# Patent

## Title
Building panels

## Abstract

Flooring material comprising sheet-shaped floor elements with a mainly square or rectangular shape. The floor elements are provided with edges, a lower side and an upper decorative layer. The floor elements are intended to be joined by means of joining members. The floor elements are provided with male joining members on a first edge while a second edge of the floor elements are provided with a female joining member. The male joining member is provided with a tongue and a lower side groove while the female joining member is provided with a groove and a cheek. the cheek being provided with a lip. The floor elements are provided with a male vertical assembly joining member on a third edge while a fourth, opposite. edge is provided with female vertical assembly joining member.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of and claims priority to U.S. application Ser. No. 13/860,315, filed Apr. 10, 2013, which is a continuation of and claims priority to U.S. application Ser. No. 13/437,597, filed Apr. 2, 2012, now U.S. Pat. No. 8,544,233, which is a continuation of and claims priority to U.S. application Ser. No. 12/240,739, filed Sep. 29, 2008, now U.S. Pat. No. 8,146,318, which is a divisional of and claims priority to U.S. application Ser. No. 11/540,583, filed Oct. 2, 2006, now U.S. Pat. No. 7,441,385, which is a continuation of and claims priority to U.S. application Ser. No. 10/286,982, filed Nov. 4, 2002, now U.S. Pat. No. 7,121,058, which is a continuation-in-part of U.S. application Ser. No. 10/242,674, filed Sep. 13, 2002 now U.S. Pat. No. 7,332,053; and is a continuation-in-part of U.S. application Ser. No. 09/988,014, filed Nov. 16, 2001; and is a continuation-in-part of U.S. application Ser. No. 09/672,076, filed Sep. 29, 2000, now U.S. Pat. No. 6,591,568; and to Swedish Application No. 0001149-4, filed Mar. 31, 2000. The entire disclosures of each of the above applications are incorporated herein by reference in their entireties.


BACKGROUND
1. Field of the Invention
The present invention relates to a flooring material comprising sheet-shaped floor elements which are joined by means of joining members.
2. Background
Prefabricated floor boards provided with tongue and groove at the edges are quite common nowadays. These can be installed by the average handy man as they are very easy to install. Such floors can, for example. be constituted of solid wood, or of wood particles consolidated by use of a binder including fibre board, such as high or medium density fibre board (HDF or MDF), particle board, chip board, oriented strand board (OSB) or any other construction comprising particles of wood bonded together with a binder. These are most often provided with a surface layer such as lacquer, or some kind of laminate. The boards are most often installed by being glued via tongue and groove. The most common types of tongue and groove are however burdened with the disadvantage to form gaps of varying width between the floor boards in cases where the installer hasn't been thorough enough. Dirt will easily collect in such gaps. Moisture will furthermore enter the gaps which will cause the core to expand in cases where it is made of wood, fibre board or particle board, which usually is the case. The expansion will cause the surface layer to rise closest to the edges of the joint which radically reduces the useful life of the floor since the surface layer will be exposed to an exceptional wear. Different types of tensioning devices, forcing the floor boards together during installation can be used to avoid such gaps. This operation is however more or less awkward. It is therefore desirable to achieve a joint which is self-guiding and thereby automatically finds the correct position. Such a joint would also be possible to utilize in floors where no glue is to be used.
Such a joint is known through WO 94/26999 (herein incorporated by reference in its entirety) which deals with a system to join two floor boards. The floor boards are provided with a locking device at the rear sides. In one embodiment the floor boards are provided with profiles on the lower side at a first long side and short side: These profiles, which extends outside the floor board itself, is provided with an upwards directed lip which fits into grooves on the lower side of a corresponding floor board. These grooves are arranged on the second short side and long side of this floor board. The floor boards are furthermore provided with a traditional tongue and groove on the edges. The intentions are that the profiles shall bend downwards and then to snap back into the groove when assembled. The profiles are integrated with the floor boards through folding or alternatively, through gluing.
According to WO 94/26999, the floor boards may be joined by turning or prizing it into position with the long side edge as a pivot point. It is then necessary to slide the floor board longitudinally so that it snaps into the floor board previously installed in the same row. A play is essential in order to achieve that. This play seems to be marked Δ in the figures. A tolerance of ±2 mm is mentioned in the application. Such a play will naturally cause undesired gaps between the floor boards. Dirt and moisture can penetrate into these gaps.
It is also known through WO 97/47834 (herein incorporated by reference in its entirety) to manufacture a joint where the floor boards are joined by turning or prizing it into position with the long side edge as a pivot point. According to this invention a traditional tongue has been provided with heel on the lower side. The heel has a counterpart in a recess in the groove of the opposite side of the floor board. The lower cheek of the groove will be bent away during the assembly and will then snap back when the floor board is in the correct position. The snap-joining parts, i.e. the tongue and groove, is in opposite to the invention according to WO 94/26999 above, where they are constituted by separate parts, seems to be manufactured monolithically from the core of the floor board. WO 97/47834 does also show how the tongue and groove with heels and recesses according to the invention is tooled by means of cutting machining. This invention does also have the disadvantage that the best mode of joining floor boards includes longitudinal sliding for joining the short sides of the floor boards, which also here will require a play which will cause unwanted gaps between the floor boards. Dirt and moisture can penetrate into these gaps.
SUMMARY OF THE INVENTION
It is, through the present invention, made possible to solve the above mentioned problems whereby a floor element which can be assembled without having to be slid along already assembled floor elements has been achieved. Accordingly, the invention relates to a flooring material comprising sheet-shaped floor elements with a mainly square or rectangular shape. The floor elements are provided with edges, a lower side and an upper decorative layer. The floor elements are intended to be joined by means of joining members. The invention is characterized in that;

    
    
        a) The floor elements are provided with male joining members on a first edge while a second, opposite, edge of the floor elements are provided with a female joining member. The male joining member is provided with a tongue and a lower side groove. The female joining member is provided with a groove and a cheek, the cheek being provided with a lip. The floor elements are intended to mainly be joined together by tilting the floor element to be joined with an already installed floor element or a row of already installed floor elements, with the male joining member of the floor element angled downwards and that the first edge is allowed to be mainly parallel to the second edge of the already installed floor element or elements. The tongue of the tilted floor element is then inserted into the groove of the female joining member of the already installed floor element or elements. The tilted floor element is then turned downwards, with its lower edge as a pivot axis, so that the lip eventually snaps into the lower side groove where the decorative upper layer of the floor elements are mainly parallel.
        b) The floor elements are moreover provided with a male vertical assembly joining member on a third edge while a fourth edge is provided with female vertical assembly joining member. The fourth edge is arranged on a side opposite to the third edge.
        c) The floor elements are alternatively provided with a male vertical assembly joining member on a third edge, while a fourth edge also is provided with male vertical assembly joining member. The fourth edge is arranged on a side opposite to the third edge. Adjacent male vertical assembly joining members are thereby joined by means of a separate vertical assembly joining profile. Two adjacent edges of a floor element can hereby be joined with a floor element adjacent to the first edge and a floor element adjacent to the third or fourth edge at the same time, and in the same turning motion.
    
    


The force needed to overcome the static friction along the joint between two completely assembled male and female joining members is preferably larger than 10N per meter of joint length, suitably larger than 100N per meter of joint length.
According to one embodiment of the invention, the floor elements are provided with male vertical assembly joining members on a third edge and provided with female vertical assembly joining members on a fourth edge. The male vertical assembly joining members are provided with mainly vertical lower cheek surfaces arranged parallel to the closest edge. The lower cheek surfaces are intended to interact with mainly vertical upper cheek surfaces arranged on the female vertical assembly joining members so that two joined adjacent floor elements are locked against each other in a horizontal direction. The male and female vertical assembly joining members are provided with one or more snapping hooks with matching under cuts which by being provided with mainly horizontal locking surfaces limits the vertical movement between two joined adjacent floor elements.
The floor elements may alternatively be provided with male vertical assembly joining members on both a third and a fourth edge. These edges are then snap joined by means of a vertical assembly profile which on both sides of a longitudinal symmetry line is designed as a female vertical assembly joining member according to the description above. Two joined adjacent floor elements are locked to each other in a horizontal direction via the vertical assembly profile while, at the same time, vertical movement between two joined adjacent floor elements is limited.
The joint between a third and a fourth edge of two joined floor elements preferably comprises contact surfaces which are constituted by the horizontal locking surfaces of the under cuts and hooks, the mainly vertical upper cheek surfaces and lower cheek surfaces as well as upper mating surfaces.
The joint between two joined floor elements suitably also comprises cavities.
According to one embodiment of the invention the snapping hook is constituted by a separate spring part which is placed in a cavity. Alternatively the undercut is constituted by a separate spring part which is placed in a cavity. The spring part is suitably constituted by an extruded thermoplastic profile, a profile of thermosetting resin or an extruded metal profile.
The vertical assembly joining profiles are suitably shaped as extended profiles which suitably are manufactured through extrusion which is a well known and rational method. The vertical assembly joining profiles are suitably shaped as extended lengths or rolls which can be cut to the desired length. The length of the vertical assembly joining profiles considerably exceeds the length of a floor element, before being cut. The lateral joints of the floor will only need shorter pieces of vertical assembly joining profiles which are positioned as each new floor board is introduced to a row. Vertical assembly joining profiles according to the present invention may be manufactured of a number of different materials and manufacturing methods. Among the most suited can, however, be mentioned injection moulding and extrusion. Suitable materials are thermoplastic materials such as polyolefins, polystyrene, polyvinyl chloride or acrylnitrile-butadiene-styrene copolymer. These may suitably be filled with, for example, wood powder or lime in order to increase the rigidity but also to increase the adhesion when glue is used. It is also possible to mill a vertical assembly joining profile from a material such as wood, fibre board or particle board.
The flooring material including the floor boards and joining profiles above is most suited when installing floors where it isn't desired to use glue. It is, however, possible to use glue or twin-faced adhesive tape in order to make the installation irreversibly permanent. The glue or tape is then suitably applied on, or in connection to, possible cavities or faces below the upper mating surfaces.



BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described further in connection to enclosed figures showing different embodiments of a flooring material whereby,
FIG. 1 shows, in cross-section, a first and a second edge 2I and 2II respectively, during joining
FIG. 2 shows, in cross-section, a second embodiment of a first and a second edge 2I and 2II respectively, during joining.
FIG. 3 shows, in cross-section, a third embodiment of a first and a second edge 2I and 2II respectively, during joining.
FIG. 4 shows, in cross-section, a fourth embodiment of a first and a second edge 2I and 2II respectively, during joining.
FIG. 5 shows, in cross-section, a third and a fourth edge 2I and 2IV respectively, during joining.
FIG. 6 shows, in cross-section, a second embodiment of a third and a fourth edge 2III and 2IV respectively, during joining.
FIG. 7 shows, in cross-section, a third embodiment of a third and a fourth edge 2III and 2IV respectively, during joining.
FIG. 8 shows, in cross-section, a fourth embodiment of a third and a fourth edge 2III and 2IV respectively and a vertical assembly joining profile 30, during joining.
FIG. 9 shows, in cross-section, a first and a second edge 2I and 2II respectively, during joining.
FIG. 10 shows, in cross-section, a second embodiment of a first and a second edge 2I and 2II respectively, during joining.
FIG. 11 shows, in cross-section, a third embodiment of a first and a second edge 2I and 2II respectively, during joining.
FIG. 12 shows, in cross-section, a fourth embodiment of a first and a second edge 2I and 2II respectively, during joining.
FIG. 13 shows, in cross-section, a third and a fourth edge 2III and 2IV respectively, during joining.
FIG. 14 shows, in cross-section, a second embodiment of a third and a fourth edge 2III and 2IV respectively, during joining.
FIG. 15 shows, in cross-section, a third embodiment of a third and a fourth edge 2III and 2IV respectively, during joining.
FIG. 16 shows, in cross-section, a fourth embodiment of a third and a fourth edge 2III and 2IV respectively and a vertical assembly joining profile 30, during joining.



DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows, in cross-section, a first and a second edge 2I and 2II respectively, during assembly. The figure shows pans of a flooring material comprising sheet-shaped floor elements 1 with a mainly square or rectangular shape. The floor elements 1 are provided with edges 2, a lower side 5 and an upper decorative layer 3. The floor elements 1 are intended to be joined by means of joining members 10. Such floors floor elements, for example, be constituted of solid wood, fibre board, such as medium density fibre board (MDF), particle board, chip board, or any other construction comprising pieces or particles of wood, including combinations of plastic elements and the particles or pieces of wood. The floor elements 1 are provided with male joining members 101 on a first edge 2I while a second edge 2II of the floor elements 1 are provided with a female joining member 10II. The second edge 2II is arranged on a side opposite to the first edge 2I. The male joining member 10I is provided with a tongue 11 and a lower side 5 groove 12. The female joining member 10II is provided with a groove 13 and a cheek 14, the cheek 14 being provided with a lip 15. The floor elements 1 are intended to mainly be joined together by tilting the floor element 1 to be joined with an already installed floor element 1 or a row of already installed floor elements 1, with the male joining member 10I of the floor element 1 angled downwards and that the first edge 21 is allowed to be mainly parallel to the second edge 2II of the already installed floor element 1 or elements 1. The tongue 11 of the tilted floor element 1 is then inserted into the groove 13 of the female joining member 10II of the already installed floor element 1 or elements 1, whereby the tilted floor element 1 is turned downwards, with its lower edge as a pivot axis, so that the lip 15 eventually falls into the lower side 5 groove 12 where the decorative upper layer 3 of the floor elements 1 are mainly parallel.
The embodiment shown in FIG. 1 corresponds mainly with the one shown in FIG. 1. The lip 15 and lower side 5 groove 12 are, however, provided with a cam 16 and a cam groove 17 which provides a snap action locking.
The embodiment shown in FIG. 3 corresponds mainly with the one shown in FIGS. 1 and 2 above. The lip 15 and lower side 5 groove 12 are, however, provided with a cam 16 and a cam groove 17 which provides a snap action locking.
The embodiment shown in FIG. 4 corresponds mainly with the one shown in FIG. 1 above. The lip 15 and cheek 14 is however shaped as a thin resilient section which provides a snap action locking.
FIG. 5 shows, in cross-section, a third and a fourth edge 2II and 2IV respectively, of a floor element 1 according to any of the FIGS. 1 to 4. The floor elements 1 are provided with a male vertical assembly joining member 10III on a third edge 2III while a fourth edge 2IV is provided with a female vertical assembly joining member 10IV. The fourth edge 2IV is placed on a side opposite to the third edge 2III. The male vertical assembly joining members 10III are provided with mainly vertical lower cheek surfaces 21 arranged parallel to the closest edge 2. The lower cheek surfaces 21 are intended to interact with mainly vertical upper cheek surfaces 22 arranged on the female vertical assembly joining members 10IV so that two joined adjacent floor elements 1 are locked against each other in a horizontal direction. The male vertical assembly joining members 10III are moreover provided with two snapping hooks 23 while the female vertical assembly joining members 10IV are provided with matching under cuts 24, which by being provided with mainly horizontal locking surfaces limits the vertical movement between two joined adjacent floor elements 1.
The joint between a third and a fourth edge 2III and 2IV respectively of two joined floor elements 1 further comprises contact surfaces which are constituted by the horizontal locking surfaces of the under cuts 24 and hooks 23, the mainly vertical upper cheek surfaces 22 lower cheek surfaces as well as upper mating surfaces 25. The joint between two joined floor elements 1 also comprises cavities 6.
The embodiment shown in FIG. 6 corresponds in the main with the one shown in FIG. 5. The male vertical assembly joining members 10′′ are, however, provided with only one snapping hook 23 while the female vertical assembly joining members 10IV are provided with a matching undercut 24, which by being provided with mainly horizontal locking surfaces limits vertical movement between to joined adjacent floor boards 1.
The embodiment shown in FIG. 7 corresponds in the main with the one shown in FIG. 6. The snapping hook 23 on the male vertical assembly joining member 10III is, however, moved somewhat inwards in the floor element 1 whereby a guiding angle is formed above the undercut 24 of the female vertical joining member 10IV.
The embodiment shown in FIG. 8 corresponds mainly with the one shown in FIG. 7. Both the third and the fourth edges 2III and 2IV respectively are, however, provided with male vertical assembly joining members 10III. A vertical assembly joining profile 30, provided with a female vertical assembly joining profile 10IV on both sides of a vertical symmetry line, is used for joining the two floor elements 1. The female vertical assembly joining members 10IV of the vertical assembly joining profile 30 are equipped similar to the female vertical assembly joining members 10IV in FIG. 7 above.
Two adjacent edges 2 of a floor element 1 can at the same time, and in the same turning motion, be joined with a floor element 1 adjacent to the first edge 21 and a floor element 1 adjacent to the third or fourth edge 2III and 2IV respectively, when assembling floor elements 1 according to the above described embodiments.
The floor elements 1 according to the present invention most often comprises a core. The core is most often comprised of particles or fibre of wood bonded with resin or glue. It is advantageous to coat the surface closest to the joint in cases where the floor will be exposed to high levels of moisture since the cellulose based material is sensitive to moisture. This coating may suitably incorporate resin. wax or some kind of lacquer. It is not necessary to coal the joint when it is to be glued since the glue itself will protect from moisture penetration. The upper decorative layer 3 is constituted of a decorative paper impregnated with melamine-formaldehyde resin. One or more so called overlay sheets of a-cellulose, impregnated with melamineformaldehyde resin may possibly be placed on top of the decorative layer. The abrasion resistance may be improved by sprinkling one or more of the sheets with hard panicles of for example α-aluminium oxide, silicon carbide or silicon oxide. The lower side 5 may suitably be coated with lacquer or a layer of paper and resin.
FIGS. 9-16 demonstrate the improvement of the radially projected dimension of the length (L) of the groove or undercut and the horizontal rotated radially projected height (L) of the lip or upper cheek surface of the boards of the invention. With respect to FIGS. 9-12, the radially projected dimension, indicated at α, corresponds to the length of the groove 13, while β indicates the horizontal rotated length of lip 15. Additionally, γ indicates the length of the tongue 11, while δ is the horizontal rotated length of the locking groove 12. Because α is greater than γ, and β is greater than δ, adjacent floor elements cannot be assembled horizontally. In other words, because tongue 11 (as well as groove 13) is greater than lip 15 (as well as locking groove 12), the floor elements depicted in these figures can only be assembled by rotating or turning one of the floor elements. Generally, in each of these figures, α is substantially equal to γ and β is substantially equal to δ. This “substantially equal” relationship provides for a close fitting, while limiting movement of adjacent panels once assembled. For example, the difference in dimensions may be from 0.005-5%, or from 0.02-0.5 mm.
In contrast, the floor elements shown in FIGS. 13-16 may be assembled through horizontal motion. Specifically, ε is the length of the undercut 24, while ζ corresponds to the horizontal rotated length of the upper cheek surface 22. Additionally, η indicates the length of the snapping hooks 23, while the horizontal rotated length of the lower cheek surface 21 is specified by θ.
Because ε is less than η and ζ is less than θ, the floor elements can only be assembled through horizontal movement. That is to say, due to the particular dimensions of the undercuts 24, upper cheek surface 22, snapping hooks 23 and lower cheek surface 21, the floor panels of the invention may be joined through substantially vertical movement of one panel with respect to a second panel.
The dimensions c and n may also be related to the thickness of the floor element itself. For example, the ratio between ε and the thickness (or η and the surface) may be in the range of about 0.025 to 0.2, typically, about 0.05 to about 0.1, and more typically, about 0.07 to 0.09. That is to say, when the thickness is 8 mm, as is common in conventional boards, ε or η would be from 0.2 to 1.5 mm. Additionally, α (or γ) can be at least 2 times greater than β (or δ), while ε (or η) is at least 2 times ζ (or θ).
Moreover, all dimension lines of FIGS. 9-16 are intended to indicate the area taken up by the inserted pan as the recesses, such as, the groove 13 and need not be deeper than the tongue 11. Although in some cases, the recesses are deeper than the length of the tongue 11. With particular reference to FIG. 9, 13 effectively is zero, meaning that there is no undercut when pivoting the panel.
Finally, the floor elements of this invention, preferably, comprise vertically-joined edges on at least two sides. For example, when the floor panel has a substantially rectangular shape, such vertically-joined edges may be found on two, three or all four sides. When the vertically-joined edges are located on less than all sides of the floor element, the remaining sides may include, for example, edges joined by rotating or horizontal movement or simple straight edges without a joining profile.
The invention is not limited by the embodiments shown since they can be varied within the scope if the invention.

## Claims

1. A surface element designed to be assembled together with similar surface elements to form a plurality of joined surface elements:
the surface element being a floor panel comprising a decorative upper surface, an opposed lower surface and at least four edges disposed between the upper and lower surfaces;
the four edges comprising a first edge and a second edge defining a first pair of opposite sides, and a third edge and a fourth edge defining a second pair of opposite sides;
the four edges including upper edge portions, towards which the surface elements seen from the top visually extend in joined condition;
wherein the first edge of the surface element comprises a first male joining member and the second edge comprises a first female joining member;
the first male joining member comprising a tongue and the first female joining member comprising a groove which is bordered by an upper lip and a lower lip, said lower lip forming a lower cheek extending in distal direction further than said upper lip;
said lower cheek having an upwardly directed lip;
said tongue having a lower side protrusion, said protrusion having a lowermost portion;
said lowermost portion being located proximally from a vertical plane through the upper edge portion belonging to said first edge;
a lower side groove located at said first edge;
the first male joining member and the first female joining member being configured such that two of such surface elements can be coupled and locked at their respective first and second edges, wherein said locking provides a vertical locking as well as a horizontal locking;
the vertical locking being realized in that the tongue fits in the groove that is bordered by the upper lip and the lower lip;
the horizontal locking being realized in that said upwardly directed lip at said lower cheek cooperates with said lower side groove;
wherein the third edge of the surface element comprises a second male joining member and the fourth edge comprises a second female joining member;
said second male joining member and second female joining member of the surface element being configured such that two of such surface elements at their respective third edge and fourth edge can be engaged by a downward motion of the third edge of one of said two surface elements with respect to the fourth edge of the other of said two surface elements;
said second male joining member being formed as an upper cheek protruding at said third edge and provided with a downward directed portion;
said second female joining member being formed as a lower cheek protruding at said fourth edge and provided with an upward directed portion;
said second male joining member comprising a male cheek surface at a lower side of said upper cheek and said second female joining member comprising a female cheek surface at an upper side of said lower cheek, the male and female cheek surfaces being arranged to interact with one another so that two joined adjacent surface elements become locked to each other in a horizontal direction;
said third and fourth edges each comprising one or more locking surfaces for locking the third edge and a fourth edge of two of such coupled surface elements against vertical separation; and
each of said locking surfaces of the fourth edge being located distally from a vertical plane through the upper edge portion belonging to the fourth edge.

2. The surface element of claim 1, wherein said lower cheek of the second edge is formed in one piece of a core material of the surface element.

3. The surface element of claim 1, wherein said lower cheek of the fourth edge is formed in one piece of a core material of the surface element.

4. The surface element of claim 1, wherein each of said joining members are formed in one piece of a core material of the surface element.

5. The surface element of claim 1, wherein said lower side protrusion is round.

6. The surface element of claim 5, wherein said lower side protrusion is formed as a substantially circle-shaped segment.

7. The surface element of claim 5, wherein said round protrusion substantially extends from the tip of the tongue up to a position that is located proximally from said lowermost portion.

8. The surface element of claim 1, wherein said lower side groove is located proximally adjacent of said lower side protrusion.

9. The surface element of claim 8, wherein said lower side protrusion has a proximally facing side, said proximally facing side defining a sidewall of said lower side groove.

10. The surface element of claim 9, wherein said lower side protrusion is formed as a substantially circle-shaped segment and said proximally facing sidewall forms part of the circle-shaped form.

11. The surface element of claim 1, wherein said tongue has an upper surface which extends upwards from a distal location to a more proximal location.

12. The surface element of claim 1, wherein said female cheek surface is inclined with respect to the plane of the surface element.

13. The surface element of claim 1, wherein the first and second edges are configured such that said tongue and groove provide a positive vertical locking, said tongue thereto extending with a distal length underneath the upper lip, said length being such that joining of the tongue and groove by means of only a plane parallel vertical lowering of one surface element in respect to the other is made impossible and as such an explicit lateral insertion of the tongue into the groove is required for joining.

14. The surface element of claim 13, wherein the first and second edges are configured such that for said lateral insertion an inclined lateral insertion is needed for bringing the tongue into the groove.