Floor panels, as well as a method for producing floor panels and a cutting tool used therein

Abstract

A floor panel has a connecting portion in the form of a tongue and groove with locking surfaces. When two such panels are joined, an open space exists between the tongue and the lower lip when viewed vertically, and between the contact portion and contact area between the horizontally functioning locking surfaces when viewed horizontally. The lower side of the tongue in the open space includes a first surface. The top side of the lower lip in the open space includes a second surface parallel to the first surface. When two such panels are joined, at least one surface is perpendicular to the panel and intersects both the first surface of the first panel being joined and the second plane of the panel joined to the first panel.

Description

Technical Field

[0001] This invention relates to floor paneling and a method for manufacturing floor paneling. The invention also relates to cutting tools used in manufacturing such paneling and / or in the method. Background Technology

[0002] More specifically, the present invention relates to floor panels intended to form a floating floor cladding and capable of being joined together at their sides during installation by means of mechanical couplings. The invention may or may not be configured to be integral with the floor panels and provides interlocking of the floor panels in both the horizontal and vertical directions, for example as described in WO97 / 47834, WO01 / 98603, WO01 / 96688 and WO2008 / 010O60A1.

[0003] As shown in WO97 / 47834, the contour of such a connecting portion can be formed using material removal machining with at least two milling cutters. WO01 / 96688 discloses providing a beveled edge at the upper edge of the floor panel, thereby allowing the connecting portion to be formed using similar cutting tools for both thin and thick floor panels. However, the method disclosed in WO01 / 96688 only involves a vertical displacement of the overall contour of the connecting portion and does not allow for optimization of the contour relative to the thickness of the floor panel.

[0004] The method described in WO2008 / 010060A1 relates to a more efficient and / or more economical manufacturing method for a range of floor panels of different thicknesses, wherein the profile of the connecting portion can be optimized as specified above.

[0005] The method described in WO2008 / 010060A1 relates to a method for manufacturing a type of floor panel having connecting portions on at least two opposing sides, wherein when two such floor panels interact with each other, the connecting portions achieve locking in a vertical direction perpendicular to the plane of the floor panel and locking in a horizontal direction perpendicular to the respective side and in the plane of the floor panel; wherein the locking in the vertical direction is achieved by means of a tongue and groove connection, wherein the groove is defined by a lower lip and an upper lip, and wherein, in order to achieve locking in the horizontal direction, the connecting portion is provided with a locking portion that is a recess in the aforementioned lower lip. The locking portion, in conjunction with a protrusion on the underside of the tenon, forms a locking surface that functions at least horizontally when two such floor panels interact; wherein the locking surface formed on the side of the aforementioned recess is at least partially located in a portion of the lower lip extending beyond the upper lip; wherein the method includes at least the step of forming a connecting portion having the aforementioned groove; wherein the outline of the connecting portion consists of at least two parts, namely, a first part extending at least from the locking surface of the aforementioned recess to the rising side portion of the recess; and a second part extending at least from the underside of the aforementioned upper lip to the top side of the aforementioned lower lip. The method of WO2008 / 010060A1 is used to manufacture at least two series of floor panels, wherein the first series of floor panels differs from the second series of floor panels in at least the fact that they have different thicknesses; the two aforementioned portions of the outline of the connecting portion having the aforementioned groove are identically configured in both series of floor panels; and at least the aforementioned first portion of the outline in the second series of floor panels is produced at a position relative to the upper edge of the floor panel, which relative position is at least laterally displaced relative to its position in the aforementioned first series of floor panels. Summary of the Invention

[0006] The object of this invention is to provide floor panels that can be more easily produced in different thicknesses and can be easily joined together by means of angular adjustment. Another object of this invention is to describe a method that allows the production of floor panels of different thicknesses using the same cutting tool, wherein the floor panels can be easily joined together by means of angular adjustment. A further object of this invention is to describe the cutting tools that can be used to produce such floor panels and / or that can be used in this method.

[0007] A first aspect of the invention relates to floor panels. The floor panels have connecting portions on a first pair of opposing sides. When two such floor panels are joined together at their first pair of opposing sides, the connecting portions establish a lock in a vertical direction perpendicular to the plane of the floor panels and in a horizontal direction perpendicular to the respective sides and in the plane of the floor panels. The vertical locking is achieved using a tenon and groove connection, wherein the groove is defined by a lower lip and an upper lip. To achieve the horizontal locking, the connecting portions are provided with a locking portion in the form of a recess in the aforementioned lower lip and a protrusion on the underside of the tenon that mates with it. When two such floor panels are joined together, the locking portion forms a locking surface that functions at least horizontally, wherein the locking surface formed on the side of the recess is at least partially located within a portion of the lower lip extending beyond the upper lip. In the joined state of the two such panels at their first pair of opposing sides, a contact area is formed between the underside of the tenon and the lower lip. The floor panel is configured such that, in the joined state of two such panels at their first pair of opposite sides, an open space exists between the contact portion and contact area between the tongue and the lower lip when viewed vertically, and between the contact portion and contact area between the horizontally functioning locking surfaces when viewed horizontally. The floor panel is characterized in that the lower side of the tongue in the open space has a first surface, and the top side of the lower lip in the open space has a second surface, wherein the first surface is parallel to the second surface; and wherein, in the joined state where the tongue of the first such panel is in the groove of the second such panel, at least one surface perpendicular to the panel thus joined and parallel to the first pair of opposite sides intersects both the first surface of the joined first panel and the second surface of the joined second panel.

[0008] According to the first aspect of the invention, the contours of the connecting portions (and more specifically the tongue and groove) on the first pair of opposite sides of the floor panel are configured such that connecting portions of floor panels with different thicknesses can be produced to the greatest extent possible using the same cutting tool. This is achieved while maintaining ease of connection of such panels on the first pair of opposite sides by means of angular adjustment movement. The ease of connection by means of angular adjustment movement is determined by various factors. The angle through which the angular adjustment must be performed and the radius of rotation (turning circle) are important. When using pretensioned connection, the connection can be easier if the pretension can be achieved better and more easily.

[0009] These advantages are achieved because the contours of the connecting portions (and more specifically, the particular first and second surfaces) of the floor panel according to the first aspect of the invention allow the cutting tool to move more easily horizontally and vertically to achieve the optimal dimensions for the connecting portions in floor panels of different thicknesses.

[0010] Preferably, the first and second faces are parallel to the plane of the panel. This is advantageous for panel production because it allows for easier adjustment of the cutting tools used to produce the first and second faces.

[0011] Preferably, the floor panel is configured such that, in the joined state at the first pair of opposite sides, the lower edge of the tongue in the open space has a third surface distal to the first surface, wherein the third surface forms a larger angle with the plane of the panel compared to the first surface. This embodiment further facilitates the production of floor panels of different thicknesses using the same cutting tool.

[0012] Preferably, the floor panel is configured such that, in the joined state at the first pair of opposite sides, the lower edge of the tongue in the open space has a fourth face near the first face, wherein the fourth face forms a larger angle with the plane of the panel compared to the first face. This embodiment further facilitates the production of floor panels of different thicknesses using the same cutting tool.

[0013] More preferably, when viewed from the far side to the near side of the panel, both the third and fourth surfaces are oriented toward the lower edge of the panel. This embodiment further facilitates the production of floor panels of different thicknesses using the same cutting tool.

[0014] Preferably, the angle between the third and fourth surfaces is less than 3°. More preferably, the third and fourth surfaces are parallel to each other.

[0015] Preferably, the side of the first pair of opposing sides containing the tenon includes a first closing surface. The side of the first pair of opposing sides containing the groove includes a second closing surface at the distal end of the upper lip. In the joined state of the two such panels at their first pair of opposing sides, there is a contact portion between the first closing surface and the second closing surface of the joined panels, wherein the extension of the first closing surface intersects with a third surface.

[0016] Preferably, the floor panel is configured such that, in the joined state at the first pair of opposite sides, the upper edge of the lower lip in the open space has a fifth surface distal to the second surface, wherein the fifth surface forms a larger angle with the plane of the panel compared to the second surface. This embodiment further facilitates the production of floor panels of different thicknesses using the same cutting tool.

[0017] Preferably, the floor panel is configured such that, in the joined state at the first pair of opposite sides, the upper edge of the lower lip in the open space has a sixth surface near the second surface, wherein the sixth surface forms a larger angle with the plane of the panel compared to the second surface. This embodiment further facilitates the production of floor panels of different thicknesses using the same cutting tool.

[0018] More preferably, when viewed from the far side to the near side of the panel, both the fifth and sixth surfaces are oriented toward the upper edge of the panel. This embodiment further facilitates the production of floor panels of different thicknesses using the same cutting tool.

[0019] Preferably, the fifth face forms a larger angle with the plane of the panel compared to the sixth face. More preferably, the difference between the angle between the fifth face and the plane of the panel and the angle between the sixth face and the plane of the panel is greater than 10°, preferably greater than 15°. This embodiment further facilitates the production of floor panels of different thicknesses using the same cutting tool.

[0020] Preferably, the side containing the tenon in the first pair of opposing sides includes a first closing surface. The side containing the groove in the first pair of opposing sides includes a second closing surface at the distal end of the upper lip. When two such panels are joined at their first pair of opposing sides, there is a contact portion between the first and second closing surfaces of the joined panels. An extension of the second closing surface intersects with a sixth surface. This embodiment further facilitates the production of floor panels of different thicknesses using the same cutting tool.

[0021] A second aspect of the invention is a floor panel, optionally as in any embodiment of the first aspect of the invention. The floor panel has a connecting portion on a first pair of opposing sides. When two such floor panels are joined together at their first pair of opposing sides, the connecting portion establishes a lock in a vertical direction perpendicular to the plane of the floor panel and in a horizontal direction perpendicular to the respective sides and in the plane of the floor panel. The vertical locking is achieved using a tenon and groove connection, wherein the groove is defined by a lower lip and an upper lip. To achieve the horizontal locking, the connecting portion is provided with a locking portion in the form of a recess in the aforementioned lower lip and a protrusion on the underside of the tenon that mates with it. When two such floor panels are joined together, the locking portion forms a locking surface that functions at least horizontally, wherein the locking surface formed on the side of the recess is at least partially located within a portion of the lower lip extending beyond the upper lip. In the joined state of the two such panels at their first pair of opposing sides, a contact area is formed between the underside of the tenon and the lower lip. The floor panel is configured such that, in the joined state of two such panels at their first pair of opposite sides, an open space exists between the contact portion and contact area between the tongue and the lower lip when viewed vertically, and between the horizontally functioning locking surfaces when viewed horizontally. The lower side of the tongue in the open space includes a first surface. The top side of the lower lip in the open space includes a second surface. In the joined state where the tongue of the first such panel is in the groove of the second such panel, at least one surface perpendicular to the joined panel and parallel to the first pair of opposite sides intersects both the first surface of the first panel and the second surface of the second panel. In the open space, the lower edge of the tongue includes a third surface distal to the first surface, wherein the third surface forms a larger angle with the plane of the panel compared to the first surface. In the open space, the lower edge of the tongue includes a fourth surface proximal to the first surface, wherein the fourth surface forms a larger angle with the plane of the panel compared to the first surface. In the open space, the upper edge of the lower lip includes a fifth surface distal to the second surface, wherein the fifth surface forms a larger angle with the plane of the panel compared to the second surface. In the open space, the upper edge of the lower lip includes a sixth surface proximal to the second surface, wherein the sixth surface forms a larger angle with the plane of the panel compared to the second surface.

[0022] According to the second aspect of the invention, the contours of the connecting portions (and more specifically the tongue and groove) on the first pair of opposite sides of the floor panel are configured such that connecting portions of floor panels with different thicknesses can be produced to the greatest extent possible using the same cutting tool. This is achieved while maintaining ease of connection of such panels on the first pair of opposite sides by means of angular adjustment movement. The ease of connection by means of angular adjustment movement is determined by various factors. The angle through which the angular adjustment must be performed and the radius of rotation are important. When using pretensioned connection, the connection can be easier if the pretension can be achieved better and more easily.

[0023] These advantages are achieved because the contours of the connecting portions (and more specifically, the particular first and second surfaces) of the floor panel according to the first aspect of the invention allow the cutting tool to move more easily horizontally and vertically to achieve the optimal dimensions for the connecting portions in floor panels of different thicknesses.

[0024] In a preferred embodiment of the second aspect of the invention, both the third and fourth surfaces are oriented toward the lower edge of the panel when viewed from the distal to the proximal direction. This embodiment further facilitates the production of floor panels of varying thicknesses using the same cutting tool.

[0025] In a preferred embodiment of the second aspect of the invention, both the fifth and sixth surfaces are oriented toward the upper edge of the panel when viewed from the distal to the proximal direction. This embodiment further facilitates the production of floor panels of varying thicknesses using the same cutting tool.

[0026] In a preferred embodiment of the second aspect of the invention, the angle between the third and fourth surfaces is less than 3°. More preferably, the third and fourth surfaces are parallel to each other. This embodiment further facilitates the production of floor panels of different thicknesses using the same cutting tool.

[0027] In a preferred embodiment of the second aspect of the invention, the fifth surface forms a larger angle with the plane of the panel compared to the sixth surface. More preferably, the difference between the angle between the fifth surface and the plane of the panel and the angle between the sixth surface and the plane of the panel is greater than 10°, more preferably greater than 15°. This embodiment further facilitates the production of floor panels of different thicknesses using the same cutting tool.

[0028] In a preferred embodiment of the second aspect of the invention, the side of the first pair of opposing sides containing the tenon includes a first closing surface. The side of the first pair of opposing sides containing the groove includes a second closing surface at the distal end of the upper lip. When two such panels are joined at their first pair of opposing sides, there is a contact portion between the first closing surface and the second closing surface of the joined panels. An extension of the first closing surface intersects with a third surface. This embodiment further facilitates the production of floor panels of different thicknesses using the same cutting tool.

[0029] In a preferred embodiment of the second aspect of the invention, the side of the first pair of opposing sides containing the tenon includes a first closing surface. The side of the first pair of opposing sides containing the groove includes a second closing surface at the distal end of the upper lip. When two such panels are joined at their first pair of opposing sides, there is a contact portion between the first closing surface and the second closing surface. An extension of the second closing surface intersects with a sixth surface. This embodiment further facilitates the production of floor panels of different thicknesses using the same cutting tool.

[0030] In a preferred embodiment of the first and / or second aspect of the invention, when two such panels are joined at their first pair of opposite sides, a second contact area is formed between the lower edge of the tenon and the upper edge of the lower lip. Considering a floor panel joined at its recess, the second contact area is positioned distally relative to the second surface.

[0031] More preferably, considering a floor panel joined at its groove, the contact portion between the second contact area and the horizontally functioning locking surface is positioned proximally.

[0032] Preferably, the second contact area extends continuously in the contact portion between the horizontally functioning locking surfaces.

[0033] In a preferred embodiment of the first and / or second aspect of the invention, in the joined state of two such panels, pretension preferably exists between the horizontally acting locking surfaces due to the curvature of the lower lip.

[0034] In a preferred embodiment of the first and / or second aspect of the invention, two such panels can be joined at their first pair of opposite sides by means of an angle adjustment movement of one such panel parallel to its first pair of opposite sides, wherein the tongue of the panel is in the groove of the second such panel.

[0035] In a preferred embodiment of the first and / or second aspect of the invention, one side of the first pair of opposing sides containing the tenon includes a first closing surface. The side of the first pair of opposing sides containing the groove includes a second closing surface at the distal end of the upper lip. In the joined state of the two such panels at their first pair of opposing sides, there is a contact portion between the first closing surface and the second closing surface of the joined panels, wherein the first surface is positioned entirely proximal to the first closing surface.

[0036] In a preferred embodiment of the first and / or second aspect of the invention, the first face is positioned distal to the lowest point of the lower edge of the tenon. This embodiment further facilitates the production of floor panels of varying thicknesses using the same cutting tool.

[0037] In a preferred embodiment of the first and / or second aspect of the invention, the floor panel includes a substrate and an optional decorative topcoat, wherein the substrate includes one or more of the following:

[0038] - Wood-based substrate, such as one or more layers of wood panels, particleboard or fiberboard (e.g. MDF or HDF).

[0039] - A synthetic substrate, wherein the synthetic substrate comprises a polymer matrix and optional fillers, wherein the polymer of the polymer matrix may be composed, for example, polyvinyl chloride, polyurethane or polypropylene, wherein the optional fillers may include one or more mineral fillers (e.g., lime, chalk, clay, talc or calcium carbonate) or wood-based fillers (e.g., wood chips or wood fibers), and optionally wherein, in one or more layers of the synthetic substrate, the polymer matrix is ​​a foamed or non-foamed polymer matrix.

[0040] - Mineral substrates, such as magnesium oxide boards, gypsum boards, fiber cement boards, or mineral fiber boards, wherein mineral fibers (e.g., glass or basalt fibers) are bonded together by means of resin.

[0041] A third aspect of the invention is a method for producing floor panels, wherein a first floor panel having a first thickness is produced, and wherein a second floor panel having a second thickness is produced. The first and second floor panels are floor panels as described in any embodiment of the first and / or second aspects of the invention. A first surface of the first floor panel is parallel to a first surface of the second floor panel; and / or a second surface of the first floor panel is parallel to a second surface of the second floor panel.

[0042] The method of the third aspect of the invention allows for the formation of connecting portions of floor panels of different thicknesses with minimal changes to the cutting tool or even with the exact same cutting tool, wherein the floor panels of different thicknesses have tongue and groove connecting portions that can be easily joined together by angular adjustment.

[0043] In a preferred embodiment of the method of the present invention, the first surface of the first floor panel and the first surface of the second floor panel are formed by the same cutting tool.

[0044] In a preferred embodiment of the method of the present invention, the second surfaces of the first floor panel and the second floor panel are formed using the same cutting tool. Preferably, the cutting tool also forms the proximal ends of the grooves in the first and second floor panels.

[0045] In a preferred embodiment of the method of the present invention, the distal ends of the tenons of the first floor panel and the second floor panel are formed by the same cutting tool. Preferably, the cutting tool also forms a third surface of both the first and second floor panels.

[0046] In a preferred embodiment of the method of the present invention, the locking surfaces on the sides of the recesses of the first floor panel and the locking surfaces on the sides of the recesses of the second floor panel are formed by the same cutting tool. Preferably, this is done using the same cutting tool used to form the fifth surfaces of the first and second floor panels.

[0047] In a preferred embodiment of the method of the present invention, the thickness difference between the first floor panel and the second floor panel is at least 2 mm, more preferably at least 3 mm, and even more preferably at least 4 mm and even more preferably at least 5 mm.

[0048] In a preferred embodiment of the method of the present invention, the first floor panel is thicker than the second floor panel, and the lower lip of the first floor panel protrudes a greater distance relative to its upper lip compared to the case of the second floor panel.

[0049] In a preferred embodiment of the method of the present invention, the first floor panel is thicker than the second floor panel. Compared to the second floor panel, the deepest point of the recess in the lower lip of the first floor panel is located at a greater distance from the lower edge of the panel. The difference in distance between the lower edge of the first floor panel and the second floor panel and the deepest point of the recess in the lower lip is less than the difference in thickness between the first floor panel and the second floor panel.

[0050] In a preferred embodiment of the method of the present invention, the first surface is formed by a first cutting tool, and the distal end of the tenon is formed by a second cutting tool.

[0051] In a preferred embodiment of the method of the present invention, the second surface is formed by a third cutting tool, and the locking surface on the side of the recess in the floor panel is formed by a fourth cutting tool.

[0052] The fourth aspect of the invention is a cutting tool for use in any embodiment of the third aspect of the invention and / or for producing floor panels as in any embodiment of the first and / or second aspects of the invention, wherein the cutting tool is configured to produce a first surface.

[0053] Preferably, the cutting tool of the fourth aspect of the invention is configured to produce a fourth face. In the joined state of two such floor panels at their first pair of opposite sides, the fourth face in the open space is located on the lower edge of the tenon and near the first face, wherein the fourth face forms a larger angle with the plane of the panel compared to the first face.

[0054] The fifth aspect of the invention is a cutting tool used in any embodiment of the third aspect of the invention and / or for producing floor panels as in any embodiment of the first and / or second aspects of the invention, wherein the cutting tool is configured to produce a second side.

[0055] Preferably, the cutting tool of the fourth aspect of the invention is configured to produce the sixth face. In the joined state of two such floor panels at their first pair of opposite sides, the sixth face in the open space is located on the upper edge of the lower lip and near the second face, wherein the sixth face forms a larger angle with the plane of the panel compared to the second face.

[0056] Preferably, the cutting tool in the third and / or fourth aspects of the present invention is a milling cutter.

[0057] The sixth aspect of the invention is a cutting tool assembly comprising a cutting tool as described in any embodiment of the fourth aspect of the invention and a cutting tool as described in any embodiment of the fifth aspect of the invention.

[0058] Primarily, but not exclusively, the present invention and its various aspects are intended for use with wood-based or wood flooring panels, such as laminated parquet flooring, instant flooring, veneered parquet flooring, or solid parquet flooring.

[0059] In laminated parquet flooring, a flooring panel typically consists of a top layer composed of one or more resin-impregnated carrier sheets. This laminated flooring panel usually comprises, for example, a monolithic substrate made of MDF or HDF (medium-density fiberboard or high-density fiberboard) and a printed decoration defining the appearance on the top side. As is known, laminated flooring panels can be manufactured in various ways. According to a first possibility, they can be manufactured using DPL (Direct Pressure Lamination) technology, in which the aforementioned carrier sheet and substrate are placed together in a press, where they are bonded under high pressure and high temperature. According to a second possibility, they can be manufactured using HPL (High Pressure Lamination) technology, in which the aforementioned carrier sheet is first bonded into a so-called tight laminate and then glued to the substrate. On the underside of the laminated flooring panel, a so-called backing layer or balancing layer is typically used, which is also preferably constructed from at least one resin-impregnated or resin-coated carrier sheet.

[0060] In instant parquet flooring, the flooring parquet has a solid wood-based top layer that is typically thicker than the veneer, for example, having a thickness of 2 to 5 millimeters, and is laid on a single or multiple veneers of wood or wood-based substrate. Attached Figure Description

[0061] Further features will be apparent from the following examples. To better illustrate the features of the invention, some preferred embodiments are described below with reference to the accompanying drawings, which are provided as examples rather than limiting features, in which:

[0062] Figure 1 A floor covering consisting of panels according to the invention is shown;

[0063] Figure 2 It shows in Figure 1 A top view of the paneling used in the floor cladding;

[0064] Figure 3 It shows Figure 2 along Figure 2 The panel of line III-III;

[0065] Figure 4 The conditions under which the connection is established are shown. Figure 2 and Figure 3 The two panels;

[0066] Figure 5 and Figure 8 With Figure 3 The same view shows the panel according to the invention;

[0067] Figure 6 It shows according to Figure 2 and Figure 5 Panels;

[0068] Figure 7a and Figure 7b It shows Figure 3 The production steps of the connecting parts of the panel;

[0069] Figures 9a to 9c It shows the production Figure 3 and Figure 8 The difference in tools used to connect the panels shown. Detailed Implementation

[0070] Figure 1 A floor covering consisting of panel 1 according to the invention is shown; Figure 2 It shows in Figure 1 A top view of the paneling used in the floor cladding. Panel 1 has connecting portions on at least one pair of opposite sides 2, 3. In this example, the panels are rectangular and elongated, and they also have connecting portions on their second pair of opposite sides 4, 5.

[0071] The panel 1 has connecting portions on its first pair of opposite sides, so that the panels can be connected together at its first pair of opposite sides by means of angular adjustment movement W.

[0072] Figure 3 It shows Figure 2 along Figure 2 Floor panel 1 of line III-III. The panel has a thickness T1, which in this example is 7 mm. Figure 4 The diagram shows the state in which the two sides are joined together at the first pair of opposite sides. Figure 2 and Figure 3Two panels. The floor panel 1 has a connecting portion 6 on a first pair of opposing sides 2, 3. When two such floor panels 1 are joined together at their first pair of opposing sides 2, 3, the connecting portion 6 establishes a lock in a vertical direction V1 perpendicular to the plane of the floor panel 1 and in a horizontal direction H1 perpendicular to the respective sides 2, 3 and in the plane of the floor panel 1. The lock in the vertical direction V1 is achieved using a tenon and groove connection 9, 10, wherein the groove 10 is defined by a lower lip 11 and an upper lip 12. To achieve the lock in the horizontal direction H1, the connecting portion 6 is provided with a locking portion in the form of a recess 14 in the lower lip 11 and a protrusion 15 on the underside of the tenon 9 that engages therewith. When two such floor panels 1 are joined together, the locking portion forms locking surfaces 16, 17 that function at least horizontally, wherein the locking surface 17 formed on the side of the recess 14 is located in a portion of the lower lip 11 extending beyond the upper lip 12. In the connection state of the two such panels at their first pair of opposite sides 2, 3, the contact area 20 is formed between the lower side of the tenon 9 and the lower lip 11.

[0073] The floor panel 1 is configured such that, when two such panels are joined at their first pair of opposing sides 2, 3, an open space 22 exists between the contact portion and the contact area between the tongue 9 and the lower lip 11 when viewed vertically, and between the horizontally functioning locking surfaces 16, 17 when viewed horizontally. The lower side of the tongue 9 in the open space includes a first surface 24. The top side of the lower lip 11 in the open space includes a second surface 25. Figure 2 and Figure 3 In the example shown, the first surface 24 is parallel to the second surface 25, and both the first surface 24 and the second surface 25 are parallel to the plane of the panel. In the connected state where the tenon 9 of the first panel 1 is in the groove 10 of the second panel, at least one surface 26, which is perpendicular to the connecting panel and parallel to the first pair of opposite sides 2, 3, intersects with both the first surface 24 of the first connecting panel and the second surface 2 of the second panel.

[0074] In the example, in the open space 22, the lower edge of the tenon 9 is included on the third surface 27, which is far from the first surface 24, and the third surface 27 forms a larger angle with the plane of the panel compared to the first surface 24.

[0075] In the example, in the open space 22, the lower edge of the tenon 9 is included in the fourth surface 28 near the first surface 24, wherein the fourth surface 28 forms a larger angle with the plane of the panel compared to the first surface 24.

[0076] Viewed from the far side to the near side of the panel, both the third face 27 and the fourth face 28 are oriented toward the lower edge of the panel.

[0077] In the example, in the open space 22, the upper edge of the lower lip 11 includes a fifth surface 31 on the far side of the second surface 25, wherein the fifth surface 31 forms a larger angle with the plane of the panel compared to the second surface 25.

[0078] In the example, in the open space 22, the upper edge of the lower lip 11 includes a sixth surface 32 near the second surface 25, wherein the sixth surface 32 forms a larger angle with the plane of the panel compared to the second surface 25.

[0079] Viewed from the far side to the near side of the panel, both the fifth face 31 and the sixth face 32 are oriented toward the upper edge of the panel.

[0080] In this example, the third face 27 and the fourth face 28 are parallel to each other.

[0081] The side 2 containing the tenon 9 includes a first closing surface 29. The side 3 containing the groove 10 includes a second closing surface 30 at the distal end of the upper lip 12.

[0082] In the connection state of the two such panels at their first pair of opposite sides 2, 3, there is a contact portion between the first closed surface 29 and the second closed surface 30 of the connected panel 1. The extension 34 of the first closed surface 29 intersects with the third surface 27. The extension 33 of the second closed surface intersects with the sixth surface 32. The first surface 24 is positioned entirely near the first closed surface 34.

[0083] Compared to the sixth face 32, the fifth face 31 forms a larger angle with the plane of the panel. Figure 3 and Figure 4 In the example, the difference between the angle between the fifth face and the plane of the panel and the angle between the sixth face and the plane of the panel is 11°.

[0084] In the example, when the two such panels are joined at their first pair of opposite sides 2, 3, a second contact area 36 is formed between the lower edge of the tenon 9 and the upper edge of the lower lip 11, wherein the second contact area 36 is positioned on the far side relative to the second surface 25.

[0085] Considering the floor panel connected at its recess 10, the second contact area 36 is positioned proximally relative to the contact portion between the horizontally functioning locking surfaces 16 and 17. The second contact area 36 extends continuously within the contact portion between the horizontally functioning locking surfaces 16 and 17.

[0086] The first face 24 is located far from the lowest point 38 of the lower edge of the tenon 9.

[0087] In the joined state of the two such panels at their first pair of opposite sides 2, 3, there is pretension between the horizontally functioning locking surfaces 16, 17 due to the curvature of the lower lip 11. This curvature is produced by the overlap of the contours. Figure 4 The panel shown has overlapping but no bending (and pretension) that occurs during the connection.

[0088] The two such panels can be adjusted by means of the angle W parallel to their first pair of opposite sides 2, 3 (see Figure 1 It is connected at its first pair of opposite sides 2, 3, and its tenon 9 is in the groove 10 of the second such panel.

[0089] Figure 3 and Figure 4 The panel 1 shown has a chamfer in the form of an inclined edge 61 at its first pair of opposite sides 2, 3.

[0090] Figure 5 With Figure 3 The same view shows another example of a floor panel according to the invention. The panel has a thickness T2 equal to 8 mm, and thus is more... Figure 3 and Figure 4 The panel shown is thicker. Figure 5 The reference numerals in the figures have the same Figure 3 The corresponding labels in the attached figures have the same meaning.

[0091] Figure 3 The first surface 24 of the floor panel is parallel to Figure 5 The first side of the floor paneling. Figure 3 The second side of the floor panel is parallel to Figure 5 The second side of the floor paneling, 25.

[0092] Figure 6 Shown at the same scale Figure 5 The first floor panel 41 (which has a first thickness T2 = 8 mm) and Figure 3 The second floor panel 40 (which has a second thickness T1 = 7 mm) and the first floor panel 41. The tenons and grooves of both panels are produced using the same cutting tool. Compared to the thinner second floor panel 40, the lower lip of the thicker first floor panel 41 protrudes a greater distance relative to its upper lip. Compared to the thinner second floor panel 40, the deepest point 39 of the recess 14 in the lower lip 11 of the thicker first floor panel 41 is located at a greater distance from the lower edge of the panel. Between the thicker first floor panel 41 and the thinner second floor panel, the difference in distance between the lower edge of the panel and the deepest point 39 of the recess 14 in the lower lip 11 is less than the difference in thickness between the two floor panels.

[0093] Figure 7a and Figure 7b The production process is shown as an example of the method according to the invention. Figure 3 The steps for forming the connecting portion of the panel in the diagram. A standard continuous milling machine with several milling cutters on both edges is used to simultaneously form the connecting portion on both sides of a pair of opposite sides 2, 3. The connecting portion is produced by means of multiple milling operations using cutting tools (more specifically, milling cutters). Figure 7a and Figure 7b Not all steps are shown; only those steps that form the tenon 9 and the groove 10 are shown. Figure 7a and Figure 7b The outline of the connecting part shown is the outline of the final connecting part of the panel.

[0094] Figure 7a The steps for forming the tenon and groove are shown. The second cutting tool 52 forms the distal end of the tenon 9 and the third surface 27 of the floor panel 1.

[0095] The third cutting tool 51A forms the second surface 25 and the sixth surface 32 of the panel, as well as the proximal end of the groove 10.

[0096] exist Figure 7b The next step in forming the tenon and groove is shown. The first cutting tool 54 forms the first face 24 and the fourth face 28. The fourth cutting tool 53 forms the fifth face 31 and the locking surface 17 located on the side of the recess 14 of the lower lip 11.

[0097] Figure 5 The connecting parts of the panels are formed using four cutting tools 51A, 52, 53, and 54 of the same design. Only the relative positions of these cutting tools with respect to the relevant panels have been modified.

[0098] Figure 8 With Figure 3 The same view shows another example of a floor panel according to the invention. The panel has a thickness T3 equal to 10 mm, and thus is more... Figure 3 and Figure 5 The panel shown is thicker. Figure 8 The reference numerals in the figures have the same Figure 3 The corresponding labels in the attached figures have the same meaning.

[0099] Figure 3 The first surface 24 of the floor panel is parallel to Figure 8 The first side of the floor paneling, 24. Figure 3 The second side of the floor panel 25 is parallel to Figure 8 The second side of the floor paneling, 25.

[0100] exist Figure 7a and Figure 7b The method shown in the figure is for forming Figure 3 and Figure 5 Three of the four cutting tools used in the tenon and groove of the panel are also used to form Figure 8 The tenons and grooves of the panel. These are tools 52, 53, and 54.

[0101] Figure 7a Used for production Figure 3 and Figure 5 The third cutting tool 51A, which is part of the recess in the panel, is replaced by a suitable tool. Figure 9a The diagram shows the production process. Figure 3 The third cutting tool 51A is located in a recessed part of the panel, while Figure 9b The diagram shows the production process. Figure 8 A suitable third cutting tool 51B for a portion of the groove in the panel. Figure 9b The third cutting tools 51A and 51B are shown.

Claims

1. A floor panel (1), wherein, The floor panel has a connecting portion (6) on the first pair of opposite sides (2, 3). When two floor panels (1) are joined together at their first pair of opposite sides (2, 3), the connecting portion (6) establishes a lock in the vertical direction (V1) perpendicular to the plane of the floor panel (1) and in the horizontal direction (H1) perpendicular to the corresponding sides (2, 3) and in the plane of the floor panel (1). The locking in the vertical direction (V1) is achieved by connecting a tenon (9) and a groove (10), wherein the groove (10) is defined by a lower lip (11) and an upper lip (12). In order to achieve locking in the horizontal direction (H1), the connecting portion (6) is provided with a locking portion in the form of a recess (14) in the lower lip (11) and a protrusion (15) that engages therewith on the underside of the tenon (9). When the two floor panels (1) are joined together, the locking portion forms a locking surface (16, 17) that functions at least horizontally. The locking surface (17) formed on the side of the recess (14) is at least partially located in a portion of the lower lip (11) that extends beyond the upper lip (12). In the case where the two panels are joined at their first pair of opposite sides (2, 3), a contact area (20) is formed between the lower side of the tenon (9) and the lower lip (11). The floor panel (1) is configured such that, in the connected state of the two panels at their first pair of opposite sides (2, 3), when viewed vertically, there is an open space (22) between the contact portion between the tongue (9) and the lower lip (11) and when viewed horizontally, between the contact portion between the horizontally functioning locking surfaces (16, 17) and the contact area (20). The tenon (9) in the open space (22) has a first face (24) on its lower side; and the lower lip (11) in the open space (22) has a second face (25) on its top side; and in the connected state where the tenon (9) of the first panel is in the groove (10) of the second panel, at least one face (26) perpendicular to the connected panel and parallel to the first pair of opposite sides (2, 3) intersects with both the first face (24) of the connected first panel and the second face (25) of the second panel; In the open space (22), the lower edge of the tenon (9) is included on a third surface (27) far from the first surface (24), wherein the third surface (27) forms a larger angle with the plane of the panel compared to the first surface (24); In the open space (22), the lower edge of the tenon (9) is included on a fourth surface (28) near the first surface (24), wherein the fourth surface (28) forms a larger angle with the plane of the panel compared to the first surface (24); In the open space (22), the upper edge of the lower lip (11) includes a fifth surface (31) on the far side of the second surface (25), wherein the fifth surface (31) forms a larger angle with the plane of the panel compared with the second surface (25); In the open space (22), the upper edge of the lower lip (11) includes a sixth surface (32) near the second surface (25), wherein the sixth surface (32) forms a larger angle with the plane of the panel compared to the second surface (25).

2. The floor panel (1) according to claim 1, wherein, The first surface (24) and the second surface (25) are parallel to the plane of the floor panel.

3. The floor panel (1) according to claim 1, wherein, Viewed from the far side to the near side of the panel, both the third surface (27) and the fourth surface (28) are oriented toward the lower edge of the panel.

4. The floor panel (1) according to claim 1, wherein, Viewed from the far side to the near side of the panel, both the fifth surface (31) and the sixth surface (32) are oriented toward the upper edge of the panel.

5. The floor panel (1) according to claim 1, wherein, The angle between the third surface (27) and the fourth surface (28) is less than 3°.

6. The floor panel (1) according to claim 5, wherein, The third and fourth surfaces are parallel to each other.

7. The floor panel (1) according to claim 1, wherein, Compared to the sixth face (32), the fifth face (31) forms a larger angle with the plane of the panel.

8. The floor panel (1) according to claim 7, wherein, The difference between the angle between the fifth face and the plane of the panel and the angle between the sixth face and the plane of the panel is greater than 10°.

9. The floor panel (1) according to claim 1, wherein, The side of the first pair of opposite sides (2, 3) containing the tenon (9) includes a first closing surface (29), and the side of the first pair of opposite sides (2, 3) containing the groove (10) includes a second closing surface (30) at the distal end of the upper lip (12), wherein, in the joined state of the two panels at their first pair of opposite sides (2, 3), there is a contact portion between the first closing surface (29) and the second closing surface (30) of the joined panels. The extension (34) of the first closed surface intersects with the third surface (27).

10. The floor panel (1) according to any one of claims 1 to 9, wherein, The side of the first pair of opposite sides (2, 3) containing the tenon (9) includes a first closing surface (29), and the side of the first pair of opposite sides (2, 3) containing the groove (10) includes a second closing surface (30) at the distal end of the upper lip (12), wherein, in the joined state of the two panels at their first pair of opposite sides (2, 3), there is a contact portion between the first closing surface (29) and the second closing surface (30) of the joined panels. The extension (33) of the second closed surface intersects with the sixth surface (32).

11. The floor panel (1) according to any one of claims 1 to 9, wherein, In the joined state of the two panels at their first pair of opposite sides (2, 3), a second contact area (36) is formed between the lower edge of the tongue (9) and the upper edge of the lower lip (11), wherein, considering the floor panel joined at its groove (10), the second contact area (36) is positioned distally relative to the second surface (25).

12. The floor panel (1) according to claim 11, wherein, Considering the floor panel connected at its groove (10), the second contact area (36) is positioned proximally relative to the horizontally functioning locking surfaces (16, 17).

13. The floor panel (1) according to claim 11, wherein, The second contact area (36) extends continuously in the contact portion between the horizontally functioning locking surfaces (16, 17).

14. The floor panel (1) according to any one of claims 1 to 9, wherein, In the connected state of the two panels at their first pair of opposite sides (2, 3), there is pretension between the horizontally functioning locking surfaces (16, 17) due to the bending of the lower lip (11).

15. The floor panel (1) according to any one of claims 1 to 9, wherein, The two panels can be joined at their first pair of opposite sides (2, 3) by means of an angle adjustment (W) of one of the panels parallel to its first pair of opposite sides (2, 3), wherein the tongue (9) of the panel is located in the groove (10) of the second panel.

16. The floor panel (1) according to any one of claims 1 to 9. in, The side of the first pair of opposite sides (2, 3) containing the tenon (9) includes a first closing surface (29), and the side of the first pair of opposite sides (2, 3) containing the groove (10) includes a second closing surface (30) at the distal end of the upper lip (12), wherein, in the joined state of the two panels at their first pair of opposite sides (2, 3), there is a contact portion between the first closing surface (29) and the second closing surface (30) of the joined panels. The first surface (24) is positioned completely on the proximal side of the first closed surface (29).

17. The floor panel (1) according to any one of claims 1 to 9, wherein, The first face (24) is located far from the lowest point (38) of the lower edge of the tenon (9).

18. The floor panel (1) according to any one of claims 1 to 9, wherein, The floor paneling includes a substrate and a decorative topcoat, wherein the substrate includes one or more of the following: - Wood-based substrate; - A synthetic substrate, wherein the synthetic substrate comprises a polymer matrix and a filler, wherein the filler comprises one or more mineral fillers or wood-based fillers, wherein, in one or more layers of the synthetic substrate, the polymer matrix is ​​a foamed polymer matrix; - Mineral substrate.

19. The floor panel (1) according to claim 18, wherein, The wood-based substrate includes one or more wood layers, particleboard or fiberboard, wherein the fiberboard is MDF or HDF.

20. The floor panel (1) according to claim 18, wherein, The polymer matrix is ​​composed of polyvinyl chloride, polyurethane, or polypropylene.

21. The floor panel (1) according to claim 18, wherein, The one or more mineral fillers include lime, clay, talc, or calcium carbonate.

22. The floor panel (1) according to claim 18, wherein, The wood-based filler is wood chips or wood fibers.

23. The floor panel (1) according to claim 18, wherein, The mineral substrate is magnesium oxide board, gypsum board, fiber cement board or mineral fiber.

24. The floor panel (1) according to claim 23, wherein, The mineral fibers are glass fibers or basalt fibers, and are bonded together with resin.

25. A method for producing floor paneling (1), in, Produce a first floor panel (41) with a first thickness (T2). Among them, the production of a second floor panel (40) with a second thickness (T1) is carried out. Wherein, the first floor panel and the second floor panel are floor panels according to any one of claims 1 to 24; Wherein, the first surface of the first floor panel is parallel to the first surface of the second floor panel; And / or wherein the second surface of the first floor panel is parallel to the second surface of the second floor panel.

26. The method of claim 25, wherein, The first surface of the first floor panel and the first surface of the second floor panel are formed using the same cutting tool.

27. The method according to claim 25, wherein, The second surface of the first floor panel and the second surface of the second floor panel are formed using the same cutting tool.

28. The method according to claim 27, wherein, The cutting tool that forms the second surface also forms the proximal end of the groove in the first floor panel and the proximal end of the groove in the second floor panel.

29. The method according to claim 25, wherein, The distal ends of the tenons of the first floor panel and the distal ends of the tenons of the second floor panel are formed by the same cutting tool.

30. The method according to claim 29, wherein, The cutting tool that forms the distal end also forms a third surface (27) of both the first floor panel and the second floor panel.

31. The method according to claim 25, wherein, The locking surfaces on the sides of the recesses of the first floor panel and the locking surfaces on the sides of the recesses of the second floor panel are formed using the same cutting tool.

32. The method according to claim 31, wherein, The cutting tool that forms the locking surface also forms a fifth surface (31) of the first floor panel and the second floor panel.

33. The method according to any one of claims 25 to 32, wherein, The thickness difference between the first floor panel and the second floor panel is at least 2 millimeters.

34. The method according to claim 33, wherein, The thickness difference between the first floor panel and the second floor panel is at least 3 millimeters.

35. The method according to claim 34, wherein, The thickness difference between the first floor panel and the second floor panel is at least 4 millimeters.

36. The method according to claim 35, wherein, The thickness difference between the first floor panel and the second floor panel is at least 5 millimeters.

37. The method according to any one of claims 25 to 32, wherein, The first floor panel (41) is thicker than the second floor panel (40), and wherein, compared with the case of the second floor panel (40), the lower lip (11) of the first floor panel (41) protrudes a greater distance relative to its upper lip (12).

38. The method according to any one of claims 25 to 32, wherein, The first floor panel (41) is thicker than the second floor panel (40), and wherein, compared with the second floor panel, the deepest point (39) of the recess (14) in the lower lip (11) of the first floor panel is located at a greater distance from the lower edge of the first floor panel; wherein, the difference in distance between the respective lower edges of the first floor panel and the second floor panel and the deepest point (39) of the recess (14) in their respective lower lips (11) is less than the difference in thickness between the first floor panel and the second floor panel.

39. The method according to any one of claims 25 to 32, wherein, The first face is formed by a first cutting tool (54), and the distal end of the tenon (9) is formed by a second cutting tool (52).

40. The method according to claim 39, wherein, The second surface is formed by a third cutting tool (51A, 51B), and the locking surface located on the side of the recess of the floor panel is formed by a fourth cutting tool (53).

41. A cutting tool for use in the method according to any one of claims 25 to 40 and / or for producing floor panels according to claims 1 to 24, wherein, The cutting tool is configured to produce the first face.

42. The cutting tool according to claim 41, wherein, The cutting tool is configured to produce the fourth face (28). In the connected state of the two floor panels at their first pair of opposite sides (2, 3), the fourth face (28) in the open space (22) is located on the lower edge of the tenon and near the first face, wherein the fourth face (28) forms a larger angle with the plane of the panel compared to the first face.

43. The cutting tool according to claim 41 or 42, wherein, The cutting tool is a milling cutter.

44. A cutting tool for use in the method according to any one of claims 25 to 40 and / or for producing the floor paneling according to claims 1 to 24, wherein, The cutting tool is configured to produce the second face.

45. The cutting tool according to claim 44, wherein, The cutting tool is configured to produce the sixth face (32). In the connected state of the two floor panels at their first pair of opposite sides (2, 3), the sixth surface (32) in the open space (22) is located on the upper edge of the lower lip (11) and near the second surface, wherein the sixth surface (32) forms a larger angle with the plane of the panel compared to the second surface.

46. ​​The cutting tool according to claim 44 or 45, wherein, The cutting tool is a milling cutter.

47. A cutting tool set, wherein, The cutting tool set includes the cutting tool according to any one of claims 41 to 43 and the cutting tool according to any one of claims 44 to 46.

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