Flooring panel and a floor covering with such panel

Abstract

A panel configured to be used for constructing a floor covering that includes a plurality of such panels. A combination of locking elements is used on the flanks of the coupling profiles on the sides of the panel that provides for replacing the well-known tongue and groove coupling.

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 of the panel is configured to be coupled to the second coupling profile of an adjacent panel among the plurality of panels for the purpose of mutually locking the panel and the adjacent panel; wherein each of the first and second coupling profile comprises a first flank that forms an inner flank of the core, a third flank that forms a respective outer edge of the panel, and a second flank that connects the first and third flanks; wherein at least the second flank of the first coupling profile comprises one of a first locking element and a second locking element, and wherein at least the second flank of the second coupling profile comprises an other of the first locking element and the second locking element, the first and second locking elements being configured to cooperate for said purpose of mutually locking the panel and the adjacent panel; wherein, in a locked state, the first flank of the panel is configured to be aligned with the third flank of the adjacent panel, the second flank of the panel is configured to be aligned with the second flank of the adjacent panel, and the third flank of the panel is configured to be aligned with the first flank of the adjacent panel; wherein the first locking element comprises a recess extending inwardly relative to the second flank of the first or second coupling profile, said recess having a bottom and side walls extending from the bottom to an outside of the relevant second flank, the first locking element further comprising a protruding portion extending from the bottom toward the outside of the relevant second flank; wherein the second locking element comprises a protruding portion comprising side walls that extend outwardly from an outside of the second flank of the second or first coupling profile, respectively, to a base portion, and a recess extending from the base portion inwardly relative to the relevant second 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.

2. The panel according to claim 1, wherein the first flank, the third flank, or the first flank and the third flank extends substantially parallel to a normal vector of the panel.

3. The panel according to claim 1, wherein the protruding portion of the first locking element is fully arranged in the recess of the first locking element and the recess of the second locking element is fully arranged in the protruding portion of the second locking element.

4. The panel according to claim 1, wherein the second flank of the first coupling profile comprises a first flank portion comprising said one of a first locking element and a second locking element, and a second flank portion connecting the first flank portion to the first flank, and wherein the second flank of the second coupling profile comprises a fourth flank portion comprising said the other of a first locking element and a second locking element and a fifth flank portion connecting the fourth flank portion to the third flank.

5. The panel according to claim 4, wherein the second flank portion comprises one of a recess and a protrusion that is complementary to said recess, and wherein the fifth flank portion comprises the other of a recess and a complementary protrusion.

6. The panel according to claim 5, wherein the second flank portion comprises a recess in the shape of a first groove, wherein the first flank portion and the third flank of the first coupling profile form a first tongue, wherein the fifth flank portion comprises a protrusion, which, together with the third flank of the second coupling profile, forms a second tongue and that defines, together with the first flank and fourth flank portion of the second coupling profile, a second groove, wherein the first tongue of the panel is configured to be received in the second groove of the adjacent panel, and wherein the second tongue of the adjacent panel is configured to be received in the first groove of the panel.

7. The panel according to claim 4, wherein the second flank of the first coupling profile comprises a third flank portion connecting the first flank portion to the third flank, and wherein the second flank of the second coupling profile comprises a sixth flank portion connecting the fourth flank portion to the first flank.

8. The panel according to claim 7, wherein the third flank portion faces away from the first flank of the first coupling profile, and wherein the fifth flank portion faces away from the first flank of the second coupling profile.

9. The panel according to claim 7, wherein the third flank portion and the sixth flank portion are essentially flat.

10. The panel according to claim 4, wherein the first flank portion and the second flank portion face substantially the same direction, and wherein the fourth flank portion and the fifth flank portion face substantially the same direction.

11. The panel according to claim 10, wherein the first flank portion and the second flank portion face a direction that is parallel to a normal vector of the panel, and wherein the fourth flank portion and the fifth flank portion face a direction that is parallel to said normal vector of the panel.

12. The panel according to claim 4, wherein the second flank portion faces a different direction than the first flank portion, and wherein the fifth flank portion faces a different direction than the fourth flank portion.

13. The panel according to claim 4, wherein the second flank portion is directed away from the first flank of the first coupling profile, and wherein the fifth flank portion is directed away from the first flank of the second coupling profile.

14. The panel according to claim 4, wherein the second flank portion and the fifth flank portion are curved.

15. The panel according to claim 1, further comprising a third locking element arranged on one of the first and third flank of the first coupling profile, and a fourth locking element arranged on one of the third and first flank of the second coupling profile, respectively, wherein the third and fourth locking elements are configured for the purpose of further mutually locking the panel and the adjacent panel.

16. The panel according to claim 15, wherein the third locking element is configured as one of the first and second locking element and wherein the fourth locking element is configured as the other of the first and second locking element.

17. The panel according to claim 15, wherein the third locking element comprises one of a recess and a protrusion that is complementary to said recess, and wherein the fourth locking element comprises the other of the recess and complementary protrusion.

18. The panel according to claim 1, wherein the first locking element comprises a pair of further protrusions arranged on opposite sides of the recess of the first locking element, and wherein the second locking element comprises a pair of further recesses arranged on opposite sides of the protruding portion of the second locking element, wherein each of the further recesses is configured to receive a respective further protrusion.

19. The panel according to claim 1, wherein the panel is a laminated floor panel, wherein the core is made from at least one of a medium-density fiberboard (MDF) and a high-density fiberboard (HDF).

20. The panel according to claim 1, wherein the panel comprises a top side comprising a decorative layer and a bottom side, wherein the first extension region partially forms the bottom side and wherein the second extension region partially forms the top side.

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

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Next, the invention will be described referring to the appended drawings wherein identical reference signs will be used to refer to identical or similar components and wherein:

(2) FIGS. 1A and 1B illustrate a schematic perspective view and a cross-sectional view of a general panel, respectively;

(3) FIG. 2 illustrates a cross-sectional view of a known panel;

(4) FIGS. 3A and 3B illustrate embodiments of a first and second locking element in accordance with the present invention; and

(5) FIGS. 4A-G illustrate various embodiments of a panel in accordance with the present invention.

DESCRIPTION OF THE INVENTION

(6) FIGS. 3A and 3B illustrate embodiments of a first and second locking element in accordance with the present invention. Here, first locking element 100 is assumed to be arranged on second flank 41 of second coupling profile 6 and comprises a recess 101 that extends inwardly relative to second flank 41. Recess 101 comprises a bottom 102 and side walls 103 extending from bottom 102 to an outside of second flank 41. First locking element 100 further comprises a protruding portion 104 extending from bottom 102 toward the outside of second flank 41. As shown, protruding portion 104 is fully arranged in recess 101.

(7) Second locking element 200, assumed to be arranged on second flank 40 of first coupling profile 5, comprises a protruding portion 201 comprising side walls 202 that extend outwardly from an outside of second flank 40 to a base portion 203, and a recess 204 extending from base portion 203 inwardly relative to second flank 40. As shown, recess 204 is fully arranged in protruding portion 201.

(8) Protruding portion 201 is divided, by recess 204, into oppositely arranged protruding sub-portions 201A, 201B. In addition, recess 101 is divided, by protruding portion 104, into oppositely arranged sub-recesses 101A, 101B.

(9) As shown in the coupled state in FIG. 3A, right hand side, protruding portion 104 is received in recess 204 and each protruding sub-portion 201A, 201B is received in a respective sub-recess 101A, 101B. In this manner, a triple lock function is obtained by first and second locking elements 100, 200.

(10) FIG. 3B illustrates a modification of first and second locking elements 100, 200 wherein first locking element 100 and second locking element 200 of FIG. 3A are each arranged in or on a respective protruding portion 110, 210. As shown, bottom 102 is substantially in line with the remaining part of second flank 41.

(11) It should be noted that the placement of first and second locking elements 100, 200 may be reversed, i.e. first locking element 100 can be provided on second flank 40 and second locking element 200 on second flank 41.

(12) The Applicant has found that locking elements 100, 200 provide a significantly improved locking effect when compared to a combination of a recess and protrusion as shown in FIG. 2, which are located on the first flank 31 and third flank 50, respectively. Furthermore, the Applicant realized that these locking elements can be used to replace the tongue-and-groove type of panels that are known in the art. The resulting panels are less complex and/or costly to manufacture and/or provide enhanced coupling strength. Next, examples of such panels will be presented.

(13) FIGS. 4A-G illustrate various embodiments of a panel in accordance with the present invention. Each figure illustrates the first coupling profile of a panel 1 next to the second coupling profile of an adjacent and identical panel 1′. Furthermore, FIGS. 4A-4C illustrate the coupling profiles in a loose state. Flank points A, B, C, D are indicated to illustrate the end points of the various portions of second flank 40. More in particular, the first flank portion extends between points B and C, the second flank portion between points C and D, and the third flank portion between points A and B. Similarly, flank points E, F, G, H are indicated to illustrate the end points of the various portions of second flank 41. More in particular, the fourth flank portion extends between points F and G, the fifth flank portion between points G and H, and the sixth flank portion between points E and F.

(14) The orientation of a flank portion can be determined by drawing a line, e.g. line L, through the end points of the respective flank portion. A line perpendicular to this line can then be taken as the normal vector corresponding to the flank portion. This is shown in FIG. 4A where a line L is drawn through points B and C to determine the orientation of the first flank portion of second flank 40. This orientation is indicated by normal vector N1. Similar vectors N2, N3 can be drawn for the second and third flank portion, respectively.

(15) As shown in FIG. 4A, each of the first, second, and third flank portion faces away from first flank 30. Moreover, each flank portions faces the same direction as the corresponding normal vectors are parallel. Similarly, each of the flank portions of second flank 41 faces the same direction away from first flank 31.

(16) In the FIG. 4A embodiment, the first, second, and third flank portion are aligned as indicated by a line that passes through points A-D. More in particularly, first coupling profile has a tapered form towards the edge of panel 1, which edge is formed by third flank 50. Similarly, the fourth, fifth, and sixth flank portion are aligned as indicated by a line that passes through points E-H. The second coupling profile also has a tapered form towards the edge of panel 1′, which edge is formed by third flank 51.

(17) A first locking element 100, which was previously shown in FIG. 3A, is provided on the fourth flank portion of second flank 41. A corresponding second locking element 200, which was previously shown in FIG. 3A, is provided on the first flank portion of second flank 40.

(18) Compared to the embodiment shown in FIG. 4A, the embodiment shown in FIG. 4B comprises a recess 42 in the second flank portion of second flank 40 of panel 1. Similarly, the fifth flank portion of second flank 41 of panel 1′ comprises a protrusion 43 that is configured to be received in recess 42. The cooperation between recess 42 and protrusion 43 provides a further mutual locking between panels 1, 1′. It is however noted that a similar locking, although maybe less pronounced, is achieved in the embodiment of FIG. 4A, where the fifth flank portion, extending between points G and H, can be seen as forming a protrusion that is received in the recess that is formed between the outer-right side-wall of locking element 200 and first flank 30.

(19) Compared to the embodiment shown in FIG. 4A, the embodiment shown in FIG. 4C comprises a fourth locking element 400, shaped as a protrusion, provided in first flank 31, and a third locking element 300, shaped as recess and provided in third flank 50. Third and fourth locking elements 300, 400 are configured to cooperate to provide a further mutual locking between panels 1, 1′.

(20) Similar to the embodiment shown in FIG. 4B, the embodiment shown in FIG. 4D comprises a recess 42 in the second flank portion of second flank 40 of panel 1. However, in this embodiment, recess 42 is rounded. Similarly, the fifth flank portion of second flank 41 of second coupling profile 6 of panel 1′ comprises a rounded protrusion (not shown) that is configured to be received in recess 42.

(21) In the FIG. 4E embodiment, the first, second and third flank portions are positioned horizontally. In addition, a fifth locking element 500, in the shape of a recess, is provided on first flank 30 of first coupling profile 5 that is configured to cooperate with a sixth locking element having a shape of a protrusion and being arranged on third flank 51 of second coupling profile 6 (not shown). Fifth locking element 500 and the sixth locking element are configured to cooperate to provide a further mutual locking between panels 1, 1′.

(22) Similar to the FIG. 4C embodiment, a third and fourth locking element 300, 400 are also provided on the third flank 50 and first flank 31 of the first and second coupling profile 5, 6, respectively. However, in this case, the position of third and fourth locking elements 300, 400 has been reversed.

(23) In the FIG. 4F embodiment, the first flank portion is directed towards first flank 30. The third flank portion is directed away from first flank 30, and the second flank portion is parallel to normal N of panel 1. Similarly, the fourth flank portion is directed towards first flank 31, the fifth flank portion is parallel to normal N′ of panel 1′, and the sixth flank portion is directed away from first flank 31.

(24) Compared to the embodiment shown in FIG. 4B, the embodiment shown in FIG. 4G comprises a seventh locking element 700 provided on third flank 30 which is shaped similar to first locking element 100 shown in FIG. 3A. Similarly, an eighth locking element 800 is provided on first flank 31 which is shaped similar to second locking element 200 shown in FIG. 3A. Seventh locking element 700 and eighth locking element 800 are configured to cooperate to provide a further mutual locking between panels 1, 1′. This particular combination of two pairs of locking elements, i.e. locking elements 100, 200 and locking elements 700, 800, wherein each of both pairs is shaped as the pair illustrated in FIG. 3, provides an improved coupling between panels 1, 1′, in terms of manufacturability and/or coupling strength.

(25) 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.

REFERENCE SIGNS

(26) 1 Panel 1′ Panel 2 Core 3 First extension region 4 Second extension region 5 First coupling profile 6 Second coupling profile 7 Upward tongue 8 Upward groove 9 Downward groove 10 Downward tongue 30 First flank first coupling profile 31 First flank second coupling profile 40 Second flank first coupling profile 41 Second flank second coupling profile 42 Recess 43 Protrusion 50 Third flank first coupling profile 51 Third flank second coupling profile 100 First locking element 101 Recess first locking element 101A, 101B Sub-recesses first locking element 102 Bottom first locking element 103 Side walls first locking element 104 Protruding portion first locking element 110 Protruding portion 200 Second locking element 201 Protruding portion second locking element 201A, 201B Protruding sub-portions second locking element 202 Side walls second locking element 203 Base portion second locking element 204 Recess second locking element 210 Protruding portion 300 Third locking element 400 Fourth locking element 500 Fifth locking element 700 Seventh locking element 800 Eight locking element A, B, C, D Flank points first coupling profile E, F, G, H Flank points second coupling profile B1 Dashed box illustrating first locking element B2 Dashed box illustrating second locking element L Line N, N′ Normal vectors panel 1, panel 1′ N1, N2, N3 Normal vectors first, second, third flank portion