 is laid a decorative layer 35 of paper impregnated with melamine. One or more layers of reinforcement layers 36a, 36b of phenolic impregnated paper are laid under the decorative layer 35 and the whole package is placed in a press where it cures under pressure and heat to a about 0.5-0.8 mm thick surface layer 31 of high pressure laminate. FIG. 5c shows how this surface layer 31 can then be glued together with a balance layer 32 to a core 30 to form a panel blank 3.

Figures 5d and 5e show direct lamination. A wear layer 34 in the form of an overlay and a decorative layer 35 of decor paper is applied directly to a core 30, after which all three parts and usually also a rear balance layer 32 are inserted into a press where they cure under heat and pressure to a panel blank 3 with a decorative surface layer 31 having a thickness of about 0.2 mm.

After lamination, the panel blank is sawn up to the floor panels. When the mechanical locking system is made integral with the core of the floorboard, the joints are formed during the subsequent machining into mechanical locking systems of various kinds, all of which lock the floorboards in horizontal D2 and vertical direction D1.

Figures 4a-d show in four steps the preparation of a floorboard. Figure 4a shows the three basic components surface layer 31, core 30 and balance layer 32. Figure 4b shows a panel blank 3 where surface layer and balance layer are applied to the core. Fig. 4c shows how floor panels 2 are made by dividing the panel blank. Fig. 4d shows how the floor panel 2, after edge machining, takes its final shape and becomes a finished floorboard 1 with a locking system 7, 7 'which in this case is mechanical, on the long sides 4a, 4b.

Figures 6a-8b show some common variants of mechanical locking systems formed by machining the core of the floorboard. Figs. 6a, b show a system that can be angled and snap with very good function. Figure 7a, b • ···· • · • ···

526 443 ·· · ·· ·&lt;

• · · · · · · · · · · · · · ···· · · · · · · · · ·, shows a snap joint that cannot be opened. Figs. 8a, b show a joint that can be angled and snapped but which has poorer strength and function than the locking system of Fig. 6. As can be seen from these figures, the mechanical locking system has parts which protrude past the upper seam edges and this gives rise to expensive spillage (w), partly because of the saw blade SB's felling when splitting the panel blank and when surface material and core are cut off in connection with the design of parts of the locking system.

These systems and manufacturing methods are fraught with a number of problems that are related, among other things, to costs and function.

The aluminum oxide and also the reinforcing layers that give the laminate floor its high abrasion resistance and impact resistance hard on the tools whose teeth are made of diamond. Frequent and expensive sanding must be done especially by the tool parts that affect the surface layer.

The machining of the joint edges gives rise to expensive spillage as core material and surface material are cut to form the locking system parts.

In order to be able to form a mechanical locking system with protruding parts, the width of the floorboard usually needs to be increased and the decor paper in many cases width-adjusted. This can lead to production problems and considerable investments, especially in the manufacture of parquet flooring.

A mechanical locking system has a more complicated geometry than a traditional locking system that is bonded with glue. The number of milling engines must, as a rule, be increased and this requires that new and more advanced milling machines must be procured.

In order to meet the requirements for strength, ductility in connection with snap-in and low friction in connection with locked position displacement, the core is of high quality. These quality requirements, which are necessary for the locking system, are not always necessary for the other properties of the floor such as stability and impact strength. As a result of the locking system, therefore, the entire core of the floorboard must be «« · &lt;· · t · «• · • · * • ···· &lt;

·· ···· »··· ··· this is increasing

526 4- ^ 3 be of unnecessarily high quality and manufacturing cost.

Different methods have been used to counter these problems. The main method is to limit the extension of the protruding parts past the upper joint edge. This usually results in poorer strength and difficulties in laying or loosening the floorboards.

Another method is to manufacture parts of the locking system in another material, for example aluminum sheet or aluminum profiles. These methods can give a high strength and good function but are generally considerably more expensive. In some cases, they can result in a slightly lower cost than a machined design, but this requires that floorboards are expensive to manufacture and that the spill is very expensive, as can be the case when the floorboards are made of, for example, high-quality high-pressure laminate. In cheaper floorboards of low pressure laminates, the cost of these locking systems of metal is higher than when the locking system is machined from the core of the board. The investment in special equipment, which is needed to shape and attach the aluminum strip to the joint edge of the floorboard, can be significant.

It is also known that separate materials can be glued as an edge portion and formed by machining in conjunction with the joint edges being otherwise machined. Bonding is cumbersome and machining cannot be simplified.

Floorboards can also be joined with separate loose metal brackets which are joined to the floorboard in connection with laying. This makes for a difficult installation and the production cost is high. Clamps are usually placed under the floorboard and attached to the back of the floorboard. They are not suitable for use in thin floors. Examples of such staples are described in DE 42 15 273 and US 4, 819,932. Metal fasteners are described in US 4,

169,688, US 5, 295, 341, DE 33 43 601 and JP 614 553. EP

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146 182 shows profiles of thermoplastic that can be snapped into the joint part and which lock the floorboards with a snap function. All of these alternatives have a poor function and are more expensive to manufacture and more difficult and therefore more expensive to install than known machined locking systems. WO 96/27721 shows separate joint parts that are fixed to the floorboard with gluing. This is an expensive and cumbersome method.

Brief description of the invention and objects thereof

It is an object of the present invention to eliminate or greatly reduce one or more of the problems encountered in the manufacture of floorboards with mechanical locking systems. This applies especially to floorboards with mechanical locking systems that are made integrally with the core of the floorboard. It is a further object of the invention to provide a rational and cost-effective manufacturing method for the manufacture of blanks, which will later form parts of the mechanical locking systems of the floorboards. A third object is to provide a rational method for joining these blanks with the joint portion of the floorboard to form an integrated mechanical locking system that locks vertically and horizontally. A fourth object is to provide a locking system which enables the laying and picking up of floorboards that are located between the first laid and last laid rows in an already joined floor. A fifth object is to provide a joint system and floorboards that can be laid by a vertical movement parallel to the vertical plane.

The invention is based on a first realization that parts of the mechanical locking system should be made of a separate molding which may have properties other than the core of the floorboard, which does not contain expensive and hardworking surface layers and which can be made of a sheet material thinner than the core of the floorboard. This enables iv

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material waste can be reduced and the locking system can be given better properties especially adapted to the function and strength requirements on the long and short sides.

The invention is based on a second understanding that the separate strip should preferably be made of a disk-shaped material which can be given its final shape in a cost-effective manner and with high precision by mechanical machining.

The invention is based on a third insight that this strip should be able to integrate with the joint edge portion of the floorboard in a rational manner with high precision and strength by preferably a mechanical joint where a preferred alternative can be snap-in the core of the floorboard substantially parallel to the horizontal plane of the floorboard. The snap-in, which can also be combined with an angular movement, should preferably be accomplished by a change in shape of a groove in the joint edge portion of the floorboard. In this way, stresses, in cases where the floorboard and the strip move differently due to the moisture and heat movements of different materials, can be eliminated. The mechanical joining gives great degrees of freedom when choosing materials since the bonding problems do not exist.

The invention is based on a fourth insight that machining the edges of the floorboards can be made simpler and faster with fewer and simpler tools that are both cheaper in purchase and cheaper to grind, and that more advanced joint geometries can be achieved if the preparation of the locking system is done by processing a separate molding. which can be formed from a sheet-shaped material with good machining properties. This separate strip can be integrated with the floorboard in a rational way after machining.

526 447 h: · insight that the list ··?

The invention is based on a fifth bending ability in conjunction with snapping of the floorboards against each other, can be improved by partly making the strip in a material which has a better bending ability than the core of the floorboard and partly that the separate strip can move in the snap joint.

Finally, the invention is based on the realization that several moldings should be manufactured in the same milling step and that they should be made in such a way that they can be joined together to form a molding. In this way, the moldings can be manufactured, handled, separated and integrated with the floorboard in a rational and cost-effective manner and with high precision.

The invention is particularly suitable for use in floorboards whose locking systems contain a separate strip which is processed from a sheet-shaped material preferably containing wood fibers, for example chipboard, MDF, HDF, compact laminate, plywood and the like. These sheet materials can be processed rationally and with high precision and shape stability. High density HDF for example about 900 kg / m3 or higher and compact laminates consisting of wood fibers and thermosetting resin, for example phenol, are very suitable as semi-finished products for the manufacture of moldings. The above-mentioned sheet material can also, for example, be impregnated with suitable chemicals, in connection with the manufacture of the sheet material or before or after processing, when they are molded into moldings or moldings. They can be given improved properties, for example, in strength, ductility, moisture resistance, friction and the like. The strips can also be colored for decorative purposes. Different colors can be used for different floor types. The sheet material may also consist of various plastic materials which are molded into molds by machining. Special board materials can be made by gluing or laminating, for example, different layers of wood fiber boards and plastic materials. Such composite materials can be adapted to provide in connection with the machining of the moldings

<img file="SE526443C2_D0006.tif" />

improved properties in, for example, joint surfaces that are heavily loaded or that should have good flexibility or low friction. It is also possible to form moldings as profiles by extrusion of thermoplastic, composite profiles or metal, for example aluminum, but this is usually more expensive than machining. The manufacturing speed is only a fraction of the speeds that can be achieved in modern machining machines.

The moldings can consist of the same material as the core of the floorboard, or of the same material type as the core, but of a different quality or of a completely different material than the core.

The moldings can also be designed so that some are visible from the surface and form a decorative part.

The strips may also have sealing means to prevent the ingress of moisture into the core of the floorboard or through the locking system. They can also be provided with compressible flexible layers of, for example, rubber material.

The strips can be on the long side and the short side or only on one side. The other side may consist of another traditional or mechanical locking system. The locking systems can be mirrored and they can enable long-side to short-side locking.

The long and short side moldings can be of the same material and the same geometry, but they can also consist of different materials and different geometries. They can be specially adapted to the different demands on function, strength and cost that are set for the locking systems on the different sides. For example, the long side contains more jointing material than the short side and is usually laid by laying. On the short side, the requirements for strength are greater and the jointing is often done by wrapping which requires flexible and strong jointing materials.

As mentioned above, angling of mainly long sides is of great importance. A joint system that enables angling and upwinding usually requires a wide list that provides

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a lot of spillage. The invention is thus particularly suitable for joint systems that can be angled around upper joint edges.

The format of the floorboard can be rectangular or square. The invention is particularly suitable for narrow floorboards or floorboards which are in the form of, for example, parquet bars. Floors with such floorboards contain many joints and separate joints give significant savings. The invention is also particularly suitable for thick laminate floors, for example 10-12 mm where the waste cost is high and about 15 mm parquet flooring with a core of wood laminates, where it is difficult to form a locking system by machining wood material along and across the fiber direction. A separate list can provide significant cost benefits and better functionality.

It is also not necessary that the strip is found along the entire joint edge. For example, the long side or the short side may have joint portions which do not contain separate joint portions. In this way, additional cost savings can be achieved especially in cases where the separate molding is of high quality, for example compact laminates.

The separate strip may form part of the horizontal and vertical joint, but it may also form only part of the horizontal or vertical joint.

The various aspects of the invention below can be used separately or in any combination. Thus, a variety of combinations of different locking systems, materials, manufacturing methods and formats can be achieved.

In particular, it should be noted that the mechanical joint between the floorboard and the separate strip can also consist of an adhesive joint which improves the joint. The mechanical joint can then be used, for example, to position the joint part and / or to keep it in the correct position until the adhesive hardens.

According to a first aspect of the invention, there is thus provided a locking system for mechanical joining of floorboards, where immediately adjacent the upper

526 443

<img file="SE526443C2_D0008.tif" />

portions of two adjacent joint edges of two joined floorboards together define one vertical plane perpendicular to the floor surfaces. In order to provide a joint of the two joint edges in a horizontal direction perpendicular to the vertical plane and parallel to the horizontal plane, the locking system comprises in a known manner a locking groove formed in the joint edge portion and extended parallel to the first joint edge, and a separate strip integrated with the second joint edge and having a protruding portion which, at a distance from the vertical plane, carries a locking element cooperating with the lock groove; which projecting portion is thus located completely outside the vertical plane as seen from the other joint edge side. The locking system also includes, for effecting a joining of the two joint edges in the vertical direction, a groove and a co-acting spring. The separate strip with its protruding portion is joined to the core of the floorboard by a mechanical snap joint which joins and locks the separate strip to the floorboard in a horizontal and vertical direction. Snapping can be done by a relative displacement of the strip and the joint edge of the floorboard against each other.

The locking system according to the invention is characterized by:

That this separate strip is formed by machining a sheet-shaped material and that the spring (22) is formed of a separate flexible material having a different material composition or material properties than the core of the floorboard, and that the spring is flexible and capable of being vertically changed and / or horizontally, alternatively displaced horizontally, to facilitate the uptake of joined floorboards.

According to a first embodiment of this first aspect, a floorboard with the above joint system is characterized by the combination that

526 443

<img file="SE526443C2_D0009.tif" />

• The strip consists of HDF, • Snap-in can be done against a groove in the joint edge of the floorboard, whereby this groove changes in connection with the snap-in, • The floorboard has at least two opposite sides that can be joined or loosened by an angular movement around the joint edge.

These and other objects of the invention are achieved with the locking system and floorboards having the features set forth in the appended independent claims. The dependent claims disclose particularly preferred embodiments of the invention.

Brief description of the drawings

<td>FIG.</td><td>a-c</td>

<td>FIG.</td><td>2a-c</td>

<td>FIG.</td><td>3a-b</td>

<td>FIG.</td><td>4a-d</td>

<td>FIG.</td><td>5a-e</td>

<td>FIG.</td><td>6a-b</td>

<td>FIG.</td><td>7a-b</td>

<td>FIG.</td><td>8a-b</td>

<td>FIG.</td><td>9a-d</td>

shows in various steps mechanical joining of floorboards according to known technology.

shows in various steps mechanical joining of floorboards according to known technology.

shows floorboards with mechanical locking system according to prior art.

shows the manufacture of laminate flooring according to prior art.

shows the manufacture of laminate flooring according to prior art.

shows a mechanical locking system according to prior art.

shows another mechanical locking system according to prior art.

shows a third embodiment of mechanical locking systems according to the prior art, schematically shows an embodiment.

Figures 10a-c show schematically joining a separate strip with a floorboard.

526 443

Figures 11a-c show the processing of moldings.

Figures 12a-c show how a molding is produced in several manufacturing steps.

Fig. 13 shows how several moldings can be handled.

Figures 14a-d show how the separate strip is joined together with the floorboard and separated from the molding.

Figs. 15a-d show a production-adapted design as well as joining of floorboards by angling and snapping.

Figures 16a-d show the joining of a production-adapted separate molding with the floorboard by snapping.

Fig. 17 shows a preferred alternative of how the separate strip is produced by machining.

Figures 18a-d show a preferred embodiment with separate strip and tongue.

Figures 19a-d show a preferred embodiment.

Figs. 20a-d show a preferred embodiment with separate strip having symmetrical edge portions.

526 44? L&gt;

Figures 21-26 show examples of different embodiments' · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · • ···· ····· «• · · · · ·« * ·· ** ·· ·····

Figures 27a-b show examples of how the separate strip can be separated from the blank.

Figs. 28a-b show how termination of panel blanks to floor panels can be done to minimize material waste.

Figs. 29a-e show machining of joint edge portions

Fig. 30 shows a format corresponding to a normal laminate floorboard with separate strip on long and short sides.

Fig. 31 shows a long and narrow floorboard with separate strip on the long and short sides.

Fig. 32 ab shows the format corresponding to a parquet bar in two mirrored designs with separate strip on long and short sides.

Fig. 33 shows a format suitable for imitating stone and clinker with separate strip on long and short sides.

Figs. 33a-c show the embodiment with a separate strip which is mechanically locked in the lower lip and which is joined together by a combination of snap-in and angling to the joint edge.

Figures 34a-c show different variants with the strip locked in the lower lip.

• »·· • · · • · · ·· *··

526 443 ·· ·· • · · · • » · • · · » · · »· ··«· ·· ···· • · · • ··· • · « • 9 ···· «··

Figs. 35a-e show an embodiment with separate flexible tongue and uptake of floorboard.

Figures 36a-f show a way to release floorboards having a separate strip.

Description of preferred embodiments

A first preferred embodiment of a floorboard 1,

1 ', which is provided with a mechanical locking system, will now be described with reference to Figures 9a-d. To facilitate understanding, the locking system has been shown schematically. It should be emphasized that a better function can be achieved with other preferred embodiments described below.

Fig. 9a schematically shows a section through a joint between a long side edge portion 4a of a disc 1 and an opposite long side edge portion 4b of a second disc 1 '.

The tops of the discs are substantially in a common horizontal plane HP, and the upper parts of the joint edge portions 4a, 4b abut each other in a vertical vertical plane VP. The mechanical locking system provides a locking of the discs relative to each other in both the vertical direction D1 and the horizontal direction D2.

In order to provide a jointing of the two joint edge portions in the D1 and D2 direction, the edges of the floorboard have in a known manner a tongue-groove groove 23 in one edge portion 4a of the floorboard and a tongue 22 formed in the other joint edge portion 4b, which extends past the vertical plane VP.

In this embodiment, the disc 1 has a frame or core 30 of wood fiber-based material.

The mechanical locking system according to the invention comprises a separate strip 6 having a projecting portion P2 which projects past the vertical plane and having a locking element. The separate strip also has an inner part PI, which is inside the vertical plane VP and which is

<img file="SE526443C2_D0010.tif" />

mechanically joined to the floorboard 1. The locking element 8 cooperates in a known manner with a locking groove 14 in the second joint edge portion and locks the floorboards in a horizontal direction D2.

The floorboard 1 further has a molding groove 36 in one of the joints of the floorboarding part 4a, and a molding tongue 38 in the inner part PI of the separate molding 6.

The groove note 36 is delimited by upper and lower lips 20, 21 and takes the form of an undercut groove 43 with an orifice between the two lips 20,21.

The various parts of the list note 36 are best shown in Fig. 9c. The groove is formed in the body or core 30 and starts from the edge of the floorboard. Above the note there is an upper edge portion or joint surface 40 extending all the way up to the horizontal plane HP. Inside the opening of the note is an upper abutment or support surface 41, which in this case is parallel to the horizontal plane HP. This abutment or support surface transitions into a locking surface 42. Inside the locking surface there is a surface portion 49 which forms the upper boundary of the groove portion 43 and a surface 44 which forms the bottom of the cut groove. The note further has a lower lip 21. On the upper side of this lip there is a abutment or support surface 46. The outer end of the lower lip has a lower joint surface 47 and a positioning surface 48. In this embodiment, the lower lip 21 does not extend to the vertical plane VP.

The shape of the molding tongue is also best shown in Fig. 9d. In this preferred embodiment, the molding tongue is formed of a wood-based sheet material, for example HDF.

The strip tongue 38 of the separate strip 6 has a strip locking element 39 which cooperates with the undercut groove 43 and locks the strip to the joint edge portion 4a of the floorboard 1 in horizontal direction D2. The strip tongue 38 is joined to the strip note by a mechanical snap joint. The latching member 39 has a latching surface 60 facing the Vertical plane VP, an upper molding surface 61 and an interior of control portion 62. which in this embodiment is

526 443 · · · · · · · · · · · · · · · · · · · · · · · · · · · · ··· · ···· ··· tilt. The rib tongue further has an upper abutment or support surface 63, which in this case extends to an oblique upper rib tongue 64 at the tip of the tongue. The strip tongue further has a lower guide portion 65 which in this embodiment transitions into lower abutment or support surface 66. This support surface transitions into a lower positioning surface 67 facing the vertical plane VP. Upper and lower abutment surfaces 45,63 and 46, 66 lock the strip in vertical direction D1. The strip 6 is made in this embodiment of a board material containing wood fiber, for example HDF.

Figures 10a-c schematically show how the separate strip 6 is integrated with the floorboard 1 by snapping. As the floor plate 1 and the strip 6 are displaced against each other according to Figure 10a, the lower guide portion 65 of the molding tongue will cooperate with the joint surface 47 of the lower lip 21. According to Figure 10b, the molding note 36 opens by bending it over the lip 20 and the lower lip 21 downwards. The strip 6 is pushed until the positioning surface 67 abuts the positioning surface 48 of the lower lip. The upper and lower lip 20,21 snap back and the locking surfaces 42, 60 lock the strip 6 to the floorboard 1 and prevent separation in the horizontal direction. The rib tongue 38 and the groove 36 prevent separation in the vertical direction D1. The locking element 8 and its locking surface 10, through this type of snap movement, come into exact position relative to the top joint edge of the floorboard and the vertical plane VP.

The floor plate 1 has thus been integrated with this wrapping movement with a machined strip made in this embodiment of a separate sheet-shaped and wood-fiber-based material.

Figures 11a-c show how a molding 15 consisting of several moldings 6 is produced by machining. TI - T4 shows machining tools of preferably diamond type, working from top to bottom. Only two tools T1 and T2 are needed to produce a mold 6. In the first manufacturing step of Figure 11a, a mold is manufactured

<img file="SE526443C2_D0011.tif" />

<img file="SE526443C2_D0012.tif" />

A Å

Γ “f ·· ···· ······

6th However, this strip is not separated from the sheet material. In the next processing, the molding element 15 is moved to the side corresponding to the width of two moldings. In the third manufacturing step this step is repeated and now two new moldings are being prepared. The molding thus grows with two moldings at each run through the processing machine. Figures 12a-c show how molding 15 with multiple moldings 6 can be manufactured in a double-sided milling machine with 4 tools on each side. In the first manufacturing step according to Figure 12a, two moldings are manufactured. In the next manufacturing step, figure 12b, another 4 moldings are manufactured. Figure 12c shows that the list topic consists of 10 lists after three steps. With a double-sided machine, for example, there are 8 milling motors and 8 tools on each side, 8 moldings can be manufactured at each run through the milling machine. Since machining can take place in HDF, for example, which has no surface layer, machining speeds of up to 200 meters per minute can be achieved with 8 moldings in each run. Since normal floor lines process the joint edges at about 100 meters per minute, such a line can provide 16 floor lines with moldings. The moldings are made of a sheet material that can be considerably thinner than the floorboard. The cost of a separate strip with a width of 15-20 mm, made of a HDF sheet of, for example, 5 mm thickness, is less than 30% of the waste cost when machining an 8 mm laminate floorboard with an integrated strip which has an extension outside the joint edge corresponding to about 8 -10 mm.

There are a number of variations. Moldings can be manufactured in conventional planing machines.

Special machines can be used consisting of, for example, a lower and an upper shaft with tools working vertically. The floorboard is advanced with rollers that push the floorboard against height and side impact and against the rotating tools

Thus, an important feature of the present invention is that the separate strip is produced by mechanical machining of a disk-shaped material.

/1 / 7

Μ- * ·

R 9 Λ · · · · · · ···· «

Figure 13 shows several list items that can be stacked on top of one another and handled rationally. It is possible to manufacture moldings that are as long as the length and width of the floorboard and consist of 10 - 20 moldings or more. The length of the strips can vary, for example, between 70 and 2400 m. The width can be, for example, about 10 - 30 m. The strips can be made with breaking instructions for separating the strips. In HDF, such breaking instructions can be made so that the thickness of the goods only amounts to, for example, about 0.5 mm. The moldings can then be joined with, for example, strands of hot melt adhesive to long ribbons which he then rolled up.

Figures 14a-d show a manufacturing method for integrating the strip with the floorboard. The blank 15 is fed between upper and lower supports 17, 18 against a stop 16 so that the strip 6 is in the correct position. The floorboard 1 is pushed against the strip according to Figure 14b so that it is snapped. Thereafter, the strip 6 is separated from the blank 15 by, for example, breaking the strip. Thereafter, this manufacturing step is repeated according to Figure 14d. The equipment required for this snap is relatively simple and manufacturing speeds corresponding to normal floor lines can be achieved. In this way, the strip 6 can be snapped onto both long side and short side. It is obvious that several variants of this manufacturing method are possible. The strip 6 can be pushed against the floorboard at different angles. Snapping can be combined with an angular movement. Sinking with minimal or no snapping can also be used. The strip can be fixed when the disc is stationary or when it is in motion. In the latter case, part of the molding is pressed against the joint edge of the floorboard closest to a corner between a long side and a short side. Thereafter, the remaining part of the strip can be rolled, pressed or angled towards the joint edge. Combinations of one or more of these methods may occur within one page or between different pages. The list can be separated into a number of other ··· «·« ·

526 • ··· :: :

way, for example by cutting, sawing etc. and this can be done even before attaching.

Figures 15a-d show a production-adapted variant of the invention. In this embodiment, the upper and lower lips 20,21 of the molding 36 and the upper and lower abutment surfaces of the molding tongue 36 are 63.66 inclined with respect to the horizontal plane HP and they follow lines L1 and L2. This substantially facilitates the snapping of the strip to the floorboard 1. The lower lip 21 has been made longer and the locking member of the strip and the undercut groove locking surface are inclined. This facilitates production and wrapping. In this embodiment, the positioning of the strip at the snap is accomplished by a portion of the upper guide portion 62 cooperating with the bottom 44 of the undercut groove. The locking element 14 has a locking surface 10 having the same slope as the key TC of the arc with the center at the upper joint edge. Such an embodiment facilitates angling but requires that the protruding portion P should have an extension which is preferably equal to the thickness T of the floorboard in order for the locking surface of the locking element to have a sufficiently high angle with respect to the underside of the board. A high locking angle increases the locking ability of the locking system. The separate strip allows joint geometries with an extended protruding portion P2 without the need to incur greater costs in manufacturing. An extended inner portion P1 facilitates integration by snap-in and provides high fastening capability. The following relationship figures have proven to be particularly favorable. P2&gt; T and P1&gt; 0.5T. As a non-limiting example, it can be mentioned that a satisfactory function can be achieved even when P2 is 0.8 * T or greater. Figure 15b shows angling with play between the locking element 8 and the locking groove 14 during the initial phase of the angling, as the upper joint edges touch each other and when parts of the lower part of the locking groove 14 are lower than the upper part of the locking element 8. Figure 15d shows snap-in of the floorboard 1 'to the floorboard 1. A separate strip 6 which is mechanically integrated with the floorboard 1 facilitates

526 443 snap in by allowing the strip 6 to move with a rotational motion in the groove 36. The strip can then rotate as shown by line L3. Remaining downward positioning of the locking element 8 to the position L4 can be achieved in known manner by deflection of the strip 6. This makes it possible to provide locking systems which are snap and angular both long and short and having a relatively high locking element 8. In this way, high strength and good angling ability can be combined with snap function and low cost. The following relationship figures have proven to be favorable. HL&gt; 0.15 T. This can also be combined with the above ratios.

Figure 16 (a) shows a snap of the strip 6 in four steps. As shown in the figures, the inclined surfaces contribute to the snap of the strip 6 to the floorboard 1 with a relatively slight bending of the upper and lower lips 20 and 21.

Figure 17 shows the manufacture of moldings where all three critical locking and positioning surfaces are made with a divided tool containing two adjustable tool parts TIA and T1B. These tool parts are clamped in the same tool holder and driven by the same milling motor. This split tool can be sharpened and adjusted with high precision and enables the manufacture of the locking surfaces 10 and 60 and the positioning surface 62 with a tolerance of a few hundredths of a millimeter. The movement of the disc between different milling motors and between different manufacturing steps thus gives no extra tolerances.

Fig. 18 a shows an embodiment of the invention in which the tongue 22 is also made of a separate material. This design can further reduce material waste. Since the tongue only locks vertically, no horizontal locking means more than friction is needed to secure the tongue to the floorboard 1 '.

Figures 19a-d show another embodiment of the invention characterized in that the protruding portion has a locking element which locks in a lower cut groove in the disc 1 '.

526 443

<img file="SE526443C2_D0013.tif" />

·· ···· • · · · • · ·· »♦ ·« ** ··· ··· «··· 'angle and

Such a locking system can be locked by snapping and it can be unlocked by winding around the upper joint edge. Since the floorboard 1 'lacks tongue, the material waste can be reduced to a minimum.

Figures 20a-e show an embodiment of the invention characterized in that the separate strip 6 consists of two symmetrical parts and that the joint parts of the floorboards 1, 1 'are identical. This embodiment allows for easy manufacture of, for example, discs which may consist of A and B discs which have mirrored locking systems. The locking system with the preferred geometry is not openable. This can be achieved by, for example, rounding the lower and outer parts of the strip 6.

Figures 21-26 show different variants of the invention. Figure 21 shows an embodiment with lower lips 21 extending substantially to the vertical plane.

Figure 22 shows the embodiment with locking elements on the top and bottom of the strip 6.

Figure 23 shows a separate strip visible from the surface and which can constitute a decorative joint portion. A list of HDF can be stained and impregnated. A molding, for example, compact laminate can have a decorative surface part which is moisture-proof and which has high wear resistance. The strip can be provided with a rubber coating that prevents moisture ingress. The strip should preferably only be fixed on the long side and preferably in such a way that part of the strip protrudes outside the surface at the short sides of the floorboard. This attachment should be made after the long side has been machined but before machining the short side, the excess material can then be cut in connection with the machining of the short sides and the strip is given a length corresponding to the length of the surface layer. Decorative moldings can be made without visible joints. The strip lock elements in this embodiment are located in the lower lip 21.

Figure 24 shows a separate strip with tapered protruding portion which improves the flexibility of the strip.

526 ^-3

Figure 25 shows an embodiment in which the inner portion of the strip P1 has a groove 36. This can facilitate the snap-in of the strip as the groove 36 can also spring by its lip 21a also being able to spring. The groove can be manufactured with inclined tools according to the prior art. This embodiment is also characterized by the inner portion P1 having two locking elements.

Figure 26 shows an embodiment where the inner portion P1 lacks locking elements. The strip 6 is pushed into the groove until it bumps against the lower positioning surface and is held in this position by the frictional forces. Such an embodiment can be combined with sizing which is appropriately activated by heat, ultrasound etc. The list 6 can be glued before insertion.

Figures 27a and b show two variants that facilitate separation by separating strip 6 from strip 6 'by refraction. In Figure 27a, the strip 6 is formed so that the outer portion of the strip tongue 33 is in the same height position as the rear part of the locking element 8. Fractures occur along line S. In Figure 27b, another variant is shown to be particularly suitable in HDF materials and other similar materials where the fibers are oriented substantially horizontally and where the fracture surface is substantially parallel to the horizontal plane HP. Crime occurs along line S with a substantially horizontal breaking surface.

Figures 28a and b show how the material waste can be minimized in embodiments of the invention where the joint edge is formed with a tongue. Termination can be done with an upper saw blade SBI and a lower saw blade SB2 which are laterally offset relative to each other. The panel blanks 2 and 2 will only have the excess size required for rational machining of the joint edges without having to take into account the shape of the tongue. By such an embodiment, the waste can be reduced to a minimum.

Figures 29a-e show machining of edge edges with diamond tools. A tool TP1 with a directional direction WD processes in a known manner the laminate surface and provides a

E26 443 milling. A minimal portion of the laminate surface is cut. According to Figure 29b, the groove groove is manufactured and the tool TP2 only works in the core material and the back side. Figure 29c shows how the undercut groove with the locking surface and an upper and below the positioning surface are formed. Thus, all critical surfaces that are essential for the horizontal positioning and fastening of the mold can be formed with high precision with the same tool. Figure 29e shows how the corresponding machining can be done with an inclined tool TP5. Finally, the upper joint edge is machined with the tool TP4 in known manner. The joint geometry and manufacturing methods according to the invention thus enable floorboards to be manufactured with advanced locking systems. At the same time, machining of the joint edges can be done with fewer tools than normal, with high precision and with minimal material waste. No need to cut TP1 in wood flooring and machining can therefore be done with only three tools. Thus, with this method, a locking system with a wood-fiber-based strip extending beyond the vertical plane can be achieved, while the manufacture of said locking system at the note / list side can take place inside the vertical plane. The method thus combines the advantages of a cheap and protruding wooden fiber strip and a manufacture that does not have to cut off large parts of the difficult surface layer.

Figure 30 shows a normal laminate floorboard with moldings 6b, and 6a according to the invention on a long side 4 and a short side 3. The moldings may be of the same material and of the same geometry, but they may also be different. The invention provides great opportunities to optimize the locking systems on the long and short side with regard to function, cost and strength. On the short sides where the strength requirements are high and where encapsulation is important, advanced, strong and resilient materials such as compact laminates can be used. In long-narrow formats, the long side contains significantly more jointing material and it has therefore been necessary in traditional locking systems to reduce the molding

526 443

<img file="SE526443C2_D0014.tif" />

extending beyond the joint edge as far as possible.

This has made it difficult or impossible to snap in, which is an advantage in certain laying moments where angling cannot be done. These limitations are largely eliminated by the present invention. Fig. 31 shows a long and narrow floorboard that requires a strong short-side locking system. The material saving that can be made by the present invention in such a floorboard is significant.

Figures 32a-b show formats that mimic parquet rods. A mechanical locking system of the traditional type can, in such a format, for example with the dimension 70 * 400 mm, give a material waste of just over 15%. Such formats do not appear on the market in laminate designs. With the present invention, these formats can be made rational with mechanical locking systems that are cheaper than even traditional systems with groove, spring and glue. They can also, as shown in these two figures, be manufactured with a mirrored system where the edge of the short side alternately snaps into the upper and lower short side respectively.

Figure 33 shows a format with a wide short side. Such a format is difficult to snap as deflection of the long strip 6a on the short side means that a high bending resistance must be overcome. With the present invention, this problem is solved by the fact that flexible materials can be used in the separate strip which can also be made partially rotatable in the inner portion as previously described.

Figs. 33 a-c show a production-adapted embodiment with a separate strip 6 having cooperating horizontal locking surfaces 60, 42 in the lower lip 21. Figs. 33b and c show how the strip is snapped into some angular position. Snap-in can be done with a deflection of the lower lip 21 which can be limited to, for example, half the height of the frame locking element 39. Thus, the lower lip can be relatively rigid and this prevents the release during tensile loading. An advantage of this design is also that of the floorboards

526 445

<img file="SE526443C2_D0015.tif" />

1, 1 'are joined together and subjected to tensile loading, tongue 22 will prevent the strip 6 from sliding upwards. In this embodiment, the strip gets a stronger attachment when the floorboards are joined than when the floorboards are unmounted. The strip 6 can also be easily removed by winding and this is an advantage when floorboards are laid against the wall in the first or last row.

Figures 34a-34c show various embodiments with lower lip outside and inside the vertical plane VP. Fig. 34c shows a strong locking system with dual horizontal locking means 14, 8 and 14 ', 8'. The separate strip 6 enables the undercut locking groove 14 'to be easily manufactured with large rotating tools since in connection with this manufacture there is no strip 6 at the joint edge portion.

Figs. 35a-e show how a joint system can be manufactured with a flexible spring 22 which can be displaced and / or compressed horizontally H1, H2 or alternatively bent vertically up VI or down V2. Fig. 35a shows a separate spring 22 of, for example, wood fiber material which can be displaced horizontally in the H1, H2 direction by means of a flexible material 70, for example a rubber mass. Fig. 35b shows an embodiment with a tongue 22 having an inner part which is resilient. Figures 35c-d show how a flexible tongue can be changed to lock and unlock with vertical movement. Fig. 35e shows how a first floorboard 1 'can be released by angling with, for example, suction cups or suitable tools applied at the edge of the floorboard closest to the wall. The floorboard has, on a long side and a short side, flexible tabs 22 ', and 22. After winding, an adjacent floorboard in the same row R2 can be released and possibly retracted in the same way. When the entire row is released, rows R1 and R3 can be recorded in known manner. Floor panels with such a preferred system have major advantages in primarily large floors. Floorboards can be replaced in any row. A damaged floor slab in the middle of a floor can with most of today's locking systems

526 443 • ···· · · · ··· · · · · · · · · · ·· ··· «····« ·· · Only be replaced if half the floor is taken up. For example, the floor may consist of one or more rows of the above-mentioned floorboards in the areas where the uptake is of particular importance. The tongue 22 should preferably be made of a flexible material such as plastic. Wood fiber based materials can also be used, for example HDF. Vertical uptake is facilitated if the flexible tongue is combined with a strong and flexible loose strip which has a preferably strong and flexible locking element which has smooth, low friction locking surfaces.

Figures 36a - 36b show how a joint system with a separate strip can be designed to enable angular movement in known manner with the backs of the floorboards facing each other. Such systems exist only with the strip made in one piece with the core of the floorboard and are difficult to use. Fig. 36b shows how, at a relative backward bending of about 10 degrees, the floorboards 1, 1 'release the spring side of floorboard 1 which can be detached at half the angle, in this case about 5 degrees. With this method, individual discs cannot be released. At least two lines must usually be angled up at the same time. Backward angling is greatly facilitated if the strip is wide, has low friction and is flexible. A rotational movement in the groove where the strip 6 is attached is also an advantage. All of this can be accomplished with a separate strip adapted for this function. Fig. 36d-f shows examples of existing locking systems on the market, for example manufactured under the Berry, Unilin, and Class brands that have been adapted to replace the existing machined strip made with one core. with a separate strip according to the invention. Thus, it is possible to provide locking systems according to the invention that are fully compatible with existing products on the market.

It is obvious that a variety of variants of the preferred embodiments is possible. First, the various embodiments and descriptions can be combined in whole or in part. The inventor has also tested a variety of alternatives where geometries and surfaces with different angles, • * ··· ··· * ·· * · · «·· · ·· ··· vertical and horizontal extensions and the like have been manufactured. A bevel and a rounding can provide relatively similar function. A number of other joint surfaces can be used as positioning surfaces. The thickness of the moldings can be varied and it is possible to process materials and mold moldings from sheet material which is thinner than 2 m m. various applications of the invention. Since the strip is mechanically integrated, there are no restrictions in connection with the bonding to the joint edge, which may be the case when materials must be bonded together

526 443rHV • ···