Panel and Floor Covering Comprising the Same

Abstract

The present invention relates to a panel and to a floor covering including the same. The present invention also relates to other coverings, such as a wall covering, which are constructed by using a plurality of the panels. According to the invention, the panel includes a first and second coupling profile on opposing sides of the panel. The first coupling profile includes an upward tongue that has a curved portion. This upward tongue is spaced apart from a first inner flank of the panel by a clearance that defines an upward groove. According to the invention, an outermost point of the curved portion is positioned further away from the first inner flank than a center point of the upward tongue.

Claims

1. A panel configured to be used for constructing a floor covering that comprises a plurality of said panels, the panel comprising: a core having a first side that is provided with a first extension region and a second side that is provided with a second extension region, wherein the first side is oppositely arranged relative to the second side, wherein the first extension region comprises a first coupling profile and wherein the second extension region comprises a second coupling profile that is complementary to the first coupling profile; wherein the first coupling profile comprises an upward tongue that runs at a distance from and parallel to a first inner flank of the core, wherein a clearance between the first inner flank of the core and the first upward tongue forms an upward groove; wherein the second coupling profile comprises a downward tongue that runs at a distance from and parallel to a second inner flank of the core, wherein a clearance between the second inner flank of the core and the downward tongue forms a downward groove; wherein the upward tongue comprises a curved portion, an upward flank extending from a bottom of the upward groove to the curved portion, and a downward flank extending from the curved portion and forming an outer edge of the panel; wherein the downward flank is provided with a first coupling element; and wherein the second inner flank is provided with a second coupling element, wherein the first coupling element is configured to co-act with the second coupling element of an adjacently arranged further panel for the purpose of mutually locking the panel and further panel; wherein an outermost point of the curved portion is positioned further away from the first inner flank than a center point of the upward tongue.

2. The panel according to claim 1, wherein the upward tongue has a width that corresponds to a distance in a direction parallel to the panel between a starting point of the upward flank and an outer point on the downward flank; wherein a distance between the starting point and the outermost point of the curved portion in a direction parallel to the panel equals x times the width of the upward tongue, wherein x is equal to or larger than 0.5.

3. The panel according to claim 1, wherein the upward flank comprises a first flank portion extending from the starting point, and a second flank portion extending between the first flank portion and the curved portion, wherein the first and second flank portions are connected at a connection point.

4. The panel according to claim 3, wherein an inclination of the first flank portion is different from an inclination of the second flank portion at least at the connection point.

5. The panel according to claim 4, wherein a distance between the starting point and the connection point is y times the width of the upward tongue, wherein y lies in a range between 0 and 0.3.

6. The panel according to claim 3, wherein the first flank portion is essentially flat.

7. The panel according to claim 3, wherein the second flank portion is essentially flat.

8. The panel according to claim 3, wherein an angle of the first flank portion relative to a normal of the panel is smaller than an angle of the second flank portion relative to the normal of the panel.

9. The panel according to claim 3, wherein the first flank portion is curved.

10. The panel according to claim 9, wherein the first inner flank comprises a curved portion connected to the first flank, the panel further comprising an outwardly extending lip to which the curved portion of the first inner flank extends, said lip defining a first locking surface that is directed towards the upward groove; wherein the downward tongue comprises an upward flank forming a further outer edge of the panel; wherein the upward flank of the downward tongue comprises a protruding edge that defines a second locking surface; wherein the first locking surface and the second locking surface are configured to lock an upward movement of an adjacent panel when the second coupling profile of an adjacent panel is coupled to the first coupling profile of the panel and the first and second locking surfaces abut each other.

11. The panel according to claim 3, wherein the second flank portion comprises a bulge that extends inwardly beyond the starting point.

12. The panel according to claim 1, wherein x lies in the range between 0.6 and 1, and more preferably between 0.65 and 0.85.

13. The panel according to claim 12, wherein the downward flank extends substantially parallel to a normal of the panel.

14. The panel according to claim 12, wherein the downward flank extends in an inwardly inclined manner relative to the normal.

15. The panel according to claim 14, wherein an inclination of the downward flank lies in a range between 0 and 30 degrees relative to the normal of the panel.

16. The panel according to claim 1, wherein x lies in the range between 0.5 and 0.7, wherein the downward flank extends in an outwardly inclined manner relative to the normal of the panel.

17. The panel according to claim 16, wherein an inclination of the downward flank lies in a range between 0 and 30 degrees relative to the normal of the panel.

18. The panel according to claim 1, wherein the downward flank is, apart from the first locking element, essentially flat.

19. The panel according to claim 1, wherein the first and second locking elements are complementary structures, wherein, preferably, the first locking element is a protruding element, such as a bulge, and the second locking element is a recess for receiving the protruding element, or vice versa.

20. The panel according to claim 19, wherein the first locking element comprises a recess extending inwardly relative to the downward flank, said recess having a bottom and side walls extending from the bottom to an outside of the downward flank, the first locking element further comprising a protruding portion extending from the bottom toward the outside of the downward flank; wherein the second locking element comprises a protruding portion comprising side walls that extend outwardly from an outside of the second inner flank to a base portion, and a recess extending from the base portion inwardly relative to the second inner flank; wherein the protruding portion of the second locking element is divided, by the recess of the second locking element, into two oppositely arranged protruding sub-portions; wherein the recess of the first locking element is divided, by the protruding portion of the first locking element, into two oppositely arranged sub-recesses; wherein the protruding portion of the first locking element is configured to be received in the recess of the second locking element; wherein each protruding sub-portion of the second locking element is configured to be received in a respective sub-recess of the first locking element.

21-34. (canceled)

35. A floor covering comprising a plurality of panels as defined in claim 1, wherein the first coupling profile of a given panel among the plurality of panels is coupled to the second coupling profile of another panel among the plurality of panels that is arranged adjacent to said given panel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0057] Next, the invention will be described in more detail referring to the appended drawings wherein:

[0058] FIG. 1 illustrates first and second coupling profiles for a known floor panel;

[0059] FIGS. 2A-2B illustrate a perspective view of a floor panel in accordance with the present invention as well as a corresponding cross section illustrating the coupling profiles on the long side, respectively;

[0060] FIG. 3 illustrates a detailed view of the first and second coupling profiles of the floor panel of FIG. 2;

[0061] FIGS. 4A-4L illustrate various different embodiments of the first and second coupling profiles in accordance with the present invention; and

[0062] FIGS. 5A and 5B illustrate two different configurations for locking elements in accordance with the present invention.

DESCRIPTION OF THE INVENTION

[0063] FIG. 2 illustrates a perspective view of a floor panel 100 in accordance with the present invention as well as a corresponding cross section.

[0064] Similar to the known panel in FIG. 1, panel 100 of the invention comprises a core 102 having a first side that is provided with a first extension region 103 and a second side that is provided with a second extension region 104.

[0065] As shown, the first side is oppositely arranged relative to the second side. Moreover, first extension region 103 comprises a first coupling profile 105 and second extension region 104 comprises a second coupling profile 106 that is complementary to first coupling profile 105. Identical panels 100 can be coupled to each other by coupling a first coupling profile 105 of one panel 100 to a second coupling profile 106 of an adjacent panel 100.

[0066] Panel 100 shown in FIG. 2 comprises coupling profiles on all sides of panel 100. For example, the coupling profile on the short side, indicated by arrow 105′ can be configured in a similar way as first coupling profile 105. Similarly, the coupling profile on the opposite short side, indicated by arrow 106′, can be configured in a similar way as second coupling profile 106. Now referring to the detailed view of FIG. 3, first coupling profile 105 comprises an upward tongue 107 that runs at a distance from and parallel to a first inner flank 108 of core 102. A clearance between first inner flank 108 of core 102 and upward tongue 107 forms an upward groove 109. Second coupling profile 106, shown here as part of an adjacent panel 100′ but equally applying to panel 100 albeit at the opposite side relative to first coupling profile 105, comprises a downward tongue 110 that runs at a distance from and parallel to a second inner flank 111 of core 102. A clearance between second inner flank 111 of core 102 and downward tongue 110 forms a downward groove 112.

[0067] Upward tongue 107 comprises a curved portion 113, an upward flank 114 extending from a bottom 115 of upward groove 109 up to curved portion 113, and a downward flank 116 extending from curved portion 113 and forming an outer edge of panel 100. Downward flank 116 comprises a first coupling element 117 in the shape of a bulge.

[0068] A width w of upward tongue 117 can be defined as the distance between a starting point S of upward flank 14 and an outer point 0 on downward flank 116. Here, the outer point can be defined as the most outer point of panel 100 on the first side.

[0069] Second inner flank 111 is provided with a second coupling element 118 in the shape of a recess. First coupling element 117 of a given panel is configured to co-act with second coupling element 118 of an adjacent panel for the purpose of mutually locking panels 100, 100′.

[0070] As shown in FIG. 3, outermost point U of upward tongue 107 is located at a distance d away from starting point S. According to the invention, the ratio between d and w, denoted by x and equaling d/w, is equal to or larger than 0.5. The combination of the configuration of upward tongue 107 and the provision of the first and second locking elements reduces the likelihood of detachment of the first and second locking elements of adjacently arranged and coupled panels under the influence of heat and moisture. Further, downward groove 112 is shaped substantially complementarily to upward tongue 107 so that upward tongue 107 can be received in downward groove 112. Similarly, downward tongue 110 is shaped substantially complementarily to upward groove 109 so that downward tongue 110 can be received in upward groove 109.

[0071] Upward flank 114 comprises a first flank portion 114A extending from starting point S, and a second flank portion 114B extending between first flank portion 114A and curved portion 113. Flank portions 114A, 114B, which are essentially flat in the embodiment in FIG. 3, are connected at connection point C. Moreover, a distance between starting point S and connection point C is roughly 0.15 times width d of upward tongue 107.

[0072] An angle a1 of first flank portion 114A relative to a normal N of panel 100, is smaller than an angle a2 of second flank portion 114B relative to the normal of panel 100.

[0073] Downward flank 116 extends substantially parallel to normal N of panel 100, and apart from first locking element 117, is essentially flat.

[0074] Downward tongue 110 comprises a connection portion 119, a downward flank 120 extending from a bottom 121 of downward groove 112 to connection portion 119, and an upward flank 122 that extends from connection portion 119 and forms a further edge of panel 100, and of panel 100′.

[0075] In FIG. 3, first inner flank 108 comprises a first inner flank portion 108A and a second inner flank portion 108B, which portions 108A, 108B are essentially flat. Moreover, a flat region 108C is present between first inner flank portion 108A and first flank portion 114A which forms the bottom of upward groove 109.

[0076] FIGS. 4A-4L illustrate various different embodiments of the first and second coupling profiles in accordance with the present invention. In each of the FIGS. 4A-4L, the first and second coupling profiles are shown in a detached state (on the left) and in a coupled state (on the right). Furthermore, the embodiment shown in FIG. 4A corresponds to the embodiment shown in FIG. 3.

[0077] In the embodiment of FIG. 4B, first inner flank portion 108A is directly connected to first flank portion 108B. Moreover, first inner flank portion 108A is curved. In addition, a third locking element 123 is provided on first inner flank 108. A complementarily shaped fourth locking element 124 is provided on upward flank 122 of downward tongue 110. As shown in the coupled configuration, third and fourth locking elements 123, 124 provide for a further coupling between adjacent panels 100, 100′.

[0078] The embodiment shown in FIG. 4C is similar to the embodiment of FIG. 4A with the exception of downward flank 116, which in FIG. 4A, is inclined inwardly. More in particular, downward flank 116 is at an angle a3 of approximately 15 degrees relative to normal N of panel 100. By having second inner flank 111 complementarily shaped relative to downward flank 116 a further locking is provided between adjacent panels due to the fact that second inner flank 111 will snap at least partially under upward tongue 107.

[0079] However, the present invention does not exclude other embodiments such as the one shown in FIG. 4D. In this embodiment, downward flank 116 is inclined outwardly. More in particular, downward flank 116 is at an angle a4 of approximately 15 degrees relative to normal N of panel 100. Similar to the embodiment shown in FIG. 4C, second inner flank 111 is shaped in a complementary shape to downward flank 116.

[0080] In the embodiment shown in FIG. 4E, both first flank portion 114A and first inner flank portion 108A are curved. An outwardly extending lip 125 is provided to which first inner flank portion 108A extends. Lip 125 defines a first locking surface 126 that is directed towards upward groove 109. Downward tongue 110 comprises an upward flank 122 forming a further outer edge of panel 100. In this embodiment, upward flank 122 of downward tongue 110 comprises a protruding edge 127 that defines a second locking surface 128. As shown in the coupled state on the right, locking surfaces 126, 128 abut each other and lock an upward movement of panel 100′ relative to panel 100.

[0081] In the embodiment shown in FIG. 4F, second flank portion 114B comprises a bulge 114C that extends inwardly beyond starting point S. More in particular, first flank portion 114A is very small in this embodiment and can even be considered part of bulge 114C.

[0082] By having bulge 114C extending beyond starting point S, a cavity is formed that can be engaged by edge 129 of downward tongue 110 thereby providing a further locking of an upward movement of panel 100′ relative to panel 100. As illustrated in FIG. 4G, a similar bulge 130 can be provided on the other side of upward tongue 107. More in particular, curved portion 113 of upward tongue 107 may bulge outwardly beyond at least a portion of downward flank 116. By providing a suitable cavity 131 in downward groove 112 a further locking against vertical movement between panels 100, 100′ can be obtained.

[0083] In the embodiment shown in FIG. 4H, a step 132 in a direction parallel to a normal of panel 100 is visible between upward flank 114, and more in particular second flank portion 114B, and curved portion 113. A similar step 133 is visible in downward groove 112. Together, steps 132, 133 provide a further locking against mutual movement of panels 100, 100′ in a direction parallel to a top surface of panels 100, 100′ and away from each other.

[0084] In the FIG. 41 embodiment, a particular configuration for first locking element 117 and second locking element 118 is shown. This configuration is shown in more detail in FIG. 5A. Here, first locking element 117 comprises a recess 200 that extends inwardly relative to downward flank 116. Recess 200 comprises a bottom 201 and side walls 202 extending from bottom 201 to an outside of downward flank 116. First locking element 117 further comprises a protruding portion 203 extending from bottom 201 toward the outside of downward flank 116. As shown, protruding portion 203 is fully arranged in recess 200.

[0085] Second locking element 118 comprises a protruding portion 300 comprising side walls 301 that extend outwardly from an outside of second inner flank 111 to a base portion 302, and a recess 303 extending from base portion 302 inwardly relative to second inner flank 111. As shown, recess 303 is fully arranged in protruding portion 300.

[0086] Protruding portion 300 is divided, by recess 303, into oppositely arranged protruding sub-portions 300A, 300B. In addition, recess 200 is divided, by protruding portion 203, into oppositely arranged sub-recesses 200A, 200B. As shown in the coupled state in FIG. 5A and FIG. 41, protruding portion 203 is received in recess 303 and each protruding sub-portion 300A, 300B is received in a respective sub-recess 200A, 200B. In this manner, a triple lock function is obtained by first and second locking elements 117, 118.

[0087] FIG. 5B illustrates a configuration wherein first locking element 117 and second locking element 118 of FIG. 5A are each arranged in or on a respective protruding portion 117A, 118A. As shown, bottom 201 is substantially in line with the remaining part of downward flank 116.

[0088] FIGS. 4J and 4K illustrate embodiments with differently shaped upward tongues 107 and upward grooves 109. More in particular, in the embodiment shown in FIG. 4J, first flank portion 114A and first inner flank portion 108A are both curved. Consequently, downward tongue 110 can be embodied using a substantially round shape, allowing a better force distribution over downward tongue 110. However, other configurations are not excluded. For example, in the FIG. 4K embodiment, first flank portion 114A is substantially vertical. Bottom 115 of upward groove 109 comprises an inclined portion 134 connecting inner flank portion 108A and first flank portion 114A.

[0089] The embodiment shown in FIG. 4L illustrates that the position of the first and second coupling profiles can be reversed. More in particular, the first coupling profile of this embodiment is arranged on the right hand side relative to the cross section shown in FIG. 2B. In this embodiment, first flank portion 114A is curved near starting point S. A flat bottom region 115 can be identified in between first inner flank portion 108A and first flank portion 114A. Moreover, first inner flank portion 108A is inclined relative to a normal of panel 100, whereas first inner flank portion 108B is substantially vertical and is provided with a third locking element 123. A complementarily shaped fourth locking element 124 is provided on upward flank 122 of downward tongue 110.

[0090] In the description above, the present invention has been explained using detailed embodiments thereof. However, the present invention is not limited to these embodiments and various modifications to the embodiments shown can be implemented without departing from the scope of the invention which is defined by the appended claims and their equivalents.

LIST OF REFERENCE SIGNS

[0091] 1, 1′ panel [0092] 2 core [0093] 3 first extension region [0094] 4 second extension region [0095] 5 first coupling profile [0096] 6 second coupling profile [0097] 7 upward tongue [0098] 8 first inner flank [0099] 9 upward groove [0100] 10 downward tongue [0101] 11 second inner flank [0102] 12 downward groove [0103] 13 curved portion upward tongue [0104] 14 upward flank [0105] 15 bottom groove [0106] 16 downward flank [0107] 16A first part downward flank [0108] 16B second part downward flank [0109] 17 first coupling element [0110] 18 second coupling element [0111] 100, 100′ panel [0112] 102 core [0113] 103 first extension region [0114] 104 second extension region [0115] 105, 105′ first coupling profile [0116] 106, 106′ second coupling profile [0117] 107 upward tongue [0118] 108 first inner flank [0119] 108A first inner flank portion [0120] 108B first inner flank portion [0121] 109 upward groove [0122] 110 downward tongue [0123] 111 second inner flank [0124] 112 downward groove [0125] 113 curved portion upward tongue [0126] 114 upward flank [0127] 114A first flank portion [0128] 114B second flank portion [0129] 114C bulge [0130] 115 bottom groove [0131] 116 downward flank [0132] 117 first coupling element [0133] 118 second coupling element [0134] 119 connection portion [0135] 120 downward flank [0136] 121 bottom downward groove [0137] 122 upward flank [0138] 123 third locking element [0139] 124 fourth locking element [0140] 125 lip [0141] 126 first locking surface [0142] 127 protruding edge [0143] 128 second locking surface [0144] 129 edge [0145] 130 bulge [0146] 131 cavity downward groove [0147] 132 step [0148] 133 step [0149] 134 inclined portion [0150] 200 recess [0151] 200A, 200B sub-recess [0152] 201 bottom [0153] 202 side-wall [0154] 203 protruding portion [0155] 300 protruding portion [0156] 300A, 300B protruding sub-portion [0157] 301 side-wall [0158] 302 base portion [0159] 303 recess [0160] U outermost point upward tongue [0161] C connection point [0162] S starting point [0163] O outer point [0164] a1, a2, a3, a4 angles [0165] N normal