Source: http://patents.com/us-9476207.html
Timestamp: 2018-11-16 07:22:01
Document Index: 490380826

Matched Legal Cases: ['arts 33', 'art 9', 'art 8', 'arts 33', 'arts 33', 'arts 33']

US Patent # 9,476,207. Panel - Patents.com
United States Patent 9,476,207
Cappelle , et al. October 25, 2016
Cappelle; Mark (Staden, BE), Devos; Pieter (Koolskamp, BE)
Family ID: 1000002187573
14/370,284
WO2013/102803
US 20150047284 A1 Feb 19, 2015
61664330 Jun 26, 2012
61585798 Jan 12, 2012
Jan 5, 2012 [BE] 2012/0007
Current CPC Class: E04F 15/02038 (20130101); E04C 2/10 (20130101); E04C 2/30 (20130101); E04F 15/02 (20130101); E04F 15/02005 (20130101); E04F 15/02022 (20130101); E04F 15/04 (20130101); E04C 2002/004 (20130101); E04F 2015/02122 (20130101); E04F 2201/0138 (20130101); E04F 2201/0146 (20130101); E04F 2201/0523 (20130101); F16B 5/008 (20130101); F16B 5/0056 (20130101)
Current International Class: E04F 15/02 (20060101); E04C 2/30 (20060101); E04C 2/10 (20060101); E04F 15/04 (20060101); F16B 5/00 (20060101); E04C 2/00 (20060101)
Field of Search: ;52/582.1,582.2,584.1,586.1,586.2,592.1
8024904 September 2011 Hannig
8132384 March 2012 Hannig
8621814 January 2014 Cappelle
8631621 January 2014 Hannig
8978334 March 2015 Engstrom
2008/0010938 January 2008 Hannig
2012/0124932 May 2012 Schulte
2013/0008119 January 2013 Vermeulen
2014/0366475 December 2014 Cappelle
200 08 708 Sep 2000 DE
201 12 474 Dec 2002 DE
299 24 454 May 2003 DE
20 2007 000 310 Apr 2007 DE
1 159 497 Sep 2005 EP
1 415 056 Jan 2006 EP
1 818 478 Aug 2007 EP
H07-300979 Nov 1995 JP
515 324 Jul 2001 SE
2004/079130 Sep 2004 WO
2005/054599 Jun 2005 WO
2006/043893 Apr 2006 WO
2006/104436 Oct 2006 WO
2007/008139 Jan 2007 WO
2007/079845 Jul 2007 WO
2009/066153 May 2009 WO
2010/082171 Jul 2010 WO
WO 2010082171 Jul 2010 WO
2012/049577 Apr 2012 WO
Search Report of Belgium Application No. BE 201200007, filed Jan. 5, 2012. cited by applicant .
International Search Report of International Application No. PCT/IB2012/056491, mailed Feb. 25, 2014. cited by applicant.
1. A panel, which, at least at two opposite sides, comprises coupling parts, with which two of such panels can be brought in a coupled condition; wherein these coupling parts form a horizontally active locking system and a vertically active locking system; wherein the horizontally active locking system comprises a male part and a female part, which allow that two of such panels can be connected to each other at said sides by providing one of these panels with the pertaining male part, by means of a downward movement, in the female part of the other panel; wherein the vertically active locking system comprises a locking element, which, in the form of an insert, is provided in the side having the male part; wherein this locking element comprises at least a pivotable lock-up body, said lock-up body being directed upward; wherein the lock-up body, at one extremity, forms a stop-forming locking portion, which can cooperate with a locking portion of a similar coupled panel, the locking element comprising a strip which is attached in a recess in the panel by means of an attachment portion which retains the strip in the recess, wherein said pivotable lock-up body in the non-coupled condition extends horizontally at least for a part underneath the attachment portion, however, wherein a vertical mutual distance is maintained between the lock-up body and the attachment portion; wherein the locking element comprises an elastic bending zone, which forms a connection between the attachment portion and the pivotable lock-up body; wherein the bending zone is a hinge portion; and wherein the bending zone and the lock-up body are formed from synthetic material with different material characteristics such that a material of the bending zone is more flexible than a material of the lock-up body.
4. The panel of claim 1, wherein said pivotable lock-up body, in the non-coupled condition, adopts an orientation which forms an angle of less than 60.degree. with the panel surface.
7. The panel of claim 1, wherein the lock-up body defines a surface which, when performing said downward movement, comes into contact with an upper edge of the other panel, wherein the surface, when said contact occurs, shows a tangent line forming an angle (A3) of 45.degree. or less with an upper surface of the panels.
8. The panel of claim 1, wherein the lock-up body has a surface which, when performing said downward movement, comes into contact with an upper edge of the other panel, wherein the surface, when contact is effected, shows a tangent line forming an angle (A3) of 20 to 45.degree. with an upper surface of the panels.
The couplings of the first type are also known as so-called "drop-in" systems. Floor panels which are provided therewith at two opposite sides are known, amongst others, from CA 991.373 and JP 07-300979. As becomes evident from these patent documents, such "drop-in" systems often are applied on a first pair of opposite sides of the floor panels only, whereas then on the second pair of opposite sides coupling parts are applied, which, in the coupled condition of two floor panels, provide for a vertical as well as for a horizontal locking and which allow that two of such floor panels can be coupled to each other by means of an angling movement. Floor panels with such a combination of coupling parts offer the advantage that they can be easily installed in rows in a successive manner, simply by coupling each newly to install floor panel to the preceding row of floor panels by means of the angling movement and by providing for, during the angling down, that such floor panel at the same time also engages in an already installed preceding floor panel of the same row. Thus, installing such floor panel requires only an angling and putting down-movement, which is a particularly user-friendly installation technique.
The invention relates to panels, and in particular to floor panels, which are of the specific type: which, at least at two opposite sides, comprises coupling parts by which two of such floor panels can be coupled to each other; wherein these coupling parts form a horizontally active locking system and a vertically active locking system; wherein the horizontally active locking system comprises a male part and a female part, which allow that two of such floor panels can be coupled to each other at the aforementioned sides by providing one of these floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel; wherein the vertically active locking system comprises a locking element, which, in the form of an insert, is provided in one of the respective sides; wherein this locking element comprises at least a lock-up body, preferably a pivotable lock-up body; and wherein the lock-up body, at one extremity, forms a stop-forming locking portion, which can cooperate with a locking portion of a similar coupled floor panel.
Floor panels of this type are known, amongst others, from the FIGS. 5-7, 8 and 9-11 of the aforementioned EP 1.415.056 B1. In these known embodiments, the locking portion, made in the form of an insert, consists of a synthetic material strip with an elastically bendable lip, which, when being bent, functions as a pivotable lock-up body. These known embodiments show the advantage that with a relatively simple construction a so-called "push-lock" connection can be realized which is active over the entire length of the synthetic material strip. However, practice has shown that this known embodiment is not always smoothly operable and that tolerances in a realized coupling sometimes are difficult to keep under control.
To this aim, the invention, according to a first aspect, relates to a panel, which, at least at two opposite sides, comprises coupling parts with which two of such panels can be brought in a coupled condition; wherein these coupling parts form a horizontally active locking system and a vertically active locking system; wherein the horizontally active locking system comprises a male part and a female part allowing that two of such panels, at said sides, can be connected to each other by providing one of these panels with the pertaining male coupling part by means of a downward movement in the female coupling part of the other floor panel; wherein the vertically active locking system comprises a locking element, which, in the form of an insert, is provided in one of the respective sides; wherein this locking element comprises at least a pivotable lock-up body; and wherein the lock-up body, at one extremity, forms a stop-forming locking portion, which can cooperate with a locking portion of a similar coupled panel, with the characteristic that said pivotable lock-up body, when the insert is provided in the recess, however, in the non-coupled condition, adopts an orientation which forms an angle of less than 60.degree., less than 50.degree. or still better of less than 45.degree. or of approximately 40.degree. with the panel surface. Herein, the orientation of the lock-up body, when the insert is provided in the recess, however, in the non-coupled condition, is determined by a line which, on the one hand, passes through the tangent point of the horizontal tangent through the support portion and, on the other hand, passes through the center point of the stop-forming locking portion. Herein, it is noted that the position of this center point is determined in coupled condition, whereas said line through this point and the orientation related thereto as such is determined in the non-coupled condition.
The, according to this first aspect, relatively flat orientation of the pivotable lock-up body entails new possibilities and is of particular interest for the design of compact locking systems. So, for example, it is possible with an orientation which deviates from the panel surface only to a limited extent, to apply a lock-up body which is relatively long compared to the thickness of the panel. The orientation of less than 60.degree. or less than 50.degree. results in a more gradual locking during the downward movement.
When the insert is provided in the male part and shows an upward-directed lock-up body, this lock-up body preferably, in the non-coupled condition, further comprises a surface which, when performing said downward movement, comes into contact with the upper edge of the other panel, wherein this surface, when said contact is made, has a tangent line which forms an angle of 20.degree. to 45.degree. with the upper surface of the panels. Such feature promotes a smooth coupling of two of such panels at the respective sides, also in the case when the upper edge at these sides is made straight, namely without chamfers or other deepened edges. Achieving a smooth coupling is particularly interesting with panels which comprise a decorative top layer comprising melamine or other thermo-hardening or other brittle transparent layers, such as layers on the basis of UV-hardened or electron beam-hardened lacquer. In such panels, having to tap on the panels for coupling them to each other best is avoided.
Preferably, said pivotable lock-up body, in coupled condition, adopts an orientation in which this lock-up body forms an angle with the panel surface which is larger than the angle formed in the non-coupled condition. Preferably, the difference between both angles is at least 5.degree. or even more than 10.degree.. In this manner, a tensioning effect is obtained between the locking portion of the lock-up body and the locking portion of the coupled-thereto panel with which the lock-up body works in conjunction.
Preferably, said pivotable lock-up body, in coupled condition, adopts an orientation in which this lock-up body forms an angle with the panel surface of less than 90.degree., however, more than 50.degree..
As aforementioned, the lock-up body preferably comprises a press-on portion which effects laterally on the lock-up body. Preferably, the press-on portion shows one or more of the following features: that it consists of an elastic material; that it consists of an elastic material which, as such, is more flexible than the material of the lock-up body, which preferably is realized, by means of coextrusion, in one piece with the lock-up body; that it consists of a foldable or bendable portion; that it is provided with an attachment portion; that it is provided with an attachment portion in the form of a clamped part; that it is provided with a portion with which it is glued to the panel; that, seen in cross-section, it consists of an elastically bendable leg; that it is provided with one or more elastic bending zones, which either form a connection between the actual press-on portion and the lock-up body, or a connection between several portions of the press-on portion.
It is clear that the third aspect extends to all "push-lock" systems which use a separate locking element which is or will be provided in a recess in the edge of a floor panel, and is not restricted exclusively to locking elements with a pivotable lock-up body.
Preferably, said pivotable lock-up body, in the non-coupled condition, however, provided in the recess, adopts an orientation which forms an angle of less than 60.degree. with the panel surface.
Also according to the above important embodiment, the pivotable lock-up body, in the non-coupled condition, however, provided in the recess, comprises a surface which, when performing said downward movement, comes into contact with the upper edge of the other panel, wherein this surface, when this contact is effected, has a tangent line which forms an angle of 20 to 45.degree. with the upper surface of the panels. This measure promotes a smooth mounting of the panels.
Further, the lock-up body 14, in the example, between the locking portion 17 and the support portion 20, in other words, between its extremities 16 and 23, as such is free from hinge portions and bending sections. To this aim, the lock-up body 14 thus is made relatively thick and preferably forms a rigid body, by which is meant that the lock-up body 14 cannot undergo any noticeable deformations between its extremities when pressures that usually can occur with "push-lock" couplings are exerted thereon.
FIG. 6 clearly illustrates that the floor panel of the example shows the characteristics of the first aspect in that the lock-up body 14, in the non-coupled condition, adopts an orientation which forms an angle A with the panel surface of less than 50.degree.. As represented here, said orientation is determined by a line 27 which, on the one hand, passes through the tangent point 28 of the horizontal tangent line 29 through the support portion 20, and, on the other hand, passes through the center point 30 of the stop-forming locking portion 17. Herein, it is noted that the position of this center point 30 is determined in coupled condition, for example, in the condition as represented in FIG. 3, whereas said line 27 through this point 30 and the tangent point 28 and the corresponding orientation and angle A as such is determined in the non-coupled condition.
In the case of rectangular floor panels, whether oblong or square, it is clear that coupling parts can also be provided on the second pair of opposite sides 31-32, which coupling parts, in coupled condition, preferably provide for a horizontal as well as vertical locking. These coupling parts at the second pair of sides can also be realized as a "push-lock" coupling, whether or not in accordance with the present invention. Preferably, however, at the second pair of sides 31-32 coupling parts will be applied which allow for a mutual coupling by means of an angling movement W between two floor panels 1 to be coupled and/or by means of a shifting movement which results in a snap connection. Such coupling parts are widely known from the state of the art and are described, for example, in WO 97/47834.
In the most preferred embodiment, at the second pair of sides 31-32 coupling parts 33-34 will be used which allow at least a connection by means of an angling movement W, as this allows to install the floor panels 1 in a simple manner, as illustrated in FIGS. 7 and 8. Then, a newly to install floor panel 1C can be angled with its side 31 into the preceding row of floor panels 1A in a simple manner, such just next to a preceding floor panel 1B in the same row. When angling the panel down, the male part of the newly to install floor panel 1C thus also will automatically engage in the female part of the preceding floor panel 1B, without having to perform another operation. Thus, in the case of oblong floor panels 1, it is preferred that the so-called "push-lock" connection then will be situated at the short sides 4-5.
FIGS. 9 to 11 represent a variant, wherein the vertically active locking system 7 comprises a locking element 12 which is provided on the side 3 in the form of an insert, more particularly is provided in a recess 13 provided in the female part 9 for this purpose. The insert comprises a downward-directed lock-up body 14, which can cooperate with an upward-directed stop-forming surface 19 on the male part 8. FIG. 11 clearly represents that the orientation of the lock-up body 14 in the non-coupled condition has an angle A with the panel surface of less than 50.degree..
FIG. 12 further represents that the lock-up body 14 in coupled condition adopts an orientation which forms an angle A1 which is larger than the also above-defined angle A. The difference is at least 5.degree. and in this case even more than 10 or 15.degree.. In this manner, a strong tensioning effect is obtained.
Preferably, said angle A1, as in the example of FIG. 12, is smaller than 90.degree. and preferably also smaller than 50.degree..
It is clear that the coupling according to the invention can be applied in combination with any floor panel 1, such as in so-called prefabricated parquet, more particularly in so-called "engineered wood". In such case, this relates to floor panels which are composed of a core material composed of strips, a top layer of wood, as well as a backing layer of wood. The top layer then consists of wood of a good quality, which functions as a visible decorative layer. The backing layer can consist of a cheaper wood species. The strips preferably also consist of a cheaper, for example, soft wood species. However, it is preferred that on the ends of the floor panels 1 strips of a material are applied which is relatively stable and is suitable for providing therein the desired profile forms, for example, milling them therein. In a practical embodiment, these strips consist of MDF (Medium Density Fiberboard) or HDF (High Density Fiberboard). It is clear that the invention can also be applied in combination with other forms of "engineered wood", for example, when the core consists of a single continuous MDF/HDF board or of a plywood board.
FIG. 19 illustrates a second possible embodiment of said eighth aspect, wherein said lock-up body 14 extends along said respective side 2 from at a distance D6 from the upper edge 57 of one of the remaining two opposite sides 31, wherein said remaining two opposite sides 31-32 comprise coupling parts 33-34, which allow that these coupling parts 33-34 can be provided in each other by means of a angling movement W, such as the coupling parts 33-34 of FIG. 8, wherein this angling movement W results in said downward movement M at the respective two opposite sides 2-3, and that said distance D6 is such that the first contact between the respective two opposite sides 2-3 at the location of said lock-up body 14 occurs in a position in which the planes of the panels 1 to be coupled enclose a mutual angle C of more than 145.degree. or still better of more than 160.degree..
Preferably, said contact surfaces 56, seen in a top view of the panel 1, globally extend in a direction forming an angle B with the upper edges 48, wherein this angle B is situated between 0.5.degree. and 5.degree., and still better between 1.degree. and 3.degree., as is the case in the example of FIG. 20.
Seen in the top view of this example, the contact surfaces 56 extend continuously according to a straight line over an operative distance D7 of more than 50% or here of even more than 75% of the width L1 of the decorative side or the usable surface of the panel 1. Also in the case of discontinuous contact surfaces 56 and/or of not straight, thus, curved contact surfaces, the overall operative distance D7 of the contact surfaces 56 preferably is maintained. By "operative distance D7" is meant that in a coupled condition of two panels 1 effectively a contact is created over this distance D7.
FIG. 23 further also represents that the lock-up body 14 has a surface 61 which, when performing said downward movement, comes into contact with the upper edge 48 of the other panel 1, wherein this surface 61, when this contact is effected, shows a tangent line 62 forming an angle A3 of 20 to 45.degree. with the upper surface of the panels 1. This measure promotes a smooth mounting of the panels 1.
FIG. 24 represents the insert which is applied in FIGS. 22 and 23. Said pivotable lock-up body 14, in the non-coupled condition, adopts an orientation which forms an angle A of less than 60.degree. with the panel surface.
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