SET OF FLOOR PANELS AND METHOD FOR INSTALLING THIS SET OF FLOOR PANELS

Abstract

A set of floor panels, which is suitable for forming a floor covering in herringbone pattern, wherein these floor panels are oblong rectangular; wherein the long and the short edges are provided with mechanical coupling means; and wherein the male coupling part on the short edge can be inserted into the female coupling part on the long edge in one and the same turning movement which is used to insert the male coupling part on the long edge into the female coupling part on the long or short edge.

Claims

1. A set of floor panels suitable for forming a floor covering, wherein the floor panels of the set are quadrangular and oblong and thus have a pair of long sides and a pair of short sides wherein the pair of long sides and the pair of short sides is provided with mechanical coupling parts which allow coupling the floor panels to each other wherein the floor panels of the set have the shape of an inclined parallelogram and the set consists of at least two types of floor panels, wherein the floor panels of a first type, regarding their shape, are mirrored in respect to the floor panels of a second type, and wherein the coupling parts show the following characteristics: the coupling parts on the long sides allow coupling a long side of a floor panel to a long side of another floor panel of the same type, by means of a turning movement; and the coupling parts on the short sides allow coupling a short side of a floor panel to a short side of a floor panel of another type in one and the same turning movement which is used for coupling a long side of the first floor panel to a long side of a second floor panel of the same type as the first floor panel.

2. The set of floor panels of claim 1, wherein the long sides of the first and second types of floor panels are realized in the form of a tongue and groove, wherein the groove is limited by an upper lip and a lower lip, wherein the lower lip protrudes beyond the upper lip.

3. The set of floor panels of claim 2, wherein the tongue and groove are provided with locking elements, which, in coupled condition, counteract the moving apart of the tongue and groove in horizontal direction.

4. The set of floor panels of claim 1, wherein the coupling parts on the short sides of the first and second types of floor panels are realized as a downward-directed upper hook-shaped part and an upward-directed lower hook-shaped part, wherein the upper hook-shaped part comprises a lip with a downward-directed locking element, and the lower hook-shaped part comprises a lip with an upward directed locking element, wherein, in coupled condition, said locking elements counteract the moving apart of the hook-shaped parts in horizontal direction.

5. The set of floor panels of claim 4, wherein the hook-shaped parts in coupled condition effect a vertical locking.

6. The set of floor panels of claim 5, wherein said vertical locking is effected by means of a separate insert, made of synthetic material.

7. The set of floor panels of claim 6, wherein said insert is situated in a recess in the upper hook-shaped part.

8. The set of floor panels of claim 6, wherein said insert is situated in a recess in the lower hook-shaped part.

9. The set of floor panels of claim 5, wherein said vertical locking is realized solely by locking elements realized in one piece with the floor panel.

10. The set of floor panels of claim 1, wherein said floor panels are composed of a substrate, which is realized on a basis of a synthetic material, and a top layer situated above the substrate and comprising a decor.

11. The set of floor panels of claim 10, wherein said synthetic material is polyvinyl chloride, polyethylene, polypropylene, polyethylene terephthalate or polyurethane.

12. The set of floor panels of claim 11, wherein said top layer comprises a translucent or transparent wear layer situated above a decor.

13. The set of floor panels of claim 12, wherein a thickness of the floor panels is situated between 3 and 6 mm.

14. The set of floor panels of claim 1, wherein said floor panels are composed of a wood-based substrate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0104] With the intention of better showing the characteristics of the invention, herein below, as an example without an limitative character, some preferred embodiments are described, with reference to the accompanying drawings, wherein:

[0105] FIG. 1 in top view represents two floor panels from a set according to the invention, as well as a partially finished floor covering in herringbone pattern;

[0106] FIG. 2 in an enlarged view represents a cross-section according to line II-II in FIG. 1 and also represents how the coupling parts shown in this cross-section can be inserted into each other;

[0107] FIG. 3 in an enlarged view represents a cross-section according to line in FIG. 1 and also represents how the coupling parts shown in this cross-section can be inserted into each other;

[0108] FIG. 4 represents a variant of the coupling parts shown in FIG. 2;

[0109] FIG. 5 represents a method according to the invention for installing a plurality of the floor panels from FIG. 1 in herringbone pattern;

[0110] FIG. 6 in an enlarged manner and in perspective view shows what is indicated by F6 in FIG. 5;

[0111] FIG. 7 represents an alternative of the method from FIG. 5;

[0112] FIG. 8 in top view represents a floor covering in herringbone pattern which is realized by means of the set of floor panels according to the deviating aspect of the invention;

[0113] FIG. 9 in an enlarged view represents a cross-section according to line IX-IX in FIG. 8;

[0114] FIG. 10 in an enlarged view represents a cross-section according to line X-X in FIG. 8;

[0115] FIG. 11 represents how the floor panels of FIG. 8 can be coupled;

[0116] FIG. 12 represents a variant of the coupling parts represented in FIG. 3; and

[0117] FIG. 13 represents a variant of the coupling parts represented in FIG. 2.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0118] FIG. 1 in top view represents two floor panels 1A-1B from a set of floor panels according to the invention. These floor panels 1A-1B are suitable for forming a floor covering in herringbone pattern, as will become clear from the following.

[0119] In FIG. 1 also a partially finished floor covering 1 in herringbone pattern is shown. In this floor covering 1 a plurality of the floor panels 1A-1B are used.

[0120] The floor panels 1A-1B are oblong rectangular and thus comprise a pair of long edges 2-3 and a pair of short edges 4-5. The long as well as the short edges 2-3-4-5 are provided with mechanical coupling parts 6-7-8-9, which allow coupling a plurality of such floor panels 1A-1B to each other. The one long edge 2 is provided with a male coupling part 6 and the other long edge 3 is provided with a female coupling part 7. The one short edge 4 is provided with a male coupling part 8 and the other short edge 5 is provided with a female coupling part 9.

[0121] From FIG. 1, it is obvious that the floor panel 1A is of another type than the floor panel 1B. The location of the coupling parts 6-7-8-9 in the floor panel 1A namely is mirrored in respect to the location of the coupling parts 6-7-8-9 in the floor panel 1B.

[0122] The appearance of the mechanical coupling parts 6-7-8-9 is described by means of FIGS. 2 and 3.

[0123] In FIG. 2, a cross-section according to line II-II in FIG. 1 is represented. This figures thus shows the appearance of the coupling parts 7-8.

[0124] Moreover, FIG. 2 also represents how these coupling parts 7-8 can be inserted into each other.

[0125] The male coupling part 8 can be inserted into the female coupling part 7 by means of the downward movement M.

[0126] Apart therefrom, the male coupling part 8 can be inserted into the female coupling part 7 in one and the same turning movement which is applied for inserting the male coupling part 6 into the female coupling part 7 or 9 of another floor panel. This then relates to the so-called fold-down movement. How this coupling movement then precisely looks, will be described in greater detail by means of FIG. 6.

[0127] The male coupling part 8 can also be inserted into the female coupling part 7 by means of a horizontal or substantially horizontal snap movement S1.

[0128] The male coupling part 8 and the female coupling part 7 effect a locking in horizontal direction H as well as a locking in vertical direction V.

[0129] The male coupling part 8 comprises a locking element 10 which cooperates with the locking element 11 of the female coupling part 7 in order to effect the locking in vertical direction V.

[0130] In the example, the locking element 10 is realized as a separate insert. There, where the insert cooperates with the locking element 11, a tangent line R1 is defined, which runs upward in the direction away from the female coupling part 7. This tangent line R1 forms an angle A1 with the horizontal which preferably is smaller than 45 degrees. In the represented example, the angle A1 is approximately equal to 38 degrees.

[0131] The insert is provided in a recess 12 in the male coupling part 8. In the example, this recess 12 is provided in a distal side or edge 13 of the male coupling part 8.

[0132] The insert comprises a locking part 14, which, when performing the coupling movement, arrives in a locking position by performing a lateral movement. In the example, this locking part 14, via a part 15, is connected to an attachment part 16 with which the insert is provided in the recess 12. The part 15 is manufactured of another, more flexible or more elastic material than the locking part 14 and the attachment part 16. This part 15 allows that the locking part 14 performs said lateral movement. This lateral movement here concerns a lateral turning or rotation movement, which in particular is dual.

[0133] In coupled condition, the locking element 22 cooperates with the lower side of the upper lip 14. There, where they cooperate with each other, a tangent line R2 is defined, which forms an angle A2 with the horizontal with is different from zero.

[0134] The male coupling part 8 also comprises the locking element 17, which cooperates with the locking element 18 in order to effect said locking in horizontal direction H.

[0135] The locking element 17 is made from the material of the floor panel and in one piece therewith.

[0136] There, where the locking elements 17-18 cooperate with each other, a tangent line R2 is defined, which runs upward in the direction away from the female coupling part 7. This tangent line R2 forms an angle A2 with the vertical which preferably is smaller than 45 degrees and more preferably is smaller than or equal to 30 degrees. In the represented example, the angle A2 is approximately equal to 30 degrees.

[0137] In general, the male coupling part 8 here comprises a protruding lip 19. In the distal side or edge 13 of this lip 19, the recess 12 is provided. The locking element 17 is realized in the form of a protrusion on the lower side of the lip 19.

[0138] Distally from the protrusion, the lower side of the lip 19 comprises a portion 20 with which it rests on the female coupling part 7. This portion 20 is situated proximally from the closing plane V1 defined between the coupled edges 3 and 4.

[0139] Between the lower side of the lip 19 and the female coupling part 7 a space 21 is present. This space 21 extends continuously between the portion 20 and there, where the locking elements 17-18 cooperate with each other.

[0140] In the example, the male coupling part 8 fits precisely into the female coupling part 7. This has as a result that in this coupling there is no tensioning force present which presses the edges 3-4 towards each other at their upper sides. This has the advantage that even with non-straight floor panels these edges 3-4 still can be coupled to each other in a smooth manner. It can even be still more advantageous that the male coupling part 8 fits into the female coupling part 7 with a certain play.

[0141] In FIG. 3, a cross-section is represented according to line in FIG. 1. This figure thus shows the appearance of the coupling parts 6-7.

[0142] Moreover, FIG. 3 also shows how these coupling parts 6-7 can be inserted into each other.

[0143] The male coupling part 6 can be inserted into the female coupling part 7 by means of the turning movement W.

[0144] The male coupling part 6 can also be inserted into the female coupling part 7 by means of a horizontal or substantially horizontal snap movement S2.

[0145] The coupling parts 6-7 are realized as a tongue 22 and a groove 23, respectively. The groove 23 is bordered by an upper lip 24 and a lower lip 25. The tongue 22 and the groove 23 are provided with locking elements 26-18, which counteract the moving apart of the tongue 22 and groove 23 in horizontal direction H.

[0146] The lower lip 25 protrudes beyond the upper lip 24. In that part of the lower lip 25 that protrudes beyond the upper lip 24, the lower lip 25 comprises the locking element 18. This locking element 18 cooperates with the locking element 26 on the lower side of the tongue.

[0147] There, where the locking elements 26-18 cooperate with each other, a tangent line R3 is defined, which runs upward in the direction away from the groove 23. This tangent line R3 forms an angle A3 with the vertical, which preferably is smaller than 45 degrees and still more preferably is smaller than or equal to 30 degrees. In the example, the angle A3 is approximately equal to 30 degrees.

[0148] The upper side of the tongue 22 cooperates with the lower side of the upper lip 24. There, where this upper and lower sides cooperate with each other, a tangent line R4 is defined, which is situated horizontally or approximately horizontally.

[0149] The tongue 22 extends underneath the upper lip 14 over a distance D1 of at least ⅙ times the overall thickness T of the floor panel, and preferably over a distance D1 of at least ¼ times the overall thickness T of the floor panel and still more preferably over a distance D1 of at least ⅓ times the overall thickness T of the floor panel. In the example, the distance D1 is approximately ⅓ times the thickness T.

[0150] The lower side of the tongue 22 comprises a portion 27 with which the tongue 22 rests on the upper side of the lower lip 25. This portion 27 is situated at least partially distally from the closing plane V1 defined between the coupled edges 2-3. In the example, this portion is situated even entirely distal from the closing surface V1.

[0151] It is clear that the first locking element 11 of the female coupling part is formed by the upper lip 24 and that the second locking element 18 concerns the locking element on the lower lip 25.

[0152] The coupling parts 6-7 are realized from the material of the floor panel and in one piece therewith.

[0153] It is also noted that the coupling parts 6-7 can be configured such that they, in the coupled condition, provide for a tensioning force, which presses the coupled edges 2-3 towards each other at their upper sides. As already described in the introduction, to this aim then the principle of FIG. 23 of the document WO 97/47834 can be applied. Then, the lower lip 25, for example, can be permanently bent downward in the coupled condition.

[0154] In the example, the female coupling part 9 on the short edge 5 is made identical to the female coupling part 7 on the long edge 3. Thus, it is not explicitly represented.

[0155] Considering that the coupling parts 7 and 9 are identical, thus the male coupling part 6 can also be inserted into the female coupling part 9 by means of the turning movement W, as well as by means of the snap movement S2.

[0156] In FIG. 4, another variant of the male coupling part 8 is represented. In this variant, the locking element 10 is realized from the material of the floor panel and in one piece therewith.

[0157] The floor panels 1A-1B preferably are composed at least of a substrate 28 and a top layer 29 situated above the substrate 28. The substrate 28 can be realized as described in the introduction and preferably is realized on the basis of a composition which comprises at least a synthetic material, such as polyvinyl chloride, polyethylene, polypropylene, polyethylene terephthalate, polyurethane and/or elastomer. The top layer 29 preferably comprises a decor as well as a transparent or translucent wear layer situated above the decor. The detailed composition of the top layer 29 is not represented in FIGS. 2 to 4.

[0158] The thickness T of the floor panels 1A-1B preferably is situated between 2 and 8 mm, wherein a thickness T between 3 and 6 mm is even more desirable.

[0159] How the floor covering 1 shown in FIG. 1 can be achieved will be described by means of FIGS. 5 to 7.

[0160] In FIG. 5, a first possible method is shown for forming the floor covering of FIG. 1.

[0161] Forming the first row X is performed by coupling floor panels 1A to floor panels 1B. The short edge 4 is coupled to the long edge 3.

[0162] The second row Y is formed by coupling, in a first step S1, the floor panels 1B with the long edge 2 to the long edge 3 and the short edge 5 of the already installed floor panels 1B-1A of the first row X by means of the turning movement W. Moreover, in that same movement W the short edge 4 of the floor panel 1B can be coupled to the long edge 3 of the already installed floor panel 1 A of the first row X. How the aforementioned turning movement W precisely is looking, is illustrated in FIG. 6. This figure represents to a larger scale and in perspective view what is indicated by F6 in FIG. 5.

[0163] In an analogous manner, in a second step S2 the floor panels 1A can be installed, which results in finishing the second row Y. It is clear that further rows of the floor covering can be installed in the same manner.

[0164] In FIG. 7, a second possible method is shown for forming the floor covering 1 of FIG. 1. This method is possible in that the coupling parts 6-7-8-9 also allow a horizontal or approximately horizontal snap coupling movement.

[0165] In FIG. 7, it is started with installing of an only partially finished first row X of the floor covering.

[0166] Thereafter, in a step S3 already the partial installation of the second row Y is started. Herein, the floor panel 1B is coupled with the long edge 2 to the long edge 3 of the already installed floor panel 1B of the first row X by means of the turning movement W. In that same movement W, the short edge 4 of the floor panel 1B can be coupled to the long edge 3 of the already installed floor panel 1A of the first row X. In an analogous manner, the floor panel 1A in the second row Y is installed.

[0167] In a following step S4, the installation of the first row X continues. In order to install the floor panel 1A, in a convenient manner use is made of the possibility of snapping. For example, the long edge 2 of the floor panel 1A is snapped into the short edge 5 of the floor panel 1B from the first row X, and the short edge 5 is snapped into the long edge 2 of the floor panel 1B from the second row Y. According to an alternative, the turn-snap technique can be applied, wherein then the long edge 2 is coupled, via a turning movement, to the short edge of the floor panel B from the first row X and then the short edge 5 is snapped into the long edge 2 of the floor panel from the second row Y. The following floor panel 1B can be installed in the first row X by snapping the long edge 3 to the short edge 4 of the then already installed floor panel 1A.

[0168] Thereafter, one may further continue with the installation of the second row Y in a manner analogous to step S3.

[0169] FIG. 8 in top view shows a floor covering 30 in herringbone pattern, or at least a part of this floor covering, wherein this pattern is realized by means of a set of floor panels 31 according to the deviating aspect. The floor panels 31 have the shape of an inclined parallelogram. They comprise a pair of parallel long sides 32-33 and a pair of parallel short sides 34-35. The long sides 32-33 enclose a non-straight angle with the short sides 34-35. The set consists of two types of floor panels 31, namely the floor panels 31A and the floor panels 31B. In respect to their shape, the floor panels 31A are mirrored in respect to the floor panels 31B. The floor panels 31, at their long as well at their short sides 32-33-34-35, are provided with mechanical coupling parts with which the floor panels 31 are coupled to each other. The form of these coupling parts will be described in greater detail with reference to FIGS. 9 and 10. From FIG. 8 is clear that the herringbone pattern is formed without coupling a long side and a short side. The long sides 32-33 of the one type of floor panels 31A are coupled to each other, the long sides 32-33 of the other type of floor panels 31B are coupled to each other, and the short sides 34-35 of the one type of floor panels 31A are coupled to the short sides 34-35 of the other type of floor panels 31B. Thus, there is no compatibility required between the long sides 32-33 and the short sides 34-35.

[0170] FIG. 9 represents the coupling parts 36-37 on the long sides 32-33 in coupled condition. These coupling parts 36-37 allow that the long side 32 of a floor panel 31A or 31B can be coupled to the long side 33 of another floor panel 31 of the same type by means of the turning movement W. The coupling parts 36-37 are realized as a tongue 38 and a groove 39. The groove 39 is bordered by an upper lip 40 and a lower lip 41. The lower lip 41 protrudes beyond the distal extremity of the upper lip 40. Locking elements 42-43 are present, which provide for a locking in the horizontal direction H. These locking elements 42-43 consist of a protrusion 44 on the lower side of the tongue 38 and an upward-directed locking element 45 as a component of the lower lip 41.

[0171] It is noted that the coupling parts 36-37 can also allow that the long side 32 of a floor panel 31A or 31B can be coupled to the long side 33 of another floor panel 31 of the same type by means of a horizontal or substantially horizontal translation or snap movement S. With this movement S a snap effect occurs. This snap effect is the result of the elastic movement EM performed by the lower lip 41 during the translation movement S.

[0172] It is possible that the lower lip 41 in coupled condition is elastically bent and thus provides a tensioning force which presses the long sides 32-33 towards each other. This is also denominated “pretension” and is known as such from document WO 97/47834. In FIG. 9, this is the case due to the presence of the downward-bent lip 41.

[0173] It is also noted that it is not required that the coupling parts 36-37 on the long sides 32-33 of the one type of floor panels 31A are identical to the coupling parts 36-37 on the long sides 32-33 of the other type of floor panels 31B, which here indeed is the case. There is no compatibility required between these coupling parts, as is clear from FIG. 8.

[0174] FIG. 10 shows the coupling parts 46-47 on the short sides 34-35 in coupled condition. These coupling parts 46-47 allow that the short side 34 of a floor panel 31A or 31B can be coupled to the short side 35 of a floor panel 31 of the other type in one and the same turning movement W which is used for coupling the long side 32 of the first-mentioned floor panel 31A or 31B to the long side 33 of another floor panel 31 of the same type as the first-mentioned floor panel 31A or 31B. The turning movement W entails a downward coupling movement DM between the short sides 34-35. How this precisely is functioning is illustrated in FIG. 11. In this figure, the floor panel 31B to be installed is shown, as well as the already installed panels 31A and 31B. The floor panel 31B to be installed is brought into an inclined position, wherein the tongue 38 on the side 32 of this panel 31B is partially inserted into the groove 39 on the side 33 of the installed panel 31B and the coupling part 46 on the short side 34 is situated above the coupling part 47 on the short side 35 of the installed floor panel 31A. From this inclined position, the floor panel 31B to be installed is turned downward, according to the movement W, by which the long side 32 as well as the short side 34 of this panel 31B are coupled. The situation is analogous when starting from a floor panel 31A to be installed.

[0175] The coupling parts 46-47 are realized as a downward-directed upper hook-shaped part 48 and an upward-directed lower hook-shaped part 49. The upper hook-shaped part 48 comprises a lip 50 with a downward-directed locking element 51, and the lower hook-shaped part comprises a lip 52 with an upward-directed locking element 53. The locking elements 51 and 53 provide for the locking in the horizontal direction H.

[0176] The hook-shaped parts 48-49 also realize a locking in the direction V. To this aim, a separate insert 54 cooperates with the locking element 55. The insert 54 consists of three parts: a locking part 56, a connection part 57 and an attachment part 58. The insert is made of synthetic material by means of coextrusion. The connection part 57 is made more flexible than the other parts 56 and 58. It provides for that the locking part 56 can be brought in the locking position in an elastic manner. During the coupling movement, the locking part 56 performs a rotational movement R and automatically arrives in the locking position. The insert 54 is provided with the attachment part 58 in the recess 59. The recess 59 is provided in the distal side 60 of the upper hook-shaped part 48.

[0177] It is noted that the coupling parts 46-47 also allow that the short side 34 of a floor panel 31A or 31B can be coupled to the short side 35 of a floor panel 31 of the other type by means of a horizontal or substantially horizontal translation or snap movement, wherein a snap effect occurs with this movement. This snap effect is the result of the elastic movement performed by the lip 52 during the translation movement.

[0178] Further, the coupling parts 46-47 also allow that the short side 34 of a floor panel 31A or 31B can be coupled to the short side 35 of a floor panel 31 of the other type by means of a turning movement.

[0179] It is possible that the lip 52 of the lower hook-shaped part 49 in coupled condition is elastically bent and in this manner provides a tensioning force pressing the short sides 34-35 towards each other. This is also denominated “pretension” and in such system with hook-shaped coupling parts is known from document BE 2015/5686.

[0180] FIG. 12 represents a variant of the coupling parts 6-7 which are represented in FIG. 3. The contact which is formed between the locking elements 18 and 26 is indicated by reference C1. This contact C1 is formed by locking surfaces 61-62 cooperating with each other. The particularity of the coupling parts 6-7 of FIG. 12 is that next to or close to the contact C1 a contact C2 is formed. This contact C2 is formed between the lower side of the tongue 22 and the upper side of the lower lip 25. The contact C2 can be situated directly next to the contact C1, such that actually a single contact is formed. Or, as is the case in FIG. 12, the contact C2 can be separated from the contact C1 by an intermediate space or free space 63. In FIG. 12, the contact C2 is situated closer to the vertical closing plane V2 than the contact C1. However, in a variant the contact C2 can be situated farther from the closing plane V2 than the contact C1. For example, the contact C1 then is situated on the upper side of the locking element 18.

[0181] The contact C2 provides for that friction at the location of the contact C1 is counteracted. This friction implies that the locking surfaces 61-62 move relatively in mutual respect. Such friction may occur, for example, when the floor panels are walked upon. Counteracting this friction reduces the risk of creaking noises which may occur as a result of the friction. This is particularly advantageous when the substrate 28 is wood-based.

[0182] The presence of the contact C2 has proven particularly advantageous when a tensioning force is present in the coupling parts 6-7 which presses the coupled edges towards each other. In FIG. 12, this tensioning force is provided by the downward-bent lower lip 25. The bending VM of this lip 25 is illustrated.

[0183] FIG. 13 represents a variant of the coupling parts 7-8 which are represented in FIG. 2. The contact which is formed between the locking elements 17 and 18 is indicated by reference C3. This contact C3 is formed by locking surfaces 64-65 cooperating with each other. The coupling part 7 is made identical to the coupling part 7 of FIG. 12. The coupling part 8 is realized such that apart from the contact C3 a contact C4 is formed. This contact C4 is formed between the lower side of the lip 19 and the upper side of the lower lip 25. In the example, both contacts C3 and C4 form a single contact, however, it is not excluded that they are separated by an intermediate space or free space. Such contact C4 reduces the risk of creaking noises.

[0184] It is also noted that the variant of FIG. 12 can be applied in combination or not in combination with the one of FIG. 13.

[0185] The present invention is in no way limited to the embodiments described herein above, on the contrary may such methods and floor panels be realized according to various variants, without leaving the scope of the present invention.