mechanical locking system for floor panels

专利摘要:
SET OF FLOOR PANELS. THEThe present invention relates to ceramic or stone tiles (1a, 1b)which are equipped with a locking system that includes a strip part separate (6) connected to the vertical (9) and horizontal (14) groovesformed on the tile edge (1, 1’).
公开号:BR112015032687A2
申请号:R112015032687-0
申请日:2014-07-08
公开日:2021-06-29
发明作者:Darko Pervan
申请人:Ceraloc Innovation Ab；
IPC主号:

专利说明:

[001] [001] The present description refers, in general, to the field of mechanical locking systems for floor panels and building panels. This description shows floors, locking systems and production methods. FIELD OF APPLICATION OF THE INVENTION
[002] [002] The modalities of the present invention are particularly suitable for use on floors and internal and external walls, which are formed by ceramic or stone material and which are intended and joined to a mechanical locking system.
[003] [003] The present invention can also be used to lock floor panels that are made of one or more top layers of wood or wood varnish, decorative laminate, powder-based surfaces or decorative plastic material, an intermediate core of material based on wood fiber or plastic material and preferably a lower balance layer on the back side of the core.
[004] [004] Floor panels made of solid wood or with a surface layer of cork, linoleum, rubber or low wear layers, for example needle felt glued to a board, surface and floors printed and also preferably varnished with hard surfaces, eg stone, tile and similar materials bonded to a sheet-shaped material are included. Embodiments of the invention can also be used to join together building panels which preferably generally contain a board material, for example wall panels, ceilings, furniture components and the like.
[005] [005] The following description of the known technique, problems of known systems and objects and resources of the invention will therefore be aimed, above all, as a non-restrictive example in this field of application and, in particular, in ceramic tiles intended for be mechanically joined together vertically and horizontally on all four edges.
[006] [006] Long and short edges are used to simplify descriptions. Tiles can also be square. BACKGROUND OF THE INVENTION
[007] [007] Ceramic tiles are one of the largest materials used for wall and floor coverings. The raw materials used to form tiles comprise clay minerals, feldspar and chemical additives required for the modeling process. A common method for producing ceramic tiles uses the following production steps. Raw materials are ground into powder and mixed. Occasionally, water is then added and the ingredients are ground by soaking. Water is removed using a filter press followed by spray drying in powder form. Then, the resulting powder is pressed under very high pressure (about 40 MPa (400 bar)) into a tile body with a thickness of 3 to 10 mm. The tile body is additionally dried in order to remove remaining moisture and to stabilize the tile body to a solid homogeneous material. One or several layers of glaze, which is a glass-like substance, is/are applied onto the tile body by wetting or drying methods. The purpose of tile glazing is to protect the tile. Glaze is available in several different colors and models. Some glazes can create different textures. After glazing, the tile is heated in a furnace or oven to very high temperatures (1300 °C). During heating, the glaze particles fuse together and form a wear-resistant layer.
[008] [008] Recently, new drying methods have been introduced and a tile can be formed by dispersing, pressing and heating in a continuous production line where the total production time is about one hour. Large raw tile blocks can be formed which, after heating, are divided into individual tiles by laser cutting, for example. New production technology provides improved strength, flexibility and size tolerances.
[009] [009] Roller shutters are often used to create a decorative pattern. The contact nature of rotary screen printing has many disadvantages, for example, breakage and long set-up times. Therefore, several tile producers have recently replaced this conventional printing technology with digital inkjet printing technology which offers several disadvantages mainly related to flexibility and production costs.
[0010] [0010] In general, tiles are installed side by side on a surface, for example a floor or a wall.
[0011] [0011] An adhesive compound is used as a base. After connection to the subfloor or a wall, mortar is spread over and between the tiles to further bond the tiles and to fill in the spaces between adjacent tiles.
[0012] [0012] The biggest advantage of a tile-based floor is that the tiles are moisture-proof and do not swell and shrink under changed moisture like other floors, eg laminate and wood floors.
[0013] Tile floors have several disadvantages compared to laminate and wood floors. A major disadvantage is that conventional tiles have significant dimensional variances in length, width and thickness. However, such production variances are continually decreasing when new and advanced production methods based on dry formation are introduced and combined with edge trimming. Another major disadvantage is that installing tiles is laborious. Ceramic tiles are very fragile and break without significant deformation. They need to be installed on preferentially rigid subfloors and the layer of adhesive compound can break if the subfloor expands and shrinks. A subfloor with stable and somewhat expensive hydration needs to be used such as cement-bonded chipboard and the like.
[0014] [0014] Floor elements comprising fine stone material are similar to ceramic tiles. They have similar properties and are stabled in a similar way.
[0015] [0015] There is a need for a tile or stone floor and wall system that is simple to install, that can cover large areas of floor without expansion joints, that can be easy to dismantle, and that can be installed in sub-floors more economical that have a greater hydration movement than ceramic tiles. DEFINITION OF SOME TERMS
[0016] [0016] In the following text, the visible surface of the installed floor or wall is called the "front side", while the opposite side, facing the subfloor or the wall, is called the "rear side". The edge between the front and rear sides is called the "joint edge". By "horizontal plane" is meant a plane, which extends parallel to the outer part of the surface layer. The top and outside of an edge define a "vertical plane" perpendicular to the horizontal plane. "Vertical locking" means locking parallel to the vertical plane. "Horizontal locking" means locking parallel to the horizontal plane.
[0017] [0017] By "upwards" is meant towards the front side, by
[0018] [0018] Typically, laminate flooring comprises a wood-based core, an upper decorative laminate surface layer and a lower balance layer. A laminated surface comprises paper impregnated with melamine. The most common core material is a fiber board with high density and good stability, commonly called HDF - High Density Fiber Board.
[0019] [0019] Laminate floor panels of this type are installed suspended on a subfloor and mechanically joined by means of so-called mechanical locking systems. These systems comprise locking means, which lock the panels horizontally and vertically. Mechanical locking systems are commonly formed by machining the core of the panel. Alternatively, the parts of the locking system can be formed of separate materials, for example aluminum or HDF, which are integrated with the floor panel, i.e. joined to the floor panel in connection with the fabrication of the same.
[0020] [0020] The main advantages of suspended floors with mechanical locking systems are that they are easy to install. They can also easily be taken out again and used again in a different location.
[0021] [0021] It is known that the mechanical joining of long edges, as well as short edges, in the horizontal and vertical directions can be done in several ways. One of the most used methods is the angulation-fit method. Long edges are installed using angulation. The panel is then moved into a locked position along the long side. The short edges are locked with a horizontal snap. A vertical connection is usually a tongue and groove. During horizontal displacement, a strip with a locking element is flexed and when the edges are in contact, the strip returns and the locking element enters a locking groove and locks the panels horizontally. Such snapping connection is complicated as a hammer and threading block have to be used to overcome friction between the long edges and flex the strip during the snapping action.
[0022] [0022] Similar locking systems can also be produced with a rigid strap and are connected with an angling method where both the long edge and the short edge are angled into a locked position. Such an installation method is difficult to use if the panels are large and heavy.
[0023] [0023] Recently, advanced locking systems so called Fold Down have been introduced that allow a very easy single-action installation with just an angling action that locks the long and short edges. A flexible tongue attached to the short edge is used to connect the short edges in a scissors-like movement when a long edge is angled lock.
[0024] [0024] Most of all mechanical locking systems used in laminate and wooden floors are formed by rotating diamond tools. Such formation can be done at high speed and with high precision. Locking systems comprise projecting parts, for example a tongue for vertical locking and a strip for horizontal locking.
[0025] [0025] Projecting parts are difficult and particularly impossible to form in ceramic material, especially in thin ceramic tiles which comprise fragile edges. Spaces between edges provide additional problems as a tongue needs to extend a considerable distance from one edge to cover the space between the edges and to enter a tongue groove from an adjacent edge.
[0026] [0026] Diamond tools can be used to form the tile edges. However, production speed is a fraction of the speed that is used to form advanced joint geometries in wood and plastic based materials. Special cooling systems, generally based on water cooling, need to be used to form tile and stone material.
[0027] [0027] Several attempts have been made to improve tile installations by affixing ceramic or stone tiles to a separate sheet-shaped material that can be formed with a mechanical locking system comprising projecting parts such that a floating installation similar to laminate flooring can be obtained.
[0028] [0028] US 8,156,705 describes a tile having at least one coupling member that cooperatively engages a coupling member of an adjacent tile so that adjacent tiles can be reasonably secured together without the use of mortar. The tiles are molded into a synthetic support structure comprising a conventional mechanical locking system,
[0029] [0029] U.S. 2011/0113713 describes a method for laying a tile in a mold and for injecting a polymer into the mold. The injected material mechanically anchors the substrate to the tile. A mechanical lock and a surrounding grout gasket can also be formed.
[0030] [0030] Fixing the tiles to a separate sheet material or mold is expensive. Floor thickness increases and a tile with stable moisture is difficult to match with wood-based sheet material that expands and shrinks when the relative humidity varies between dry and wet conditions.
[0031] [0031] It is known that a locking strip can be formed of a separate material such as aluminum or HDF and that such strip can be affixed in recessed grooves or fixed to a horizontally extending groove formed in an edge of a laminated panel by pressing by snapping and/or turning. Such systems are described in WO 94/26999 and WO 03/083234 (Välinge Innovation AB). Furthermore, it is known that several pieces of spaced apart strips can be attached to a long side edge in order to obtain further cost savings.
[0032] [0032] The document WO 2001075247 describes a locking system for joining sheet-shaped floor elements to tight joints. The floor elements are made of solid wood, fiber board or chipboard. The long edges are locked with a conventional locking system comprising a projecting tongue and a projecting strip. The short edges are joined by vertical offset and by means of a separate vertical mounting joining profile. The short edge comprises an edge geometry, which requires substantial amounts of the material edge to be removed. The locking system is not suitable for installing tiles that are spaced apart.
[0033] [0033] The document WO 03/083234 describes a locking system comprising a strip and a tongue made of separate material. This system is not suitable for locking tiles with edges that are spaced apart. The geometry of the locking system is very complicated to produce in ceramic material.
[0034] [0034] In short, it can be mentioned that known locking systems are not suitable for connecting ceramic tiles that have a fragile tile body, as the required strength and flexibility of projecting portions formed in the ceramic material are not sufficient and that the Edge geometry is difficult to produce with molding or machining ceramic material.
[0035] [0035] The above description of various known aspects is the present applicant's characterization of the same and is not an admission that any aspect of the above description is considered to be prior art. SUMMARY OF THE INVENTION
[0036] [0036] A general objective of the embodiments of the present invention is to provide an improved and more economical locking system for the primary floating installation of ceramic or stone tiles that allows the edges to be locked together mechanically through angulation and/or horizontal snapping and/or vertical snapping.
[0037] [0037] A specific objective is to form a locking system comprising a very simple joint geometry and a minimal amount of separate material fixed to a tile and which can be formed with as little machining of the tile edges as possible, preferably, without any fragile projecting parts.
[0038] [0038] Other specific objectives are to provide tiles with an integrated mortar material, improved decoration properties, to eliminate size tolerances and to provide panels comprising combination of ceramic material and other lighter and more economical materials.
[0039] [0039] The above objects of the embodiments of the invention can be achieved completely or partially by locking systems and formed tiles, according to the description. Embodiments of the invention are evident from the description and drawings.
[0040] [0040] The invention is based on the observation that vertical and horizontal grooves with a specific geometry can be formed with high precision in edge portions of a fine ceramic tile or stone body and that such grooves can be used as a part of a locking system that allows a mechanical locking.
[0041] [0041] The invention is also based on a second understanding that separate strip-shaped material comprising vertically projecting locking element and horizontally projecting tongues can be mechanically connected to such grooves and that such materials with the shape of Separate strips and grooves can be used to achieve a tough, economical and simple floating installation of ceramic or stone tiles on a floor or wall in indoor or outdoor applications.
[0042] [0042] The invention is based on a third understanding that the grooves and separate strip-shaped material can be formed in such a way that it is possible to overcome the size tolerance of ceramic tiles that are installed, in general, with a space between edges and that machining of edges larger than a predetermined perfect size can be avoided.
[0043] [0043] The invention is based on a fourth understanding that preformed tiles comprising vertical and horizontal grooves can be produced and that such preformed tiles can reduce the final edge machining that is required for the formed geometry.
[0044] [0044] Thin ceramic surfaces can also be bonded to materials that have stable hydration, and the ceramic surface can be used to form a part of the locking system.
[0045] [0045] A first aspect of the invention is a set of ceramic or stone tiles comprising a first tile having a first edge and a second tile having a second edge. Tiles are provided with a locking system to lock the first edge to the second edge in a horizontal direction parallel to a tile surface and in a vertical direction perpendicular to the horizontal direction. The locking system comprises a first and a second tongue and a strip part provided with a first and a second locking element. The first edge is provided with a first horizontal groove and a first vertical groove formed in a body of the first tile. The first locking element is configured to cooperate with the first vertical groove for locking in the horizontal direction, and the first pawl is configured to cooperate with the first horizontal groove for locking in the vertical direction,
[0046] [0046] The second edge is provided with a second horizontal groove and a second vertical groove formed in a body of the second tile. The second locking element is configured to cooperate with the second vertical groove for locking in the horizontal direction, and the second pawl is configured to cooperate with the second horizontal groove for locking in the vertical direction. Each of the first and second horizontal grooves comprises an upper edge and a lower edge. The lower edge of the first horizontal groove extends horizontally to an upper and outer part of the first edge, or is within it, and the lower edge of the second horizontal groove extends horizontally to an upper and outer part of the second edge, or is within of the same. There is a space between the top and outside of the first edge and the top and outside of the second edge in a locked position of the first and second edges.
[0047] [0047] The lower edge of the first horizontal groove can extend essentially horizontally to the top and outside of the first edge, and the bottom edge of the second horizontal groove can extend essentially horizontally to the top and outside of the second edge.
[0048] [0048] The depth of one of the horizontal grooves of the first or second tiles, measured as the horizontal distance of a vertical plane, located on the upper and outer edge of the edge, and the furrow bottom, may vary along the same edge from one of the tiles or between the same edges of two different tiles.
[0049] [0049] The depth of the horizontal groove can vary by at least 0.10 mm.
[0050] [0050] The strip portion may comprise a vertically extending tongue body and a first tongue projecting from the vertically extending tongue body.
[0051] [0051] The locking system can be configured so as to be locked through angulation and/or vertical and/or horizontal fitting of the first and second tiles.
[0052] [0052] A second aspect of the invention is a set of ceramic or stone tiles, each comprising a first and a second edge that are provided with a locking system for locking in a horizontal direction to a tile surface and in a vertical direction perpendicular to the horizontal direction. The first edge of the first tile is lockable on the second edge of the second tile. The second edge of the first tile is lockable on the first edge of the second tile in a horizontal direction parallel to a tile surface and in a vertical direction perpendicular to the horizontal direction, said locking system comprising a first and a second tongue and a strip part provided with first and second locking elements. The first edge is provided with a first horizontal groove and a first vertical groove formed in a body of the first and second tiles.
[0053] [0053] In a first and second edge locked position, there may be a space between the outer tops of the first and second edges.
[0054] [0054] Each of the first and second horizontal grooves may comprise an upper edge and a lower edge. The lower edge of the first horizontal groove may extend horizontally to an upper and outer part of the first edge, or is within it, and the lower edge of the second horizontal groove may extend horizontally to an upper and outer part of the second edge, or is within it.
[0055] [0055] The strip portion may comprise a vertically extending tongue body with a first tongue projecting from the vertically extending tongue body.
[0056] [0056] The locking system can be configured so as to be locked through angulation and/or vertical fitting of the first and second tiles.
[0057] [0057] A third aspect of the invention is a ceramic tile provided with a stamped surface and decoration. The stamping is in register with the decoration. The stamping comprises an upper and lower surface portion. An upper surface portion comprises a different gloss level than a lower surface portion.
[0058] [0058] The decoration can be a wooden model and the different levels of shine can be formed by a powder applied digitally.
[0059] [0059] A fourth aspect of the invention is a set of floor panels comprising a first and a second panels comprising a ceramic surface layer and a core comprising thermoplastic material mixed with shape and mineral fillers. A mechanical locking system is formed at the core of the first and second panels. The mechanical locking system comprises a strip provided with a locking element on a first edge of the first panel and a locking groove on a second edge of the second panel. The locking element and the locking groove are configured to cooperate to lock the first and second edges in a horizontal direction parallel to the ceramic surface layer. The mechanical locking system comprises a tongue on the second edge and a tongue groove formed on the first edge. The tongue and tongue groove are configured to cooperate to lock the first and second edges in a vertical direction perpendicular to the horizontal direction. The thickness of the ceramic surface layer is in a range from 2 mm to 5 mm. The tongue groove comprises an upper edge which is essentially formed by the ceramic surface layer.
[0060] [0060] In a locked position of the first and second edges, there may be a space of about 1 to 10 mm between the ceramic surface layers.
[0061] [0061] A fifth aspect of the invention is a preformed ceramic tile intended to be provided with a locking system. A groove is formed on the back side of a tile edge.
[0062] [0062] A first thickness of an outer edge of the preformed ceramic tile may be less than a second average thickness of the tile body of the preformed ceramic tile.
[0063] [0063] The difference in thickness between the first thickness and the second average thickness can be about 1 to 3 mm.
[0064] [0064] The groove may be an equalizing groove comprising an upper surface which is essentially parallel to an upper surface of the preformed ceramic tile. The top surface can extend from the outside of the edge and inwards.
[0065] [0065] The upper surface of the equalizing groove may extend over a horizontal distance of about 3 to 20 mm.
[0066] [0066] The back side of the edge preformed ceramic tile may comprise a vertical groove spaced from the outer edge and an equalizing groove extending from the vertical groove and towards the outside of the edge.
[0067] [0067] A sixth aspect of the invention is an assembly comprising a first tile, a second tile and a strip part, which preferably comprises a polymeric or metal material, wherein said first and second tiles are tiles ceramic or stone. A first edge of the first tile or a second edge of the second tile comprises a vertical groove and a horizontal groove formed in a body of the first or second tiles respectively. Said strip part is configured to be connected to one or more vertical grooves and to one of the horizontal grooves, formed on the same edge, for vertical locking perpendicular to the tile surface and for horizontal locking parallel to the tile surface of the first and the second tiles. In the locked position, there is space between the tops of the first and second edges.
[0068] [0068] Vertical and horizontal grooves can be formed on the first edge of the first tile and on the second edge of the second tile. The strip part can be configured to be connected to the horizontal and vertical grooves formed on the first edge of the first tile and on the second edge of the second tile.
[0069] [0069] The horizontal groove of the first edge or the second edge may comprise an upper edge and a lower edge. The lower edge may extend horizontally to an upper and outer part of the respective first or second edge, or inwardly thereof.
[0070] [0070] The strip part may comprise a pawl having a vertically extending pawl body located in the space.
[0071] [0071] The tiles can be connected through horizontal vertical or horizontal snapping in which the tongue body is horizontally displaced in space during locking.
[0072] [0072] The greatest advantages of the invention are in the fact that a locking system can be formed through a very limited machining of the tile edges and it is not necessary that the projecting parts formed in the tile body perform a mechanical locking. The locking system is formed by a geometry that is adapted to the tile production methods and the possibility of preforming the tiles that comprise grooves that can be used as a part of the final joint geometry. This will reduce the material that needs to be removed during the final edge formation. The locking system is adapted to position and align the tiles to normal size tolerance and generally does not need to machine the tops of the edges. The strip part comprises a simple geometry that can be economically formed by punching or extruding a plastic or metallic material. The strip portion is also formed so that it is easy to be connected at the factory to a tile edge before installation or by the installer during installation. BRIEF DESCRIPTION OF THE DRAWINGS
[0073] [0073] Hereinafter, the present disclosure will be described in connection with the exemplary embodiments and in more detail with reference to the accompanying exemplary drawings, in which:
[0074] [0074] Figures 1a to 1d illustrate locking systems according to known technology.
[0075] [0075] Figures 2a to 2d illustrate displaceable tongues and separate parts of strips, according to known technology.
[0076] [0076] Figures 3a to 3d illustrate floorboard locking systems, according to known technology.
[0077] [0077] Figures 4a to 4e illustrate a locking system, according to an embodiment of the invention.
[0078] [0078] Figures 5a to 5f illustrate a method for affixing a strip portion to an edge, according to an embodiment of the invention, which locks through angling and snapping.
[0079] [0079] Figures 6a to 6e illustrate alternative embodiments of the invention.
[0080] [0080] Figures 7a to 7d illustrate embodiments of strip parts.
[0081] [0081] Figure 8 illustrates an embodiment of a tile with four parts of strips.
[0082] [0082] Figures 9a to 9d illustrate embodiments of an underfloor panel with edges comprising a mechanical locking system, a tile mechanically connected to a panel and the formation of edge portions.
[0083] [0083] Figures 10a to 10e illustrate modalities of preformed tiles.
[0084] [0084] Figures 11a to 11d illustrate an alternative embodiment of the invention.
[0085] [0085] Figures 12a to 12e illustrate an alternative embodiment of the invention.
[0086] [0086] Figures 13a to 13d illustrate embodiments of a tile installation, a stamped tile surface and a backing material connected to a tile
[0087] [0087] Figures 14a to 14e illustrate modalities of locking systems suitable for locking short edges.
[0088] [0088] Figures 15a to 15e illustrate flexible tongue modalities
[0089] [0089] Figures 16a to 16e illustrate an alternative embodiment of the invention and a method for connecting a strip part.
[0090] [0090] Figures 17a to 17e illustrate an alternative embodiment of the invention and tiles installed in a wall.
[0091] [0091] Figures 18a to 18d illustrate an alternative embodiment of the invention and a method for disassembling installed tiles
[0092] [0092] Figures 19a to 19d illustrate embodiments of a locking system with a resilient snapping tab.
[0093] [0093] Figures 20a to 20d illustrate an embodiment of a locking system comprising an integrated mortar material.
[0094] [0094] Figures 21a to 21e illustrate one embodiment of a method for eliminating size tolerance.
[0095] [0095] Figures 22a to 22b illustrate an embodiment of an application of a mortar material.
[0096] [0096] Figures 23a to 23d illustrate modalities of application of a mortar material and an installation with horizontal fitting.
[0097] [0097] Figures 24a to 24b illustrate an embodiment of an installation with the horizontal fitting of two perpendicular edges.
[0098] [0098] Figures 25a to 25b illustrate an embodiment of a strip part that can be used to connect corner sections. DETAILED DESCRIPTION OF THE MODALITIES OF THE INVENTION
[0099] [0099] In order to facilitate understanding, several locking systems in the Figures are shown schematically. It should be emphasized that enhanced or different functions can be achieved using combinations of the modalities.
[00100] [00100] All modalities can be used separately or in combinations. Angles, dimensions, round parts, spaces between surfaces, etc. they are just examples and can be adjusted and can be adjusted within the basic principles of the invention.
[00101] [00101] Figures 1a and 1b show a known locking system used in laminated and wooden floors that are locked through angulation. Horizontal locking is achieved by a locking strip 6 with a locking element 8 formed in one edge of panel 1 which interlocks in a locking groove 14 formed in another adjacent panel edge V. Formation of strip 6 creates a waste Ws , as shown in Figure 1b, when considerable amounts of material are removed. The locking system comprises projecting parts, for example a tongue 10 and a strip 6 which are formed by machining the panel edge.
[00102] [00102] Figure 1c shows a known locking system used in laminate flooring comprising a separate aluminum strip 6 secured to a lower part of a panel edge. A portion of the strip 6 is flexed around a vertically slanted inwardly extending surface. Such connection of strip 6 to the panel edge is made in an operation separate from edge machining. The strip comprises three different cross-cuts A-A, B-B and C-C which are used to connect the strip to the panel edge and to lock the panels horizontally. The length L of the strip is the same along the width W. The strip part extends from the edge which comprises a small cavity 23, which is formed when a part of the strip body is punched and flexed around an edge of panel. One-piece projecting tongue with core is used for vertical connection.
[00103] [00103] Figure 1d shows a strip 6, which is used by fitting into a groove that extends horizontally. The strip is formed by machining and has the same cross-section along its length. An advanced edge profile is required to attach the strip to the edge. The locking system can also comprise a separate flexible tongue. Such locking systems have several disadvantages. The material content is high due to the design and only material savings can be achieved. Attaching the strip to the edge is somewhat complicated and slow.
[00104] [00104] Figures 2a to 2b show a locking system with a separate flexible displacementable tongue 10a inserted into a horizontally extending displacement groove 9a formed in the short edge of a panel. The separate tongue is inserted at high speed and is mainly used for greater flexibility when the panels are locked with a vertical snap. The locking system can be used to connect tiles. The locking system is difficult to produce in thin ceramic tile material as the projecting strip 6 can break.
[00105] [00105] Figures 2c and 2d show locking systems comprising a separate plastic strip part 6 that can be connected to a tile edge. This locking system is also difficult to produce in ceramic and stone material as much of the material needs to be removed by rotating tools. Projecting tongue 10 is fragile and may crack.
[00106] [00106] Figure 3a shows a known conventional panel with a strip 6 that extends along the entire long edge. Material savings can be increased if several pieces of strips 6 are connected on a long side of a panel as shown in Figure 3b.
[00107] [00107] One of the basic principles of the invention is the understanding that simple grooves can be formed in the tile body and that such grooves can be used to connect separate materials comprising projecting parts and to form the locking system that allows a mechanical locking resistant in a floating way.
[00108] [00108] Figures 4a to 4d show a locking system, according to an embodiment of the invention that can be connected through angulation, vertical snapping and horizontal snapping. The locking system can also be unlocked by angling and sliding along the edge. Figures 4a, 4b and 4c are side views and Figures 4d and 4e are top views.
[00109] [00109] Figure 4a shows two adjacent edges 1, 1’ of a first 1 and a second 1b tiles. Each tile 1a, 1b comprises a first horizontal groove 9a formed on the first edge 1, a second horizontal groove 9b formed on the second edge 1', a first vertical groove 14a formed on the first edge 1 and a second vertical groove 14b formed on the second edge V and a strip part 6 mechanically connected to the first horizontal 9a and vertical 14a grooves.
[00110] [00110] Horizontal grooves 9a, 9b are formed in the vertical outer portion of the tile edge. Figure 4b shows that the horizontal grooves 9a, 9b comprise a horizontal groove opening 17 in a vertical plane VP located on the upper and outer part of the tile edge, an upper lip 12, a lower lip 11, an upper groove wall 18 , a lower groove wall 19 and a groove bottom 20. The vertical grooves 14a, 14b are formed on the back side of the tile and are spaced apart from the outer edges. The vertical grooves 14a, 14b comprise a vertical groove opening that points 23 downwards, with a first 24 and a second 25 groove walls and an interior groove wall 25 located on top of the vertical grooves 14a, 14b. The first 24 groove wall is located closer to the vertical plane VP than the second groove wall 25.
[00111] [00111] The strip part 6 is used, according to the invention, preferably to lock the edges 1, 1' horizontally inwards and outwards and vertically upwards and downwards. The top edges are preferably connected to each other with a predetermined horizontal space S. This is the biggest difference compared to conventional technology where the top edges are locked in contact with each other, and the strip part 6 is only used for prevent horizontal separation. Space S can be used to form a specific locking system with a favorable geometry and function, as described below. Angular and snapping properties can be improved, and the locking system can be formed with a more economical geometry.
[00112] [00112] The locking system comprises a strip part 6 having a strip body 7 and first 8a and second 8b locking elements extending oppositely upwards, and an outer part of the strip body 7. A part The top of the locking element 8b preferably comprises an upper guide surface 22 which is used to guide the locking element 8b in the second vertical groove 14b during angling, horizontal engagement and vertical locking.
[00113] [00113] The strip body 7 comprises a first 10a and a second 10b flexible tongue which extend upwards. The pawls 10a, 10b preferably have an upwardly extending flexible pawl body 30, an upper sliding surface 31 which may be flexible and a pawl locking surface 32.
[00114] [00114] The tongue body 30 is preferably located at least partially in the space S formed by the adjacent edges. Such a locking system provides the advantage that no material has to be removed from the edge in order to accommodate a vertically extending pawl body 30. The space S can also be used to allow the pawl body 30 to be displaced horizontally in the S space during vertical and/or horizontal snapping.
[00115] [00115] The strip part 6 is configured to be locked at the first edge 1 by the first tongue 10a which is inserted into the first horizontal groove 9a and by the first locking element 8a which is inserted into the first vertical groove 14a. The strip body 7 preferably comprises a display element 16 on an outer part which can be used in some embodiments to obtain a firm connection of the strip part 6 to the tile. The display element can be flexible and can lock against the second groove wall 25.
[00116] [00116] The locking elements 8a, 8b cooperate with the vertical grooves 14a, 14b and lock the edges 1, 1' in a horizontal direction and prevent horizontal separation. Flexible tongues 10a, 10b cooperate with horizontal grooves 9a, 9b and lock edges 1, 1' vertically and prevent horizontal displacement of panel edges towards each other. Other parts formed in the strip body can be used to prevent such horizontal displacement of the panels towards each other.
[00117] [00117] The tile and stone material can be formed by turning a carbide or diamond tools. Even notching, scraping or grinding tools can be used.
[00118] [00118] Test production shows that small grooves can be economically formed with rotating diamond tools and that such grooves can have sufficient strength even in fragile materials, for example, ceramic or stone material, if the content of the material adjacent to the groove is sufficient in relation to the groove width and depth. A joint geometry with high strengths can be obtained if the edge preferably comprises only very small parts or even more preferably no part which extends horizontally beyond the upper edge.
[00119] [00119] Preferably, the locking system according to the invention does not have projecting parts, for example, a tongue or a strip that are formed in the tile body and that protrude beyond the upper edge.
[00120] [00120] Rather small grooves extending inward, eg 0.5 to 2 mm on an edge or on a back side can be formed and such grooves can have sufficient strength even in fine stone and ceramic materials and fragile. Preferably, there are no projecting parts that extend beyond the top edge, or only very small parts, especially if such projecting parts are formed by machining the tile edges.
[00121] [00121] A strong edge groove, for example 2mm deep, can be formed at high speed with five rotating tools where each tool removes about 0.4mm of material. Formation must be done when a tile is shifted relative to the rotating tools. The tile can also be connected to a stationary container and the tools are moved in one or several machining steps in relation to the tile edge.
[00122] [00122] It is advantageous if there is no removal of material or very small amounts of material at the top of the edges, especially if such edges are formed in bevels or round parts. Tiles are generally not completely square or rectangular, and one edge may be a different length than another edge. Two edges that meet may not be completely perpendicular.
[00123] [00123] Such production tolerances are, in general, eliminated by the spaces between the edges that are filled with mortar material. It is most advantageous if the locking system is formed and configured so that the tiles are installed and aligned at a predetermined mean distance between the edges and so that distance deviations are minimized. Preferably, the horizontal grooves are more precisely formed than the top edges. This means that the depth of one or several horizontal grooves, measured as the horizontal distance from a vertical plane located at the top and outside of a tile edge and to the inside surface of a horizontal groove, can vary along the edge. The groove depth of a horizontal groove can be at least 0.10 mm or even 0.20 mm greater on one part of the edge than on another part of the same edge. The horizontal groove on all four edges of a tile can be formed with smaller tolerances than the top edges. For example, a set of tiles according to the invention may have long edges of 40.0 +- 0.2 mm and short edges of 30.0 +- 0.2 mm measured at the tops of the tile. The distance between the interior surfaces of the horizontal grooves can be 36.0 +- 0.10 mm and 26.0 +- 0.10 mm when grooves with a depth of 2 mm are formed at the edge.
[00124] [00124] The locking system, according to the invention, will automatically align all the tiles in a predetermined position vertically and horizontally. This allows the space S between tiles to be reduced compared to a conventional installation. A space S of 2 to 3 mm can be sufficient and such a small space can be used to decrease the amount of mortar material.
[00125] [00125] Grooves are preferably formed in the tile body with rotating diamond tools in a separate production step after production of the tile. Grooves can also be formed in two steps. The first step can be rough formation that is formed during tile production. The second step is the final formation with diamond tools. These two forming steps can be used to reduce the amount of material that needs to be removed in order to obtain the joint geometry that is required for a high-quality locking system that guides the tiles into a correct position vertically and horizontally. during installation.
[00126] [00126] New and advanced production methods to produce tiles are being developed and such methods will enable the production of grooves with sufficient precision in line with tile production. No machining or additional training is required to form a locking system.
[00127] [00127] The strip part 6 can be formed from metallic material, preferably from steel or aluminum. The strip part 6, in this modality, is formed by punching or pressing.
[00128] [00128] Figure 4d shows that the flexible tongues 10a, 10b can be spaced apart in the length direction of the tile edge. The material, which is needed to form a tongue 10, is obtained from the strip body. A cavity 59 is formed when the tongue is formed by punching a sheet of metal. In this embodiment, a cavity is formed between the first tongue 10a and the locking element 8b.
[00129] [00129] Figures 5a to 5e show a method for affixing a strip part 6, as described in Figures 4a to 4e, to an edge of a tile or stone material. The strip can be angled or edge-fitted from the rear side, as shown in Figure 5a, through which the flexible tongue 10a is flexed and/or compressed. Alternatively, the strip can be inserted along the edge from one of the tile corners, or the tongue 10a can be inserted in the groove 9a and the locking element 8a can be pressed into the vertical groove 14a, as shown in Figure 16d .
[00130] [00130] Figure 5b shows a connection with angulation of the second edge V against the first edge 1. The first edge 1 can also be angled relative to the second edge 1’ with the strip body 7 inserted into the second edge before the angulation. Figure 5c shows vertical snapping, and Figure 5d shows horizontal snapping. Figure 5e shows two connected edges with a space S between the top edges, and Figure 5f shows a mortar material 13 applied to the space S which can be a flexible polyurethane material.
[00131] [00131] Figure 5b shows that angulation can occur around a rotation point Rp which is located on the pawl locking surface 32 below the top of the pawl. This allows a locking element 8 to be transformed with a high locking angle and can be combined with a locking distance LD, defined as the horizontal distance from the vertical plane to the locking element, which can be 1 to 1.5 times the thickness of T tile or even smaller, for example 0.5 to 1.0 times the thickness of T tile. The advantage is that a strong locking system can be formed with a compact strip part and less material will be needed to form the locking system.
[00132] [00132] A tile 1a with an edge 1 comprising a strip part 6 which is fixed before installation, as shown in Figure 5c, is called a "strip tile". A tile 1b with an edge that is connected to the strip tile 1a with vertical folding or vertical offset is called a "folded tile".
[00133] [00133] A flexible tongue that can be used to connect edges with a vertical offset may have flexible bulges on the inside or outside of it. The flexible tongue may also comprise an engagement tab at the outer end thereof. All of the separate flexible tongues described in the present description can be connected to the strip tile 1a or to the lap tile 1b.
[00134] [00134] Preferably, the strip part 6 is mechanically connected to the edge. A glue can also be used and can be combined with a mechanical connection.
[00135] [00135] The strip part 6 can be a plastic or metallic section. Flexible or rigid tongues can be formed as punched, extruded or injection molded plastic or metallic components.
[00136] [00136] The strip part may comprise vertically projecting locking elements that prevent a horizontal displacement of the edges towards each other.
[00137] [00137] Figure 6a shows that the horizontal groove 9 may comprise a lower edge 11 that extends horizontally beyond the upper edge and the vertical plane VP or that is located inwardly spaced from the vertical plane VP with a horizontal distance to the edge top as shown in Figure 6b. Preferably, the edge distance Ld, defined as the horizontal distance from the outer part of the lower edge 11 and to the vertical plane VP, is less than 0.5 times the space S between two adjacent tile edges when a lower edge extends beyond the vertical plane VP as shown in Figure 6a. The edge distance is preferably smaller than the space S between adjacent upper edges when the lower edge 11 is disposed inwardly with respect to the vertical plane VP, as shown in Figure 6b. Such locking systems can be economically formed, and limited amounts of materials have to be removed.
[00138] [00138] Figure 6c shows that the edge may also comprise an equalizing groove 21 which reduces the average thickness of a tile T1 to a smaller thickness T2 in an edge portion and allows a strip part with a thick strip body can be connected to a tile edge. The equalizing groove can also be used to reduce the thickness tolerance between adjacent tile edges.
[00139] [00139] Figure 6d shows that a part of pawl 6b can be flexed away from the edge and shifted partially in an adjacent horizontal groove 9a during vertical bending.
[00140] [00140] The strip body can be made of a metallic sheet material with a thickness of about 0.3 to 0.6 mm, preferably a stainless steel material. A more preferred thickness is about 0.3 to 0.4 mm.
[00141] [00141] Figure 6e shows that the thickness of the metal strip part can be arranged so that a counter layer 2, for example a foam can be used to go over the thickness of the strip body 7 when the tiles are installed in a sub-floor 3.
[00142] [00142] A flexible mortar material 13 can be factory connected to the two edges that meet on a corner section of the tile.
[00143] [00143] The sub-floor 3 may comprise panels with a mechanical locking system on long and short edges.
[00144] [00144] Figures 7a to 7d show modalities of the strip part 6 which can be a metal part (Figure 7a), an extruded plastic or metallic section (Figure 7b) or an extruded and machined plastic or metallic section (Figure 7c) wherein the parts have been removed in order to provide increased flexibility of the flexible tongues 10a, 10b. The strip parts 6 can also be formed by injection molding.
[00145] [00145] A locking with a vertical displacement can be made with less resistibility if the flexible tongue 10a can be flexed and shifted horizontally, for example, by 1 to 2 mm during the locking. Figure 7d shows a flexible pawl 10b comprising a flexible pawl body 30 and a flexible sliding surface 31. The flexible pawl 10b is flexed and the sliding surface 31 is flexed and compressed inwardly during locking.
[00146] [00146] The edges can be formed so that a portion of the tongue 10b can be moved in one of the horizontal grooves 9a, then towards its locked position in the other adjacent groove 9b, as shown in Figure 6d.
[00147] [00147] Figures 8 show a tile 1a with 4 pieces of strips 6 connected to two edges 4b, 4d. The strip parts can be fixed by snapping or inserting along the edge.
[00148] [00148] The strip parts can be factory connected to the tile edge or supplied as an individual component that is fixed to a tile edge prior to installation. The strip parts 6 can be formed and adapted to a space S between the edges which can vary from 0 to 10 mm and this can be used to create different widths of mortar. The vertical 14 and horizontal 9 grooves can extend from the entire edge 1 or they can only be formed in a part of the edge 1.
[00149] [00149] Several pieces of strips can be connected to one edge. The strip parts can have different geometries on different edges or on the same edge. The edge may also comprise a strip portion that extends essentially along the entire edge.
[00150] [00150] It is obvious from the drawings that a first edge 1 of a first tile 1a can be connected to a second edge 1' of a second tile 1b and that a second edge of a first tile 1a can be connected to a first edge of a second tile 1b.
[00151] [00151] Figure 9a shows that a strip part 6 can be connected to a panel that can be used as a subfloor 3. The connection can be made mechanically, preferably by bending some parts of the strip body 7 into grooves set in the subfloor panel. Figure 9b shows that one or several tiles 1a, 1b can be mechanically connected to the subfloor plane 3 which can comprise a conventional mechanical locking system, for example a locking system shown in Figures a and 2a. One or several tiles can be mechanically installed by connecting the 3 subfloor panels together.
[00152] [00152] The advantage is that the tiles are mechanically connected to the underfloor panel without glue. The mechanical connection and flexible tongues allow tiles with stable hydration 1, 1’ and a hydration sensitive subfloor 3 to be moved independently of each other when the relative humidity changes from dry to wet conditions. This makes it possible to use subfloors comprising, for example, wood-based materials, for example, HDF and particleboard that expands and shrinks when the relative humidity is changing.
[00153] [00153] All embodiments of the invention can be used to connect the tiles to form a floating floor or to connect the tiles in a vertical application to a wall. The strip part can be nailed to a vertical sheet material that forms a part of a wall system.
[00154] [00154] Ceramic tiles produced with dry pressure of powder under high pressure can be formed with a thickness of about 2 to 5 mm and with high flexibility and strength.
[00155] [00155] Figure 9c shows that such thin tiles can be used as a ceramic surface layer 27 in floor panels 1a, 1b comprising a core material with stable hydration 28, for example mineral or cement board with fiber or a board comprising a mixture of thermoplastic material, e.g. PVC, PE or PP, and mineral fillers, similar to the so-called LVT material, or such thermoplastic material and fiber fillers so-called similarly, the WPC material. Preferably, the fillers constitute about at least 50% of the weight of a core comprising thermoplastic material.
[00156] Ceramic material 27 with a preferential thickness Ta of about 2 to 5 mm, or 2 to 4 mm or 2 to 3 mm can be bonded to such a core material with stable hydration 28. Preferably, the thickness Tb of the core is about 3 to 5 mm or 3 to 4 mm. A two-layer material with a total thickness Tc of, for example, 5 to 10 mm can be formed. Preferably, the thickness Tb of the core 28 is greater than the thickness Ta of the ceramic surface layer 27.
[00157] [00157] A locking system comprising a tongue 10 and a tongue groove 9 for vertical locking and a strip 7 with a locking element 8 cooperating with a locking groove 14 formed on an adjacent edge for horizontal locking can be formed in the core material 28. Preferably, the upper edge 12 of the tongue groove 9 essentially comprises ceramic material which provides the strength and prevents vertical displacement of the tongue 10. Preferably, at least 60% or at least 80% of the thickness of the upper rim 12 comprises ceramic material. Preferably, the upper edges are spaced apart with a predetermined space S that is formed when the locking element 8 enters the locking groove 14 during installation. The cooperating surface of the locking element 8 and the locking groove 14 can be used to prevent the separation of the panel edges from one another and the displacement of the panel edge towards each other. The cooperating surfaces of the tongue 10 and the tongue groove 9 can also be used to create a predetermined space S and to prevent displacement of the panel edges towards one another.
[00158] [00158] Figure 9d shows that the horizontal groove 9 can be formed by a horizontal rotation tool 41 and that the vertical groove 14 can be formed by a vertical rotation tool 40.
[00159] [00159] Figures 10a to 10e show that preformed tiles 1a comprising a part of the locking system can be formed. Preforming is preferably done before the production step when the tile is heated in a furnace or oven. Grooves can be formed very economically during pressing of the powder material and after the pressing step when the tile body is not yet malleable and easy to form, for example by rotating tools. Grooves can extend along the entire edge or along one of an edge and can be formed on one edge or on several edges, preferably on a pair of opposite edges. Figure 10a shows a preformed tile edge 1 comprising a vertical groove 14. The horizontal distance D1 from the vertical plane VP to a first groove wall 24 is preferably between about 3 to 20 mm or even more preferably from 5 to 15 mm. The final shape can be formed, for example, by the rotation tools that form a tile edge 1" comprising a vertical groove 14 and a horizontal groove 9 adapted to the shape of the strip part and the defined geometry of a specific locking system Figure 10b shows a preformed tile 1 comprising an edge having a thickness T which is preferably about 1 to 3 mm smaller than the average thickness T of the tile body. The edge comprises a groove of equalization 21 with an upper surface 21a which is essentially parallel to the upper surface of the tile and which preferably extends from the vertical plane VP and inwards a horizontal distance D1, preferably from 5 to 25 mm. Figure 10c shows a preformed tile comprising a vertical groove 14 and an equalization groove 21, and Figure 10d shows a preformed tile comprising a vertical groove 14, an equalization groove 21 and a horizontal groove 9. The figure 10e shows that a lower projecting rim can be preformed and can be used to connect a strip portion. Preforming can be used to reduce the material content that needs to be removed to form edge geometry. The advantage is increased production speed and less wear to the tool.
[00160] [00160] Figure 11a shows a second embodiment of the invention. The flexible tongue comprises a vertically extending tile body 30 with a tongue locking surface 32 and an upper portion formed as a sliding surface 31 above the locking surface 32.
[00161] [00161] Figure 11b shows that the outer part of the tongue locking surface can be used as a sliding surface 31 which, during vertical displacement, cooperates with a tile sliding surface 33 formed at the bottom and outside of the tile edge. The tongue's sliding surface 31 can be quite small due to the fact that the ceramic material is hard and allows sliding relative to small, sharp surfaces. The locking system can also be locked through angulation and horizontal snapping.
[00162] [00162] The bottom wall 19 of the horizontal groove 9a is located in an upper horizontal first plane H1 which is closest to the tile surface and the second lower horizontal plane H2 that crosses the upper surface 26 of the vertical groove 14a. The vertical distance between the first H1 and second H2 horizontal planes is preferably at least 0.1 times the tile thickness T. The horizontal distance D1 between the vertical plane VP and the first groove wall 24 of the vertical groove 14 is , preferably about the same size as the tile thickness
[00163] [00163] This modality offers that a strong edge portion can be formed in a tile material and that the strip part 6 can be formed more economically with a simple punching operation, as shown in Figure 11c.
[00164] [00164] Figure 11a shows a flexible mortar material 13 formed as a flexible strip that is inserted after installation between the top edges. Figure 11d shows a flexible material which, prior to installation of a second tile, is located between the edges, preferably at least partially in the horizontal grooves 9a, 9b and which can be used as an edge seal 15. edge 15 can be used when tiles are installed with a small space S which can be as small as, for example, less than 1.0 mm.
[00165] [00165] Figures 12a to 12d show another embodiment of the invention. In general, tiles are produced with considerable thickness tolerances, which are much greater than the tolerances that are acceptable in, for example, laminate floors connected to tight edges. Such comparatively large tolerances are acceptable as tiles are often produced with beveled edges and installed with a distance filled with grout material. Conventional tiles can also be pressed into the adhesive composite material to adjust thickness tolerances.
[00166] [00166] When tiles are installed suspended in a foam material, thickness tolerances will be visible. The locking system is preferably formed with the rear side as the preferred side. The high quality tiles already have enough thickness tolerances to allow a high quality installation with a mechanical locking system. The thickness tolerance can be improved and this allows the space S between the tiles to be reduced considerably to about 1mm and the tiles to be formed without beveled edges. Further improvement can be obtained if infill layers 34a, 34b are applied to the back side of the tile as shown in Figure 12a, preferably after heating in the furnace. An embodiment of the invention is a tile comprising a ceramic tile body and an infill 34a, 34b on the back side. Filling is used to reduce thickness tolerances. Thicker tiles 1 may have a thinner fill layer 33a, and thinner tiles may have a thicker fill layer 34b. The fills make it possible to reduce thickness tolerances from about 1 mm to 0.1 to 0.2 mm. A portion of the infill layer 33 may be formed as an equalizing groove 21 which can be used to house a portion of the strip part 7. The infill may comprise thermoplastic or mineral-based material which is preferably waterproof. hydration. The fill 34 can be used to eliminate the thickness tolerance even in tiles without a mechanical locking system.
[00167] [00167] The strip part 6, in this embodiment of the invention, is preferably formed as an extruded plastic or metallic section which is preferably used to connect adjacent tile edges through angling and/or horizontal snapping. The strip body 7 comprises a vertically extending tongue body 30 and two horizontally projecting tongues 10a and 10b connected to the tongue body 30. The tongue body and the projecting tongues may or may not be flexible. One of the projecting tongues 10b preferably comprises upper 42 and lower contact surfaces 43a which prevent vertical separation and which are horizontally offset from each other so that the lower contact surface 43a is closer to the vertical plane VP than the upper contact surface 42. This geometry facilitates easy angulation, and the rotation point Rp may be located under the projecting tongue 10b, as shown in Figure 12c. Figure 12b shows that a lower contact surface 43b which prevents vertical separation can also be formed between a tile lower part and the strip body 7.
[00168] [00168] Figure 12d shows that the locking system can be installed with a horizontal fitting. The projecting part of the strip body is bent downwards and the locking element 8b fits into the vertical groove 14b.
[00169] [00169] Figure 12e shows that the locking elements 8a, 8b can comprise flexible display elements 16a, 16b that create a frictional force between the horizontal grooves 14a, 14b and the locking elements 8a, 8b and can prevent displacement of two adjacent edges 1, 1' along the edges. Such locking systems can be formed on two adjacent edges, eg the long edges, and can be used to prevent the separation of the other two edge parts, eg the short edges, as friction between the strip part 6 and tiles 1, 1' prevent mutual displacement. Of course, the strip part can be glued to the edge of one of the tiles 1a.
[00170] [00170] Figure 13a shows a tile 1a made of ceramic material comprising a pair of opposing long edges 4a, 4b and a pair of opposing short edges 4c, 4d. The tile can be a plank-shaped panel with a length of, for example, 0.8 to 1.2 m, and a width of 0.1 to 0.2 m. The thickness is preferably 8 to 10 mm. Such ceramic panels with a wooden decoration can be used to replace, for example, laminate floors with a wooden decoration in areas where a high resistance to hydration is required. In particular, a mechanical locking system is suitable for connecting and installing plank-shaped ceramic panels and for forming a waterproof floating floor. The installation is preferably done with offset short edges similar to an installation of wood and laminate floors. Long edges can be used to obtain high frictional forces and to prevent displacement along the joint. The ceramic material is rigid and, in many applications, it is not necessary to use a tongue to lock the short edges vertically, as the short edges can be locked vertically with the long edges connected. The edges can be formed with bevels and the space between the top edges can be reduced to about 1 mm or even to a few tenths of a millimeter. Panels can also be installed with contact between the top edges. Flexible material can be applied between the edges to prevent water from penetrating through the joint and locking system and down the subfloor.
[00171] [00171] The ceramic panel in plank or tile format is preferably digitally printed with a wooden decoration. The surface preferably comprises an embossing 29 which is made in registration with the template as shown in Figure 13d. A ceramic tile or panel may comprise a so-called stamped register surface structure similar to structures formed in laminate floors. The stamping is formed by steel plates or structured sheets that are pressed against the powder material before the heating process.
[00172] [00172] The strip part 6 extends, in this mode, along the entire long edge 4b, and an edge portion 6a extends beyond the short edge 4d. The panels, according to this modality, do not have a locking system on the short edges. Figure 13b shows the rear side. All locking systems used in accordance with the present description can be used on short and/or long edges.
[00173] [00173] Figure 13c shows an installation of several tiles or panels 1a to 1e. A first tile 1a is installed in a first row R1. A second tile 1b in a second row R2 is connected via angulation to the first tile 1a in the first row R1. A third tile 1c is installed by angling against the first tile 1a in the first row R1. The edge portion 6a of the strip part provides precise spacing of the short edges 4c, 4d. A fourth tile 1d is installed and locked in the second 1b and third tile 1c in the second row R2. The long locked edges of the first 1a and fourth 1d tiles prevent a separation of the short edges 4c and 4d of the second 1b and third 1c tiles in the second row R2 and all edges are locked vertically and horizontally.
[00174] [00174] Figure 13d shows a tile 1a with a back layer 2 attached to the back side. The back layer preferably covers most of the strip and can be used to reinforce the strip part and/or to increase the connection between the strip part and the tile 1a. The underlay can be a foam, a cork material, a rubber, or similar materials, and can also be used to increase the friction between the underlay 2 and the subfloor 3. The underlay can also comprise fiberglass or it can be a sheet. of LVT or WPC.
[00175] [00175] Core grooves 56 can be formed on the back side of a tile in order to reduce weight. The strength of the tile can still be sufficient especially if the core grooves are covered with suitable backing materials which, preferably, are bonded to the back side. Preferably, such a backing material 2 comprises glass fibers which are combined with a polymer material.
[00176] [00176] Figure 13d shows that the stamp 29 can be formed with different levels of brightness 44a or 44b. Preferably, such different gloss levels are combined with a stamped register structure. The upper part 44a of the embossed structure may have a lower or higher gloss level than the lower part 44b. The advantage is that the visual stamping will be more evident even when the bottoms of the stamped portions are only about 0.2 to 0.5 mm below the tops and such tiles are easier to clean.
[00177] [00177] Different gloss levels can be formed with digital printing. A binder pattern can be applied to a digital ink head, powder can be applied to the pattern, and unbound powder can be removed.
[00178] [00178] Obviously, the modalities described above comprising a backing, embossing with different levels of gloss and core grooves can be used individually, in combinations and on conventional tiles without a mechanical locking system.
[00179] [00179] Figures 14a to 14e show embodiments that can be used, preferably, to connect the short edges with vertical folding. Figure 14a shows straight edge portions. Figures 14b and 14c show edge portions comprising a tongue 10 and a recess 45 that are used to obtain a correct space between the edges and to horizontally position the edges so that a new tile can be easier to connect through angulation to long edges. Figures 14d and 14e show a strip part that locks only horizontally.
[00180] [00180] Figure 15 shows a flexible tongue 10 that can be used to connect adjacent edges. The tongue comprises flexible protrusions 46 located in an inner part of an essentially horizontal groove or in an outer part of the tongue and which can project beyond a vertical plane. Figures 15a, 15c, 15e show the flexible tongue in an outer position and Figures 15b, 15d show the tongue in an inner position during bending.
[00181] [00181] One advantage is to use a tongue comprising flexible protrusions that protrude along the vertical plane when the tiles are locked with a space S between top edges. The tongue can be firmly affixed to the groove 9, as there is no part that has to be moved inside the groove 9 during locking. The tile edges are rigid, and sufficient locking strength can be obtained even in the case where the projecting protrusions are spaced apart.
[00182] [00182] Figures 16a show an embodiment comprising a strip part 6 having a vertically projecting tongue body 30 comprising a horizontally extending tongue 10a' in an upper part connected to a first horizontal groove 9a' . A flexible tongue 10a with flexible protuberances 46 located in an inner part of the horizontal groove 9a is connected to a second horizontal groove 9a located on the same edge and above the first horizontal groove 9a'. Adjacent edge V comprises an essentially rigid tongue 10b located in a horizontal groove 9b. The flexible pawl 10a comprises a sliding surface 33a on the outer and upper portion thereof which cooperates, during locking, with a sliding surface 33b located on the lower and outer portion of the adjacent rigid pawl 10b.
[00183] [00183] Figure 16b shows edges 1, 1’ in locked position. Tongue body 30 is preferably used to prevent displacement of the edges towards one another.
[00184] [00184] Figure 16c shows an embodiment in which a rigid tongue 10a and the strip part 6 are located and connected to the same edge 1. The flexible tongue 10b is located on the adjacent edge V. The rigid tongue 10a comprises a sliding surface 33a on the upper and outer part thereof, and the flexible tongue 10b comprises a sliding surface 33b on the outer and lower part thereof.
[00185] [00185] The separate tongues and the strip part 6 can be used separately or in combination. A strip part 6 that only horizontally connects the edges can be attached, preferably to the underside of the edges, as shown in Figure 16a. The long edges can be locked, for example, with a locking system, as described in Figure 12d. The strip part combined with the separate tongues can be used to connect, for example, the long edges or the short edges through angling or horizontal snapping.
[00186] [00186] Figure 16d shows a method for connecting the strip part 6 to the first edge 1. The strip part 6 is moved essentially horizontally with respect to the edge and is connected to the first horizontal groove 9a. The locking element 8a is pressed into the first vertical groove 14a. Preferably, a pressure wheel 49 is used.
[00187] [00187] Figure 16e shows that the strip part can be glued to the first edge 1. A layer of glue 57a, 57b can be applied between the strip body 7 and a lower part of the tile and/or between an edge part vertical and the tongue body 30. A sublayer 2 can be bonded or glued with a glue layer 57d to a back side of the tile 1, and the strip part 6 can also be glued with a glue layer 57c to the sublayer 2. This modality is distinguished by a vertical groove 14b and a horizontal groove 9b groove being formed only on one of two opposite edges 1, 1'. One of the edges preferably comprises an edge 1 which is essentially vertical from the tile surface and towards the rear side of the tile. The gluing of the strip part to a tile can be combined with all the other modalities described in the present description.
[00188] [00188] Figure 17 shows a locking system comprising a flexible tongue 10a that has flexible protrusions 46 that protrude beyond the vertical plane VP, as shown in Figure 15c. The strip part 6 is similar to the strip part 6 shown in Figure 16a. The flexible protrusions comprise a sliding surface 33a at the top and outside which, during vertical displacement, cooperates with a sliding surface 33b formed at the bottom of an adjacent tile edge V. The flexible protrusions 46 are displaced essentially horizontally within the space S between edges. The locking element 8b and a locking groove 14b prevent a horizontal displacement in and out. Such displacement can also be prevented with horizontally projecting parts 30’ located between the edges.
[00189] [00189] Figures 17d and 17e show that all embodiments of the present description can be used to connect the tiles 1a, 1b to an inner and outer wall 58. Preferably, the strip part is mechanically connected with nails, screws, clips special or extruded profiles, and the like. The tiles can also be glued to a wall and the strip part 6 can be used to position the tiles.
[00190] Figures 18a to 18c show a strip portion comprising a pawl body 30 having a pawl 10a and a pawl groove 9b. The adjacent edge preferably comprises a flexible tongue 10b located in a horizontal groove 9c. Figure 18d shows that the tile edges can be designed so that it is possible to release them after installation. The grout material is removed, and a dismounting tool 55 is inserted through space S and into a groove 9b so that a flexible tongue is pressed inwards towards the tile edge, and the locking system is released. All embodiments of the invention which comprise a flexible tongue can be similarly disassembled. Flexible tongue locking systems allow tiles to be dismantled in an intermediate section of a floor. Tiles can also be removed from the first and second rows.
[00191] [00191] Figures 19a to 19c show essentially the same modality as in Figures 18a to 18c. The flexible tongue 10b comprises a flexible engagement tab 47 at its outer end. The flexible tongue 10b can be connected to the foldable tile as shown in Figure 19a, or to the strip tile 1 comprising the projecting part of strip 6 as shown in Figure 19d.
[00192] Figures 20a to 20c show a strip part 6 comprising a tongue body 30 having a tongue 10a and a tongue groove 9a' formed in the tongue body 30. The adjacent edge 1' preferably comprises an essentially rigid tongue 10b located in a horizontal groove 9b. Figure 20d shows that a rigid tongue 10b can also be formed in the tile material. The horizontal groove 9a' can be formed close to the adjacent edge and the rigid tongue 10b can be quite small and can protrude about 1 to 2 mm beyond the upper edge even in the case where the tiles are installed with a space of 2 to 5 mm between the top edges. Figure 20c shows that a flexible mortar material 13 can be connected to the upper part of the tongue body 30. Figure 20d shows that the mortar material 13 can be mechanically connected to the tongue body 30.
[00193] [00193] Figure 21 shows that the tiles are not completely rectangular or square. Length L or width W may vary. The long and short edges 4a, 4b, 4c, 4d are often not completely parallel to each other, and the long edges are often not completely perpendicular and formed with a perfect 90 degree angle.
[00194] [00194] Theoretically, tiles can be machined so that size tolerances are eliminated. This is practically not a suitable method due to the high costs and the fact that the bevels or round edges will be changed. Horizontal 9 and vertical 14 grooves cannot be formed with the top edges as a reference surface as tolerance will accumulate and larger areas comprising several tiles installed in several rows not possible to install.
[00195] [00195] The locking system needs to be designed so that each row is aligned perfectly and so that the size tolerance of the tiles is compensated for variations in the space S between the edges. This is a big difference compared to laminate and hardwood floors that are machined to a perfect rectangular shape and installed with a tight fit between the top edges.
[00196] [00196] The problem can be solved with a positioning system that, before the formation of the grooves, aligns the tiles to a predetermined position of a long edge 4a and a short edge 4c. Such alignment can be done with cameras or with a positioning tool 50, as shown in Figure 21. The positioning tool comprises a first positioning surface 51 and a second positioning surface 52 that are completely perpendicular to each other. A long edge 4a or a first edge, in case the tiles are square, is shifted so that it is in contact with the first positioning surface 51. After that, the tile is shifted along the positioning surface until an edge 4c or a second edge is in contact with the second positioning surface 52. Figure 21 shows a tile with a contact point 53 at an outer tile corner.
[00197] [00197] After positioning the tile, the vertical and horizontal grooves are formed parallel to the first and second positioned surfaces and with predefined distances D1, D2, D3, D4, D5, D6, D7. One of the edges, preferably one of the long edges 4a which has been positioned against the first positioning surface 51 comprises grooves 14a, 9a which are essentially parallel to the edge. At least one of the other edges can comprise vertical or horizontal grooves with an actual horizontal distance Ad3, Ad4 in relation to the edge that varies along the edge, if the edges are not parallel to a predefined geometry. Such a distance may vary between the same edge of two different tiles, for example with respect to the vertical groove 14a which is used to connect the strip part or with respect to the adjacent vertical groove 14b which, during locking, is connected to the strip parts , as shown in Figure 20a, if the length L or the width W deviates from a predetermined geometry.
[00198] [00198] Figure 21b shows a cross-section A-A on one part of the short edges 4c, and Figure 21c shows a cross-section B-B on another part of the short edge 4c. The edge is not completely parallel to the placement tool. The horizontal groove 9 and the vertical groove 14c are formed at predefined distances D2, D3 from an aligned position defined by the positioning tool 50. The actual horizontal distances Ad3, Ad4, Ad5, Ad6 from the vertical plane VP and for the inner wall 20 of the horizontal groove 9 and for the first wall 24 of the vertical groove 14c it varies along the edge 1. The Figures show that even the lower lip 11 can be formed against a predetermined position. This means that the actual horizontal distance Ad7, Ad8 between the outer part of the lower edge 11 and the upper edge or vertical plane VP may vary along the edge.
[00199] [00199] Figures 21d and 21e show that the distances described above Ad7, Ad8 on an edge 4b of a first tile and the distances Ad7', Ad8' and on an edge 4b' of a second tile can vary between the same parts of tile 24, 24', 20, 20' located on the same edge 4b, 4b' of days different tiles 1a and 1b when tiles 1a, 1b have different widths or lengths.
[00200] [00200] Preferably, the tiles according to the invention are distinguished by having a first horizontal distance Ad7 between a first groove wall 24 of a first edge 1 of a first tile 1a and an upper and outer part of the first edge 1 of the first tile 1a, in that there is a second horizontal distance Ad9 between a first groove wall 24 of a second edge 1' of a first tile 1a and an upper and outer part of the second edge 1' of the first tile 1a, in that there is a third horizontal distance Ad7' between a first groove wall 24 of a first edge 1 of a second tile 1b and an upper and outer part of a first edge 1 of the second tile 1a, in that there is a fourth horizontal distance between a first groove wall 24 of a second edge 1' of the second tile 1b and an upper and outer part of the second edge 1' of the second tile 1b.
[00201] [00201] The first horizontal distance may vary along the first edge 1 of the first tile 1a, and/or the second horizontal distance may vary along the second edge 1' of the second tile 1b. The third horizontal distance may vary along the first edge.
[00202] [00202] The method described above can be used to form floor panels as described in Figure 9c. The horizontal distance from the vertical plane VP to the outer part of the tongue 10, and/or the inner part of the tongue groove 9, and/or to a surface in the locking element 8, and/or to a surface in the groove of locking 14 may vary along at least one of the panel edges or between two opposite edges.
[00203] [00203] A big advantage is if flexible mortar material can be integrated with a tile edge and connected at the factory before installation. The mortar material serves several purposes. It is used to compensate for size tolerance, to prevent water from penetrating the joint, and to create decorative effects. The grout material can be attached to all four edges or just one long edge and one short edge only. The downside is that an installation will comprise many joints between the mortar materials.
[00204] [00204] Figure 22a shows that a preferred flexible mortar material 13a can be attached to only one edge of a tile, preferably to a short edge 4d, if the tiles are rectangular. Two rows R1, R2 of tiles 1a to 1i can be installed as shown in Figure 22a. A continuous mortar material 13b preferably formed as a flexible strip can be inserted and pressed between two installed rows R1, R2, as shown in Figure 22b. The advantage is that a corner section will comprise only two joints 54a, 54b or just one joint 54b if the tiles are installed with short offset edges 1f, 1j as shown in Figure 22b. The grout materials can be pressed together at the joints with a permanent pre-strain, and an almost invisible moisture resistant joint can be formed.
[00205] [00205] Figure 23a shows an embodiment comprising upper 9a', 9b' and lower 9a, 9b horizontal grooves formed in the edge. The upper grooves 9a’, 9b’ can be used to accommodate a portion of the grout material 13 and can be formed in such a way as to prevent vertical displacement of the edges when a grout material is applied between the edges. In some embodiments, it is possible to exclude the lower horizontal grooves 10a, 10b and the strip part can be connected to the edge with vertically extending tongue parts 10a, 10b which are locked in the vertical part of the edge with frictional forces. The strip part 6 can mainly be used to lock the edges in the horizontal direction, and the mortar material can be used to lock the edges vertically. The locking system can be locked through angulation, horizontal snapping and vertical snapping. The vertical grooves 14a, 14b and the locking elements 8a, 8b are preferably formed with cooperating locking surfaces that extend vertically upwards with a locking angle A of about 90 degrees against a horizontal plane H. The advantage is that a strong horizontal locking can be obtained and can be combined with an easy locking and connection of the strip part. This can be achieved with vertically extending tongue bodies 30a, 30b which can be flexible and can be flexed in space S when the strip part 6 is connected to the first edge 1 and during locking.
[00206] [00206] Figure 23b shows a strip part 6 comprising tongues 10a, 10b and locking elements 8a, 8b formed by punching a metal plate, preferably a stainless steel plate with a thickness of preferably 0.3 to 0.5 mm. The cavity 59a, which is necessary to form the first pawl 10a, is located between the first locking element 8a and the first pawl 10a. The cavity 59b, which is required to form the second tongue 10b, is located between the second tongue and the locking element 8b.
[00207] [00207] This modality provides an increased flexibility, if the tiles 1a, 1b are connected through horizontal fitting, as shown in Figures 23c and 3d. During snapping, the tongue 10b is pushed towards the adjacent edge horizontally, and the tongue locking surface 32 is slightly displaced vertically upwards so that an easy locking can be obtained when the strip part 7 is flexed backwards.
[00208] [00208] The locking system can be configured so that the horizontal locking force that prevents the edges from separating from each other is greater than the locking force that prevents the edges from being displaced towards each other. The displacement of the edges towards each other can be prevented by the mortar material applied to the space S.
[00209] [00209] Figures 24a, 24b show the installation of tiles with a snapping action that connects both a first edge 4a and a second edge 4b of a tile 1d with an essentially diagonal displacement towards two adjacent tiles 1b, 1c. Preferably, a first 4a and a second edge 4c of a first tile 1d are placed on adjacent strip portions 6c, 6d, 6e, 6f of a second 1b and third 1c tiles, and the first tile 1d displaced substantially horizontally on towards the second and third tiles so that a snap connection is obtained. The advantage is that it is not necessary to connect, for example, a first edge 4a of a tile 1d to an adjacent tile 1c with horizontal snapping and then shift the tile 1d in a locked condition and with high frictional forces along the long edge 4a to fit short edge 4c to another tile 1b.
[00210] [00210] All embodiments of the invention can be combined and used combined on different edges, but also on the same edge. Figure 24a shows that, for example, an edge 4a, 4b of a tile 1d can comprise several different separate materials 10a and strip parts 6a connected to vertical and/or horizontal grooves. The strength of the vertical locking can be increased if, for example, a separate tongue 10a is fixed in a horizontal groove. Such a separate tongue 10a can be located, for example, between two parts of strips 6a, 6b. Tongue 10a can be rigid or flexible and can be used to connect the tiles via angulation, vertical snapping and horizontal snapping.
[00211] [00211] A separate tongue 10a located between two parts of strips 6 can be used, for example, to replace the second tongue 10b in Figure 23c and engagement can be achieved only by bending the projecting strip body 7. It is obvious that the separate tongue 10a can be connected to horizontal grooves formed in the first 1 and/or the second edges and that several separate tongues can be attached to both edges, preferably offset to one another in the length direction of the joined edges.
[00212] [00212] Figure 24b shows that a back layer 2 can be factory connected to the back side of the tile 1d and under the strip parts 6a, 6b. The backing material can comprise flexible material that increases the friction between the backing and the subfloor and can be combined with an electric floor heating system.
[00213] [00213] Figures 25a and 25b show a strip part 6 which can be used as a corner part to lock eight adjacent edges of four tiles 1a, 1b, 1c, 1d. The strip part 6 comprises locking elements 8a, 8a' and tongues 10a, 10a' configured to be locked to a first edge 4b and a second edge 4d which are perpendicular and adjacent to each other and form a part of a section of corner of a tile. Such strip parts 6 configured to be used as corner parts 6 are particularly suitable for connecting tiles, which are installed vertically on a wall, and only one screw may be needed to connect a corner part 6 to a wall.
[00214] [00214] All horizontal and vertical grooves and all equalizing grooves may extend along the entire edge or may be formed into only a preferred edge part where the strip parts 6 are intended to be connected to an edge . Preferably, the jump tool head rotation tools can be used to form grooves in a portion of an edge.

权利要求:
Claims (11)
[1]
1. Floor panel assembly comprising a first (1a) and a second (1b) panels comprising a ceramic surface layer (27) and a core (28), the ceramic surface layer (27) being bonded to the core (28), whereby a mechanical locking system is formed in the core (28) of the first (1a) and second (1b) panels, the mechanical locking system comprises a strip (7) provided with a locking element ( 8) on a first edge (1) of the first panel (1a) and a locking groove (14) on a second edge (1') of the second panel (1b), wherein the locking element (8) is the groove locks (14) are configured to cooperate to lock the first (1) and second (1') edges in a horizontal direction parallel to the ceramic surface layer (27), and the mechanical locking system comprises a tongue. (10) on the second edge (1') and a tongue groove (9) formed on the first edge (1), wherein the tongue (10) and the tongue groove (9) are configured to cooperate to lock the first (1) and second (1') edges in a vertical direction perpendicular to the horizontal direction, wherein the tongue groove (9) comprises an upper edge (12) which is formed essentially in the layer. of ceramic surface (27), characterized in that: the core (28) comprises a thermoplastic material mixed with mineral fillers, the thickness (Tb) of the core (28) is greater than the thickness Ta) of the surface layer of ceramic (27), the thickness (Ta) of the ceramic surface layer (27) being in the range of 2 mm to 5 mm, the first edge (1) and the second edge (1') are configured to be locked one to the other mechanically by means of angulation, and in a locked position of the first (1) and second (1') edges there is a space (S) of between 1 to 10 mm between the ceramic surface layers (27) of the first (1st ) and second (1b) panels, the space (S) being configured to be formed when the locking element nt (8) enters the locking groove (14).
[2]
2. Assembly according to claim 1, characterized in that the upper edge (12) is configured to prevent the vertical displacement of the tongue (10) and in that the upper edge (12) essentially comprises ceramic material.
[3]
3. Set according to any one of the preceding claims, characterized in that at least 60% of a thickness of the upper edge (12) comprises ceramic material.
[4]
4. Set according to any one of the preceding claims, characterized in that at least 80% of a thickness of the upper edge (12) comprises ceramic material.
[5]
An assembly as claimed in any one of the preceding claims, wherein the thermoplastic material comprises PVC, PE or PP.
[6]
6. Assembly according to any one of the preceding claims, characterized in that the material fillers constitute at least 50% of a core weight (28).
[7]
7. Set according to any one of the preceding claims, characterized in that a thickness (Tb) of the core (28) is from 3 to 5 mm.
[8]
8. Set according to any one of the preceding claims, characterized in that a total thickness (Tc) of the ceramic surface layer (27) and the core (28) is between 5 and 10 mm.
[9]
9. Assembly according to any one of the preceding claims, characterized in that the cooperative surfaces of the locking element (8) and the locking groove (14) are used to prevent the separation of the first (1) and second ( 1') edges distant from each other and to prevent displacement of the first (1) and second (1') edges towards each other.
[10]
10. Assembly according to any one of the preceding claims, characterized in that the cooperative surfaces of the tongue (10) and the tongue groove (9) are used to create a predetermined space (S) and to prevent the displacement of the first (1) and second (1') edges towards each other.
[11]
11. Assembly according to any one of the preceding claims, characterized in that the core material (28) is stable in moisture.

类似技术:

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同族专利:

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公开号 | 公开日

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CN105358777A|2016-02-24|

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MX2015018045A|2016-10-07|

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CA2916212A1|2015-01-15|

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US10060139B2|2018-08-28|

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WO2015005860A1|2015-01-15|

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CN108118860B|2020-04-14|

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US20160168865A1|2016-06-16|

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CN108118860A|2018-06-05|

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US20180355620A1|2018-12-13|

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EA031216B1|2018-12-28|

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US10633870B2|2020-04-28|

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EP3019677A4|2017-03-29|

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US20200208413A1|2020-07-02|

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CN108252483A|2018-07-06|

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EA201690148A1|2016-06-30|

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CA2916212C|2021-06-15|

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EP3019677A1|2016-05-18|

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CN105358777B|2018-03-02|

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CN108118859A|2018-06-05|

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US20200208412A1|2020-07-02|

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法律状态:
2018-04-03| B25A| Requested transfer of rights approved|Owner name: CERALOC INNOVATION AB (SE) |

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2020-05-26| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2021-07-20| B350| Update of information on the portal [chapter 15.35 patent gazette]|

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2021-12-07| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

优先权:

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申请号 | 申请日 | 专利标题

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SE1350856|2013-07-09|

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SE1350856-9|2013-07-09|

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SE1400291|2014-06-10|

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SE1400291-9|2014-06-10|

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PCT/SE2014/050877|WO2015005860A1|2013-07-09|2014-07-08|Mechanical locking system for floor panels.|

---