Source: http://patents.com/us-9816270.html
Timestamp: 2018-12-16 17:44:45
Document Index: 215296049

Matched Legal Cases: ['Application No. 13', 'Application No. 61', 'Application No. 1250656', 'Application No. 1250691', 'Application No. 1350027', 'Application No. 61', 'Application No. 1250656', 'Application No. 1250691', 'Application No. 1350027', 'art 16', 'art 8']

US Patent # 9,816,270. Mechanical locking system for floorboards - Patents.com
United States Patent 9,816,270
Pervan , et al. November 14, 2017
Pervan; Darko (Viken, SE), Palsson; Agne (Hasslarp, SE)
Family ID: 1000002946369
13/920,647
US 20130333182 A1 Dec 19, 2013
61661645 Jun 19, 2012
Jun 19, 2012 [SE] 1250656-4
Jun 26, 2012 [SE] 1250691-1
Jan 11, 2013 [SE] 1350027-7
Current CPC Class: E04B 5/02 (20130101); B27F 1/02 (20130101); B27M 3/04 (20130101); E04F 15/02038 (20130101); Y10T 29/49819 (20150115); E04F 2201/0153 (20130101); E04F 2201/025 (20130101); Y10T 29/49815 (20150115); Y10T 29/49817 (20150115); E04F 2201/0115 (20130101)
Current International Class: E04B 5/02 (20060101); B27M 3/04 (20060101); B27F 1/02 (20060101); E04F 15/02 (20060101)
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The present application claims priority to U.S. Provisional Application No. 61/661,645, filed on Jun. 19, 2012, and claims the benefit of Swedish Application No. 1250656-4, filed on 19 Jun. 2012, Swedish Application No. 1250691-1, filed on 26 Jun. 2012, and Swedish Application No. 1350027-7, filed on 11 Jan. 2013. The entire contents of each of U.S. Provisional Application No. 61/661,645, Swedish Application No. 1250656-4, Swedish Application No. 1250691-1, and Swedish Application No. 1350027-7 are hereby incorporated herein by reference in their entirety.
1. A method for dividing a floor element, into a first floor panel and a second floor panel, said floor element comprises a core provided with a decorative surface layer and a balancing layer, wherein the method comprises the step of forming, through the balancing layer or the decorative surface layer, a first groove; and forming a second groove through the other of the balancing layer or the decorative layer by displacing the floor element along a feeding path past a first fixed tool, wherein the first fixed tool comprises a plurality of carving teeth, and wherein the plurality of carving teeth are fixed and non-rotating relative to the feeding path during displacement of the floor element, and dividing the floor element between the first groove and the second groove into said first floor panel and said second floor panel by a second fixed tool having a plurality of carving teeth that are fixed and non-rotating relative to the feeding path during displacement of the floor element.
2. The method as claimed in claim 1, wherein the step of forming is through the balancing layer.
3. The method as claimed in claim 1, wherein the method comprises the step of forming, by the first fixed tool, a part of the second groove that extends horizontally under the decorative surface layer and/or the balancing layer of the floor element.
4. The method as claimed in claim 1, wherein at least one of the plurality of carving teeth is arranged to form the second groove at a different vertical and/or horizontal position than the other carving teeth.
5. The method as claimed in claim 1, wherein the first groove is formed by cutting the first groove through the balancing layer or the decorative surface.
6. The method as claimed in claim 5, wherein the step of forming is through the decorative surface layer.
7. The method as claimed in claim 5, wherein the cutting of the first groove is made by sawing by a rotating saw blade.
8. The method as claimed in claim 5, wherein the forming of the second groove is made before the cutting of the first groove.
9. The method as claimed in claim 1, wherein the method comprises the step of arranging the floor element on a carrier.
10. The method as claimed in claim 9, wherein the carrier is a conveyor belt or chain.
11. The method as claimed in claim 9, wherein the carrier is provided with a pushing device.
12. The method as claimed in claim 9, comprising the step of arranging the decorative surface of the floor element against the carrier and facing downwards.
13. The method as claimed in claim 1, wherein the method comprises the step of removing chips created when forming the second groove by the first fixed tool by compressed air.
14. The method as claimed in claim 13, wherein the step of removing the chips comprises removing by a compressed air nozzle.
15. The method as claimed in claim 13, wherein the step of removing the chips comprises removing by a suction device.
16. The method as claimed in claim 1, comprising the step of removing chips created by the forming, and sorting and disposing into separate containers the chips from the core and the balancing layer and/or the decorative layer.
17. The method as claimed in claim 1, wherein when said floor element is displaced past the plurality of carving teeth of said first fixed tool, each successive carving tooth contacts said floor element at a location deeper into the second groove.
18. The method as claimed in claim 1, wherein the second groove is offset from the first groove in a direction parallel with a main plane of the floor element.
19. A method for dividing a floor element, into a first floor panel and a second floor panel, said floor element comprises a core provided with a decorative surface layer and a balancing layer, wherein the method comprises the step of forming, through the balancing layer, a first groove by displacing the floor element along a feeding path past a first fixed and non-rotating tool, and the step of forming, through the decorative surface layer, a second groove by displacing the floor element along the feeding path past a second fixed and non-rotating tool, wherein the first fixed and non-rotating tool and the second fixed and non-rotating tool each comprise at least one non-rotating and fixed chip-removing surface that is non-rotating and fixed relative to the feeding path during displacement of the floor element, and the method further comprises dividing the floor element between the first groove and the second groove into said first floor panel and said second floor panel by a third fixed and non-rotating tool comprising at least one non-rotating and fixed chip-removing surface that is non-rotating and fixed relative to the feeding path during displacement of the floor element.
20. The method as claimed in claim 19, wherein a horizontally extending groove between the first groove and the second groove is formed by displacing the floor element past the third fixed and non-rotating tool.
21. The method as claimed in claim 20, wherein the third fixed and non-rotating tool passes through the first groove or the second groove.
22. The method as claimed in claim 19, wherein said first fixed and non-rotating tool comprises a plurality of carving teeth, wherein when said floor element is displaced past the plurality of carving teeth of said first fixed and non-rotating tool, each successive carving tooth contacts said floor element at a location deeper into the first groove, wherein each carving tooth comprises a non-rotating and fixed chip-removing surface.
Laminate flooring usually comprise of a core of 6-11 mm fibreboard, a 0.1-0.8 mm thick upper decorative surface layer of laminate and a 0.1-0.6 mm thick lower balancing layer of laminate, plastic, paper or like material. The surface layer provides appearance and durability to the floorboards. The core provides stability, and the balancing layer keeps the board plane after pressing and when the relative humidity (RH) varies during the year. The floorboards are laid floating, i.e. without gluing, on an existing subfloor. Traditional hard floorboards of this type were usually joined by means of glued tongue-and-groove joints. However the majority of all laminate floorboards are presently joined mechanically by means of so-called mechanical locking systems. These systems comprise locking means, which lock the boards horizontally and vertically. The mechanical locking systems are usually formed by machining of the core. Alternatively, parts of the locking system may be formed of separate materials, for example aluminium or plastic, which are factory integrated with the floorboard.
The most common core material is a fibreboard with high density and good stability usually called HDF--High Density Fibreboard. Sometimes also MDF--Medium Density Fibreboard--is used as core.
In all cases, the above-mentioned floor panels are individually machined along their edges to floorboards. The machining of the edges is carried out in advanced milling machines where the floor panel is exactly positioned between one or more chains and belts, so that the floor panel may be moved at high speed and with great accuracy past a number of milling motors, which are provided with rotating diamond cutting tools or metal cutting tools and which machine the edge of the floor panel. By using several milling motors operating at different angles, advanced joint geometries may be formed at speeds exceeding 200 m/min and with an accuracy of about .+-.0.05 mm. The accuracy in the vertical direction is generally better than in the horizontal direction since it is difficult to avoid so called swimming which occurs when panels move horizontally in relation to the chain/belt during milling.
With a view to facilitating the understanding of embodiments of the present invention, known mechanical locking system will now be described with reference to FIGS. 1a-1e. In applicable parts, the subsequent description of known technique also applies to the embodiments of the present invention described below.
As shown in FIG. 1a the floorboards have a tongue 10 and a groove 9 that locks the edges in a vertical direction. A strip 6, which extends along a first edge 1, protrudes from the edge and has a locking element 8 that cooperates with a locking groove 14 in the adjacent second edge 1' and locks the edges horizontally.
It is evident from this figure and FIG. 1b, that since the mechanical locking systems have parts, such as the tongue 10 and the strip 6, that project beyond the upper joint edges, expensive waste W is created when the large board 1b is cut by a sawblade 20 into several floor panels and when the locking system is formed.
Even when individual floor panels are produced, for example floors of solid wood, as shown in FIG. 1c, considerable waste (W) is caused by forming the strip 6 and the tongue 10.
It is known that a locking system may be formed with overlapping edges A, B and a lower tongue C as shown in FIG. 1d (WO 2005/068747 Valinge Innovation AB). Such locking system will not reduce the waste. The overlapping edge or small tongue A is mainly used to facilitate horizontal displacement between the edges. FIG. 1e shows a known locking system (WO 2006/043893 Valinge Innovation AB) that has a separate flexible tongue 10 attached above the strip 6 and that is mainly intended to lock the short edges with vertical folding or vertical snapping.
A first aspect of embodiments of the invention is a method for dividing a board into a first panel and a second panel, wherein the method comprises the step of displacing the board and dividing the board by a fixed tool, such as scraping or carving tool.
A second aspect of embodiments of the invention is method of forming a mechanical locking system for locking of a first and a second panel, wherein the method comprises the steps: dividing a board into a first and a second panel according to the methods described herein and thereby forming a lower protruding part at a first edge of the first panel and a lower groove at a second edge of the second panel; forming a locking element at the lower protruding part; and forming a locking groove at the lower groove.
A third aspect of embodiments of the invention are building panels, each comprising an upper surface and a core, provided with a locking system for vertical and horizontal locking of a first edge of a first building panel to an adjacent second edge of a second building panel. The upper parts of the first and the second edge together define in a locked position a vertical plane, which perpendicular to a horizontal plane, which is parallel to the upper surface of the first and the second building panel. The locking system is configured to enable assembling of the first and the second edge by angling the first and the second building panel relative each other. The locking system comprises a tongue, made in one piece with said core, and a tongue groove configured to cooperate for vertical locking, and a strip at the first edge, made in one piece with the core, which is provided with a locking element, and configured to cooperate for horizontal locking with a downwardly open locking groove formed in the second edge. The first and the second building panel (may obtain a relative position with a distance between the first and the second edge, in said position the upper surface of the first and the second building panel (1, 1') are in the same horizontal plane and an edge part of the second edge is located vertically above the upper part of the locking element and that there is a vertically extending space S of at least about 0.5 mm between the locking element and all parts of the second edge which is located above the locking element.
The space may be larger than 0.6 mm.
A fourth aspect of embodiments of the invention is a method to divide a board, comprising a core and a surface, wherein the method comprises the step of: forming in the core a first and a second essentially vertical grooves, which are horizontally offset, wherein the first groove comprises an opening towards the front side and the second groove comprises an opening towards the rear side of the board; dividing the board into a first floor panel with a first edge and a second floor panel with a second edge, wherein the first edge is adjacent the second edge; and forming a locking system on the first and second edge comprising a strip, a locking element and a locking groove for horizontal locking and a tongue and a tongue groove for vertical locking.
The first or the second groove may be formed by a carving tool with carving teeth that are displaced horizontally with a distance of at least about 0.2 mm.
A fifth aspect of embodiments of the invention is building panels comprising a surface and a core, provided with a locking system for vertical and horizontal locking of a first edge of a first building panel to an adjacent second edge of a second building panel. The upper parts of the first and the second edge, in a locked position, together define a vertical plane perpendicular to a horizontal plane, which is parallel to the surface. The locking system is configured to enable assembling of the first and the second edge by angling the first and the second building panel relative each other. The locking system comprises a tongue, made in one piece with said core, and a tongue groove configured to cooperate for vertical locking. The first edge comprises a strip, made in one piece with the core, which is provided with a locking element, which is configured to cooperate for horizontal locking with a downwardly open locking groove formed in the second edge. The tongue, which is provided on the first edge, cooperates with a lower lip of the tongue groove, which is provided at the second edge and comprises lower vertically locking surfaces. The locking element and the locking groove cooperate at horizontally locking surfaces. The tongue protrudes outwardly beyond the vertical plane and the tongue groove comprises an upper lip. The horizontal extension of the lower lip, in relation to the upper lip, is smaller than the horizontal extension of the tongue.
The horizontally locking surfaces may have a locking angle of about 40-60 degrees against the horizontal plane.
A sixth aspect of embodiments of the invention is a method to divide a board, comprising a core and a surface, wherein the method comprises the step of: forming in the core a first and a second essentially vertical groove, which are horizontally offset, wherein the first groove comprises an opening towards the front side and the second groove comprises an opening towards the rear side of the board; dividing the board into a first floor panel with a first edge and a second floor panel with a second edge, wherein the first edge is adjacent the second edge; and forming a locking strip and a tongue for vertically and horizontally locking of the first and the second floor panel, wherein the locking strip and the tongue protrude horizontally beyond an upper part of the first edge of the first panel.
A seventh aspect of embodiments of the invention is a building panel, such as a floor panel, according to the third or fifth aspect and produced according to the first, the second, the fourth or the sixth aspect.
FIGS. 1a-e illustrate known technology.
FIGS. 2a-d illustrate a locking system according to an embodiment of the invention.
FIGS. 3a-f show alternative embodiments of the invention.
FIGS. 4a-f show alternative embodiments of the invention.
FIGS. 5a-b show a preferred embodiment of the locking system.
FIGS. 6a-6g show separation of a board into several floor panels according to an embodiment of the invention.
FIGS. 7a-b show separation with a band saw according to an embodiment of the invention.
FIG. 7c shows a method to divide a board into two panels by a fixed tool(s), such as a carving or scraping tool, according to an embodiment of the invention.
FIGS. 8a-e show a locking system and a method to divide the panels with carving tools according to embodiments of the invention.
FIGS. 9a-f show how conventional locking systems may be adjusted and divided according to embodiments of the invention.
FIGS. 10a-b show a carving tool according to an embodiment of the invention.
FIGS. 11a-b show carving of horizontal and vertical grooves according to embodiments of the invention.
A first embodiment of floorboards 1, 1' provided with a mechanical locking system according to the invention is shown in FIGS. 2a-2d.
A building panel is shown that in this embodiment is a floorboard comprising a surface 2 attached to, or of, a core 3. The floorboard is provided with a locking system for vertical and horizontal locking of a first 1 and a second edge 1' of adjacent panel edges. The upper parts of two edges 1,1' of two joined floorboards together define a vertical plane VP. The vertical plane is perpendicular to a horizontal plane HP that is parallel to the panel surface. The locking system is configured to lock the edges 1, 1' by angling two adjacent edges relative each other. The locking system comprises a tongue 10 made in one piece with said core 3 that cooperates with tongue groove 9 in the adjacent edge 1' for vertical locking. The tongue groove 9 comprises a lower lip 9a and an upper lip 9b above the lower lip. The first edge 1 comprises a strip 6 made in one piece with the core 3 and provided with a locking element 8 which cooperates for horizontal locking with a downwardly open locking groove 14 formed in the second adjacent edge 1'. The tongue 10 is located on the first edge 1 above the strip 6 and protrudes outwardly beyond the vertical plane VP. FIG. 2b shows that the tongue 10 and the tongue groove 9 comprise upper 12 and lower 13 cooperating vertically locking surfaces. The locking element 8 and the locking groove 14 comprises cooperating horizontally locking surfaces 15 that lock horizontally and prevents a horizontal separation of the adjacent edges 1, 1'.
The geometry of an angling locking system is limited in many respects by the rotating movement that is needed to accomplish a locking. The locking surfaces are, during the final stage of the angling motion, rotated along circles C1, C2, which have a centre point at the vertical plane in the upper part of the joint edges. A tangent line defines the "free angle" A that is the angle when the edges may be locked and separated without any locking surfaces that overlap each other and prevents such locking or disconnection. The free angle A increases when the locking element 8 is closer to the surface and/or more distant horizontally to the vertical plane VP. This means that a low locking angle makes it possible to design compact and cost efficient locking system. However this has a negative effect on the locking strength and the final guiding into a locked position. Over angling with locking angles LA higher than the free angle may be used if the locking surfaces are small and the material is partly compressible. Generally the horizontally locking surfaces 15 should comprise a locking angle of more than about 30 degrees in order to provide sufficient strength and guiding. Higher locking angles are even more preferable and a high quality locking system requires generally a locking angle of 45-60 degrees. Locking systems with higher locking angles that may be up to 90 degrees provides very strong locking. All such locking angles may be obtained with a locking system according to certain embodiments of the described invention.
The tongue 10 and the tongue groove 9 should also be formed and adapted to the rotation during the final locking step. Rounded locking surfaces are optimal for a locking with angling but are in practice not suitable to use due to production tolerance. The ideal geometry is therefor essentially plane locking surfaces parallel with the surface that allow that the rotating tools may be displaced horizontally without any effect on the vertical position of the upper edges. The locking system has therefore in this embodiment preferably a lower lip 9a located under the tongue 10 that extends beyond the upper lip 9b and that allows forming of plane vertically locking surfaces 12, 13 that are essentially parallel with the horizontal plane HP. The tongue 10 and the tongue groove 9 comprises preferably upper 12 and lower 13 vertically locking surfaces that are essentially parallel with the horizontal plane HP and offset horizontally such that a part of the upper vertically locking surfaces 12 are closer to the locking element 8 than the lower vertically locking surfaces 13.
The horizontal extension TE of the tongue 10 is larger than the horizontal extension LE of the lower lip 9a extending beyond the upper lip 9b. The locking system may also be formed with a lower lip 9b that is not extending beyond the upper lip 9b or even with an upper lip 9b that protrudes horizontally beyond the lower lip 9a. Having the eventual extension LE of the lower lip 9b as small as possible may limit the material waste. It is preferred that the extension of the lower lip 9a does not exceed more than about 0.5 times the extension TE of the tongue 10. A small extending lower lip 9b will not create additional waste since the saw blade must generally cut at a small distance from the edge in order to allow a final machining of the edges that removes chipping caused by the saw. This cutting distance to the final edge is also used to machine and form "banana shaped" edges into a straight edge. A small extension LE of about 1 mm will therefore not increase the material waste but may be used to form locking surfaces and/or guiding surfaces in the lower lip 9a. A strong vertical locking force may be obtained in a wood or HDF core with vertically locking surfaces 12, 13 that comprises a horizontal extension of about 1 mm and even less for example 0.5 mm may be sufficient in some applications.
The tongue 10 and the groove 9 comprises preferably guiding surfaces 17a, 17b that are in contact with each other during angling when an edge portion EP of the second edge 1' is in contact with the strip 6 and/or the locking element 8 as shown in FIG. 2c
The guiding surfaces 17a, 17a', 17b, 17b' are preferably inclined relative the vertical plane VP and may be located on the upper and/or lower parts of the tongue 10 and the tongue groove 9. The guiding surfaces may also be rounded. At least two cooperating guiding surfaces 17a, 17b should preferably be in contact with each other when the second edge 1' is position in an angle of about 10-20 degrees against the horizontal plane and with an edge portion EP in contact with the strip and/or the locking element as shown in FIG. 2c.
FIGS. 3a-3f show that the locking system may more compact if the locking element 8 is moved towards the upper part of the floorboard.
FIG. 3c shows that the horizontally locking surfaces 15 may be located both below and above the horizontal strip plane HPS.
FIG. 3e shows that the horizontally locking surfaces 15 may also be located above the horizontal strip plane HPS. The locking angle LA is in this embodiment about 60 degrees. The free angle is about 50 degrees which means that this locking system comprises an over angling of about 10 degrees. The strip 6 comprises a rear side 6b, which is somewhat angled upwards and where the balancing layer and/or the core has been removed. This increases the flexibility of the strip and allows a small bending during locking and unlocking. It may also be used to create a pre-determined flexibility of the strip that may be used to create a pre tension inwardly and upwardly. This may be used to increase the angle of the horizontally locking surfaces and to eliminate some production tolerances. The floorboards may also be connected to the sub floor by nailing down and the tongue 10 provides a strong base for a nail 24. A nailing groove 26 may be formed on the rear side in order to prevent splitting of the rear side.
FIGS. 4a-4f describe embodiments of the invention. FIG. 4a shows that the locking system may be formed without a protruding lower lip and without a space between the strip 6 and the lower part of the adjacent edge. FIG. 4c shows that vertical locking may be obtained with lower vertically locking surfaces 13 located on the lower part of the tongue 10 and on the upper part 16 of the strip 6 and the lower part of the second edge 1'.
FIGS. 5a-b show that it is also possible to use only the lower vertically locking surfaces 13 and the horizontally locking surfaces 15 for the vertical locking. There may be a space S over the tongue 10 and between the upper part of the strip 6 and the lower part of the second edge 1'. The strip may be used to create a pre tension P inwardly P1 and upwardly P2 with the inclined locking surfaces 15 at the locking element 8. This pre tension may create a pressing force P3 that presses the lower locking surface 13 together. The strip is slightly bended downwards in locked position. This makes it possible to eliminate the need for tight production tolerances even further. Only the position of the lower locking surfaces 13 must be accurately controlled in order to produce a floor without so called "over wood" at the upper joint edges.
A locking angle of about 40-60 degrees is preferable to create such horizontal and vertical pre tension. The vertical pre tension may also be created by an upper part of the locking element 8a that presses against an inner part of the locking groove 14a.
FIG. 5b shows that essentially the same joint geometry may be used even if the floor thickness is increased. The lower part of the strip 6b may be such that the strip thickness is reduced. Alternatively a horizontal groove may be formed in the strip under the locking element in order to increase the flexibility.
FIGS. 6a-6g show several production methods of dividing a board. The board may be a laminate board comprising a core 3, an upper surface 2, preferably comprising a decorative layer, and a lower surface, preferably comprising a balancing layer, into a first and a second panel, with first and second adjacent edges 1,1'. Two adjacent edges 1,1' are formed comprising a locking system that locks vertically and horizontally. The first and the second panel may be e.g. building panels or floor panels.
FIG. 6b shows breaking or splitting that may be obtained by angling or pressing apart the edges 1, 1'. This method is very suitable when HDF is used as a core since the fibres are oriented horizontally and the crack is essentially horizontal. The same method may be used in a plywood core with different layer that may be design to create a controlled crack along one of the veneers. Preferably the fibre orientation is essentially oriented from one groove towards the other groove.
The methods of dividing may also comprise the step of cutting by a fixed tool or fixed tools, such as a knife(s) 21, and/or scraping and/or carving tool(s) 22, as shown in FIG. 6c.
FIG. 6d shows that the first vertically open groove may be formed by a rotating saw blade 20 and the second vertically open groove may be formed by a scraping or carving tool 22. FIG. 6e shows that a knife 21 may be used to divide the first and second panel.
FIGS. 6f and 6g shows an embodiment including forming of the first vertically open groove and of the second vertically open groove that overlap each other. The second vertically open groove may be formed by a sawblade and the first vertically groove by a scraping or carving tool 22. The step of splitting or forming of the horizontal groove is not required in this embodiment
FIGS. 7a and 7b shows that the final separation may be made with a band saw 23 that cuts the core. Such a separation gives a very controlled cut and may be used in materials that are difficult to split, cut or carve.
FIG. 7c shows an embodiment for dividing a board to a first panel (1) and a second panel 1' by a by displacing the board past a fixed tool 22, such as a carving or scraping tool. The board may be provided with a balancing layer and/or a decorative layer and a fixed tool makes it possible to sort and dispose into separate containers chips from the core and the balancing layer and/or the decorative layer. The chips are preferably removed by several compressed air nozzles. Adjacent edges of the first and the second panel are preferably vertically overlapping and comprise a lower protruding part at a first edge of the first panel and a lower groove at a second edge of the second pane. A mechanical locking system, e.g. as described herein, may be formed at the adjacent edges by e.g. milling, carving or scraping. A locking element may be formed at the lower protruding part that is configured to cooperate with a locking groove, which may be formed at the lower groove. The vertically overlapping edges may reduce the waste of the board material relating to the dividing of the board and the forming the mechanical locking system. The method illustrated in FIG. 7c is preferably used for dividing MDF or HDF boards or boards comprising plastic, such as PVC.
FIG. 8a show a preferred locking system with a tongue 10 on the strip side 1. FIG. 8b show that the edges 1, 1' can obtain a relative position such that the upper surfaces 2 are positioned along the same horizontal plane HP and such that an edge part EP of one of the adjacent edges is located vertically above the upper part 8a of the locking element 8 and that there is a vertically extending space S of at least about 0.5 mm between the locking element 8 and the whole adjacent edge which is located above the locking element 8. The space S may be smaller but this makes the final separation much more costly and complicated.
Such edge geometry as shown in FIG. 8b makes it possible to divide the board into floor panels with a carving tool, which may have sufficient size in order to divide the board in high speed and with a sufficient accuracy and tool lifetime. FIG. 8c show that the overlapping OL of the final machined edge portions may be even larger if the joint geometry is such that the necessary space S above the locking element 8b exists on and along the vertical plane VP. An even larger overlapping and cost saving may be reached if the space S exists when the edge part EP is located at the vertical plane VP and vertically above one of the horizontally locking surfaces 15a on the locking element 8.
FIG. 8e show that the first 19 and/or the second 18 vertically open groove may be formed by a rotating saw blade 20 and/or a carving tool 22. In this preferred embodiment the second vertically groove 18 is formed by a rotating saw blade 20 and the first by a carving tool 22a.
It is preferred that second groove 18 is made by sawing by the rotating saw blade 22, and that the first groove 19 is made before the cutting of the second groove 18.
Such non-linear separation combined with overlapping edges OL may be used to decrease material waste W in all types of locking systems. The material waste W in a laminate floor may be less than the floor thickness T. It is possible to reduce the waste to about 5 mm and less in a laminate floor with a thickness of about 6-12 mm.
FIG. 9a-9f show that considerable material waste W savings may be reached with a nonlinear panel separation and with overlapping edges OL even if the tongue 10 is formed on the second edge 1' as in conventional locking systems as shown in FIGS. 9a-9b. FIG. 9b shows that the waste W may be decreased with two offset vertical grooves and with a small carving. FIG. 9c shows that it is possible to modify the locking system such that it may be compatible with the old locking system and that an increased overlapping of the edges may be obtained as shown in FIG. 9d. A part of the lower part of the tongue 10 and the upper outer part of the locking element 8 may be removed by a small rotating milling tool that may be angled or more preferably by a carving tool such that a space S may be created when the edges 1, 1' are in an overlapped position as described above. It is preferred that the space S is larger above an outer part of the locking element than above the top of the locking element such that a strong and rather large carving tool edge 22b may be used to divide the panels. FIG. 9e-9f show that further cost savings and a larger overlapping may be reached if the tongue 10 is moved upwards.
FIG. 10a shows a carving tool with four carving teeth 30a-30d. The teeth are connected to a tool body 31.
FIG. 10b shows that the tool body may be slightly inclined such that each tooth carves a depth of for example 0.2 mm when the panel is displaced in the feeding direction against the fixed carving tool. Each tooth may be designed to carve a distance of for example 0.2-0.6 mm in a wood based core. HDF is especially suitable to be formed with carving.
FIG. 11a shows how the first tooth 30a cuts the first cut under the backing laminate 11. The tooth edges comprise 3 cutting edges that formed the groove bottom 31a and two sidewalls 31b, 31c. It is preferred that the teeth have gradually smaller width along the feeding direction. Slightly V shaped teeth may be used to provide a more accurate cut with reduced chipping of the laminate. This reduces tool wear and the heat that may be created at high feeding speeds.
FIG. 11b shows carving of an essentially horizontal groove that provides the final separation. The groove angle in the final groove may vary from zero to 45 degrees against the horizontal plane HP.
It is possible according to embodiments of the invention to separate the panels and to form the completed locking system with a tongue 10, a tongue groove 9, a strip 6, a locking element 8 and a locking groove 14, as shown in FIG. 8e by just using carving tools. Bevels or decorative grooves at the upper edges may also be formed by carving.
1. A method for dividing a board into a first panel (1) and a second panel (1'), wherein the method comprises the step of displacing the board and dividing the board by a fixed tool (22), such as scraping or carving tool.
2. The method as in embodiment 1, wherein the method comprises the step of forming a first vertically open groove (19), through a rear side of the board and an offset second vertically open groove (19), through the front side of the board.
3. The method as in embodiment 2, wherein the first vertically open groove (18) is formed by a fixed tool or a saw blade.
4. The method as in any one of embodiments 2 or 3, wherein the second vertically open groove (19) is formed by a fixed tool or a saw blade.
5. The method as in any one of the embodiments 2-4, wherein the method comprises the step of forming, by a fixed tool (22b), a first horizontally extending groove that extends horizontally under the front side and/or the rear side of the board.
6. The method as in embodiment 5, wherein the first horizontally extending groove extends from the second groove (19) towards the first groove (18).
7. The method as in embodiment 5, wherein the first horizontally extending groove extends from the first groove (18) towards the second groove (19).
8. The method as in any one of the embodiments 5-7, wherein the first horizontally extending groove connects the first vertically open groove and the second vertically open groove.
9. The method as in embodiment 5, wherein the method comprises the step of forming, by a fixed tool (22b), a second horizontally extending groove that extends horizontally under the front side and/or rear side of the board, wherein the second horizontally extending groove extends from the second vertically open groove towards the first vertically open groove and the first horizontally extending groove extends from the first vertically open groove towards the second vertically open groove.
10. The method as in embodiment 9, wherein the first horizontally extending grooves is connected with the second horizontally extending grooves.
11. The method as in any one of the embodiments 2-10, wherein the forming of the second vertically open groove (18) is made by sawing by a rotating saw blade (22).
12. The method as in embodiment 11, wherein the forming of the first vertically groove (19) is made before the cutting of the second vertically open groove (18) and wherein the first vertically open groove is made by a fixed tool.
13. The method as in any one of the preceding embodiments, wherein the method comprises the step of arranging the board on a carrier, such as a conveyor belt/chain, preferably provided with a pushing device, such as a cam or ridge.
14. The method as in embodiment 7, comprising the step of arranging the front side of the board against the carrier and facing downwards.
15. The method as in any one of the preceding embodiments, wherein the fixed tool comprises several carving teeth, arranged for forming at different vertical and/or horizontal positions.
16. The method as in any one of the preceding embodiments, wherein the method comprises the step of removing the chips created by the fixed tool by compressed air, preferably by a compressed air nozzle, and preferably collected by a suction device.
17. The method as in any one of the preceding embodiments, wherein the board is a laminated board, such as a floor element (1b).
18. The method as in embodiment 17, wherein the laminated board comprises a core (3) provided with a decorative surface layer (2) and a balancing layer.
19. The method as in embodiment 18, comprising the step of removing the chips created by the forming, preferably by several compressed air nozzles, and preferably sorting and disposing into separate containers the chips from the core and the balancing layer and/or the decorative layer.
20. A method of forming a mechanical locking system for locking of a first and a second panel, wherein the method comprises the steps: dividing a board into a first and a second panel according to the method as in any one of the embodiments 1-19 and thereby forming a lower protruding part at a first edge of the first panel and a lower groove at a second edge of the second panel; forming a locking element (8) at the lower protruding part; and forming a locking groove (14) at the lower groove.
21. Building panels, each comprising an upper surface (2) and a core (3), provided with a locking system for vertical and horizontal locking of a first edge of a first building panel (1) to an adjacent second edge of a second building panel (1'), wherein upper parts of the first and the second edge in a locked position together define a vertical plane (VP), which is perpendicular to a horizontal plane (HP), which is parallel to the upper surface (2) of the first and the second building panel (1, 1'), said locking system is configured to enable assembling of the first and the second edge by angling the first and the second building panel (1, 1') relative each other, the locking system comprises a tongue (10), made in one piece with said core (3), and a tongue groove (9) configured to cooperate for vertical locking, and a strip (6), made in one piece with the core, which is provided with a locking element (8) configured to cooperate for horizontal locking with a downwardly open locking groove (14) formed in the second edge (1'), the edges (1, 1') can obtain a relative position with a distance between the first and the second edge, characterised in
that there is a vertically extending space S of at least about 0.5 mm between the locking element and all parts of the second which edge, which is located above the locking element.
22. The building panels as in embodiment 21, wherein the edge part (EP) is located at the vertical plane (VP).
23. The building panels as in embodiment 21 or 22, wherein the locking element (8) comprises a locking surface (15a) that cooperates with a locking surface at the locking groove (14) for horizontal locking and wherein the edge part (EP) is located vertically above the locking surface (15a) of the locking element.
24. The building panels as in any one of the preceding embodiments 21-23, wherein the space S is larger than 0.6 mm.
25. The building panels as any one of the preceding embodiments 21-25, wherein the space S is equal or larger above the outer part of the locking element than above the upper part of the locking element.
26. The building panels as in any one of the preceding embodiments 21-25, wherein the edge portion EP comprises a lower part that is inclined downwards and inwardly.
27. The building panels as in any one of the preceding embodiments 21-26, wherein the edge part comprises a lower part of the tongue (10)
28. The building panels as in any one of the preceding embodiments 21-28 wherein the building panel is a floor board.
29. Building panels, comprising a surface (2) and a core (3), provided with a locking system for vertical and horizontal locking of a first edge of a first building panel (1) to an adjacent second edge of a second building panel (1'), wherein upper parts of the first and the second edge in a locked position together define a vertical plane (VP) perpendicular to a horizontal plane (HP), which is parallel to the surface (2), said locking system is configured to enable assembling of the first and the second edge by angling the first and the second building panel (1, 1') relative each other, the locking system comprises a tongue (10), made in one piece with said core (3), and a tongue groove (9) configured to cooperate for vertical locking, the first edge (1) comprises a strip, made in one piece with the core, which is (6) provided with a locking element (8), which is configured to cooperate for horizontal locking with a downwardly open locking groove (14), which is formed in the second edge (1'), characterised in that:
that the tongue (10) protrudes outwardly beyond the vertical plane (VP),
that the tongue groove (9) comprises an upper lip (9b), and
that the horizontal extension (LE) of the lower lip (9a), in relation to the upper lip (9b), is smaller than the horizontal extension (TE) of the tongue (10).
30. The building panels as in embodiment 29, wherein the cooperating horizontally locking surfaces (15) lock the edges both horizontally and vertically with horizontal (P1) and vertical (P2) pre tension.
31. The building panels as in embodiment 29 or 30, wherein the tongue (10) cooperates with the upper lip (9b) at upper vertically locking surfaces (12).
32. The building panels as in any one of the preceding embodiments 35-37, wherein the tongue (10) and the tongue groove (9) comprises upper (12) and lower (13) vertically locking surfaces that are essentially parallel with the horizontal plane (HP) and offset horizontally such that a part of the upper vertically locking surfaces (12) are horizontally closer to the locking element (8) than the lower vertically locking surfaces (13).
33. The building panels as any one of the preceding embodiments 29-32, wherein the lower lip (9a) protrudes beyond the upper lip (9b) and the vertical plane (VP).
34. The building panels as in any one of the preceding embodiments 29-33, wherein the horizontal extension (TE) of the tongue (10) is at least about twice as large than the horizontal extension (LE) of the lower lip (9a).
35. The building panels as in any one of the preceding embodiments 29-34, wherein the tongue (10) and the tongue groove (9) comprise guiding surfaces (17a, 17b) that are configured to be in contact with each other, during the assembling by angling, when an edge part (EP) of the second edge (1') is in contact with the strip (6) and/or the locking element (8).
36. The building panels as in any one of embodiments 29-35, wherein the guiding surfaces (17a 17b) are inclined relative the vertical plane (VP) and located on the upper and/or lower parts of the tongue (10) and the tongue groove (9)
37. The building panels as in any one of the preceding embodiments 29-35, wherein the horizontal locking surfaces are located below a horizontal strip plane (HPS) that intersects an upper part (6a) of the strip (6), which is located essentially vertically under the outer part of the tongue (10)
38. The building panels as in any one of the preceding embodiments 29-37, wherein the horizontal locking surfaces are located both below and above the horizontal strip plane.
39. The building panels as in any one of the preceding embodiments 29-38, wherein the horizontal locking surfaces are located above the horizontal strip plane.
40. The building panels as in any one of the preceding embodiments 29-39, wherein the locking system comprises a space (S) between the upper part of the strip (6) and an edge portion (EP) of the second panel (1') located essentially under the tongue (10).
41. The building panels as in any one of the preceding embodiments 29-40, wherein the upper vertically locking surfaces are offset horizontally in relation to the horizontally locking surfaces.
42. The building panels as in any one of the preceding embodiments 29-42, wherein the vertically and horizontally locking surfaces are offset horizontally with a horizontal distance (D) that is larger than the horizontal extension (TE) of the tongue (10).
43. The building panels as in any one of the preceding embodiments 29-42, wherein the core comprises HDF, particle board, plastic or plywood material.
44. The building panels as in any one of the preceding embodiments 29-43, wherein the horizontally locking surfaces (15) have a locking angle of about 40-60 degrees against the horizontal plane (HP).
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