Panel of a floor system

The invention concerns a panel of a flooring system, in particular a laminate floor, with a first side edge, and with a second side edge which is arranged opposite the first edge, wherein the side edges can be locked with corresponding side edges of further panels, wherein the side edges can be brought into engagement with each other, wherein the first side edge is fitted with at least one locking lip, and with an elasticity groove adjacent to the locking lip, wherein the second side edge is fitted with a locking element and wherein the locking element in the locked state is in engagement with the locking lip. To be able to set the elasticity of the locking lip more satisfactorily, it is provided that the elasticity groove is at least partly filled with at least one filling compound.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention concerns a panel of a flooring system, in particular a laminate floor, with a first side edge and with a second side edge which is arranged opposite the first side edge, wherein the side edges can be locked with corresponding side edges of further panels, wherein the side edges can be brought into engagement with each other, wherein the first side edge is fitted with at least one locking lip and with an elasticity groove adjacent to the locking lip, wherein the second side edge is fitted with a locking element and in the locked state the locking element is in engagement with the locking lip.

2. Description of Related Art

Panels of this type are known for example from DE 102 31 921 A1. These panels have a carrier board of a wooden material such as a medium density fibre board (MDF) or high density fibre board (HDF). Also a laminate coating can be provided on this carrier board. The disadvantage of these panels is that the elasticity of the locking lip can only be set inadequately by the geometry of the elasticity groove.

SUMMARY OF THE INVENTION

The present invention therefore is based on the technical problem of specifying a panel in which the elasticity of the locking lip can be set more satisfactorily.

This object is achieved according to the invention by a panel of the type cited initially in that the elasticity groove is at least partly filled with at least one filling compound.

The elasticity of the locking lip can thus be set by suitable introduction of a filling compound. The locking lip is preferably made from a wooden material like the carrier board of the panel. The carrier board can be a medium density fibre board (MDF) or a high density fibre board (HDF). The material for the carrier board can also be a mixture of a wooden material and a plastic, known as a wood-plastic composite. The carrier board of the panel can have a coating on the top and/or underside such as in the form of a lacquer coating and/or a laminate coating. Corresponding coatings are known from the prior art so these are not described in more detail below.

The elasticity groove can have an opening perpendicular and/or parallel to the panel so that the locking lip can be bent suitably. In other words the elasticity groove can run substantially horizontally or substantially vertically as required, in particular depending on whether the locking lip runs substantially horizontally or vertically. The terms horizontal and vertical in this context should be understood as merely preferential directions, so that both the extent of the elasticity groove and the extent of the locking lip can be aligned clearly obliquely to the horizontal and/or the vertical and thus be provided more horizontally or more vertically.

A particularly simple locking can be achieved if the side edges can be brought into engagement substantially by a vertical movement, such that the first side edge is provided with a locking lip preferably directed downward from the top and with an elasticity groove arranged on the side of the locking lip facing away from the outer end of the first side edge, that the locking element of the second side edge is formed as a locking tongue and that in the locked state the locking tongue is engaged with the locking lip.

If two locking lips are provided, higher extraction forces can be tolerated. For common adjustment of the elasticity of the locking lips, the elasticity groove is suitably adjacent to both locking lips.

To simplify and/or strengthen the locking of two corresponding side edges, the locking element of the second side edge can be formed as a locking lip and an elasticity groove adjacent to the locking lip of the second side edge and at least partly filled with at least one filling compound can be provided on the second side edge.

A simple and secure locking of the panels in the horizontal and vertical direction is guaranteed in a preferred embodiment in that the first side edge is fitted with a fitting tongue preferably directed downward from the top and with a locking groove arranged between the fitting tongue and the locking lip, that the second side edge is fitted with a fitting groove adjacent to the locking tongue and that in the locked state the fitting tongue is in engagement with the fitting groove, wherein the distal end of the fitting tongue lies on the groove base of the fitting groove and wherein the locking tongue is in engagement with the locking groove and the locking lip.

To provide a suitable elasticity, the filling compound is an elastic compound, in particular a silicone, acrylate and/or melt adhesive.

Preferably the filing compound is an at least partly foaming filling compound in order to be able to adjust the elasticity of the locking lip suitably. A foaming filling compound is a compound which has a multiplicity of small gas-filled cavities or pores, wherein the cavities in turn can form an open and/or a closed porosity. Thus adaptation of the elasticity of the filling compound and hence the locking lip can easily take place by the selection of the degree of foaming i.e. the proportion of the gas-filled cavity or pore volume in relation to the total volume of the filling compound. In this context foaming degrees in the range of 10 to 35%, in particular 15 to 20%, have proved particularly suitable.

By the use of a foamed filling compound, alternatively or additionally a material saving can be achieved and hence a cost saving. Foamed filling compounds have the additional benefit that the elasticity groove is filled to its flanks and if required a full surface connection can be achieved between the filling compound and the flanks of the elasticity groove, in particular the flank adjacent to the locking lip.

Optionally the filling compound can be introduced into the elasticity groove at least in a substantially foamed state or at least in a substantially unfoamed state. In the latter case the filling compound substantially foams within the elasticity groove, wherein this is filled to the desired extent. In principle the filling compound can be foamed chemically and/or physically, such as by blowing in a gaseous medium. The gas enclosed in the filling compound, in particular for physical foaming, is air.

Good adhesive properties for joining the filling compound to the flanks of the elasticity groove are achieved with the foamed melt adhesives, also called hot melt adhesives. Corresponding filling compounds can be stored in a molten and foamed state in a tank and from there injected via a heated hose into the elasticity groove, wherein the panel and an application nozzle are moved relative to each other along the elasticity groove.

In particular if the panels are moved past the application nozzle in succession at a certain distance from each other i.e. with gaps in between, it is suitable if the output of filling compound is pulsed. The output can thus be adapted to the dimensions, advance speed and spacing of the panels such that no filling compound enters the gaps between the panels. This avoids contaminating plant parts and saves filling compound.

A pulsed output of filling compound can alternatively or additionally achieve the fact that the elasticity groove is only partly filled in the longitudinal extent. The introduction of filling compound can in principle take place directly after milling the elasticity groove out of the panel material.

To ensure as stable as possible a connection between adjacent panels with low force and without damaging the panels, it is suitable if the filling compound hardens slowly. Slow hardening in this context means hardening which takes place so slowly that on proper use the filling compound is only partly hardened during laying and only hardens fully after laying. During laying of the panel the filling compound and hence the locking lip are still quite flexible, while the filling compound only hardens some hours, days or weeks after laying so that a very stable connection is achieved between the panels.

As the filling compound should be prevented from hardening completely during storage, hardening can take place at least partly by drying and/or contact with air oxygen. The loss of moisture and the addition of air oxygen can be prevented or at least controlled suitably for example in the packed state of the panels by a suitable choice of packing material. After unpacking of the panels from the packing, the filling compound can, as required, harden much faster than before.

Alternatively or additionally the filling compound can be connected by material connection with the panel, such as via the filling compounds previously mentioned. Thus the filling compound and/or the locking lip are securely fixed even if the locking lip breaks.

For a precise setting of the bending behaviour of the locking lip over its length, the elasticity groove can be filled at least partly with at least two different filling compounds with different modulus of elasticity. A filling compound with a higher modulus of elasticity in the region of the groove base of the elasticity groove can reduce the bending of the locking lip so that lower stress peaks occur there.

A saving of filling compound and hence material costs can be achieved if the at least one filling compound is provided in segments along the longitudinal extent of the elasticity groove. Different filling compounds can also be provided along the longitudinal extent of the elasticity groove. In both cases the bending behaviour of the locking lip can be adapted in segments to particular requirements.

The elasticity groove can be angled in relation to the vertical such that the groove base of the elasticity groove in the horizontal direction is arranged closer to the outer end of the first side edge of the panel than the opening of the elasticity groove which preferably points towards the underside of the panel. As a result a suitable bending behaviour of the locking lip can be achieved and the locking lip stabilised.

Further preferably the flank of the locking lip adjacent to the elasticity groove can run substantially obliquely to the vertical as a whole, wherein the flank is spaced further in the horizontal direction from the outer end of the first side edge in the region of the opening of the elasticity groove than in the region of the base of the elasticity groove. Also the elasticity groove can have a main orientation aligned obliquely to the vertical between the opening of the elasticity groove and the base of the elasticity groove, without all flank regions of the elasticity groove also having to run obliquely to the vertical. By all these measures the bending behaviour of the locking lip can be improved or adjusted.

A particularly robust locking lip can be achieved if the locking lip has at least one tapered segment in the region of the base of the elasticity groove. This can be achieved in that the width of the locking lip in the region of the base of the elasticity groove has a taper at least in one cross section perpendicular to the side edge. The taper forms a nominal break point or break edge if the taper runs substantially along the entire locking lip, so that if the stress is too high, the locking lip breaks in the region of the base of the elasticity groove. Then the locking lip is fixed over a large surface by the filling compound in the elasticity groove. Firstly the locking lip does not detach from the panel. Secondly the locking lip can continue substantially to fulfil its function.

The elasticity groove in the region of the groove base can be expanded or widened in relation to the adjacent region of the elasticity groove in order to provide, in a particularly simple fashion, a nominal break point in the region of the groove base of the elasticity groove and/or to be able to introduce the filling compound into the elasticity groove particularly well without disruptive air inclusions, preferably adjacent to the locking lip. If the groove base is also or alternatively rounded, at corresponding points the stress peaks in the material can be reduced. The rounding can be provided at the groove base in the longitudinal extent of the elasticity groove and/or adjacent to the locking lip in the region of the groove base of the elasticity groove. A widening in the region of the groove base can be produced simply and precisely by a broaching tool or an end milling cutter.

The presence of an elasticity groove with at least one filling compound allows the locking lip to be made very thin in order to increase the influence of the elasticity groove and/or filling compound on the mechanical properties of the locking lip and optimise these mechanical properties. The locking lip therefore preferably has a smaller, in particular very much smaller horizontal width than the elasticity groove.

A better distinction of the panel sides can be achieved if the filling of the elasticity groove is dyed. The side edges can in this way be colour-coded so that the fitter can determine the correct arrangement of the panels more quickly and easily.

In a particularly preferred embodiment of the panel, the modulus of elasticity of the at least one filling compound is adapted to the application. For example the flexibility of the locking lip can be adapted by choice of the at least one filling compound and/or by targeted filling of the elasticity groove in segments.

The panels can be laid more easily if the panels have a third side edge and a fourth side edge opposite the third side edge, and the third and fourth side edges can be brought into engagement, preferably locked, with corresponding side edges of further panels substantially by a swivel movement about a parallel to the side edges to be joined. Not all side edges are thus brought into engagement by a substantially vertical movement. Via the swivel movement at the same time a first side edge and a third side edge can be connected, preferably locked, with a second and a third side edge of further panels.

In principle it is suitable if the first and second side edges are provided on the short narrow sides of the panel. Alternatively or additionally the panel is formed square.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The first side edge3has a fitting tongue6directed down away from the top side5, a locking lip7directed down from the top side5, a locking groove8arranged between the fitting tongue6and the locking lip7, and an elasticity groove9arranged on the side of the locking lip7facing away from the locking groove8. The second side edge4however is fitted with a locking tongue11directed up from the underside10and with a fitting groove12adjacent to the locking tongue11. In locked state the fitting tongue6is in engagement with the fitting groove12, wherein the distal end13of the fitting tongue6lies on the groove base14of the fitting groove12. Furthermore the locking tongue11is in engagement with the locking groove8and the locking lip7.

To achieve the horizontal and vertical locking, the profile elements previously explained have the following fitting and locking surfaces. The fitting tongue6has a first fitting surface15adjacent to the top5, a second fitting surface16arranged on the inside and a lower third fitting surface13, namely the distal end of the fitting tongue6previously mentioned. The locking lip7is fitted with a first locking surface17running obliquely to the top5. Furthermore on the second side edge4is provided a fourth fitting surface18adjacent to the top5. The locking tongue11in turn has a second locking surface19running obliquely to the underside10and a fifth fitting surface20. The groove base14of the fitting groove12forms the sixth fitting surface.

In the locked state the first fitting surface15lies on the fourth fitting surface18, the second fitting surface16on the fifth fitting surface20, the third fitting surface13on the sixth fitting surface14and the first locking surface17on the second locking surface19. In other words the fitting surface pair15and18and the fitting surface pair16and20form the horizontal lock as these fitting surfaces run substantially vertically. Fitting surface pair13and14and locking surface pair17and19however form the vertical lock. As the locking surfaces17and19run obliquely, these have an effect both in relation to the horizontal and the vertical locking.

The locking groove8at the side opposite the fitting tongue6can have a first contact surface21while the locking tongue7on the side facing away from the fitting groove12can have a second contact surface22so that in the locked state the two side edges3and4lie against the first contact surface21and second contact surface22. This is not itself necessary for locking of the profiles but leads to a stabilisation of the entire profile.

FIGS. 3ato3cshow a derivation of the panel1shown inFIGS. 1 and 2. The common features of the panel arise as described above. The derivation lies substantially in that the elasticity groove9is filled with a filling compound30. Therefore inFIGS. 1 to 3the same reference numerals are used for the same elements.

The filling compound30is preferably an elastic compound, in particular a silicone, acrylate and/or melt adhesive. The elasticity groove9can if necessary also be filled only partly with the filling compound or different filling compounds. Optionally the elasticity groove can also be unfilled. The elasticity groove9of the panel1shown is angled in relation to the vertical such that the groove base32of the elasticity groove9is arranged in the horizontal direction closer to the outer end34of the first side edge3of the panel1than the opening36of the elasticity groove9. The opening36in the embodiment example shown is aligned parallel to panel1. The outer end is the end of the panel in a direction perpendicular to the first edge and parallel to the panel.

The elasticity groove9in the region37of the groove base32is furthermore widened in relation to the adjacent region38of the elasticity groove9so as to form a nominal break point40in the form of a tapered segment23of the locking lip7. On mechanical failure, a crack42is formed at the nominal break point40. The locking lip7is held at the flank44adjacent to the elasticity groove by the filling compound30over a large area as the filling compound30is connected by material fit with the panel1and in particular the locking lip7.

In the panel1shown inFIG. 3, the locking lip7provided on the first side edge3runs substantially from top to bottom, wherein the elasticity groove9extends in the same direction on the side of the locking lip7facing away from the outer end34of panel1. The locking tongue11provided on the second side edge4runs corresponding to said groove and in the connected state of the panel1,2is in engagement with the locking lip7while the downwardly directed fitting tongue6is in engagement with the fitting groove12and the distal end13of the fitting tongue6lies on the groove base14of the fitting groove12. The locking tongue11in the joined state of the panels1,2is in engagement both with the locking lip7and with the locking groove8, the locking groove8being arranged between the fitting tongue6and the locking lip7.

FIG. 4shows two similar panels50,52with a first side edge54which for connection are arranged substantially in a direction parallel to panels50,52and vertical to the first side edge54. The first side edge54has a catch element55with two substantially horizontal locking lips56,58. Between and adjacent to the locking lips56,58is an elasticity groove62filled with a filling compound60. The elasticity groove62extends substantially parallel to the panel50and has an opening63which is oriented vertically to the panel50. The second side edge64has a recess66corresponding to the catch element55. On connection of the catch element55and recess66in the direction of the arrow68, the filling compound60is compressed and the locking lips56,58are bent in the direction of the elasticity groove62.

FIG. 5shows two further panels70,72which are provided for connection by a substantially vertical movement. The first side edge74of panels70,72has an outer end75and two downwardly pointing locking lips76,78adjacent to an elasticity groove82that is filled with a filling compound80and open to the bottom. In the regions facing away from the free ends of the locking lips76,78, tapered segments77,79are also provided which on increased load can serve as nominal break points for the locking lips76,78. The locking element84of the second side edge86of the similar panels70,72has two locking lips88,90with correspondingly tapered segments89,91, wherein each of the locking lips88,90is adjacent to an elasticity groove92. The elasticity grooves92in a region adjacent to the groove base and in a region adjacent to the opening of the elasticity groove92have filling compounds94,96with different moduli of elasticity.

FIG. 6shows panels100,102with a first side edge104which has a tongue106while the second side edge108of the panels100,102has a corresponding recess110. The tongue106can be locked with recess110via a swivel movement. The second side edge108on a lower segment largely parallel to panel102and protruding outward thus has a protruding locking lip112and an elasticity groove116filled with filling compound114and extending substantially in a horizontal direction. The elasticity groove116expands in the direction of the protruding end of the elasticity groove116which there ends in an opening117perpendicular to panel72.

FIG. 7shows two panels120,122which resemble the panels100,102inFIG. 6. The lower protruding lip122of the second side edge123is largely formed as an elastic element124of an elastic filling compound. At the end of the elastic element124is a locking means126made of a wooden material and connected with the remaining panel only via the elastic element124.

FIG. 8shows two further panels130,132with corresponding first side edges134with a catch element136and second side edges137with a recess140. The catch element has a thickening138. In the extension of the recess140is provided an elasticity groove144filled with a filling compound142and also extending in the horizontal direction. When the panels130,132are joined in the direction of arrow146, the locking lips148,150adjacent to the elasticity groove144on both sides are spread apart. Because of the filling compound142in the elasticity groove144, the panel132does not crack in the region of recess140, in particular in the region of the groove base of recess140.

FIG. 9shows panels160,162in which the first side edge164has a tongue166and the second side edge168has a corresponding groove170. The side edges164,168can be brought into engagement with each other substantially by a swivel movement of the first panel160about a parallel to the side edges164,168to be connected. The tongue166furthermore has a locking lip172extending downwards with an elasticity groove174adjacent thereto. The elasticity groove174is adjacent to the side of the locking lip172facing the outer end of the panel160. Furthermore a tapered segment175is provided on the locking lip172in the region facing away from the free end. Here usually the locking lip172will break first under increased load. The elasticity groove174is filled with two filling compounds176,178of different moduli of elasticity. The locking element180is formed as a lower lip182protruding outwards parallel to panel162with a protrusion184at the distal end. The lower lip182on the underside186has a recess188with is filled with a filling compound190that positively influences the bending of the lower lip182on joining of panels160,162.

The panel200shown inFIG. 10has a locking lip206on a first side edge202on the underside204. The locking lip206is adjacent to an elasticity groove208which is filled with a filling compound210in segments with interruptions212. Such a segmented filling of an elasticity groove is in principle also possible with the other embodiment examples. The second side edge of the panel200corresponding to the first side edge202can if necessary be formed corresponding to the second side edge4shown inFIG. 3a.