PANEL FOR PRODUCING A FREE-LYING FLOOR COVERING

Abstract

A panel (1) having the shape of a plank or a tile for the production of a floor covering, the panel (1) comprising two pairs of opposed sides defining: two opposed edges for inclined assembly (2), wherein one edge comprises male coupling means (4) provided from a lateral wall of the panel (1), and an opposed edge comprising complementary female coupling means (5) provided from a lateral wall of the panel (1); two opposed edges for vertical assembly (3), wherein one edge comprises male coupling means (6) provided from a lower face of the panel (1), and an opposed edge comprising complementary female coupling means (7) provided from an upper face of the panel (1);
characterized in that: the male coupling means (6) of the edges for vertical assembly (3) comprise a male groove (6a) extending along the edge and opening onto the lower face of the panel (1) in a manner such as to define a male tenon (6b), the male tenon (6b) having an outer wall (6c) which is inclined with respect to a vertical plane and towards the outside of the panel (1); the female coupling means (7) of the edges for vertical assembly (3) comprise a female groove (7a) extending along the edge and opening onto the upper face of the panel (1) in a manner such as to define a female tenon (7b); the male coupling means (6) of the edges for vertical assembly (3) comprise a lug (10) or a notch (11) and the female coupling means (7) of the edges for vertical assembly (3) comprise a complementary notch (11) or lug (10) which, after assembly of two adjacent panels (1), form abutment stops to counteract a vertical displacement between two adjacent assembled panels (1).

Claims

1. A panel (1) having a shape of a plank or a tile for a production of a floor covering, the panel (1) comprising two pairs of opposed sides defining: two opposed edges for inclined assembly (2), wherein one edge comprises male coupling means (4) provided from a lateral wall of the panel (1), and an opposed edge comprising complementary female coupling means (5) provided from a lateral wall of the panel (1); two opposed edges for vertical assembly (3), wherein one edge comprises male coupling means (6) provided from a lower face of the panel (1), and an opposed edge comprising complementary female coupling means (7) provided from an upper face of the panel (1); characterized in that: the male coupling means (6) of the edges for vertical assembly (3) comprise a male groove (6a) extending along the edge and opening onto the lower face of the panel (1) in a manner such as to define a male tenon (6b), the male tenon (6b) having an outer wall (6c) which is inclined with respect to a vertical plane and towards the outside of the panel (1); the female coupling means (7) of the edges for vertical assembly (3) comprise a female groove (7a) extending along the edge and opening onto the upper face of the panel (1) in a manner such as to define a female tenon (7b); the male coupling means (6) of the edges for vertical assembly (3) comprise a lug (10) or a notch (11) and the female coupling means (7) of the edges for vertical assembly (3) comprise a complementary notch (11) or lug (10) which, after assembly of two adjacent panels (1), form abutment stops to counteract a vertical displacement between two adjacent assembled panels (1).

2. The panel (1) as claimed in claim 1, characterized in that the female tenon (7b) comprises a portion which is chamfered (12) at a level of the lower face of the panel (1) and forms an angle of between 2° and 20° with respect to the lower face of the panel (1).

3. The panel (1) as claimed in claim 2, characterized in that the chamfered portion (12) of the female tenon (7b) extends to level with the upper inner ridge of the female tenon (7b).

4. The panel (1) as claimed in claim 1, characterized in that the male tenon (6b) has an inner wall which is inclined with respect to a vertical plane and towards the outside of the panel (1).

5. The panel (1) as claimed in claim 1, characterized in that the outer wall (6c) and inner wall of the male tenon (6b) are inclined at an angle of between 1° and 45°, and preferably of between 5° and 15°.

6. The panel (1) as claimed in claim 5, characterized in that the outer wall (6c) and inner wall of the male tenon (6b) are inclined at a same angle.

7. The panel (1) as claimed in claim 1, characterized in that the male tenon (6b) comprises a portion (13) which is chamfered at a level of the upper face of the panel (1) and which forms an angle of between 2° and 20° with respect to the upper face of the panel (1).

8. The panel (1) as claimed in claim 1, characterized in that the lug (10) or notch (11) is provided on the outer wall of the male tenon (6b) and, in a complementary manner, the notch (11) or lug (10) is provided on an inner wall of the female groove (7a).

9. The panel (1) as claimed in claim 1, characterized in that the lug (10) or notch (11) is provided on the outer wall of the female tenon (7b) and, in a complementary manner, the notch (11) or lug (10) is provided on an inner wall of the male groove (6a).

10. The panel (1) as claimed in claim 1, characterized in that the male coupling means (6) of the edges for vertical assembly (3) comprise two lugs (10) or notches (11), and the female coupling means (7) of the edges for vertical assembly (3) comprise two complementary notches (11) or lugs (10).

11. The panel (1) as claimed in claim 1, characterized in that the male coupling means (4) of the edges for inclined assembly (2) comprise a tongue (8) which protrudes from the lateral wall of the panel (1) and over an entire length of the edge, and the female coupling means (5) of the edges for inclined assembly (2) comprise a complementary groove (9) provided in the lateral wall of the panel (1) and over an entire length of the edge.

12. The panel (1) as claimed in claim 11, characterized in that the tongue (8) comprises a lug (8a) which protrudes vertically, and the complementary groove (9) comprises a complementary notch (9a) which, after assembly of two adjacent panels (1), form abutment stops to counteract a horizontal displacement between two adjacent assembled panels (1).

13. The panel (1) as claimed in claim 11, characterized in that the groove (9) defines a flexible lower female tongue (8) which is intended to be displaced during inclined engagement of the tongue (8) of the male coupling means (4), then to resume its position after engagement in order to increase the resistance of the two adjacent assembled panels (1) to vertical and horizontal uncoupling.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0032] Other advantages and features will become apparent from the following description of several embodiments, given by way of non-limiting examples of the panel in accordance with the invention, made with reference to the accompanying drawings in which:

[0033] FIG. 1 is a diagrammatic representation illustrating the male and female coupling means of a panel of the prior art making a vertical movement;

[0034] FIG. 2 is a diagrammatic representation of two panels in accordance with the invention, with two opposed edges for inclined assembly, and two opposed edges for vertical assembly;

[0035] FIG. 3 is a partial cross sectional view of a particular embodiment of the edges for inclined assembly of two panels during the course of assembly;

[0036] FIG. 4 is a partial cross sectional view of a particular embodiment of the edges for vertical assembly of two panels during the course of assembly;

[0037] FIG. 5 is a partial cross sectional view similar to that of FIG. 4, with the two panels having been assembled;

[0038] FIG. 6 is a partial cross sectional view of another particular embodiment of the edges for inclined assembly of two panels during the course of assembly.

DETAILED DESCRIPTION OF THE INVENTION

[0039] With reference to FIG. 2, the invention concerns a panel (1) in the shape of a plank or tile for the production of a loose laid floor covering.

[0040] The floor panel (1) in accordance with the invention is preferably produced from a plastic material such as polyvinyl chloride, for example plasticized, and optionally comprising a mineral filler. Clearly, however, the panel (1) in accordance with the invention may be obtained from any appropriate plastic material.

[0041] In accordance with a particular embodiment, the panel (1) is resilient, for example produced from plasticized or rigid polyvinyl chloride.

[0042] Preferably, the panel (1) has a core bonded to a decorative layer constituted by a decor film bonded to a transparent surface layer.

[0043] The core may be single-layered or multi-layered and, for example, produced from a plastic material such as polyvinyl chloride, polypropylene, polyurethane, thermoplastic polyurethane, polyethylene, polyethylene terephthalate, or any other appropriate plastic material, and optionally comprising fillers in the form of fibres, chips, wood dust or sawdust and/or mineral fillers, for example chalk, lime, talc, and one or more plasticizers in order to define the rigidity of the core.

[0044] The core, or a layer of the core in the case of a multi layered core, may optionally be based on urea formaldehyde or melamine formaldehyde and wood, for example layers of medium density fibres (MDF) or high density fibres (HDF). Each layer may also be a layer of laminated wood or wood composite (WPC, wood plastic composite).

[0045] Each layer may be compact or foamed. By way of example, the core may be produced with a foamed layer of rigid polyvinyl chloride interposed between two layers of compact rigid polyvinyl chloride.

[0046] In known manner, the panel (1) comprises a rectangular shape and comprises two pairs of opposed sides defining four edges, of which two opposed edges are for inclined assembly (2), and two other opposed edges are for vertical assembly (3). Clearly, the panel (1) may also be square in shape.

[0047] From the foregoing, assembly of this type of panel (1) is carried out in accordance with an inclined movement on a first edge (2), for example at an angle of between 10° and 50°, and in accordance with a vertical movement on an adjacent second edge (3).

[0048] In particular, when fitting this type of panel (1), the fitter fits a first line of panels (1), by assembling them side, by side in a vertical assembly movement. Next, the fitter starts a second line of panels (1) by assembling a first panel (1), in accordance with a movement which is inclined with respect to the panels (1) of the preceding line. The panels (1) of the second line are assembled in accordance with a movement which is inclined with respect to the panels (1) of the preceding line and, by a pivoting movement of the panel (1) in the direction of the floor, the panel (1) is assembled with the adjacent panel (1) in accordance with a vertical movement.

[0049] Preferably, when the panels (1) are rectangular in shape, the long sides are assembled in accordance with an inclined movement, while the short sides are assembled in accordance with a vertical movement.

[0050] Referring now to FIG. 3, the opposed edges for inclined assembly (2) consist of an edge comprising male coupling means (4) provided from a lateral wall of the panel (1), and of an opposed edge comprising complementary female coupling means (5) provided from a lateral wall of the panel (1).

[0051] With reference to FIG. 4, the opposed edges for vertical assembly (3) consist of an edge comprising male coupling means (6) provided from a lower face of the panel (1) and of an opposed edge comprising complementary female coupling means (7) provided from an upper face of the panel (1).

[0052] With reference to FIG. 5, after assembly, the facing upper ridges the two panels (1) are preferably in contact for an optimal aesthetic appearance.

[0053] In accordance with the invention and with reference to FIG. 3, the male coupling means (4) of the inclined assembly edges (2) comprise a tongue (8) which protrudes from the lateral wall of the panel (1) and over the entire length of the edge. The female coupling means (5) of the inclined assembly edges (2) comprise a complementary groove (9) provided in the lateral wall of the panel (1) and over the entire length of the edge.

[0054] The cooperation between the tongue (8) and the groove (9) means that vertical uncoupling of the two panels (1) can be resisted in an optimal manner.

[0055] In order to resist horizontal uncoupling, the tongue (8) comprises a lug (8a) which protrudes vertically, and the complementary groove (9) comprises a complementary notch (9a) which, after assembly of two adjacent panels (1), forms stop abutments to counteract a horizontal displacement between two adjacent assembled panels (1). Clearly, the tongue (8) may comprise a notch and the groove (9) may comprise a lug without departing from the scope of the invention.

[0056] As mentioned above, engagement of the tongue (8) in the groove (9) occurs in accordance with an inclined movement, then by pivoting the panel (1), the tongue (8) is displaced horizontally towards the bottom of the groove.

[0057] In accordance with another embodiment of the opposed inclined assembly edges (2) illustrated in FIG. 6, the complementary groove (9) of the female coupling means (5) defines a flexible lower female tongue (9b) which is intended to be displaced during inclined engagement of the tongue (8) of the male coupling means (4), then to resume its position after engagement in order to increase the resistance to vertical and horizontal uncoupling of two adjacent panels (1).

[0058] With reference to FIGS. 4 and 5, the male coupling means (6) of the vertical assembly edges (3) comprise a male groove (6a) extending along the edge and opening onto the lower face of the panel (1) in a manner such as to define a male tenon (6b).

[0059] In the same manner, the female coupling means (7) of the vertical assembly edges (3) comprise a female groove (7a) extending along the edge and opening onto the upper face of the panel (1) in a manner such as to define a female tenon (7b).

[0060] The male and female tenons (6b, 7b) comprise substantially rectangular cross sections and are flexible and elastically deformable in order to allow them to engage in the corresponding female and male grooves (6a, 7a).

[0061] The male tenon (6b) has an outer wall (6c) which is inclined with respect to a vertical plane and towards the outside of the panel (1), at an angle of between 1° and 45°, and preferably of between 5° and 15°. An inclination of the outer wall (6c) of between 5° and 15° can be used to obtain a good compromise between the ease of assembly of the panels and resistance to horizontal uncoupling of the coupling means. Thus, during engagement of the male tenon (6b) in the female groove (7a) in accordance with a vertical movement, the male tenon (6b) will come into abutment with the upper portion of the female tenon (7b). As a consequence, during the fitting operation, the fitter can see the female groove (7a) and can therefore easily position the outer wall (6c) of the male tenon (6b) level with the female groove (7a) in order to commence assembly. This very substantially facilitates the vertical assembly operation during the rotational movement. Furthermore, and in an advantageous manner, given the inclination towards the outside of the outer wall (6c) of the male tenon (6b) and the complementary inclination of the inner wall of the female groove (7a), the two panels (1) approach each other during pivoting. This further facilitates the fitting operation and machining constraints which are involved in the production of a perfect contact at the surface of the panels (1) are also easier to accommodate.

[0062] In accordance with a particular embodiment, the male tenon (6b) has an inner wall which is inclined with respect to a vertical plane and towards the outside or inside of the panel (1).

[0063] Preferably, and to facilitate assembly of two adjacent panels (1), the male tenon (6b) has an inner wall which is inclined towards the outside of the panel (1) at an angle of between 1° and 45°, and preferably of between 5° and 15°. An inclination of the inner wall of the male tenon (6b) of between 5° and 15° also enables a good compromise to be obtained between the ease of assembly of the panels and the resistance to horizontal uncoupling of the coupling means, More preferably, the male tenon (6b) has an inner wall which is inclined at the same angle as the outer wall (6c). This feature also means that manufacture is facilitated, and in particular machining of the complementary male (6) and female (7) coupling means.

[0064] The engagement of the male tenon (6b) in the female groove (7a) means that horizontal uncoupling of two assembled panels (1) can be resisted.

[0065] In order to contribute to the resistance to vertical uncoupling, the male coupling means (6) of the vertical assembly edges (3) comprise a lug (10) or a notch (11), and the female coupling means (7) of the vertical assembly edges (3) comprise a complementary notch (11) or a lug (10) which, after assembly of two adjacent panels (1), form stop abutments which counteract a vertical displacement between two adjacent assembled panels (1).

[0066] A number of embodiments may be envisaged from the foregoing. As an example, the lug (10) or notch (11) is provided in the outer wall of the male tenon (6b) and in a complementary manner, the notch (11) or lug (10) is provided on an inner wall of the female groove (7a).

[0067] In accordance with another embodiment, the lug (10) or notch (11) is provided on the outer wall of the female tenon (7b) and, in a complementary manner, the notch (11) or lug (10) is provided on an inner wall of the male groove (6a).

[0068] Preferably, these two embodiments are combined in a manner such that the male coupling means (6) of the vertical assembly edges (3) comprise two lugs (10) or notches (11), and the female coupling means (7) of the vertical assembly edges (3) comprise two complementary notches (11) or lugs (10).

[0069] In order to further improve the resistance to vertical uncoupling, the male (6a) and female (7a) grooves each have an outer wall, i.e. not positioned on the side of the body of the panel (1), but positioned on the side of the outside of the panel (I), which are intended to come into contact after assembly of the two panels (1). In order to obtain contact, the grooves (6a, 7a) and tenons (6b, 7b) have appropriate widths and/or inclinations. By way of example, the tenons (6b, 7b) and grooves (6a, 7a) have widths of the order of 2 mm, and are inclined by 10° with respect to the vertical and towards the outside of the panel (1).

[0070] Thus, the outer wall of the male groove (6a) is in contact with the outer all of the female groove (7a). In practice, after assembly, these walls which are in contact are parallel to each other. After assembly, and preferably, the male tenon (6b) is in contact with the bottom of the female groove (7a) for vertical abutment. Furthermore, after assembly, there is preferably a clearance of a few tenths of a millimetre between the outer vertical wall of the female tenon (7b) located below the notch (11) and the vertical wall facing the male groove (6a) located below the lug (10). This feature can facilitate assembly.

[0071] In accordance with another feature of the invention, the female tenon (7b) comprises a chamfered portion (12) at the level of the lower face of the panel (1) and forms an angle of between 2° and 20° with respect to the lower face of the panel (1). Thus, during assembly of two adjacent panels (1), the chamfered portion (12) permits the female tenon (7b) to drop down in order to come into contact with the floor by deformation and thereby ensure a reduction in the force of assembly. In order to further facilitate the assembly operation, the chamfered portion (12) of the female tenon (7b) extends up to level with the upper inner ridge of the female tenon (7b).

[0072] Furthermore, the upper face of the panel (1) may also have chamfers 13) at the level of the male tenon (6b) and of the female groove (7a) in order to contribute to the general aesthetic appearance of the panels (1) after assembly. Each chamfer (13) forms an angle of between 2° and 20° with respect to the upper face of the panel (1). The interface between the two assembled panels (1) then forms a V-shaped groove, see FIG. 5.

[0073] It is apparent from the foregoing that the invention in fact provides a panel (1) for the production of a loose laid floor covering for which assembly is facilitated, while having an optimal resistance to horizontal and vertical uncoupling, as well as a satisfactory aesthetic appearance.