Floor Covering And Locking Systems

Abstract

Abstract of the Disclosure Floorboards with a mechanical locking system that allows movement between the floorboards when they are joined to form a floating floor.

Description

Detailed Description of the InventionCross-Reference to Related Applications[0001] The present application claims priority of Swedish Patent Application No. 0400068-3, filed in Sweden on January 13, 2004 and U.S. Provisional Application No. 60 / 537,891, filed in the United States on January 22, 2004, the entire contents of which are hereby incorporated herein by reference.Field of the Invention[0002] The invention relates generally to the technical field of locking systems for floorboards. The invention concerns on the one hand a locking system for floorboards which can be joined mechanically and, on the other hand, floorboards and floor systems provided with such a locking system and a production method to produce such floorboards.[0003] The present invention is particularly suited for use in floating wooden floors and laminate floors, such as massive wooden floors, parquet floors, floors with a surface of veneer, laminate floors with a surface layer of high pressure laminate or dir...

AI Technical Summary

Benefits of technology

[0021] A first object of the present invention is to provide a floating floor of rectangular floorboards with mechanical locking systems, in which floor the size, pattern of laying and locking system of the floorboards cooperate and allow movements between the floorboards. According to an embodiment of the invention, the individual floorboards can change in shape after installation, i.e., shrink and swell due to changes in the relative humidity. This can occur in such a manner that the change in shape of the entire floor surface can be reduced or preferably be eliminated while at the same time the floorboards remain locked to each other without large visible joint gaps.

[0022] A second object is to provide locking systems, which allow a considerable movement between floorboards without large and deep dirt-collecting joint gaps and / or where open joint gaps could be excluded. Such locking systems are particularly suited for moisture sensitive materials, such as wood, but also when large floating floors are installed using wide and / or long floorboards.

[0027] According to several preferred embodiments of this invention, it is an advantage if the floor comprises rather small floorboards and many joints, which could compensate swelling and shrinking. The production tolerances should be rather small since well-defined plays and joint openings are generally required to produce a high quality floor according to the invention.

[0030] The most used equipment is an end tenor, double or single, where a chain and a belt are used to move the floorboard with great accuracy along a well defined feeding direction. Pressure shoes and support unites are used in many applications together with the chain and the belt mainly to prevent vertical deviations. Horizontal deviation of the floorboard is only prevented by the chain and the belt.

[0032] A third object of the present invention is to provide equipment and production methods which make it possible to produce floorboards and mechanical locking systems with an end tenor but with better precision than what is possible to accomplish with known technology.

[0033] Equipment for production of building panels, especially floorboards, comprises a chain, a belt, a pressure shoe and a tool set. The chain and the belt are arranged to displace the floorboard relative the tool set and the pressure shoe, in a feeding direction. The pressure shoe is arranged to press towards the rear side of the floorboard. The tool set is arranged to form an edge portion of the floorboard when the floorboard is displaced relative the tool set. One of the tools of the tool set forms a guiding surface in the floorboard. The pressure shoe has a guiding device, which cooperates with the guiding surface and prevents deviations in a direction perpendicular to the feeding direction and parallel to the rear side of the floorboard.

Problems solved by technology

The drawback is that the continuous floor surface must as a rule be limited even in the cases where the floor consists of relatively dimensionally stable floorboards, such as laminate floor with a fiberboard core or wooden floors composed of several layers with different fiber directions.

Without such a division, it is a risk that the floor when shrinking will change in shape so that it will no longer be covered by baseboards.

Also the load on the locking system will be great since great loads must be transferred when a large continuous surface is moving.

The load will be particularly great in passages between different rooms.

They collect dirt, give an unwanted appearance and are rather expensive.

Due to these limitations on maximum floor surfaces, laminate floorings have only reached a small market share in commercial applications such as hotels, airports, and large shopping areas.

Even if such an installation would be possible, the continuous floor surface must be restricted significantly.

This method of installation involving attachment to the subfloor has, however, a number of considerable drawbacks.

The main drawback is that as the floorboards shrink, a visible joint gap arises between the boards.

The joint gap can be relatively large, especially when the floorboards are made of moisture sensitive wood materials.

The installation methods are time-consuming, and in many cases the subfloor must be adjusted to allow gluing / nailing to the subfloor.

Small floorboards are however difficult to produce with the required tolerance since they have a tendency to turn in an uncontrolled manner during machining.

The main reason why small floorboards are more difficult to produce than large floorboards is that large floorboard has a much large area, which is in contact with a chain and a belt during the machining of the edges of the floorboards.

The problem is that in many applications this is not sufficient, especially when panels are small.

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