THE LONGITUDINAL SIDES AND/OR END SIDES TO EACH OTHER

The present invention relates to, on the one hand, a profiled strip comprising a visible side, a first longitudinal side, provided with first male connecting means, and a second longitudinal side situated opposite the first longitudinal side, provided with first female connecting means, which profiled strip is furthermore, on a first end side, provided with second male connecting means and, on a second end side situated opposite the first end side, is provided with second female connecting means, wherein said connecting means are suitable for connecting the longitudinal sides and/or the end sides of adjacent profiled strips to each other, wherein the second male connecting means comprise a locking element and wherein the first and second female connecting means comprise a locking part cooperating with the locking element. The profiled strip according to the invention may be both a floor or a wall panel (element) in the form of a tile or board. The present invention relates in particular to a profiled strip (panel) made of plastic, preferably vinyl or PVC. On the other hand, the present invention relates to a method for producing such a profiled strip.

When connecting floor elements without the use of gluing techniques, several systems are known which differ in the way in which the floor elements can be joined. The large groups are the following:

For the long side o f the floor element: a) Connect a floor element horizontally and the other floor element via a corner to the first floor element;

b) Connect a floor element horizontally and the other floor element via a rotating movement to the first floor element. The most well-known current systems are described in the following patent publications: BE 9600527; BE 9700344; EP 0843763 and EP 1026341.

For the short side of the floor element, after the longitudinal connection has been brousht about: a) Joining both floor elements via a horizontal movement with respect to each other, the so-called“snap connection”;

b) Connecting a floor element horizontally and the other floor element via a vertical movement to the first floor element. The so-called“fall-down” or“push-down” connections.

A significant drawback of the horizontal movement, better known as the snap movement, of the floor elements with respect to each other is the fact that, on the one hand, an accessory and a hammer are required in order to connect the floor elements to each other by using a hammering movement with the hammer. On the other hand, the force of the hammering movement applied to the floor elements may cause damage to the decorative top layer. The same phenomenon may occur when the accessory is not handled correctly, which is intended to prevent damage of the projecting tooth at the other end of the floor element to be connected. When using the hammer for moving the floor elements horizontally with respect to each other, a well-measured force has to be used to hammer on the correctly placed accessory in order to achieve a secure connection. In addition, it is also important that the moving floor element is brought to the other floor element at a steady pace to likewise prevent damage. In practice, it has been found that this is also practically impossible due to the point load of the hammer.

Because of the described problematic nature of the horizontal snap connection, a user- friendly technology is being developed, i.e. connecting the panel to be attached vertically with respect to the horizontally placed panel. More specifically, the fall- down or push-down technology. By means of this technology, the issues regarding the use of accessories and the well-measured joining by means of a hammer are largely resolved.

However, with most commonly known techniques, a problem remains with regard to any damage of the two decorative sides because of the vertical scraping movement with respect to each other during the“falldown” process.

Another common problem is the fact that the connection is not able to absorb any relatively large upward forces caused by uneven structures in the floor. The reason for this is that often the force used to join the floor elements to each other is also the force with which these can become detached from each other (Cfir EP 0085196 and EP 0562402). Due to the fact that the floor elements are pressed down by means of a simple press of the thumb, this relatively low force is the same with which these floor elements may become detached from each other. In order to improve this last problem, certain versions are already known which use inserts made of a different material from that of the floor element itself (cfr EP 1 650 375 and EP 1 415 056).

The above-described connection methods were developed specifically to either connect the longitudinal sides of adjacent profiled strips to each other or to connect the end sides of adjacent profiled strips to each other. The described connection methods do not make it possible to connect all sides, both vertically and horizontally to other similar profiled strips in order thus to create different laying patterns in this way.

International patent publication WO 2006/043893 describes a solution which allows the longitudinal side of a floor panel to be connected to the end side of an adjacent floor panel in order thus to create different laying patterns. In this case, a displacement groove is provided in the edge of one first floor panel into which a flexible projection is arranged which is designed, in the connected position, to cooperate with a groove provided in the edge of an adjacent second floor panel. While connecting (locking) both floor panels by means of so-called vertical bending, the flexible projection is displaced twice in the displacement groove, a first displacement is brought about by vertically bending the second floor panel, in which case at least a part of the flexible projection is bent in the horizontal direction, and a second displacement towards its inital position which is brought about by a spring effect caused by bending of the flexible projection. However, this solution has the drawback that the panels have to be sufficiently thick to thus have sufficient space (matter) for producing the receiving groove. For panels whose thickness is limited to between 3 mm and 6 mm, this solution is not feasible.

The so-called DreamClick system by Berry Alloc also makes it possible to connect vinyl tiles and boards to each other by means of their different sides. To this end, each side provided with a number of spaced-apart projections which can be received in a fitting manner in corresponding recesses provided in the sides of an adjacent tile or board. A drawback of this system is the fact that the sides are only supported at the locations where the projections are situated and consequently not along their entire length.

European patent publication EP 3 121 348 describes a panel in which the longitudinal sides and/or the end sides are provided with complementary hook-shaped connecting means. In order to prevent the connection between two adjacent panels (sides) from coming apart, the connecting surface of the one side is provided with a locking element in the form of a groove and the connecting surface of the adjacent side is provided with a locking part which is in the form of a projecting part cooperating with the locking element. However, with the longitudinal and end connection proposed in EP 3 121 348, it is not possible to connect an end side of one panel to the longitudinal side of an adjacent panel. In addition, according to the proposed method of milling the flexible locking lip, there is a considerable risk of this lip breaking off when installing the floor elements after the connection has been brought about due to material fatigue in combination with a notch effect.

It is now an object of the present invention to provide a profiled strip of limited thickness, preferably a thickness of between 3 mm and 10 mm, in which the user has the possibility to connect profiled strips to each other in any desired direction in order thus to be able to produce different laying patterns. Furthermore, the profiled strip serves to make a convenient connection of different profiled strips possible, in which the connection can be disconnected retrospectively, if necessary, in a relatively simple manner and this without causing damage to the connecting means, so that the profiled strip can still be used later. In addition, it is also an object, in view of the innovative production method, to be able to adjust the connection in a simple way in case of a changing material composition or environmental conditions, such as changing ambient temperatures during milling of the connecting means.

The object of the invention is achieved by providing a profiled strip comprising a visible side, a first longitudinal side, provided with first male connecting means, and a second longitudinal side situated opposite the first longitudinal side, provided with first female connecting means, which profiled strip is furthermore, on a first end side, provided with second male connecting means and, on a second end side situated opposite the first end side, is provided with second female connecting means, wherein said connecting means are suitable for connecting the longitudinal sides and/or the end sides of adjacent profiled strips to each other, wherein the second male connecting means comprise a locking element and the first and second female connecting means comprise a locking part cooperating with the locking element, wherein the locking element is formed by a bent element which is made from the same material as the profiled strip, wherein the lateral face of the second male connecting means comprises a first inwardly facing recess and an adjacent second inwardly facing recess, wherein the transition between the first and second recess forms a contact surface for the locking element. In order to produce the locking element, a projecting lip was first formed during production by means of a milling operation and this was then bent in the direction of the lateral face of the second male connecting means. For the sake of clarity, the respective lateral face of the second male connecting means is the milled lateral face in which inter alia the first and second inwardly facing recesses are provided and this for bending the projecting lip. In order to bend the lip, its base was first heated. After bending, the lip was cooled down while being held in its bent position.

By constructing the second male connecting means in this way, it is possible to connect the first end side of a profiled strip to both the second end side of an adjacent profiled strip and to the second longitudinal side of an adjacent profiled strip, and this by means of performing a pressure movement in a direction perpendicular to the face of the visible side. Said inwardly facing first and second recess are grooves which extend along the direction of the end side. Preferably, the first and second recess are of a rounded design.

Due to the fact that the user, with a profiled strip which is designed in such a way, has the possibility to choose if he wants to connect the end sides of adjacent profiled strips to each other or to connect the end side to a longitudinal side of an adjacent profiled strip, different laying patterns may be produced. In addition, support will be provided along the entire length with this connection, due to the fact that both the locking element and the locking part cooperating therewith extend along the entire length of the side on which they have been provided. The locking element and the locking part cooperating therewith is provided to produce a vertical lock between adjacent profiled strips. In the context of the present invention, the vertical lock is to be regarded as a lock in the vertical direction, virtually perpendicular to the face of the visible side.

The locking element is preferably a flexible locking element which was bent in the direction of the milled lateral face (for bending) of the second male connecting means during the production of the profiled strip. Due to the fact that the locking element is bent, the lateral face of the second male connecting means can be provided with a first and second recess. Preferably, the second recess is deeper than the first recess. The respective recesses allow a greater flexibility of the locking element and make it readily possible for the profiled strip to be uninstalled again without causing damage, in particular to the locking element, provided it is connected to an adjacent profiled strip. With the known profiled strips, a profiled strip could only be detached again by performing a sliding movement. It was not possible to detach the profiled strips from each other by means of a simple turning movement without damaging the locking elements.

Due to the second recess, the risk of the bent locking element breaking off during installation, but mainly during removal, is much reduced. The reason for this is that the notch effect has been reduced as a result of the projecting lip having been heated and bent.

Due to the way in which this second male locking means is produced, namely by means of milling, heating, bending and subsequently cooling again, it is also possible to produce said connecting means which are suitable for connecting the longitudinal sides and/or end sides of adjacent profiled strips to each other for smaller thicknesses, preferably from 3 mm, more particularly for thicknesses of between 3 and 6 mm.

Because of the second recess, which is situated under said contact surface, the locking element will have some clearance when the bent locking element bears against the contact surface and this will allow the locking element to move (tilt away) in a direction away from the lateral face. There is an additional (extra) spring effect, as it were, which will absorb, in particular, the forces on the bent locking element during installation and removal of two adjacent profiled strips.

By adjusting the depth of the first recess, the thickness of the projecting lip of the locking element can be modified; a deeper first recess makes it possible to make the locking element (lip) thicker.

In practice, the width of the bent locking element will be adjusted, preferably at the location of the base thereof, to the type of material from which the profiled strip is made. The profiled strip is preferably made of a plastic material. Thus, for example, depending on the density and mechanical properties of the base material of the profiled strip, the bent lip of the locking element can easily be modified to form a design which can guarantee the best locking action for absorbing horizontal or vertical forces after installing the profiled strips or floor or wall.

In a preferred embodiment of the profiled strip according to the invention, the lateral face of the second male connecting means has a connecting surface situated at the location of the edge of the upper face of the profiled strip, followed by said first and second recess. The base of the bent locking element adjoins the second recess. The locking element extends in the direction of the visible side of the profiled strip. Preferably, the locking element is directed upwards.

Due to its design and position, the bent element is displaceable while the profiled strips are being connected (locked), partly bearing against the lateral face (the end side) and partly (in particular the end thereof) at a distance from the lateral face.

While executing the vertical movement of a (second) profiled strip, which is to be placed, in the direction of a first profiled strip, which has already been placed, the bent element will be displaced twice. A first displacement is brought about by moving the second profiled strip vertically, with at least a part of the bent element of the first profiled strip, in particular its distal end, being bent in the direction of the lateral face of the first profiled strip, and a second displacement into its initial position which is brought about by a spring effect, caused by the bending of the distal end of the bent element. In this way, the locking element will come to lie against the locking part of the adjacent profiled strip in an easy manner, thus producing the vertical lock. This connection, with regard to the first embodiment, requires less force, as a result of which the use of an accessory is no longer required. Preferably, the distal end of the bent element contacts a wall of the female connecting means in the coupled position of two profiled strips. This portion of the wall of the female connecting means will then form the locking part for the locking element.

In a particular embodiment of the profiled strip according to the invention, the first and second female connecting means comprise a bendable projection and the first and second male connecting means furthermore comprise a recess, wherein the bendable projection is provided to perform a bending movement in the direction of the adjacent longitudinal or end side while adjacent profiled strips are being connected in order subsequently to bend back, at least partly, to its original position when the first or second male connecting means engage in the first or second female connecting means. Said bendable projection will also produce a vertical lock by engaging in the adjacent recess.

In a more preferred embodiment, the profiled strip according to the invention is of a single-part design. The profiled strip according to the invention, and thus also the bendable projection and the bent projection, as the case may be, are preferably made of plastic, more particularly of PVC, PP and PE. This has the advantage that such profiled strips may be used to produce a floor covering or wall covering which is water- resistant.

In a preferred embodiment, the profiled strip comprises a decorative top layer. This top layer is preferably fixedly connected to the visible side of the profiled strip.

According to a more particular embodiment of the profiled strip according to the invention, the longitudinal sides of adjacent profiled strips are connected to each other by rotation (turning movement). In order to achieve the longitudinal connection, the first female connecting means comprise a recess and the first male connecting means comprise a projecting part with a shape similar to the shape of said recess. A part of this recess will form the locking part for the locking element of the second male connecting means in case an end side is connected to a longitudinal side. In particular, the first longitudinal side of a profiled strip is connectable to the second end side of an adjacent profiled strip by means of rotation. More particularly, the first end side of a profiled strip is connectable to the second end side and/or second longitudinal side of an adjacent profiled strip by means of a vertical movement.

The profiled strip according to the present invention preferably has a thickness of between 3 mm and 10 mm, more particularly of between 3 and 6 mm, most particularly of between 4 and 6 mm.

The present invention furthermore relates to a set of profiled strips comprising at least two profiled strips as described above. Such a set forms a floor covering or wall covering.

Another subject of the present invention relates to a method for producing a profiled strip, comprising: a first longitudinal side, provided with first male connecting means, and a second longitudinal side situated opposite the first longitudinal side, provided with first female connecting means, which profiled strip is furthermore, on a first end side, provided with second male connecting means and, on a second end side situated opposite the first end side, is provided with second female connecting means, wherein said connecting means are suitable for connecting the longitudinal sides and/or the end sides of adjacent profiled strips to each other, wherein the method comprises the following steps:

supplying a panel-shaped profiled section made of plastic;

sawing the profiled section produced to the desired length;

performing one or several milling operations in order to produce at least one bendable projection and a first inwardly facing recess and an adjacent second inwardly facing recess on the first end side of the sawed profiled section; heating the produced projecting element and subsequently bending it at a desired angle until it touches the transition between the first and second formed recess in order to form a locking element.

Heating will be effected by means of a heating element, e.g. an infrared heater or a heat gun or a nozzle with hot air which will bring the material to a suitable temperature at which the material of the projection becomes mouldable. Once the material is mouldable, the projection is bent at a desired angle until it touches the end side and is temporarily held there. Preferably, the material is cooled while it is being temporarily held, for example by passing coolant through the element which will bend the projection or via additional air circulation. After cooling, a bent projection is formed which partly bears against the end side. When the bent projection bears against the transition between the first and second recess, this transition forms a contact surface for the bent projection (locking element). In this case, the locking element will acquire additional flexibility as a result of the second recess. This is of particular importance when installing or removing the profiled strip. Due to the additional flexibility, the profiled strip can be detached from the adjacent profiled strip again more easily without damaging the locking means.

The distal end of the bent projection does not lie against the head end, as a result of which it is displaceable (compressible), as a result of which it will be displaced in the direction of the end side while it is being connected to an adjacent profiled section and will move back to its original position after the connection has been produced and will thus, in its connected position, contact a wall of the female connecting means.

The method according to the present invention is suitable for producing a profiled strip as described above.

In order to explain the properties of the present invention and to indicate additional advantages and features thereof, there now follows a more detailed description of the profiled strip (the floor panel) according to the invention. It will be clear that nothing in the following description may be interpreted as a limitation of the scope of protection defined in the claims.

In this description, reference numerals are used to refer to the attached drawings, in which:

Fig. 1 shows a representation of the second end side of the profiled strip according to the invention, provided with the second female connecting means;

Fig. 2 shows a representation of the first longitudinal side of the profiled strip according to the invention, provided with the first male connecting means; Fig. 3 shows a representation of the second longitudinal side of the profiled strip according to the invention, provided with the first female connecting means;

Fig. 4 shows a representation of the connection of the first longitudinal side, as illustrated in Fig. 2, to the second longitudinal side of an adjacent profiled strip; Fig. 5 shows the bending of a projection in order to produce the bent projection which forms the locking element in an embodiment of the profiled strip according to the invention;

Fig. 6 shows a representation of the connection of the first end side to the second end side or the second longitudinal side of an adjacent profiled strip;

Figs. 7 and 8 show, in a stepwise manner, two different ways of bending a projecting element in order to produce a locking element;

Figs. 9 to 11 show a number of variants of the locking lip;

Fig. 12 shows a detail representation of the projecting lip which will form the locking element after it has been bent after it has been produced by executing one or several milling operations and before it is bent;

Fig. 13 shows a detail representation of the locking element formed by bending the projecting lip;

Figs. 14 to 16 show a number of possible laying patterns which may be produced using the profiled strip according to the invention.

The present profiled strips 1 and which are to be connected to each other are preferably elongate floor elements which are substantially composed of a polymer or polyolefins, such as for example PVC. Obviously, other embodiments, such as e.g. square, or wall parts provided with connecting means as described in this text, also fall within the scope of protection of the present invention. The profiled strip according to the invention has two pairs of parallel sides, wherein the pairs have corresponding connecting means in order to connect different profiled strips to each other by means of their sides.

In their connected position, the floor elements define a vertical plane. The materials which could possibly be used for producing the profiled strip (1) depend on the mechanical properties. The profiled strip (1) has a decorative finish on the upper side. Preferably, the profiled strip according to the present invention has a thickness of between 3 mm and 10 mm, more particularly of between 3 mm and 6 mm. The profiled strip (1) has a first longitudinal side (2A), provided with first male connecting means, and a second longitudinal side (2B) situated opposite the first longitudinal side, provided with first female connecting means. The profiled strip (1) is furthermore, on a first end side (3 A), provided with second male connecting means and, on a second end side (3B) situated opposite the first end side (3 A), is provided with second female connecting means. By means of the connecting means, profiled strips (1) can be connected or coupled to each other, so that they are locked to each other both in a horizontal direction, perpendicular to the side of a profiled strip and in the plane of the floor panels, and in a vertical direction, perpendicular to the plane of the coupled floor panels. For vertical locking, the second male connecting means are provided with a locking element (4) and the first and second female connecting means have a locking part (5) which cooperates with the locking element (4) and is in the form of a groove extending in the longitudinal direction of the respective side.

The present invention inter alia provides a solution which offers the user the possibility to choose whether he wants to connect the end sides (3A,3B) of adjacent profiled strips (1, G) to each other or wants to connect the end side (3 A) to a longitudinal side (2B) of an adjacent profiled strip. As Figs. 14 to 16 show, this makes it possible to produce various laying patterns.

In order to connect the end side to both the end side and the longitudinal side of an adjacent profiled strip, the second male connecting means comprise a locking element (4) of a specific design. Due to the fact that both the first and second female connecting means are provided with a locking part (5) which cooperates with the locking element (4), the first end side (3 A) of a profiled strip is connectable to the second end side (3B) and the second longitudinal side (2B) of an adjacent profiled strip (G) by means of a vertical movement, more specifically via the fall-down or push-down technology.

The respective locking element (4) and the locking part (5) cooperating therewith are provided to produce a vertical lock between adjacent profiled strips.

The locking element (4) (locking lip) is formed by a bent element (6b) which is made from the same material as the profiled strip. The bent element (6b) is produced, as is illustrated in Figs. 7 and 8, by bending a projecting element (6a) formed during the manufacture of the profiled strip in the direction of the lateral face (11) (see Fig. 5) of the second male connecting means by means of heat. Due to its design and position, this bent element (6b) partly bears against the lateral face (the end side) and is partly (in particular the end) displaceable at a distance from the lateral face (11) while the connection (locking) is being brought about. While performing the vertical movement of the (second) profiled strip to be installed in the direction of a first, already installed, profiled strip, the bent element (6b) will be displaced twice, a first displacement is brought about by moving the second profiled strip vertically, with at least a part of the bent element (6b) of the first profiled strip, in particular its distal end, being bent in the direction of the lateral face (11) of the first profiled strip, and a second displacement into its initial position which is brought about by a spring effect, caused by the bending of the distal end of the bent element (6b). In a connected position, the locking element (4), in the form of the bent element (6b), comes to lie against the locking part (5) of the adjacent profiled strip and the vertical lock is produced. This connection requires less force, as a result of which the use of an accessory is no longer required. As can be seen in Fig. 6, the bent element (6b) or bent projection (6b), in a coupled position of two profiled strips, contacts a wall of the female connecting means with its distal end. This portion of the wall of the female connecting means will then form the locking part (5) for the locking element (4).

Due to the fact that the locking element (4) is only formed after the various milling operations have been performed by bending the projecting element (6a), the lateral face (1 1) of the end side where the locking element is situated, may be provided with a first (9) and second recess (10), with the second recess (10) being deeper than the first recess (9). As can clearly be seen in Figs. 12 and 13, the recesses (9, 10) adjoin each other. They have a curved shape. In this case, the transition (12) between the first (9) and second recess (10) will form a contact surface for the locking element (6b).

The respective recesses (9 and 10) allow the locking element to have greater flexibility and make it possible for the profiled strip to be removed again easily, if it is connected to an adjacent profiled strip, without causing damage, in particular to the locking element. By modifying the depth (see Figs. 10 and 11) of the first recess (9), the thickness and the design of the projecting lip of the locking element may be adjusted. A deeper first recess (9) (see Fig. 11) makes it possible to make the locking element (lip) thicker. As is shown in Fig. 9, the shape of the projecting lip may also be modified. Providing a constriction will contribute to the flexibility of the lip.

As can be seen in, inter alia, Figs. 1 and 3, the second end side and the second longitudinal side have a design which makes them suitable to receive the second male connecting means. In one possible embodiment, the first and second female connecting means comprise a bendable projection (7) and the first and second male connecting means furthermore comprise a recess (8), with the bendable projection being provided to perform a bending movement in the direction of the adjacent longitudinal or end side while adjacent profiled strips are being connected, in order to then at least partly bend back to its original position when the first or second male connecting means engage in the first or second female connecting means. Said bendable projection (7) will also produce a vertical lock as a result of engaging in the adjacent recess.

Coupling two adjacent profiled strips by means of their longitudinal sides (2A, 2B) will be effected through a turning movement. In order to bring about the longitudinal connection, the first female connecting means comprise a recess and the first male connecting means comprise a projecting part having a shape similar to the shape of said recess. A part of this recess will form the locking part for the locking element of the second male connecting means in case an end side is connected to a longitudinal side.

A profiled strip (1) comprising: a first longitudinal side (2A), provided with first male connecting means, and a second longitudinal side (2B) situated opposite the first longitudinal side, provided with first female connecting means, which profiled strip (1) is furthermore, on a first end side (3 A), provided with second male connecting means and, on a second end side (3B) situated opposite the first end side (3 A), is provided with second female connecting means, wherein said connecting means are suitable for connecting the longitudinal sides (2A,2B) and/or the end sides (3A,3B) of adjacent profiled strips to each other, is produced by means of a method which at least comprises the following steps: supplying a panel-shaped profiled section made of plastic;

sawing the profiled section produced to the desired length;

performing one or several milling operations in order to produce at least one bendable projecting element (6a) and a first inwardly facing recess (9) and an adjacent second inwardly facing recess (10) on the first end side (3 A) of the sawed profiled section;

heating the produced projecting element (6a) and subsequently bending it at a desired angle until it touches the transition between the first and second formed recess in order to form a locking element (4).

Figs. 7 and 8 show two possible embodiments of the method according to the invention. Heating will be carried out by means of a heating element, e.g. infrared heater, a heat gun or a heating nozzle with hot air which will, at the location of the base, bring the material of the projecting lip (6a) to the suitable temperature at which the material of the projecting element (6a) becomes mouldable. Once the material is mouldable, the projecting element (6a) is bent by means of an element which was specifically developed for the purpose in order to bend it at a desired angle, in the direction of the end side, and temporarily hold it there, while it is cooled until the material has cooled down and will remain in position. After cooling, a bent projecting element (6b) is formed which almost or partly bears against the transition (12) (contact surface) between the first (9) and second (10) recess end side. The distal end of the bent element (6b) does not lie against the head end, but is at a small distance therefrom, as a result of which it is very slightly displaceable (compressible). Such an embodiment makes it possible for the bent element (6b) to be displaced, at least partly, in the direction of the end side while being connected to an adjacent profiled section in order to facilitate locking. After the connection has been brought about, the displaced part of the bent element (6b) will move back to its original position, so that it will contact a wall of the female connecting means in the connected position and is locked.

The method for producing the profiled strip according to the invention and the profiled strip itself are described still further in the French priority application FR 1850487 whose description, claims and figures form an integral part of this description.