PANELS WITH A DETACHABLE PROTRUDING LIP FOR WALL-, CEILING- OR FLOOR COVERINGS

Abstract

A panel with a detachable protruding lip for wall-, ceiling- or floor coverings is provided. Furthermore, methods are provided for manufacturing wall-, ceiling- or floor coverings comprising or consisting of a plurality of the panels.

Claims

1. A panel for wall-, ceiling- or floor coverings with a quadrilateral shape, the panel comprising: an upper side, a lower side, a pair of opposing first sides and a pair of opposing second sides, a first second side and a second second side and front ends, defining a circumference of the panel in the installed state, at least one front end is protruded with respect to the circumference by a detachable protruding lip having a predetermined break-off surface formed at the lower side, and a horizontal locking groove at the lower side, wherein the front ends of the first sides comprise a joint profile with an upper female locking element and a lower female locking element, wherein the front end of the first second side comprises a joint profile with an upper male locking element adapted to engage with the upper female locking element of the first sides and/or an upper female locking element of the second side; and, a lower female locking element, and the front end of the second side comprises a joint profile with an upper female locking element and a lower male locking element adapted to engage with the lower female locking element of the first sides and/or the lower female locking element of the first second side.

2. The panel of claim 1 wherein the female locking elements are configured as grooves and/or the male locking elements are configured as protrusions.

3. The panel of claim 1 wherein the predetermined break-off surface is formed by one or more start notches, one or more cuttings, preferably laser cuttings, one or more drillings, one or more milled slots, a density gradient within the panel, by means of introducing a film, adhesives, binders and/or primers and/or by using different materials in the area of the predetermined break-off surface.

4. The panel of claim 1 wherein the protruding lip comprises at least one horizontal locking element, being suitable for engaging in configured to engage the horizontal locking groove of a neighbored panel, wherein the protruding lip of said neighbored panel has been removed.

5. The panel of claim 1 wherein the horizontal locking element retains the neighbored panel in vertical and/or horizontal direction.

6. The panel of claim 1 wherein at least two detachable protruding lips are fixed at the panel, preferably at opposite sides of the panel.

7. The panel of claim 1 wherein all front ends are protruded with respect to the circumference by a detachable protruding lip formed at the lower side.

8. The panel of claim 1 wherein a vertical locking groove is incorporated in the horizontal locking groove and the protruding lip comprises a vertical locking element being suitable for engaging in the vertical locking groove of a neighbored panel, wherein the protruding lip of said neighbored panel has been removed.

9. The panel of claim 1 wherein the panel comprises a material selected from the group consisting of MDF, HDF, cork, OSB, solid wood, plywood, plastics, preferably PVC, cement fibers, basalt, rock wool, ceramics, genuine stone, metal, preferably aluminum or steel panel, glass, plastics, chipboard, laminate floorboards, and mixtures or pairings thereof.

10. The panel of claim 1 wherein the panel has a rectangular shape, an quadratic shape or the shape of a parallelogram, preferably rectangular shape wherein the length of the panel is an integer multiple of the width, more preferably the ratio between length and width is 1:1, 1:2, 1:3, 1:4, 1:5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:11 or 1:12, most preferably the ratio between length and width is 1:6.

11. The panel of claim 1 wherein the protruding lip comprises a trough, preferably said trough comprises an adhesive, e.g. a double-sided adhesive tape.

12. The panel of claim 1 wherein the predetermined break-off surface is formed by a start notch and an end notch, wherein the end notch is preferably arranged in the horizontal locking groove.

13. The panel of claim 1 wherein the start notch is oriented in a vertical distance in the range from 0.1 to 10 mm above the upper lip surface for forming a crack gap.

14. The panel of claim 1 wherein the protruding lip comprises a material selected from the group consisting of MDF, HDF or plastics, and the core comprises a material selected from the group consisting of MDF, HDF or plastics, preferably PVC, more preferably the protruding lip consists of plastic and the core consists of MDF or HDF or PVC or mixtures thereof.

15. The panel of claim 1 wherein: a decorative layer and/or an abrasion resistant layer is arranged on the upper side, and/or a layer for insulating footstep sounds and/or a counterdraw layer is oriented below the lower side.

16. A method for manufacturing wall-, ceiling- and/or floor coverings comprising a plurality of panels according to claim 1, wherein a first panel at its front end is connected with the front end of a neighbored panel by removing the protruding lip at the predetermined break-off surface and by joining the protruding lip of the first panel with the horizontal locking groove of the neighbored panel.

17. The method of claim 16 wherein two neighbored panels are joined along their first sides, in that a first side of a first panel is joined with a second side of a neighbored panel, wherein the upper male locking element or the lower male locking element of the neighbored panel, respectively, engage with the upper female locking element or the lower female locking element, respectively, of the first side of the first panel, in that the first second side of a first panel is joined with a second second side of a neighbored panel, wherein the upper male locking element of the first panel and the lower male locking element of the neighbored panel engage with the upper female locking element of the neighbored panel and the lower female locking element of the first panel.

18. The method of claim 16 wherein the protruding lip of the first panel comprises at least one horizontal locking element being suitable for engagement in the horizontal locking groove of the neighbored panel, whose protruding lip has been removed, wherein during joining the horizontal locking element is incorporated in the horizontal locking groove.

19. The method of claim 17 wherein adhesive means are provided for locking in the vertical direction.

20. The method of claim 17 wherein an adhesive or a glue is provided onto at least a part of the surface of the protruding lip for providing a locking function in the vertical direction or the adhesive or a glue is provided onto at least a part of the front end.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] Preferred embodiments of the disclosure are described in the following with reference to the drawings, which are for the purpose of illustrating the present preferred embodiments of the disclosure and not for the purpose of limiting the same.

LIST OF REFERENCE SIGNS

[0052] 1, 1: Panel [0053] 2, 2: Upper side of the panel [0054] 3, 3: Lower side of the panel [0055] 4: Front end of the panel [0056] 5: Protruding lip [0057] 6: Horizontal locking groove [0058] 7, 7: Predetermined break-off surface [0059] 8: Start notch [0060] 9: Horizontal locking element [0061] 10: Distal vertical locking groove [0062] 11: Distal vertical locking element [0063] 13: Crack gap [0064] 14: Upper lip surface [0065] 15: End notch [0066] 16, 16: Abutment surface [0067] 18: Locking surface [0068] 19: Guiding surface [0069] 20: Decorative bevel [0070] 23: Core of the panel [0071] 24: Joint profile [0072] 25: Upper half of joint profile [0073] 26: Lower half of joint profile

[0074] FIG. 1 shows a side view of a long side panel (1) profile with a detachable protruding lip (5) according to the present disclosure.

[0075] FIG. 2 shows a side view of two long side panel (1, 1) profiles in the coupled condition according to the disclosure. The lower lip (5) of the right hand panel (1) has been detached.

[0076] FIG. 3 FIG. 3 shows a side view of a panel (1) first short side profile according to the disclosure, of which the lower lip (5) has been detached.

[0077] FIG. 4 shows side view of a panel (1) second short side profile according to the disclosure, of which the lower lip (5) has been detached.

[0078] FIG. 5 shows a side view of a long side panel (1) profile and a first short side panel (1) profile in the coupled condition according to the disclosure. The lower lip (5) of the right hand panel (1) has been detached.

[0079] FIG. 6 shows a side view of a second short side panel (1) profile and a first short side panel (1) profile in the coupled condition according to the disclosure. The lower lip (5) of the left hand panel (1) has been detached.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0080] FIG. 1 displays a panel according to the present disclosure, a section through a long side (L) is shown. The panel (1) has a core (23), a horizontal locking groove (6) along with a distal vertical locking groove (10) and a detachable protruding lip (5). A horizontal locking element (9) is mounted on a protruding lip (5). The horizontal locking element is designed in such a way, that it fits into a horizontal locking groove (6) of a neighboring panel (1, not shown in FIG. 1) and thereby provides locking in a horizontal direction. The panel (1) has an upper side (2), which may or may not be decorated or covered by an additional abrasion resistant surface. Furthermore, the panel (1) may or may not have a decorative bevel (20) at its edge. With the embodiment shown in FIG. 1, a start notch (8) is created in the panel (1). By applying a downward force at the end of the protruding lip (5), for example by applying a downward pressure by hand on the abutment surface (16), a lever is created by the protruding lip (5). This lever is further lengthened by the start notch (8) which thereby acts as starting point for a crack. This crack intentionally propagates from the start notch (8) to an end notch surface (15).

[0081] The protruding lip (5) comprises a horizontal locking element (9), on which distal vertical locking element (11) is present. The horizontal locking element (9) can engage with a horizontal locking groove (6) as well as a distal vertical locking groove (10) of a neighboring panel (1, not shown), in which the protruding lip (5) has been detached along the predetermined break-off surface (7).

[0082] According to the present disclosure, the front end (4) of a long side (L) of the panel (1) according to the present disclosure comprises a joint profile (20, which consists of a upper locking element, i.e. a upper female locking element (25) and a lower locking element, i.e. a lower female locking element (26.sup.L).

[0083] FIG. 2 shows a side view of two long side panel (1, 1) profiles in the coupled condition according to the disclosure. The lower lip (5) of the right hand panel (1) has been detached by propagating a crack beginning form the start notch (8) and ending in the end notch (15) whereby a predetermined break-off surface (7) has been formed.

[0084] When two panels (1, 1) are aligned along their long side as shown in FIG. 2, the horizontal locking element (9) ensures both a horizontal and vertical locking of the respective neighboring panels (1, 1). The locking surface (18) ensures a horizontal fixing of the panels (1,1) with respect to each other, the guiding surface (19) enables the secure gliding of the second panel (1) into the locking mechanism to ensure that the protruding lip (5) is not detached. Furthermore, a vertical locking element (11), when engaged with the vertical locking groove (10) also hinders vertical displacement panels (1, 1) with respect to each other. Due to the fact that the long sides of the panels (1, 1) are installed with each other, the vertical locking is sufficient, so that no additional vertical locking, such as e.g. with the joint profile (24) is necessary.

[0085] In the embodiment of FIG. 2, vertical locking is additionally achieved in the following manner:

[0086] Firstly, vertical locking against a movement of both panels (1,1) towards the lower side of the panels (3,3) is prevented by the substrate onto which the panels (1,1) are mounted, which is the floor, the wall, the ceiling or any further coverings thereof.

[0087] Secondly, vertical locking against a movement of the second panel (1) towards the lower side if the panel (3) is prevented by the abutment surfaces (16,16).

[0088] It is clear that with the many different types of possible materials or material combinations out of which the panels (1) according to the disclosure can be made, it cannot be expected that the predetermined break-off surface (7) is always a smooth and straight, perfect surface. For panel materials such as e.g. wood based fiber boards known as MDF/HDF laminate, a generally irregular break-off surface (7) is rather to be expected. The geometry of the break off surface (7) can only be predetermined within limits. This is why it is important to choose the start notch (8) at some vertical distance above the upper lip surface (14). By this measure, a crack gap (13) is achieved, which can accommodate any irregular break off surface (7). This is important in that only the abutment surfaces (16, 16) are intended to touch in the horizontal plane and not the upper lip surface (14) somewhere at the irregular break-off surface (7), as this would result in panels which have their respective upper sides (2, 2) in different planes thereby resulting in an irregular paneled surface. It is also important to add a well defined end notch surface (15) into which the crack will exit because it enables the crack to travel the shortest available distance. A slightly inclined contact surface (18) is chosen, which enables horizontal locking. The inclination of the locking surface (18) enables to pull two panels (1, 1) towards each other in the final laying stage and is chosen to be 40 to 80 degrees to laying plane. A further inclined surface on the horizontal locking element (9) between the locking surface (18) and the abutment surface (16) additionally also serves as a guiding surface (19) to help to align the panels during laying.

[0089] FIG. 3 shows a section through a front end (4) of the first short side (S1) of a panel (1) according to the present disclosure. The protruding lip (5) already has been detached along the break-off surface (7). It becomes apparent that the joint profile (24) of the panel (1) along its first short side (S1) is shaped differently than along the long sides (L) as shown above in FIG. 1. The joint profile of the first short side (24.sup.S1) encompasses an upper male locking element (25.sup.S1) as well as well as a lower female locking element (26.sup.S1).

[0090] FIG. 4 shows the front end (4) of the opposite short side (S2) of the first side (S1) of a panel (1) according to the present disclosure. The joint profile (24) of the panel (1) along its second short side (S2) has the opposite configuration as the joint profile (24) of the first short side (S1). At the second short side (S2), the joint profile (24.sup.S1) has an upper female locking elements (25.sup.S1) as well as a lower male locking element (26.sup.S2).

[0091] Accordingly, the panels (1) according to the present disclosure have different joint profiles (24) at their short sides (S1, S2), which in addition is different from the joint profile (24) at their long side (L).

[0092] FIG. 5 shows the joining of panel (1) of the present disclosure along its long side (L) with a second panel (1) of the present disclosure along its first short side (S1).

[0093] It becomes apparent; that the joint profile (24) of both panels (1, 1) allows an alignment of the both panels (1, 1) in virtually every combination. The protruding lip (5) of the second panel (1) has been removed. The upper male locking element (25 S1) of the first side (S1) of the second panel (1) engages with the upper female locking elements (25) of the long side (L) of the first panel (1) contributing additionally to a vertical locking which already has been provided by the distal vertical locking element (11) and the distal vertical locking groove (10).

[0094] In the same manner, also a second side (S2) of the second panel (1) can be aligned with the long side (L) of the first panel (1) (not shown), with the only difference that the male locking element would in this case be the lower locking element (26), engaging with the lower female locking groove (26) of the first panel (1).

[0095] FIG. 6 shows an embodiment in which two panels (1, 1), according to the present disclosure, are installed along their short side (S1, S2). The inverse locking profile (24) being provided at the respective opposite short sides (S1, S2) allows complete engagement of the male locking elements with the female locking elements of the respective other panel. Accordingly, the panels can be secured vertically when installed along their short sides (S1, S2).

[0096] To clarify the use of and to hereby provide notice to the public, the phrases at least one of <A>, <B>, . . . and <N> or at least one of <A>, <B>, . . . or <N> or at least one of <A>, <B>, . . . <N>, or combinations thereof or <A>, <B>, . . . and/or <N> are defined by the Applicant in the broadest sense, superseding any other implied definitions hereinbefore or hereinafter unless expressly asserted by the Applicant to the contrary, to mean one ore more elements selected from the group comprising A, B, . . . and N. In other words, the phrases mean any combination of one or more of the elements A, B, . . . or N including any one element alone or the one element in combination with one or more of the other elements which may also include, in combination, additional elements not listed. Unless otherwise indicated or the context suggests otherwise, as used herein, a or an means at least one or one or more.