Panel and Covering

Abstract

The last decades has seen enormous advance in the market for flooring for floor covering. It is known to install floor panels on an underlying floor in various ways. The present invention relates to an improved panel, such as a floor panel, in particular a decorative floor panel. The invention also relates to a covering, in particular a floor covering, including multiple interconnected panels according to the invention.

Claims

1-45. (canceled)

46. A panel, in particular a floor panel, comprising: a. at least one first coupling part and at least one second coupling part arranged on opposite panel sides, wherein the first coupling part of said panel and the second coupling part of another panel are arranged to be coupled with a downward motion; b. wherein the first coupling part comprises an upward tongue, at least one upward flank lying at a distance from the upward tongue and an upward groove formed in between the upward tongue and the upward flank, wherein the upward groove is adapted to receive at least a part of a downward tongue of a second coupling part of another panel, wherein the side of the upward tongue facing towards the upward flank is the inside of the upward tongue and the side of the upward tongue facing away from the upward flank is the outside of the upward tongue, wherein at least a part of the inside of the upward tongue is inclined towards the upward flank; c. wherein the second coupling part comprises a downward tongue, at least one downward flank lying at a distance from the downward tongue, and a downward groove formed in between the downward tongue and the downward flank, wherein the downward groove is adapted to receive at least a part of an upward tongue of a first coupling part of another panel, wherein the side of the downward tongue facing towards the downward flank is the inside of the downward tongue and the side of the downward tongue facing away from the downward flank is the outside of the downward tongue), wherein at least a part of the inside of the downward tongue is inclined towards the downward flank; d. wherein the outside of the downward tongue and the upward flank both comprise an upper contact surface near or towards the top of the panel, wherein at least one of said contact surfaces preferably extends vertically at least partly, and wherein the upper contact surface of the outside of the downward tongue of said panel is configured to engage the upper contact surface of the upward flank of an adjacent panel, in coupled condition of said panels; e. wherein the outside of the upward tongue comprises a first locking element comprising an outward bulge and wherein the downward flank is provided with a second locking element comprising a recess, wherein, in coupled condition of adjacent panels, at least a part of the first locking element of said panel and at least a part of second locking element of an another panel are in contact to realize a locking effect, preferably a vertical locking effect, of the panels with respect to each other; f. wherein the outside of the outward bulge comprises an upper portion and an adjoining lower portion, wherein the lower portion comprises a planar inclined locking surface and the upper portion comprises a curved, guiding surface, wherein said inclined locking surface forms a crease with the curved upper portion; g. wherein the recess comprises a curved upper portion and an adjoining lower portion, wherein the lower portion comprises a planar inclined locking surface wherein said inclined locking surface forms a crease with the curved upper portion; and wherein, in coupled condition of adjacent panels, the inclined locking surface of the lower portion of the outward bulge and the inclined locking surface of lower portion of the recess are in contact to realize said locking effect between the panels and wherein, in coupled condition of adjacent panels, the upper portions of the first locking element and the second locking element are spaced apart at least partially.

47. The panel according to claim 46, wherein the entire inside of the upward tongue is inclined towards the upward flank, and wherein the entire inside of the downward tongue is inclined towards the downward flank.

48. The panel according to claim 46, wherein, in coupled condition of adjacent panels, the upper portions of the first locking element and the second locking element are entirely spaced apart.

49. The panel according to claim 46, wherein, in coupled condition of adjacent panels, solely a part of the inclined locking surface of the lower portion of the outward bulge co-acts with solely a part of the inclined locking surface of lower portion of the recess.

50. The panel according to claim 46, wherein at least a part of the upper portion of the outward bulge is positioned at a higher level than a level defined by the lowest point of the upward groove, and wherein at least a part of the upper portion of the recess is positioned at a higher level than a level defined by the lowest point of the upward groove.

51. The panel according to claim 46, wherein the length of the inclined locking surface of the lower portion of the outward bulge is larger, preferably at least 1.5 times larger, than the inclined locking surface of the lower portion of the recess.

52. The panel according to claim 46, wherein the upper portion extends over a larger vertical section compared to the lower portion, wherein, preferably, the height of the upper portion is at least three times the height of the lower portion.

53. The panel according to claim 46, wherein the outside of the upward tongue comprises an upper outside portion, and a lower outside portion, wherein the first locking element is arranged between the upper and lower outside portion, wherein the lower outside portion is arranged closer to the inside of the upward tongue compared to the upper outside portion.

54. The panel according to claim 53, wherein the upper outside portion is preferably substantially vertical and defines an outer vertical plane, wherein the first locking element protrudes from the outer vertical plane at least partially, preferably maximally 2 mm in horizontal direction.

55. The panel according to claim 46, wherein an outermost portion of the first locking element is arranged at a horizontal level which is lower compared to the upward groove.

56. The panel according to claim 46, wherein the upper contact surface of the downward tongue extends in vertical direction, and wherein the upper contact surface of the upward flank is downwardly inclined in a direction away from the upward tongue, wherein, preferably, the vertical upper contact surface of the downward tongue and the inclined upper contact surface of the upward flank mutually enclose angle of between 0 and 2 degrees.

57. The panel according to claim 46, wherein adjoining the upper contact surfaces both the downward tongue and the upward flank comprise an inclined contact surface, wherein the inclined contact surface of the downward tongue of said panel is configured to engage the inclined contact surface of the upward flank of an adjacent panel, in coupled condition of said panels, wherein each vertical part of the upper contact surface and each adjoining inclining surface mutually enclose an angle (a) between 100 and 175 degrees.

58. The panel according to claim 57, wherein the inclined contact surface of the downward tongue defines at least a part of the third locking element, and wherein the inclined contact surface of the upward flank defines at least a part of the fourth locking element.

59. The panel according to claim 57, wherein adjoining the inclined contact surface the downward tongue comprises an outer surface, situated below the inclined contact surface of the downward tongue, and wherein adjoining the inclined contact surface the upward flank comprises an inner surface, situated below the inclined contact surface of the upward flank, wherein the outer and inner surface run substantially parallel and, preferably extend at least partly in vertical direction and/or are at least partly curved.

60. The panel according to claim 46, wherein, in coupled condition of adjacent panels, a space is present between at least a part of the outer surface of said panel and at least a part the inner surface of an adjacent panel.

61. The panel according to claim 46, wherein, in coupled condition of adjacent panels, a bottom of the downward tongue contacts the upper side of the upward groove at a groove contact surface, and wherein a gap is present between the first and second coupling parts, extending from the inclined contact surfaces to the groove contact surface.

62. The panel according to claim 46, wherein, in coupled condition of adjacent panels, a bottom of the downward tongue contacts the upper side of the upward groove at a substantially horizontally, groove contact surface, and wherein gaps are present between the first and second coupling parts at both sides of said groove contact surface.

63. The panel according to claim 46, wherein an upper surface of the upward tongue and an upper surface of the downward groove, in coupled condition, are at least partly distanced from each other such that a gap is present between the two surfaces.

64. The panel according to claim 46, wherein the outside of the upward tongue comprises an upper outside portion which defines an outer vertical plane which divides the upward tongue into an inner section directed towards the upward flank, and an outer section which comprises the first locking element, wherein the maximum width of the inner section is at least 8 times the maximum width of the outer section.

65. The panel according to claim 46, wherein the panel comprises at least one third coupling part and at least one fourth coupling part arranged on another pair of opposite sides of the panel, wherein the third coupling part of said panel and the fourth coupling part of another panel are preferably arranged to be coupled by means of an angling down motion.

66. The panel according to claim 65, wherein the third coupling part comprises: a sideward tongue extending in a direction substantially parallel to the upper side of the core, at least one second downward flank lying at a distance from the sideward tongue, and a second downward groove formed between the sideward tongue and the second downward flank, and wherein the fourth coupling part comprises: a third groove configured for accommodating at least a part of the sideward tongue of the third coupling profile of an adjacent panel, said third groove being defined by an upper lip and a lower lip, wherein said lower lip is provided with an upward locking element, wherein the third coupling part and the fourth coupling part are configured such that two of such panels can be coupled to each other by means of a turning movement, wherein, in coupled condition: at least a part of the sideward tongue of a first panel is inserted into the third groove of an adjacent, second panel, and wherein at least a part of the upward locking element of said second panel is inserted into the second downward groove of said first panel.

67. The panel according to claim 46, wherein the panel is a decorative panel, comprising: at least one core layer, and at least one decorative top section, directly or indirectly affixed to said core layer, wherein the top section defines a top surface of the panel, a plurality of side edges at least partially defined by said core layer and/or by side top section, which at least two opposing side edges are provided with the first coupling part and the second coupling part, respectively.

68. A covering, in particular a floor covering, comprising multiple interconnected panels according to claim 46.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0066] The invention will now be elucidated on the basis of non-limitative exemplary embodiments which are illustrated in the following figures. Corresponding elements are denoted in the figures by corresponding reference numbers. In the figures:

[0067] FIG. 1 schematically shows two interconnected panels with first and second coupling parts according to the present invention;

[0068] FIG. 2 schematically shows a first coupling part of a panel according to the present invention and FIG. 1;

[0069] FIG. 3 schematically shows a second coupling part of a panel according to the present invention and FIG. 1;

[0070] FIG. 4 schematically shows an embodiment of two interconnected panels with first and second coupling parts according to the present invention;

[0071] FIG. 5 schematically shows a detailed view of part A of the embodiment shown in FIG. 4; and

[0072] FIG. 6 schematically shows a detailed view of part B of the embodiment shown in FIG. 4.

DESCRIPTION OF THE INVENTION

[0073] FIG. 1 shows a floor panel (1), comprising a first coupling part (2) and a second coupling part (3) in coupled condition. The first coupling part (2) comprises an upward tongue (4), an upward flank (5) lying at a distance from the upward tongue (4) and an upward groove (6) formed in between the upward tongue (4) and the upward flank (5), wherein the upward groove (6) adapted the downward tongue (7) of a second coupling part (3) of another panel (1). The side of the upward tongue (4) facing towards the upward flank is the inside (8) of the upward tongue (4) and the side of the upward tongue (4) facing away from the upward flank (5) is the outside (9) of the upward tongue (4).

[0074] The second coupling part (3) comprises a downward tongue (7), a downward flank (10) lying at a distance from the downward tongue (7), and a downward groove (11) formed in between the downward tongue (7) and the downward flank (10). The side of the downward tongue (7) facing towards the downward flank (10) is the inside (12) of the downward tongue (7) and the side of the downward tongue (7) facing away from the downward flank (10) is the outside (13) of the downward tongue (7).

[0075] The outside (13) of the downward tongue (7) and the upward flank (5) both comprise an upper contact surface (14) at the top of the panel (1), which upper contact surfaces (14) are in contact extend vertically. Adjoining the upper contact surfaces (14) both the downward tongue (7) and the upward flank (5) comprise an inclined contact surface (15), which inclined contact surfaces (15) are in contact, wherein the upper contact surfaces (14) on the one hand, and the inclined contact surfaces (15) of the upward flank (5) and/or the outside (13) of the downward tongue (7) on the other hand preferably mutually enclose an angle (a) of approximately 125 degrees. The upper contact surface (14) and the inclined contact surface (15) of the upward flank (5) mutually enclose a first angle of about 125 degrees, and the upper contact surface (14) and the inclined contact surface (15) of the downward tongue (7) mutually enclose a second angle of about 125 degrees.

[0076] Adjoining the inclined contact surface (15) the downward tongue (7) comprises an outer surface (16), and adjoining the inclined contact surface (15) the upward flank (5) comprises an inner surface (17), wherein the outer (16) and inner (17) surface are parallel and vertical. Between the outer surface (16) and the inner surface (17) a space (18) is present.

[0077] The upper contact surfaces (14) define an inner vertical plane (19), wherein the inclined contact surface (15) of the downward tongue (7) extends beyond the inner vertical plane (19) the inclined contact surface (15) of the upward flank (5) lies inward compared to the inner vertical plane (19). A portion (20) of the downward tongue (7) extends beyond the inner vertical plane (19), wherein said portion (20) is substantially trapezium-shaped or wedge-shaped. The inclined contact surfaces (15) are both arranged completely outside and adjoining the inner vertical plane (19). The portion (20) is elongated with a larger vertical portion compared to the horizontal portion.

[0078] The bottom (21) of the downward tongue (7) contacts the upper side (22) of the upward groove (6) at a groove contact surface (23), wherein a gap (24) is present between the first (2) and second (3) coupling parts, extending from the inclined contact surfaces (15) to the groove contact surface (23). Additionally the upper surface (25) of the upward tongue (4) and the upper surface (26) of the downward groove (11), are distanced from each other such that a gap (27) is present between the two surfaces (25, 26).

[0079] The outside (9) of the upward tongue (4) comprises a first locking element (28), in the form of an outward bulge and the downward flank (10) is provided with a second locking element (29), in the form of a recess, wherein the first (28) and at least a part of second (29) locking element are in contact, and form a locking element surface (30).

[0080] FIGS. 2 and 3 show the first and second coupling parts individually. The outside of the outward bulge (28) comprises an upper portion (31) and an adjoining lower portion (32), wherein the lower portion (32) comprises an inclined locking surface (30a) and the upper portion (31) comprises a curved, guiding surface (32′). The recess (29) comprises an upper portion (33) and an adjoining lower portion (34), wherein the lower portion comprises an inclined locking surface (30B). The upper portion (31, 33) extends over a larger vertical section compared to the lower portion (32, 34).

[0081] The parts of the first (28) and second (29) locking element that are in contact are the inclined locking surfaces (30, 30A, 30B) of the locking elements (28, 29) and the upper portions (31, 33) of the first (28) and second (29) locking elements are spaced apart at least partially.

[0082] The outside (9) of the upward tongue (7) comprises an upper outside portion (35), and a lower outside portion (36), wherein the first locking element (28) is arranged between the upper (35) and lower outside portion (36). The lower outside portion (36) is arranged closer to the inside (8) of the upward tongue (4) compared to the upper outside portion (35).

[0083] The upper outside portion (35) is substantially vertical and defines an outer vertical plane (37), wherein the first locking element (28) protrudes from the outer vertical plane (37). The lower outside portion (36) is substantially vertical and the inclined locking surface (30A) or the lower portion (32) and the lower outside portion (36) enclose an angle (β) between 100 and 175 degrees. The angle (a) enclosed by the upper contact surfaces and the inclined contact surfaces and the angle (β) enclosed by the lower outside portion (36) and the inclined locking surface (30A) or the lower portion (32) is about the same.

[0084] An outermost portion (38) of the first locking element (28) is arranged at a horizontal level which is lower compared to the upward groove (6).

[0085] FIG. 4 schematically shows an embodiment of two interconnected panels (1) with first and second coupling parts according to the present invention. The panels (1) comprising a first coupling part (2) and a second coupling part (3) in coupled condition. The shown embodiment comprises all features as shown in FIG. 1 and further comprises a recess (40) positioned below the upper contact surface (14a) of the second coupling part (3). The recess (40) comprises an upper inclined surface and a lower inclined surface. The lower inclined surface is aligned with the inclined contact surface (15a) of the downward tongue (7). The recess (40) may act as expansion chamber to allow the panel material to swell, e.g. upon exposure to heat and/or moisture, and moreover, reduces the contact surface area at the top seam in between two panels (1) which allows clamping forces to be more prominently present at the top seam in between said panels (1) to improve the water barrier properties of the panel coupling as such.

[0086] FIG. 5 schematically shows a detailed view of part A of the embodiment shown in FIG. 4 around the upper contact surfaces of two interconnected panels. The figure shows two points or zones of contact (41, 42), wherein the engagement force (or clamping force) in this specific area of the coupling parts (2, 3) is higher than in other shown parts in this figures. These two points or zones of intensive contact (41, 42) leads to a significantly improved water barrier, and therefore a further improved watertight connection between said panels (1). The figure shows that the upper contact area 14b and 14a are not completely parallel but the upper contact area 14b is slightly inclined with respect to the opposite vertical upper contact area 14a, and more in particular (slightly) runs away from the vertical upper contact area 14a in downward direction. This does not necessarily means that the upper contact areas 14a, 14b will become separated from each other in downward direction, but does commonly lead to the effect that the contact between the upper portions of the upper contact areas 14a, 14b, is more intense than the contact between lower portions of the upper contact areas 14a, 14b.

[0087] It is conceivable that due to the locking force the area at or around the inclined contact surface 15a of the downward tongue is elastically or plastically deformed during engagement of adjacent inclined contact surfaces. Locally the area at or around the inclined contact surface 15b may also deform elastically or plastically.

[0088] FIG. 6 schematically shows a detailed view of part B of the embodiment shown in FIG. 4 of and around the interlocking elements (28,29) of two interconnected panels.

[0089] The upper outside portion (35) is substantially vertical and defines an outer vertical plane (37), wherein the first locking element (28) protrudes from the outer vertical plane (37). The distance (39a) between an outermost portion (38) of the first locking element (28) and the outer vertical plane (37) is substantially half of the distance (39b) between an outermost portion of the second locking element (29) and the vertical plane (37). The distance 39b is preferably less than 0.75 mm and the distance 39a is preferably less than 0.375 mm. In an embodiment the horizontal distance between the outer vertical plane (37) and the upper contact surface is a distance D. The distance 39b may be about 0.4 times that distance D and the distance 39a may be about 0.2 times that distance D.

[0090] The ordinal numbers used in this document, like “first”, “second”, “third”, etcetera, are used only for identification purposes. The panels according to the invention may also be referred to as tiles. The core (layer) of the panel may also be referred to as base (layer), and may be composed of a plurality of sub-layers, which may e.g. include a reinforcement layer, such as a glass-fiber layer. The coupling parts may also be referred to as coupling profiles or as connecting profiles. By “complementary” coupling profiles is meant that these coupling profiles can cooperate with each other. However, to this end, the complementary coupling profiles do not necessarily have to have complementary forms. By locking in “vertical direction” is meant locking in a direction perpendicular to the plane of the panel. By locking in “horizontal direction” is meant locking in a direction perpendicular to the respective coupled edges of two panels and parallel to or falling together with the plane defined by the panels. In the context of this document, the expressions “foamed composite” and “foamed plastic material” (or “foam plastic material”) are interchangeable, wherein in fact the foamed composite comprises a foamed mixture comprising at least one (thermo)plastic material and at least one filler (non-polymeric material).

[0091] The above-described inventive concepts are illustrated by several illustrative embodiments. It is conceivable that individual inventive concepts may be applied without, in so doing, also applying other details of the described example. It is not necessary to elaborate on examples of all conceivable combinations of the above-described inventive concepts, as a person skilled in the art will understand numerous inventive concepts can be (re)combined in order to arrive at a specific application.

[0092] The verb “comprise” and conjugations thereof used in this patent publication are understood to mean not only “comprise”, but are also understood to mean the phrases “contain”, “substantially consist of”, “formed by” and conjugations thereof.