COATED PANEL

Abstract

A coated panel with a substrate and a decorative top layer. The substrate includes an, optionally filled, plastic composite. The coated panel is provided on at least a first pair of two opposite edges with mechanical coupling means that allow two such panels to be coupled to each other on the first pair of edges in question. Locking is obtained both in a vertical direction perpendicular to the plane of the coupled panels, and in a horizontal direction perpendicular to the respective edges and in the plane of the coupled panels. The mechanical coupling means or coupling parts allow a displacement in the direction along the coupled edges.

Claims

1.-20. (canceled)

21. A coated panel with a substrate and a decorative top layer, wherein the substrate comprises an, optionally filled, plastic layer, wherein the coated panel is provided on at least a first pair of two opposite edges with mechanical coupling means that allow two such panels to be coupled to each other on the first pair of edges in question, wherein locking is obtained both in a vertical direction perpendicular to the plane of the coupled panels, and in a horizontal direction perpendicular to the respective edges and in the plane of the coupled panels, wherein the aforementioned mechanical coupling means or coupling parts allow a displacement in the direction along the coupled edges, and wherein on the first pair and/or on the second pair of opposite edges a horizontally acting locking and/or contact surface is formed, directly under the position where the upper surfaces of the coupled panels abut against each other, and in that this contact surface is formed mainly on a compressible portion of the substrate and/or the top layer.

22. The coated panel of claim 21, wherein the aforementioned horizontally acting locking or contact surface is formed on a first layer of the substrate and the superjacent decorative top layer, wherein the aforementioned first layer is more flexible than an underlying second layer of the substrate, wherein both the first layer and the second layer comprise PVC and the aforementioned first layer of the substrate comprises a higher proportion of plasticizer than the second layer located thereunder.

23. The coated panel of claim 21, wherein the aforementioned mechanical coupling means or coupling parts of the first pair of opposite edges are configured with a clearance, fitting or with a clamping.

24. The coated panel of claim 21, wherein the energy per unit length necessary for the mutual displacement of the first pair of edges in the coupled state over a certain distance is less than the energy per unit length necessary for the displacement of the second pair of edges in an installed state of two such panels, over the same distance.

25. The coated panel of claim 21, wherein the force required to overcome the static gripping force, per unit length, is smaller on the first pair of edges in the coupled state, than on the second pair of edges in the installed state of two such panels.

26. The coated panel of claim 21, wherein the aforementioned mechanical coupling means of the first pair of edges are configured as a tongue and a groove that is delimited by an upper lip and a lower lip, wherein the aforementioned tongue and groove are provided with locking parts that counteract the moving apart of the aforementioned tongue and groove in the aforementioned horizontal direction, wherein the aforementioned lower lip in a coupled state is unloaded or displays a maximum deflection of less than 0.07 millimeter.

27. The coated panel of claim 21, wherein the panel is rectangular, wherein the panel is provided both on the pair of long edges and on the pair of short edges with coupling means, wherein the coupling means on the pair of long edges allow two such panels to be coupled to each other by means of a rolling motion, and the coupling means on the pair of short edges allow two such panels to be coupled to each other by means of a downward motion, wherein the pair of long edges form the aforementioned first pair of edges, and the pair of short edges form the aforementioned second pair of edges.

28. The coated panel of claim 21, wherein at least one portion of the coupling means is provided on the first pair of edges with a water-repellent substance.

29. The coated panel of claim 21, wherein the aforementioned decorative top layer comprises a print and a thermoplastic wearing layer applied thereon.

30. The coated panel of claim 29, wherein the aforementioned panel has a lowered edge region at least on one edge, wherein both the aforementioned print and the aforementioned wearing layer extend continuously from on the central area of the panel over the aforementioned lowered edge region.

31. The coated panel of claim 30, wherein the aforementioned lowered edge region relates to a chamfer.

32. The coated panel of claim 30, wherein the surface of the aforementioned lowered edge region is formed essentially by the aforementioned wearing layer.

33. The coated panel of claim 30, wherein the aforementioned print extends at the location of the aforementioned lowered edge region in one and the same plane as at the location of the central area.

34. The coated panel of claim 29, wherein the aforementioned wearing layer has, at the location of the central area, a thickness of 0.3 mm or more, but less than 0.75 mm.

35. The coated panel of claim 29, wherein the aforementioned wearing layer consists mainly of a thermoplastic, such as polyvinyl chloride.

36. The coated panel of claim 29, wherein the aforementioned print is applied on a thermoplastic carrier film.

37. The coated panel of claim 29, wherein the aforementioned substrate comprises several layers, wherein a first layer with a first hardness is located between the aforementioned print and a second layer with a second hardness that is greater than the aforementioned first hardness.

38. The coated panel of claim 37, wherein both the first layer and the second layer contain polyvinyl chloride, wherein the content of plasticizer in the aforementioned first layer is higher than in the aforementioned second layer.

39. The coated panel of claim 32, wherein in the coupled state of two such panels, a contact surface arises directly under the join of the respective upper surfaces of the coupled panels, wherein this contact surface mainly, or even exclusively, is formed on the material of the aforementioned first layer and the superjacent layers of the decorative top layer.

40. The coated panel of claim 21, wherein the coated panel is a floor panel for forming a floating floor covering.

Description

[0049] For better illustration of the features of the invention, some preferred embodiments are described hereunder, as examples without any limiting character, referring to the appended drawings, in which:

[0050] FIG. 1 shows a coated panel with the features of the invention;

[0051] FIGS. 2 and 3 show, on a larger scale, a cross section along lines II-II and shown in FIG. 1;

[0052] FIG. 4 shows, on a larger scale, a view of the region that is marked with F4 in FIG. 3;

[0053] FIG. 5 shows in perspective how the panels from FIGS. 1 to 4 can be assembled into a floating floor covering;

[0054] FIGS. 6 and 7 show the coupled state, in a view similar to that in FIGS. 2 and 3;

[0055] FIG. 8 shows the contour of the coupling means with the groove from FIG. 7; and

[0056] FIGS. 9 and 10 further illustrate possible advantages of the invention.

[0057] FIG. 1 shows a rectangular and elongated coated panel 1, in this case a floor panel with a first pair of long opposite edges 2-3 and a second pair of short opposite edges 4-5.

[0058] FIGS. 2 and 3 show that the panel 1 comprises a substrate 6 and a decorative top layer 7, wherein the decorative top layer 7 contains a print 8 and a transparent wearing layer 9 applied thereon.

[0059] The panel 1 has on at least one edge, and in this case on both edges of both the pair of short opposite edges 4-5 and the pair of long opposite edges 2-3, a lowered edge region 10. In this case the lowered edge region 10 is a chamfer that makes an angle A with the horizontal of less than 25°, in this case about 11°.

[0060] FIG. 4 shows that the wearing layer 7 has a thickness T of at least 0.3 millimeter, in this case about 0.55 mm. The wearing layer 7 consists mainly of thermoplastic, in this case polyvinyl chloride, and has on the surface a surface layer 11, for example based on a radiation-cured polyurethane or acrylate compound.

[0061] Both the print 8 and the aforementioned wearing layer 9 extend continuously from on the central area 12 of the panel 1 over the lowered edge regions 10, and the surface of the aforementioned lowered edge region is essentially formed by the aforementioned wearing layer 9, except for the aforementioned surface layer 11. The print 8 extends at the location of the lowered edge region 10 in one and the same plane as at the location of the central area 12.

[0062] In the example, the print 8 is applied on a thermoplastic carrier film 13 and the substrate 6 consists mainly of plastic and/or fillers, such as PVC and calcium carbonate. On the underside of the substrate 6, a, preferably foamed, layer 14 is applied, for example based on crosslinked polyethylene, with a view to noise damping and/or accommodation of irregularities of the substrate.

[0063] FIGS. 2 and 3 clearly show that the floor panel 1 is provided on both pairs of opposite edges 2-3; 4-5 with coupling means 15 that allow two such panels 1 to be coupled to each other on the respective edges 2-3; 4-5. In the coupled state, locking occurs both in a vertical direction V1 perpendicular to the plane of the coupled floor panels 1, and in a horizontal direction H1-H2 perpendicular to the respective edges 2-3; 4-5 and in the plane of the coupled panels 1. The coupling means 15 are in each case configured as a male coupling part 16 and a female coupling part 17, wherein in the coupled state horizontally acting locking surfaces 18 are formed, which counteract the moving apart of the coupled floor panels 1 in the horizontal direction. On the pair of long opposite edges 2-3 the male coupling part 16 is formed by a sideways projecting tongue 19, and the female coupling part by a groove 20.

[0064] As is shown, the substrate 6 comprises several layers 21-22, wherein a first layer 21 with a first hardness is located between the aforementioned print 8 and a second layer 22 with a second hardness that is greater than the aforementioned first hardness. Both the first layer 21 and the second layer 22 contain polyvinyl chloride. The content of plasticizer in the aforementioned first layer 21 is higher than in the aforementioned second layer 22. In the coupled state of two such panels 1, a horizontally acting contact surface 23 arises directly under the join of the respective upper surfaces, wherein this contact surface 23 is formed exclusively on the aforementioned first layer 21 and the superjacent layers 8-9 of the decorative top layer 7, namely in particular at least on the first layer 21, and the wearing layer 9, except for the surface layer 11. The aforementioned horizontally acting locking surfaces 18, which counteract the moving apart of the tongue 19 and the groove 20, are formed exclusively on the material of the aforementioned second layer 22.

[0065] FIG. 4 further shows that at least one portion of the surface of the coupling means 15 is provided with a water-repellent substance 24. Preferably the water-repellent substance is at least provided directly under the join of the upper surfaces of the coupled panels 1, namely at a position above the actual coupling means 15, namely, in the case of the long opposite edges 2-3, above the engagement of the tongue 19 in the groove 20, namely above the level of any vertically acting locking surfaces 25. In this case the water-repellent substance 24 is at least provided on the aforementioned horizontally acting contact surface 23 that is located directly under the join of the upper surfaces.

[0066] FIG. 5 shows that the floor panel 1 from FIGS. 1 to 4 is suitable for assembling a floating floor covering. In this case the coupling means 15 on the pair of long edges 2-3 may be coupled to each other by means of a rolling motion W, and the coupling means 15 on the pair of short edges 4-5 may be coupled to each other by means of a downward motion N.

[0067] FIGS. 6 and 7 show the coupled state of the coupling means 15 on the pair of short opposite edges 4-5 and the pair of long opposite edges 2-3, respectively. The coupling means 15 and the associated upper edge 26 are produced on the basis of a milling operation with rotating milling tools.

[0068] The coupling means 15 on the pair of short opposite edges 4-5, shown in FIG. 6, are configured as a male coupling part 16 and a female coupling part 17, which can be fitted in one another. The male coupling part 16 comprises a hook-shaped portion 27 that projects on the upper side of the panel 1, and the female coupling part 17 comprises a hook-shaped portion 27 in the form of a lip that projects on the underside of the panel 1. The hook-shaped portion 27 of the male coupling part 16 comprises a downwards projecting locking part 28 that can interact with a recess 29 in the hook-shaped portion 27 of the female coupling part 17. The interaction of the downwards projecting locking part 28 and the recess 29 is substantially responsible for the locking in the horizontal direction H1. The hook-shaped portions 27 are further provided with one or more snap portions 30 and undercuts 31 interacting therewith, which provide the locking in the vertical direction V1.

[0069] The coupling means 15 on the pair of long opposite edges 2-3, shown in FIG. 7, are, as mentioned above, configured as a tongue 19 and a groove 20, delimited by an upper lip 32, or uppermost lip, and a lower lip 33, or bottommost lip. The tongue 19 and groove 20 provide the locking in the aforementioned vertical direction V1, and are provided with locking parts 34-35, mainly responsible for the locking in the aforementioned horizontal direction H2. In the example the locking parts comprise a projection 34 on the underside of the tongue 19 and a recess 35 in the lower lip 33 of the groove 20.

[0070] In this case the mechanical coupling means 15 are configured with pretension, obtained on the basis of a lower lip 33 bent outwards in the coupled position, which in an attempt to spring back, presses against the underside of the tongue 19.

[0071] The coupling means 15 shown here also allow coupling on the basis of a horizontal sliding movement S of the panels 1 toward each other.

[0072] Also in the example in FIG. 6, a pretension is applied because a portion 36 of the projecting lip of the female coupling part 17 is bent, in this case the upwards extending element 36 on the hook portion 27 of the female coupling part 17. This element 36 presses, in an attempt to spring back, against the male part 16, more particularly against the downwards projecting locking part 28 thereof.

[0073] FIG. 7 further shows that the lower lip 33 of the groove 20, in a coupled state, displays a maximum deflection B. In this case the maximum deflection B is less than 0.07 millimeter, namely about 0.04 millimeter.

[0074] FIGS. 7 and 8 further show that the coupling means 15 of the first pair of edges 2-3 in a coupled state always have one or more contact surfaces 37-38-39, in this case three contact surfaces 37-38-39, namely a contact 37 at the location of the aforementioned locking or contact surface 23, a contact 37 at the location of the vertically acting locking surfaces 25, namely between the upper side of the tongue 19 and the underside of the upper lip 33, and a contact 38 at the location of the locking surfaces 18. As can be seen in a cross section through the coupled edges, and in this example illustrated in FIG. 8, together the contact surfaces 37-38-39 only cover a limited portion of the contour 40 of the edge 3. In this case the contact surfaces 37-38-39 cover less than 10% of the length of this contour, as seen in the cross section perpendicular to the coupled edges, and illustrated in FIG. 8.

[0075] FIGS. 9 and 10 show a floor covering 41 assembled on the basis of panels 1 with the features of the invention, more particularly on the basis of the panels 1 shown in FIGS. 1 to 8. The floor coverings 41 only differ in that they are placed in different directions, namely in directions that are at right angles to each other.

[0076] The floor covering 41 is in each case provided in a room with a window section 42 through which sunlight can enter directly on the floor covering. This results in a hot spot on the floor covering 41, as indicated with the dashed line 43. Within the dashed line 43, the panels will expand. In the floor coverings from the prior art, this would give rise to formation of a bubble in this place and possibly to peaking on the seams 44.

[0077] With the coated panels 1 of the invention, in the case of FIG. 9, the expansion in the direction L will be able to push the other panels in the respective rows 45 where the hot spot is manifested and to allow them to be displaced, so that no bubble is formed. The expansion in the direction W of the panels that are located in the hot spot may be compensated by compression at the location of the contact surface 23 without peaking occurring. A displacement in the direction W is limited because the panels that are not located in the hot spot prevent or counteract a displacement. Now, these panels do not expand to the same extent, so that the width of the rows 45 barely changes, if at all.

[0078] The same action takes place in the case of the floor covering 41 in FIG. 10. The dimensional expansion in the direction L is compensated by displacement, whereas the dimensional expansion in the direction W leads to a compression at the location of the locking or contact surface 23.

[0079] The present invention is by no means limited to the embodiments described above, but coated panels of this kind, methods for the manufacture thereof, and milling tools employed therein may be realized while remaining within the scope of the present invention.