Floor panel for forming a floor covering
10648182 ยท 2020-05-12
Assignee
Inventors
Cpc classification
E04F2201/043
FIXED CONSTRUCTIONS
E04F15/105
FIXED CONSTRUCTIONS
E04F2201/041
FIXED CONSTRUCTIONS
E04F15/02038
FIXED CONSTRUCTIONS
E04F15/107
FIXED CONSTRUCTIONS
International classification
E04F15/02
FIXED CONSTRUCTIONS
Abstract
A floor panel for forming a floor covering, wherein the floor covering consists of floor panels, which, on at least one pair of edges, are provided with coupling parts. The coupling parts substantially are manufactured from the material of the floor panel, and the coupling parts are configured such that two such floor panels, at the pair of edges, can be installed and locked to each other by means of a downward movement and/or by means of the fold-down principle.
Claims
1. A floor panel for forming a floor covering, wherein this floor panel comprises a first pair of opposite edges, as a second pair of opposite edges; wherein the first pair of opposite edges comprises first coupling parts, which allow that two of such floor panels mutually can be coupled to each other, and wherein said first coupling parts show the following characteristics: the first coupling parts comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels, effects a locking in a plane of the floor panels and perpendicular to the respective edges; the first coupling parts also comprise a first vertically active locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels; the first coupling parts substantially are realized from the material of the floor panel itself; and the first coupling parts are configured such that two of such panels can be coupled to each other at these edges by means of a turning movement; wherein the second pair of opposite edges also comprises second coupling parts on both of said edges, which allow that two of such floor panels mutually can be coupled to each other, wherein said second coupling parts show the following characteristics: the second coupling parts comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels, effects a locking in the plane of the floor panels and perpendicular to the respective edges; the second coupling parts also comprise a second vertically active locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels; the second coupling parts substantially are realized from the material of the floor panel itself; the horizontally active locking system of the second pair of edges is formed at least of an upward-directed lower hook-shaped part which is situated on one of said two edges, as a downward-directed upper hook-shaped part, which is situated on the opposite edge, wherein the lower hook-shaped part consists of a lip with an upward-directed locking element, which proximally thereof defines a female part in the form of a recess, whereas the upper hook-shaped part consists of a lip with a downward-directed locking element forming a male part; the second coupling parts are configured such that two of such floor panels can be coupled to each other at their respective edges by means of a downward movement of the one floor panel in respect to the other; the second vertically active locking system comprises vertically active locking parts, which, by means of respective contact surfaces, define at least a first contact zone and a second contact zone, which are situated at opposite sides of the male part and female part; the second vertically active locking parts comprise a first locking part and a second locking part at the respective opposite sides of the male part, as a third locking part and a fourth locking part at the respective opposite sides of the female part; the first and third locking part, in the coupled condition of two of such floor panels, define said first contact zone, while having contact surfaces which, in coupled condition, define at least one inclined tangent line; the second and fourth locking part, in the coupled condition of two of such floor panels, define said second contact zone, while having contact surfaces, which, in the coupled condition, also define at least one inclined tangent line; said male part has a distal side and a proximal side, wherein the second locking part is situated at a distal side; and said two tangent lines are upwardly inclined towards each other from their respective contact zones, wherein said floor panel is characterized in that on the second pair of edges further the following combination of features is present: the tangent line which is defined by the first and third locking part is steeper in respect to the plane of the floor panel than the tangent line which is defined by the second and fourth locking part, or, in other words, the angle of the first-mentioned tangent line with the horizontal is larger than the angle of the second-mentioned tangent line with the horizontal; the difference in size between both mentioned angles is at least 5 degrees and at least 10 degrees; at the male part, at a height lower than the second contact zone, a contact surface is provided, which, in the coupled condition, together with a contact surface at the female part of the then coupled floor panel forms a support point which limits the movement of the male part in downward direction; at a distal side of its distal end, the lower hook-shaped part is free from vertically active mechanic locking parts; wherein said floor panel is characterized in that the upward-directed locking element, the downward-directed locking element and contact surfaces of the upward-directed locking element and downward-directed locking element in the first contact zone are configured such that the upward-directed locking element with the contact surface thereof in the coupled condition adopts a tilted position in respect a position condition; and the contact surfaces of both the upward-directed locking element and downward-directed locking element of the first contact zone in the non-coupled condition mutually are oriented deviating more than in the coupled condition in which the contact surfaces of both the upward-directed locking element and downward-directed locking element deviate less or do not deviate relative to one another.
2. The floor panel of claim 1, wherein, when the second and fourth locking part define a plurality of tangent lines because the cooperating contact surfaces are not flat, then the tangent line from the second contact zone forms a smallest angle with the horizontal, whereas when the first and third locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the first contact zone forms the largest angle with the horizontal.
3. The floor panel of claim 1, wherein, when the second and fourth locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the second contact zone is determined by a middle of the second contact zone, whereas when the first and third locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the first contact zone is determined by a middle of the first contact zone.
4. The floor panel of claim 1, wherein the floor panel further comprises one or more characteristics selected from the below listed features, or any combination of these characteristics, this as far as such combination does not have any contradictory characteristics: at least one of the first and second coupling parts are realized such at the floor panel that the floor panels can be installed according to the fold-down principle; the floor panel is oblong rectangular and the first pair of opposite edges form the long sides of the floor panel, whereas the second pair of opposite edges form the short sides of the floor panel; the second coupling parts at the second pair of edges can be joined into each other by means of a downward snapping movement; the first and/or second coupling parts at the first and/or second pair of edges are made substantially as profiled parts in the material of the floor panel, substantially or entirely by means of a machining treatment, by means of one or more milling treatments, for example, with milling cutters which are active under different operative angles; the first and/or second coupling parts at the first and/or second pair of edges are made as millable profiled parts, which can be milled by means of milling cutters with a rotational axis which during milling is situated external to the floor panels; the aforementioned male part is or is not split; at the second pair of edges, only one male part is applied, whether or not split; at the aforementioned male part, only one vertically active locking part is present, which defines a tangent line of less than 70 degrees with the horizontal, whereas other, one or more, vertically active locking parts with a tangent line of 70 degrees or more may be present at the male part, at a distal side thereof; the contact surfaces of the second and/or fourth locking part, and of both, is, are, respectively, made flat; the contact surfaces of the second and/or fourth locking part, and of both, is, are, respectively, made curved; herein, the contact surface of the fourth locking part is convex, whereas the contact surface of the second locking part is flat or curved, and is concave; the lower hook-shaped part and the lip thereof is resiliently bendable and/or deformable; at the bottom of the lip, a recess is present, configured such that the upward-directed locking element is elastically tillable; underneath the male part, a space is present; in coupled condition, a space is present behind the distal end of the lower hook-shaped part; in coupled condition, a space is present above the upward-directed locking element, which space is made continuous with the space mentioned in the preceding paragraph; the previously mentioned angle of the tangent line at the first contact point is larger than 75 degrees; the previously mentioned angle of the tangent line at the first contact point is smaller than 90 degrees; the previously mentioned angle of the tangent line at the second contact point is more than 45 degrees; the previously mentioned angle of the tangent line at the second contact point is smaller than 75 degrees; the two contact surfaces of the second contact zone, including possible extensions thereof, seen in cross-section, extend to a first side and second side opposite to the first side of a respective closing surface, wherein the closing surface is defined as a vertical plane through upper edges of the coupled floor panels or at least the location where the floor panels come together at a top; the center point of the second contact zone is situated higher than the center point of the first contact zone; the second contact zone is a local contact zone, by which is meant that the second contact zone does not extend over the complete height of the male part; wherein this contact zone is situated with its upper end at a distance from an upper side of the floor panel and is situated with its lower end at a distance above a lower end of the male part; the second contact zone, seen in height, is situated between and of the overall thickness of the male part, in other words, the vertical height measured between the lowest point of the male part and the upper side of the floor panel; the first coupling parts at the first pair of edges and/or at the second pair of edges are manufactured completely in one piece from the material of the floor panel, and from a substrate forming part of the floor panel; above said second contact zone, the distal end of the upper hook-shaped part is completely free from downwardly active support points, or anyhow at least free from support points which, in the coupled condition, define tangent lines forming an angle with the horizontal which is smaller than 45 degrees; at the male and/or female part, inclined and/or rounded portions are formed, which are configured such that the male part, during the downward movement thereof, automatically is guided into the female part, this during a joining according to the fold-down principle and/or during joining via a plane-parallel downward movement, the first and/or second coupling parts at the first pair and/or second pair of edges are configured such that in coupled condition a so-called pretension is existing, which forces the respective floor panels at the respective edges towards each other, wherein this is performed by applying overlapping contours, and wherein the pretension is the result of a deformation, either an elastic bending or an elastic compression, or a combination of both; the second coupling parts at the second pair of edges are free from hook and loop fasteners and/or adhesive connections; the floor panel is provided with chamfers on the first and/or second pair of edges; the floor panel has a top layer and/or decor layer which extends in one piece from the horizontal upper surface of the floor panel up to the chamfers; the chamfers are formed by impressions; the floor panel has a top layer with a decor; the floor panels comprise a substrate which is or is not consisting of multiple pieces and does or does not consist of a plurality of substrate layers, wherein the substrate, or, in the case of a plurality of layers, at least one of the substrate layers consists of a material fulfilling one or more, or any combination of the following characteristics, as far as such combination is not contradictory: synthetic material-based material, foamed or not foamed, resilient or hard, whether or not with plasticizer, and whether or not filled with wood-based or bamboo-based material, for example, in the form of fibers, chips, dust or sawdust, and/or filled with other substances, for example, chalk, lime, talcum, ground fillers based on stone species; synthetic material-based material, which is foamed with fine pores, such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm; synthetic material-based material, which is obtained by extruding synthetic material-based starting material in the form of plate material, wherein, in a preferred embodiment, this material is foamed, with fine pores which are such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm; synthetic material-based material, which is obtained by strewing synthetic material-based material, whether or not combined with other materials, by means of a strewing process and consolidating under the influence of pressure and possibly increased temperature in the form of plate material, wherein in a preferred embodiment the obtained material is foamed, with fine pores, which are such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm; synthetic material consisting of, or on the basis of, or comprising one of the following materials: PP, PE, PET, PUR, PVC, PIR or other suitable synthetic materials; synthetic material-based material with plasticizers, wherein the synthetic material-based material is chosen from the materials listed in the preceding paragraph; wood-based material, for example, MDF, HDF, prefabricated wood panels, engineered wood panels, possibly with adapted core or end strips; the floor panel is made as one of the following kinds: as a laminate floor panel; as a so-called resilient floor panel; a LVT panel or CVT panel or comparable thereto panel on the basis of another synthetic material than vinyl; a floor panel with a first synthetic material-based, foamed, substrate layer, with thereon a thinner second substrate layer of or on the basis of vinyl or another synthetic material; as a floor panel with a hard synthetic material-based substrate.
5. A floor panel for forming a floor covering, wherein this floor panel comprises a first pair of opposite edges, as a second pair of opposite edges; wherein the first pair of opposite edges comprises first coupling parts, which allow that two of such floor panels mutually can be coupled to each other, and wherein said first coupling parts show the following characteristics: the first coupling parts comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels, effects a locking in a plane of the floor panels and perpendicular to the respective edges; the first coupling parts also comprise a first vertically active locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels; the first coupling parts substantially are realized from the material of the floor panel itself; and the first coupling parts are configured such that two of such panels can be coupled to each other at these edges by means of a turning movement; wherein the second pair of opposite edges also comprises coupling parts on both of said edges, which allow that two of such floor panels mutually can be coupled to each other, wherein said second coupling parts show the following characteristics: the second coupling parts comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels, effects a locking in the plane of the floor panels and perpendicular to the respective edges; the second coupling parts also comprise a second vertically active locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels; the second coupling parts substantially are realized from the material of the floor panel itself; the horizontally active locking system of the second pair of edges is formed at least of an upward-directed lower hook-shaped part which is situated on one of said two edges, as a downward-directed upper hook-shaped part, which is situated on the opposite edge, wherein the lower hook-shaped part consists of a lip with an upward-directed locking element, which proximally thereof defines a female part in the form of a recess, whereas the upper hook-shaped part consists of a lip with a downward-directed locking element forming a male part; the second coupling parts are configured such that two of such floor panels can be coupled to each other at their respective edges by means of a downward movement of the one floor panel in respect to the other; the second vertically active locking system comprises vertically active locking parts, which, by means of respective contact surfaces, define at least a first contact zone and a second contact zone, which are situated at opposite sides of the male part and female part; the second vertically active locking parts comprise a first locking part and a second locking part at the respective opposite sides of the male part, as a third locking part and a fourth locking part at the respective opposite sides of the female part; the first and third locking part, in the coupled condition of two of such floor panels, define said first contact zone, while having contact surfaces which, in coupled condition, define at least one inclined tangent line; the second and fourth locking part, in the coupled condition of two of such floor panels, define said second contact zone, while having contact surfaces, which, in the coupled condition, also define at least one inclined tangent line; said male part has a distal side and a proximal side, wherein the second locking part is situated at a distal side; and said two tangent lines are upwardly inclined towards each other from their respective contact zones, wherein said floor panel is characterized in that the second pair of edges also shows the following characteristic: the two contact surfaces of the second contact zone, including possible extensions thereof, seen in cross-section, extend to a first side and second side opposite to the first side of a respective closing surface, wherein the closing surface is defined as a vertical plane through upper edges of the coupled floor panels, or at least the location where the floor panels meet each other at a top; wherein said floor panel is characterized in that the upward-directed locking element, the downward-directed locking element and contact surfaces of the upward-directed locking element and downward-directed locking element in the first contact zone are configured such that the upward-directed locking element with the contact surface thereof in the coupled condition adopts a tilted position in respect a position condition; and the contact surfaces of both the upward-directed locking element and downward-directed locking element of the first contact zone in the non-coupled condition mutually are oriented deviating more than in the coupled condition in which the contact surfaces of both the upward-directed locking element and downward-directed locking element deviate less or do not deviate relative to one another.
6. The floor panel of claim 5, wherein said closing surface intersects the second contact zone, possibly including extensions thereof, halfway or approximately halfway thereof.
7. The floor panel of claim 5, wherein said intersection is located at a height which is higher than the entire first contact zone is situated.
8. The floor panel of claim 5, wherein, when the second and fourth locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the second contact zone forms a smallest angle with the horizontal, whereas when the first and third locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the first contact zone forms a largest angle with the horizontal.
9. The floor panel of claim 5, wherein, when the second and fourth locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the second contact zone is determined by a middle of the second contact zone, whereas when the first and third locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the first contact zone is determined by a middle of the first contact zone.
10. The floor panel of claim 5, wherein the floor panel further comprises one or more characteristics selected from the below listed features, or any combination of these characteristics, this as far as such combination does not have any contradictory characteristics: at least one of the first and second coupling parts are realized such at the floor panel that the floor panels can be installed according to the fold-down principle; the floor panel is oblong rectangular and the first pair of opposite edges form the long sides of the floor panel, whereas the second pair of opposite edges form the short sides of the floor panel; the second coupling parts at the second pair of edges can be joined into each other by means of a downward snapping movement; the first and/or second coupling parts at the first and/or second pair of edges are made substantially as profiled parts in the material of the floor panel, substantially or entirely by means of a machining treatment, by means of one or more milling treatments, for example, with milling cutters which are active under different operative angles; the first and/or second coupling parts at the first and/or second pair of edges are made as millable profiled parts, which can be milled by means of milling cutters with a rotational axis which during milling is situated external to the floor panels; the aforementioned male part is or is not split; at the second pair of edges, only one male part is applied, whether or not split; at the aforementioned male part, only one vertically active locking part is present, which defines a tangent line of less than 70 degrees with the horizontal, whereas other, one or more, vertically active locking parts with a tangent line of 70 degrees or more may be present at the male part, at a distal side thereof; the contact surfaces of the second and/or fourth locking part, and of both, is, are, respectively, made flat; the contact surfaces of the second and/or fourth locking part, and of both, is, are, respectively, made curved; herein, the contact surface of the fourth locking part is convex, whereas the contact surface of the second locking part is flat or curved, and is concave; the lower hook-shaped part and the lip thereof is resiliently bendable and/or deformable; at the bottom of the lip, a recess is present, configured such that the upward-directed locking element is elastically tiltable; in coupled condition, a downward-directed support point is provided at the male part; underneath the male part, a space is present; in coupled condition, a space is present above the upward-directed locking element, which space is made continuous with the space mentioned in the preceding paragraph; the previously mentioned angle of the tangent line at the first contact point is larger than 75 degrees; the previously mentioned angle of the tangent line at the first contact point is smaller than 90 degrees; the previously mentioned angle of the tangent line at the second contact point is more than 45 degrees; the previously mentioned angle of the tangent line at the second contact point is smaller than 75 degrees; the center point of the second contact zone is situated higher than the center point of the first contact zone; the second contact zone is a local contact zone, by which is meant that the second contact zone does not extend over the complete height of the male part; this contact zone is situated with its upper end at a distance from an upper side of the floor panel and is situated with its lower end at a distance above a lower end of the male part; the second contact zone, seen in height, is situated between and of the overall thickness of the male part, in other words, the vertical height measured between the lowest point of the male part and the upper side of the floor panel; the first and/or second coupling parts at the first pair of edges and/or at the second pair of edges are manufactured completely in one piece from the material of the floor panel; above said second contact zone, the distal end of the upper hook-shaped part is completely free from downwardly active support points, or anyhow at least free from support points which, in the coupled condition, define tangent lines forming an angle with the horizontal which is smaller than 45 degrees; at the male and/or female part, inclined and/or rounded portions are formed, which are configured such that the male part, during the downward movement thereof, automatically is guided into the female part, this during a joining according to the fold-down principle and/or during joining via a plane-parallel downward movement, the first and/or second coupling parts at the first pair and/or second pair of edges are configured such that in coupled condition a so-called pretension is existing, which forces the respective floor panels at the respective edges towards each other, wherein this is performed by applying overlapping contours, and wherein the pretension is the result of a deformation, either an elastic bending or an elastic compression, or a combination of both; the second coupling parts at the second pair of edges are free from hook and loop fasteners and/or adhesive connections; the floor panel is provided with chamfers on the first and/or second pair of edges; the floor panel has a top layer and/or decor layer which extends in one piece from the horizontal upper surface of the floor panel up to the chamfers; the chamfers are formed by impressions; the floor panel has a top layer with a decor; the floor panels comprise a substrate which is or is not consisting of multiple pieces and does or does not consist of a plurality of substrate layers, wherein the substrate, or, in the case of a plurality of layers, at least one of the substrate layers consists of a material fulfilling one or more, or any combination of the following characteristics, as far as such combination is not contradictory: synthetic material-based material, foamed or not foamed, resilient or hard, whether or not with plasticizer, and whether or not filled with wood-based or bamboo-based material, for example, in the form of fibers, chips, dust or sawdust, and/or filled with other substances, for example, chalk, lime, talcum, ground fillers based on stone species; synthetic material-based material, which is foamed with fine pores, such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm; synthetic material-based material, which is obtained by extruding synthetic material-based starting material in the form of plate material, wherein, in a preferred embodiment, this material is foamed, with fine pores which are such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm; synthetic material-based material, which is obtained by strewing synthetic material-based material, whether or not combined with other materials, by means of a strewing process and consolidating under the influence of pressure and increased temperature in the form of plate material, wherein in a preferred embodiment the obtained material is foamed, this with fine pores, which are such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm; synthetic material consisting of, or on the basis of, or comprising one of the following materials: PP, PE, PET, PUR, PVC, FIR or other suitable synthetic materials; synthetic material-based material with plasticizers, wherein the synthetic material-based material is chose from the materials listed in the preceding paragraph; wood-based material, for example, MDF, HDF, prefabricated wood panels; the floor panel is made as one of the following kinds: as a laminate floor panel; as a so-called resilient floor panel; a LVT panel or CVT panel or comparable thereto panel on the basis of another synthetic material than vinyl; a floor panel with a first synthetic material-based, foamed, substrate layer, with thereon a thinner second substrate layer of or on the basis of vinyl or another synthetic material; as a floor panel with a hard synthetic material-based substrate.
11. A floor panel for forming a floor covering, wherein this floor panel comprises a first pair of opposite edges, as a second pair of opposite edges; wherein the first pair of opposite edges comprises first coupling parts, which allow that two of such floor panels mutually can be coupled to each other, and wherein said first coupling parts show the following characteristics: the first coupling parts comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels, effects a locking in a plane of the floor panels and perpendicular to the respective edges; the first coupling parts also comprise a first vertically active locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels; the first coupling parts substantially are realized from the material of the floor panel itself; and the first coupling parts are configured such that two of such panels can be coupled to each other at these edges by means of a turning movement; wherein the second pair of opposite edges also comprises second coupling parts on both of said edges, which allow that two of such floor panels mutually can be coupled to each other, wherein said second coupling parts show the following characteristics: the second coupling parts comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels, effects a locking in the plane of the floor panels and perpendicular to the respective edges; the second coupling parts also comprise a second vertically active locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels; the second coupling parts substantially are realized from the material of the floor panel itself; the horizontally active locking system of the second pair of edges is formed at least of an upward-directed lower hook-shaped part which is situated on one of said two edges, as a downward-directed upper hook-shaped part, which is situated on the opposite edge, wherein the lower hook-shaped part consists of a lip with an upward-directed locking element, which proximally thereof defines a female part in the form of a recess, whereas the upper hook-shaped part consists of a lip with a downward-directed locking element forming a male part; the second coupling parts are configured such that two of such floor panels can be coupled to each other at their respective edges by means of a downward movement of the one floor panel in respect to the other; the second vertically active locking system comprises vertically active locking parts, which, by means of respective contact surfaces, define at least a first contact zone and a second contact zone, which are situated at opposite sides of the male part and female part; the second vertically active locking parts comprise a first locking part and a second locking part at the respective opposite sides of the male part, as a third locking part and a fourth locking part at the respective opposite sides of the female part; the first and third locking part, in the coupled condition of two of such floor panels, define said first contact zone, while having contact surfaces which, in coupled condition, define at least one inclined tangent line; the second and fourth locking part, in the coupled condition of two of such floor panels, define said second contact zone, while having contact surfaces, which, in the coupled condition, also define at least one inclined tangent line; said male part has a distal side and a proximal side, wherein the second locking part is situated at a distal side; and said two tangent lines are upwardly inclined towards each other from their respective contact zones, wherein said floor panel is characterized in that the second pair of edges also shows the following characteristic: at the male part, at a height lower than the second contact zone, a contact surface is provided, which, in the coupled condition, together with a contact surface on the then coupled floor panel, forms a support point which limits the movement of the male part in downward direction; the second coupling parts at the second pair of edges also show one of the following three characteristics or any combination of two or three of these characteristics: at a distal side of its distal end, the lower hook-shaped part is free from vertically active mechanical locking parts; the contact surfaces forming said support point are situated on a lower side of the male part and on an upper side of the lip of the lower hook-shaped part, respectively, wherein in coupled condition, distally from this support point a space is present between the lower side of the male part and the upper side of said lip, underneath the entire portion of the male part situated distally from said support point, wherein this space is formed in that a portion of the upper side of the lip is situated deeper than the support point, and/or wherein this space, seen in a cross-section of the respective edge, extends over a distance which is at least of the width of the male part; at the lower side of the lip of the lower hook-shaped part, a recess is present, which extends up to the distal end of the lip and which allows a bending of the lip in downward direction; wherein said floor panel is characterized in that the upward-directed locking element, the downward-directed locking element and contact surfaces of the upward-directed locking element and downward-directed locking element in the first contact zone are configured such that the upward-directed locking element with the contact surface thereof in the coupled condition adopts a tilted position in respect a position condition; and the contact surfaces of both the upward-directed locking element and downward-directed locking element of the first contact zone in the non-coupled condition mutually are oriented deviating more than in the coupled condition in which the contact surfaces of both the upward-directed locking element and downward-directed locking element deviate less or do not deviate relative to one another.
12. The floor panel of claim 11, wherein, when the second and fourth locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the second contact zone forms the smallest angle with the horizontal, whereas when the first and third locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the first contact zone forms the largest angle with the horizontal.
13. The floor panel of claim 11, wherein, when the second and fourth locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the second contact zone is determined by a middle of the second contact zone, whereas when the first and third locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the first contact zone is determined by a middle of the first contact zone.
14. The floor panel of claim 11, wherein the floor panel further comprises one or more characteristics selected from the below listed features, or any combination of these characteristics, this as far as such combination does not have any contradictory characteristics: at least one of the first and second coupling parts are realized such at the floor panel that the floor panels can be installed according to the fold-down principle; the floor panel is oblong rectangular and the first pair of opposite edges form the long sides of the floor panel, whereas the second pair of opposite edges form the short sides of the floor panel; the second coupling parts at the second pair of edges can be joined into each other by means of a downward snapping movement; the first and/or second coupling parts at the first and/or second pair of edges are made substantially as profiled parts in the material of the floor panel, substantially or entirely by means of a machining treatment, by means of one or more milling treatments, for example, with milling cutters which are active under different operative angles; the first and/or second coupling parts at the first and/or second pair of edges are made as millable profiled parts, which can be milled by means of milling cutters with a rotational axis which during milling is situated external to the floor panels; the aforementioned male part is or is not split; at the second pair of edges, only one male part is applied, whether or not split; at the aforementioned male part, only one vertically active locking part is present, which defines a tangent line of less than 70 degrees with the horizontal, whereas other, one or more, vertically active locking parts with a tangent line of 70 degrees or more may be present at the male part, at a distal side thereof; the contact surfaces of the second and/or fourth locking part, and of both, is, are, respectively, made flat; the contact surfaces of the second and/or fourth locking part, and of both, is, are, respectively, made curved; herein, the contact surface of the fourth locking part is convex, whereas the contact surface of the second locking part is flat or curved, and is concave; the lower hook-shaped part and the lip thereof is resiliently bendable and/or deformable; in coupled condition, a space is present behind the distal end of the lower hook-shaped part; in coupled condition, a space is present above the upward-directed locking element, which space is made continuous with the space mentioned in the preceding paragraph; the previously mentioned angle of the tangent line at the first contact point is larger than 75 degrees; the previously mentioned angle of the tangent line at the first contact point is smaller than 90 degrees and is smaller than 87 degrees; the previously mentioned angle of the tangent line at the second contact point is smaller than 75 degrees; the two contact surfaces of the second contact zone, including possible extensions thereof, seen in cross-section, extend to a first side and second side opposite to the first side of a respective closing surface, wherein the closing surface is defined as a vertical plane through upper edges of the coupled floor panels or at least the location where the floor panels come together at a top; the center point of the second contact zone is situated higher than the center point of the first contact zone; the second contact zone is a local contact zone, by which is meant that the second contact zone does not extend over the complete height of the male part; wherein this contact zone is situated with its upper end at a distance from the upper side of the floor panel and is situated with its lower end at a distance above a lower end of the male part; wherein the second contact zone, seen in height, is situated between and of the overall thickness of the male part, in other words, the vertical height measured between the lowest point of the male part and the upper side of the floor panel; the first and/or second coupling parts at the first pair of edges and/or at the second pair of edges are manufactured completely in one piece from the material of the floor panel, and from a substrate forming part of the floor panel; above said second contact zone, the distal end of the upper hook-shaped part is completely free from downwardly active support points, or anyhow at least free from support points which, in the coupled condition, define tangent lines forming an angle with the horizontal which is smaller than 45 degrees; at the male and/or female part, inclined and/or rounded portions are formed, which are configured such that the male part, during the downward movement thereof, automatically is guided into the female part, this during a joining according to the fold-down principle and/or during joining via a plane-parallel downward movement, the first and/or second coupling parts at the first pair and/or second pair of edges are configured such that in coupled condition a so-called pretension is existing, which forces the respective floor panels at the respective edges towards each other, wherein this is performed by applying overlapping contours, and wherein the pretension is the result of a deformation, either an elastic bending or an elastic compression, or a combination of both; the second coupling parts at the second pair of edges are free from hook and loop fasteners and/or adhesive connections; the floor panel is provided with chamfers on the first and/or second pair of edges; the floor panel has a top layer and/or decor layer which extends in one piece from the horizontal upper surface of the floor panel up to the chamfers; the chamfers are formed by impressions; the floor panel has a top layer with a decor; the floor panels comprise a substrate which is or is not consisting of multiple pieces and does or does not consist of a plurality of substrate layers, wherein the substrate, or, in the case of a plurality of layers, at least one of the substrate layers consists of a material fulfilling one or more, or any combination of the following characteristics, as far as such combination is not contradictory: synthetic material-based material, foamed or not foamed, resilient or hard, whether or not with plasticizer, and whether or not filled with wood-based or bamboo-based material, for example, in the form of fibers, chips, dust or sawdust, and/or filled with other substances, for example, chalk, lime, talcum, ground fillers based on stone species; synthetic material-based material, which is foamed with fine pores, such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm; synthetic material-based material, which is obtained by extruding synthetic material-based starting material in the form of plate material, wherein, in a preferred embodiment, this material is foamed, with fine pores which are such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm; synthetic material-based material, which is obtained by strewing synthetic material-based material, whether or not combined with other materials, by means of a strewing process and consolidating Rill under the influence of pressure and possibly increased temperature in the form of plate material, wherein in a preferred embodiment the obtained material is foamed, this with fine pores, which are such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm; synthetic material consisting of, or on the basis of, or comprising one of the following materials: PP, PE, PET, PUR, PVC, PIR or other suitable synthetic materials; synthetic material-based material with plasticizers, wherein the synthetic material-based material is chosen from the materials listed in the preceding paragraph; wood-based material, MDF, HDF, prefabricated wood panels, engineered wood panels, possibly with adapted core or end strips; the floor panel is made as one of the following kinds: as a laminate floor panel; as a so-called resilient floor panel; a LVT panel or CVT panel or comparable thereto panel on the basis of another synthetic material than vinyl; a floor panel with a first synthetic material-based, foamed, substrate layer, with thereon a thinner second substrate layer of or on the basis of vinyl or another synthetic material; as a floor panel with a hard synthetic material-based substrate.
15. A floor panel for forming a floor covering, wherein this floor panel comprises a first pair of opposite edges, as a second pair of opposite edges; wherein the first pair of opposite edges comprises first coupling parts, which allow that two of such floor panels mutually can be coupled to each other, and wherein said first coupling parts show the following characteristics: the first coupling parts comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels, effects a locking in a plane of the floor panels and perpendicular to the respective edges; the first coupling parts also comprise a first vertically active locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels; the first coupling parts substantially are realized from the material of the floor panel itself; and the first coupling parts are configured such that two of such panels can be coupled to each other at these edges by means of a turning movement; wherein the second pair of opposite edges also comprises second coupling parts on both of said edges, which allow that two of such floor panels mutually can be coupled to each other, wherein said second coupling parts show the following characteristics: the second coupling parts comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels, effects a locking in the plane of the floor panels and perpendicular to the respective edges; the second coupling parts also comprise a second vertically active locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels; the second coupling parts substantially are realized from the material of the floor panel itself; the horizontally active locking system of the second pair of edges is formed at least of an upward-directed lower hook-shaped part which is situated on one of said two edges, as a downward-directed upper hook-shaped part, which is situated on the opposite edge, wherein the lower hook-shaped part consists of a lip with an upward-directed locking element, which proximally thereof defines a female part in the form of a recess, whereas the upper hook-shaped part consists of a lip with a downward-directed locking element forming a male part; the second coupling parts are configured such that two of such floor panels can be coupled to each other at their respective edges by means of a downward movement of the one floor panel in respect to the other; the second vertically active locking system comprises vertically active locking parts, which, by means of respective contact surfaces, define at least a first contact zone and a second contact zone, which are situated at opposite sides of the male part and female part; the second vertically active locking parts comprise a first locking part and a second locking part at the respective opposite sides of the male part, as a third locking part and a fourth locking part at the respective opposite sides of the female part; the first and third locking part, in the coupled condition of two of such floor panels, define said first contact zone, while having contact surfaces which, in coupled condition, define at least one inclined tangent line; the second and fourth locking part, in the coupled condition of two of such floor panels, define said second contact zone, while having contact surfaces, which, in the coupled condition, also define at least one inclined tangent line; said male part has a distal side and a proximal side, wherein the second locking part is situated at a distal side; and said two tangent lines are upwardly inclined towards each other from their respective contact zones, wherein said floor panel is characterized in that at the second pair of edges further the following combination of characteristics is present: the contact surfaces of the second and fourth locking part, and possible extensions of these surfaces, are made flat or substantially flat; the contact surfaces of the second and fourth locking part, and the tangent line defined thereby, form an angle with the horizontal which is smaller than 45 degrees; the contact surfaces of the second and fourth locking part, and possible extensions of these surfaces, in upward direction each terminate at locations which are situated lower than an upper surface of the floor panels; starting from upper ends of the contact surfaces of the second and fourth locking part, and from possible extensions of these surfaces, up to the upper surface of the floor panel, lateral edge portions are formed, which extend more straight upward than said contact surfaces and are vertical or approximately vertical; at lower edges of the male part, guiding surfaces, such as inclined parts or rounded parts, are present, which are configured such that the male part during the downward movement thereof automatically is guided into the female part; wherein said floor panel is characterized in that the upward-directed locking element, the downward-directed locking element and contact surfaces of the upward-directed locking element and downward-directed locking element in the first contact zone are configured such that the upward-directed locking element with the contact surface thereof in the coupled condition adopts a tilted position in respect a position condition; and the contact surfaces of both the upward-directed locking element and downward-directed locking element of the first contact zone in the non-coupled condition mutually are oriented deviating more than in the coupled condition in which the contact surfaces of both the upward-directed locking element and downward-directed locking element deviate less or do not deviate relative to one another.
16. The floor panel of claim 15, wherein the upward-directed locking element, which at the same time is configured to function as a third locking element, is elastically tillable, assisted by the presence of a recess on a lower side of the lip of the lower hook-shaped part.
17. The floor panel of claim 15, wherein, when the second and fourth locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the second contact zone forms the smallest angle with the horizontal, whereas when the first and third locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the first contact zone which forms the largest angle with the horizontal.
18. The floor panel of claim 15, wherein, when the second and fourth locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the second contact zone is determined by a middle of the second contact zone, whereas when the first and third locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the first contact zone is determined by a middle of the first contact zone.
19. The floor panel of claim 15, wherein the floor panel further comprises one or more characteristics selected from the below listed features, or any combination of these characteristics, this as far as such combination does not have any contradictory characteristics: at least one of the first and second coupling parts are realized such at the floor panel that the floor panels can be installed according to the fold-down principle; the floor panel is oblong rectangular and the first pair of opposite edges form the long sides of the floor panel, whereas the second pair of opposite edges form the short sides of the floor panel; the second coupling parts at the second pair of edges can be joined into each other by means of a downward snapping movement; the first and/or second coupling parts at the first and/or second pair of edges are made substantially as profiled parts in the material of the floor panel, substantially or entirely by means of a machining treatment, by means of one or more milling treatments, for example, with milling cutters which are active under different operative angles; the first and/or second coupling parts at the first and/or second pair of edges are made as millable profiled parts, which can be milled by means of milling cutters with a rotational axis which during milling is situated external to the floor panels; the aforementioned male part is or is not split; at the second pair of edges, only one male part is applied, whether or not split; at the aforementioned male part, only one vertically active locking part is present, which defines a tangent line of less than 70 degrees with the horizontal, whereas other, one or more, vertically active locking parts with a tangent line of 70 degrees or more may be present at the male part, at a distal side thereof; the lower hook-shaped part and the lip thereof is resiliently bendable and/or deformable; in coupled condition, a downward-directed support point is provided at the male part; underneath the male part, a space is present; in coupled condition, a space is present behind the distal end of the lower hook-shaped part; in coupled condition, a space is present above the upward-directed locking element, which space is made continuous with the space mentioned in the preceding paragraph; the previously mentioned angle of the tangent line at the first contact point is larger than 75 degrees; the previously mentioned angle of the tangent line at the first contact point is smaller than 90 degrees and is smaller than 87 degrees; the two contact surfaces of the second contact zone, including possible extensions thereof, seen in cross-section, extend to a first side and second side opposite to the first side of a respective closing surface, wherein the closing surface is defined as a vertical plane through upper edges of the coupled floor panels or at least the location where the floor panels come together at a top; the center point of the second contact zone is situated higher than the center point of the first contact zone; the second contact zone is a local contact zone, by which is meant that the second contact zone does not extend over the complete height of the male part; wherein this contact zone is situated with its upper end at a distance from the upper side of the floor panel and is situated with its lower end at a distance above a lower end of the male part; wherein the second contact zone, seen in height, is situated between and of the overall thickness of the male part, in other words, the vertical height measured between the lowest point of the male part and the upper side of the floor panel; the first and/or second coupling parts at the first pair of edges and/or at the second pair of edges are manufactured completely in one piece from the material of the floor panel, and from a substrate forming part of the floor panel; above said second contact zone, the distal end of the upper hook-shaped part is completely free from downwardly active support points, or anyhow at least free from support points which, in the coupled condition, define tangent lines forming an angle with the horizontal which is smaller than 45 degrees; at the female part, inclined and/or rounded portions are formed, which are configured such that the male part, during the downward movement thereof, automatically is guided into the female part, this during a joining according to the fold-down principle and/or during joining via a plane-parallel downward movement, the first and/or second coupling parts at the first pair and/or second pair of edges are configured such that in coupled condition a so-called pretension is existing, which forces the respective floor panels at the respective edges towards each other, wherein this is performed by applying overlapping contours, and wherein the pretension is the result of a deformation, either an elastic bending or an elastic compression, or a combination of both; the second coupling parts at the second pair of edges are free from hook and loop fasteners and/or adhesive connections; the floor panel is provided with chamfers on the first and/or second pair of edges; the floor panel has a top layer and/or decor layer which extends in one piece from the horizontal upper surface of the floor panel up to the chamfers; the chamfers are formed by impressions; the floor panel has a top layer with a decor; the floor panels comprise a substrate which is or is not consisting of multiple pieces and does or does not consist of a plurality of substrate layers, wherein the substrate, or, in the case of a plurality of layers, at least one of the substrate layers consists of a material fulfilling one or more, or any combination of the following characteristics, as far as such combination is not contradictory: synthetic material-based material, foamed or not foamed, resilient or hard, whether or not with plasticizer, and whether or not filled with wood-based or bamboo-based material, for example, in the form of fibers, chips, dust or sawdust, and/or filled with other substances, for example, chalk, lime, talcum, ground fillers based on stone species; synthetic material-based material, which is foamed with fine pores, such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm; synthetic material-based material, which is obtained by extruding synthetic material-based starting material in the form of plate material, wherein, in a preferred embodiment, this material is foamed, with fine pores which are such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm; synthetic material-based material, which is obtained by strewing synthetic material-based material, whether or not combined with other materials, by means of a strewing process and consolidating under the influence of pressure and possibly increased temperature in the form of plate material, wherein in a preferred embodiment the obtained material is foamed, this with fine pores, which are such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm; synthetic material consisting of, or on the basis of, or comprising one of the following materials: PP, PE, PET, PUR, PVC, PIR or other suitable synthetic materials; synthetic material-based material with plasticizers, wherein the synthetic material-based material is chosen from the materials listed in the preceding paragraph; wood-based material, for example, MDF, HDF, prefabricated wood panels, engineered wood panels, possibly with adapted core or end strips; the floor panel is made as one of the following kinds: as a laminate floor panel; as a so-called resilient floor panel; a LVT panel or CVT panel or comparable thereto panel on the basis of another synthetic material than vinyl; a floor panel with a first synthetic material-based, foamed, substrate layer, with thereon a thinner second substrate layer of or on the basis of vinyl or another synthetic material; as a floor panel with a hard synthetic material-based substrate.
20. A floor panel for forming a floor covering, wherein this floor panel comprises a first pair of opposite edges, as a second pair of opposite edges; wherein the first pair of opposite edges comprises first coupling parts, which allow that two of such floor panels mutually can be coupled to each other, and wherein said first coupling parts show the following characteristics: the first coupling parts comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels, effects a locking in a plane of the floor panels and perpendicular to the respective edges; the first coupling parts also comprise a first vertically active locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels; the first coupling parts substantially are realized from the material of the floor panel itself; and the first coupling parts are configured such that two of such panels can be coupled to each other at these edges by means of a turning movement; wherein the second pair of opposite edges also comprises second coupling parts on both of said edges, which allow that two of such floor panels mutually can be coupled to each other, and wherein said second coupling parts show the following characteristics: the second coupling parts comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels, effects a locking in the plane of the floor panels and perpendicular to the respective edges; the second coupling parts also comprise a second vertically active locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels; the second coupling parts substantially are realized from the material of the floor panel itself; the horizontally active locking system of the second pair of edges is formed at least of an upward-directed lower hook-shaped part which is situated on one of said two edges, as a downward-directed upper hook-shaped part, which is situated on the opposite edge, wherein the lower hook-shaped part consists of a lip with an upward-directed locking element, which proximally thereof defines a female part in the form of a recess, whereas the upper hook-shaped part consists of a lip with a downward-directed locking element forming a male part; the first and second coupling parts are configured such that two of such floor panels can be coupled to each other at their respective edges by means of a downward movement of the one floor panel in respect to the other; the second vertically active locking system comprises vertically active locking parts, which, by means of respective contact surfaces, define at least a first contact zone and a second contact zone, which are situated at opposite sides of the male part and female part; the second vertically active locking parts comprise a first locking part and a second locking part at the respective opposite sides of the male part, as a third locking part and a fourth locking part at the respective opposite sides of the female part; the first and third locking part, in the coupled condition of two of such floor panels, define said first contact zone, while having contact surfaces which, in coupled condition, define at least one inclined tangent line; the second and fourth locking part, in the coupled condition of two of such floor panels, define said second contact zone, while having contact surfaces, which, in the coupled condition, also define at least one inclined tangent line; said male part has a distal side and a proximal side, wherein the second locking part is situated at a distal side; and said two tangent lines are upwardly inclined towards each other from their respective contact zones, wherein said floor panel is characterized in that the second pair of edges further shows the following combination of characteristics: at a lower side of the lower hook-shaped part, a recess is present which extends from a certain location at the lower side up to an end of the lower hook-shaped part; and seen in cross-section, said location is situated proximally from the upward-directed locking element, and at a horizontal distance therefrom, which is more than 1/10 of the overall thickness of the floor panel; wherein said floor panel is characterized in that the upward-directed locking element, the downward-directed locking element and contact surfaces of the upward-directed locking element and downward-directed locking element in the first contact zone are configured such that the upward-directed locking element with the contact surface thereof in the coupled condition adopts a tilted position in respect a position condition; and the contact surfaces of both the upward-directed locking element and downward-directed locking element of the first contact zone in the non-coupled condition mutually are oriented deviating more than in the coupled condition in which the contact surfaces of both the upward-directed locking element and downward-directed locking element deviate less or do not deviate relative to one another.
21. The floor panel of claim 20, wherein the recess consists of a recessed portion, which is recessed in respect to the actual lower side of the floor panel, and a transition portion, which is situated between the actual lower side and the recessed portion and which provides for a gradual transition.
22. The floor panel of claim 20, wherein, when the second and fourth locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the second contact zone forms the smallest angle with the horizontal, whereas when the first and third locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the first contact zone forms the largest angle with the horizontal.
23. The floor panel of claim 20, wherein, when the second and fourth locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the second contact zone is determined by a middle of the second contact zone, whereas when the first and third locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the first contact zone is determined by a middle of the first contact zone.
24. The floor panel of claim 20, wherein the floor panel further comprises one or more characteristics selected from the below listed features, or any combination of these characteristics, this as far as such combination does not have any contradictory characteristics: the first and second coupling parts are realized such at the floor panel that the floor panels can be installed according to the fold-down principle; the floor panel is oblong rectangular and the first pair of opposite edges form the long sides of the floor panel, whereas the second pair of opposite edges form the short sides of the floor panel; the second coupling parts at the second pair of edges can be joined into each other by means of a downward snapping movement; the first and/or second coupling parts at the first and/or second pair of edges are made substantially as profiled parts in the material of the floor panel, substantially or entirely by means of a machining treatment, preferably by means of one or more milling treatments, for example, with milling cutters which are active under different operative angles; the first and/or second coupling parts at the first and/or second pair of edges are made as millable profiled parts, which can be milled by means of milling cutters with a rotational axis which during milling is situated external to the floor panels; the aforementioned male part is or is not split; at the second pair of edges, only one male part is applied, whether or not split; at the aforementioned male part, only one vertically active locking part is present, which defines a tangent line of less than 70 degrees with the horizontal, whereas other, one or more, vertically active locking parts with a tangent line of 70 degrees or more may be present at the male part, at a distal side thereof; the contact surfaces of the second and/or fourth locking part, and of both, is, are, respectively, made flat; the contact surfaces of the second and/or fourth locking part, and of both, is, are, respectively, made curved; herein, the contact surface of the fourth locking part is convex, whereas the contact surface of the second locking part is flat or curved, and is concave; the lower hook-shaped part and the lip thereof is resiliently bendable and/or deformable; in coupled condition, a downward-directed support point is provided at the male part; underneath the male part, a space is present; in coupled condition, a downward-directed support point is provided at the male part; in coupled condition, a space is present above the upward-directed locking element, which space is made continuous with the space mentioned in the preceding paragraph; the previously mentioned angle of the tangent line at the first contact point is larger than 75 degrees; the previously mentioned angle of the tangent line at the first contact point is smaller than 90 degrees and is smaller than 87 degrees; the previously mentioned angle of the tangent line at the second contact point is more than 45 degrees; the previously mentioned angle of the tangent line at the second contact point is smaller than 75 degrees; the two contact surfaces of the second contact zone, including possible extensions thereof, seen in cross-section, extend to a first side and second side opposite to the first side of a respective closing surface, wherein the closing surface is defined as a vertical plane through upper edges of the coupled floor panels or at least the location where the floor panels come together at a top; the center point of the second contact zone is situated higher than the center point of the first contact zone; the second contact zone is a local contact zone, by which is meant that the second contact zone does not extend over the complete height of the male part; wherein this contact zone is situated with its upper end at a distance from an upper side of the floor panel and is situated with its lower end at a distance above a lower end of the male part; wherein the second contact zone, seen in height, is situated between and of the overall thickness of the male part, in other words, the vertical height measured between the lowest point of the male part and the upper side of the floor panel; the first and/or second coupling parts at the first pair of edges and/or at the second pair of edges are manufactured completely in one piece from the material of the floor panel, and from a substrate forming part of the floor panel; above said second contact zone, the distal end of the upper hook-shaped part is completely free from downwardly active support points, or anyhow at least free from support points which, in the coupled condition, define tangent lines forming an angle with the horizontal which is smaller than 45 degrees; at the male and/or female part, inclined and/or rounded portions are formed, which are configured such that the male part, during the downward movement thereof, automatically is guided into the female part, this during a joining according to the fold-down principle and/or during joining via a plane-parallel downward movement, the first and/or second coupling parts at the first pair and/or second pair of edges are configured such that in coupled condition a so-called pretension is existing, which forces the respective floor panels at the respective edges towards each other, wherein this is performed by applying overlapping contours, and wherein the pretension is the result of a deformation, either an elastic bending or an elastic compression, or a combination of both; the second coupling parts at the second pair of edges are free from hook and loop fasteners and/or adhesive connections; the floor panel is provided with chamfers on the first and/or second pair of edges; the floor panel has a top layer and/or decor layer which extends in one piece from the horizontal upper surface of the floor panel up to the chamfers; the chamfers are formed by impressions; the floor panel has a top layer with a decor; the floor panels comprise a substrate which is or is not consisting of multiple pieces and does or does not consist of a plurality of substrate layers, wherein the substrate, or, in the case of a plurality of layers, at least one of the substrate layers consists of a material fulfilling one or more, or any combination of the following characteristics, as far as such combination is not contradictory: synthetic material-based material, foamed or not foamed, resilient or hard, whether or not with plasticizer, and whether or not filled with wood-based or bamboo-based material, for example, in the form of fibers, chips, dust or sawdust, and/or filled with other substances, for example, chalk, lime, talcum, ground fillers based on stone species; synthetic material-based material, which is foamed with fine pores, such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm; synthetic material-based material, which is obtained by extruding synthetic material-based starting material in the form of plate material, wherein, in a preferred embodiment, this material is foamed, with fine pores which are such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm; synthetic material-based material, which is obtained by strewing synthetic material-based material, whether or not combined with other materials, by means of a strewing process and consolidating under the influence of pressure and possibly increased temperature in the form of plate material, wherein in a preferred embodiment the obtained material is foamed, with fine pores, which are such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm; synthetic material consisting of, or on the basis of, or comprising one of the following materials: PP, PE, PET, PUR, PVC, PIR or other suitable synthetic materials; synthetic material-based material with plasticizers, wherein the synthetic material-based material is chosen from the materials listed in the preceding paragraph; wood-based material, for example, MDF, HDF, prefabricated wood panels, engineered wood panels, possibly with adapted core or end strips; the floor panel is made as one of the following kinds: as a laminate floor panel; as a so-called resilient floor panel; a LVT panel or CVT panel or comparable thereto panel on the basis of another synthetic material than vinyl; a floor panel with a first synthetic material-based, foamed, substrate layer, with thereon a thinner second substrate layer of or on the basis of vinyl or another synthetic material; as a floor panel with a hard synthetic material-based substrate.
25. A floor panel for forming a floor covering, wherein this floor panel comprises a first pair of opposite edges, as a second pair of opposite edges; wherein the first pair of opposite edges comprises first coupling parts, which allow that two of such floor panels mutually can be coupled to each other, and wherein said first coupling parts show the following characteristics: the first coupling parts comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels, effects a locking in a plane of the floor panels and perpendicular to the respective edges; the first coupling parts also comprise a first vertically active locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels; the first coupling parts are substantially realized from the material of the floor panel itself; and the first coupling parts are configured such that two of such panels can be coupled to each other at these edges by means of a turning movement; wherein the second pair of opposite edges also comprises second coupling parts on both of said edges, which allow that two of such floor panels mutually can be coupled to each other, and wherein said second coupling parts show the following characteristics: the second coupling parts comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels, effects a locking in the plane of the floor panels and perpendicular to the respective edges; the second coupling parts also comprise a second vertically active locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels; the second coupling parts are substantially realized from the material of the floor panel itself; the horizontally active locking system of the second pair of edges is formed at least of an upward-directed lower hook-shaped part which is situated on one of said two edges, as a downward-directed upper hook-shaped part, which is situated on the opposite edge, wherein the lower hook-shaped part consists of a lip with an upward-directed locking element, which proximally thereof defines a female part in the form of a recess, whereas the upper hook-shaped part consists of a lip with a downward-directed locking element forming a male part; the first and second coupling parts are configured such that two of such floor panels can be coupled to each other at their respective edges by means of a downward movement of the one floor panel in respect to the other; the second vertically active locking system comprises vertically active locking parts, which, by means of respective contact surfaces, define at least a first contact zone and a second contact zone, which are situated at opposite sides of the male part and female part; the second vertically active locking parts comprise a first locking part and a second locking part at the respective opposite sides of the male part, as a third locking part and a fourth locking part at the respective opposite sides of the female part; the first and third locking part, in the coupled condition of two of such floor panels, define said first contact zone, while having contact surfaces which, in coupled condition, define at least one inclined tangent line; the second and fourth locking part, in the coupled condition of two of such floor panels, define said second contact zone, while having contact surfaces, which, in the coupled condition, also define at least one inclined tangent line; said male part has a distal side and a proximal side, wherein the second locking part is situated at a distal side; and said two tangent lines are upwardly inclined towards each other from their respective contact zones, wherein said floor panel is characterized in that the upward-directed locking element, the downward-directed locking element and contact surfaces of the upward-directed locking element and downward-directed locking element in the first contact zone are configured such that the upward-directed locking element with the contact surface thereof in the coupled condition adopts a tilted position in respect to a position of the contact surface of the upward-directed locking element adopts in a non-coupled condition; and the contact surfaces of both the upward-directed locking element and downward-directed locking element of the first contact zone in the non-coupled condition mutually are oriented deviating more than in the coupled condition in which the contact surfaces of both the upward-directed locking element and downward-directed locking element deviate less or do not deviate relative to one another.
26. The floor panel of claim 25, wherein the contact surfaces of the first contact zone in coupled condition coincide with each other or approximately coincide with each other.
27. The floor panel of claim 25, wherein the aforementioned contact surfaces, when for their free condition the contours thereof are presented over each other, approach each other in downward direction or, in other words, provide for a decreasing overlap in downward direction.
28. The floor panel of claim 27, wherein the aforementioned contact surfaces substantially are flat and that, when for their free condition the contours of the first and second coupling parts are presented over each other, the respective contact surfaces show an angle difference of 2 to 10 degrees.
29. The floor panel of claim 25, wherein the tangent line, which is determined by said second contact zone, forms an angle with the horizontal which is smaller than 45.
30. The floor panel of claim 25, wherein, when the second and fourth locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the second contact zone forms the smallest angle with the horizontal, whereas when the first and third locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the first contact zone forms the largest angle with the horizontal.
31. The floor panel of claim 25, wherein, when the second and fourth locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the second contact zone is determined by a middle of the second contact zone, whereas when the first and third locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the first contact zone is determined by a middle of the first contact zone.
32. The floor panel of claim 25, wherein the floor panel further comprises one or more characteristics selected from the below listed features, or any combination of these characteristics, this as far as such combination does not have any contradictory characteristics: the first and second coupling parts are realized such at the floor panel that the floor panels can be installed according to the fold-down principle; the floor panel is oblong rectangular and the first pair of opposite edges form the long sides of the floor panel, whereas the second pair of opposite edges form the short sides of the floor panel; the second coupling parts at the second pair of edges can be joined into each other by means of a downward snapping movement; the first and/or second coupling parts at the first and/or second pair of edges are made substantially as profiled parts in the material of the floor panel, substantially or entirely by means of a machining treatment, by means of one or more milling treatments, for example, with milling cutters which are active under different operative angles; the first and/or second coupling parts at the first and/or second pair of edges are made as millable profiled parts, which can be milled by means of milling cutters with a rotational axis which during milling is situated external to the floor panels; the aforementioned male part is or is not split; at the second pair of edges, only one male part is applied, whether or not split; at the aforementioned male part, only one vertically active locking part is present, which defines a tangent line of less than 70 degrees with the horizontal, whereas other, one or more, vertically active locking parts with a tangent line of 70 degrees or more may be present at the male part, at a distal side thereof; the contact surfaces of the second and/or fourth locking part, and of both, is, are, respectively, made flat; the contact surfaces of the second and/or fourth locking part, and of both, is, are, respectively, made curved; herein, the contact surface of the fourth locking part is convex, whereas the contact surface of the second locking part is flat or curved, and is concave; the lower hook-shaped part and the lip thereof is resiliently bendable and/or deformable; at the bottom of the lip, a recess is present, configured such that the upward-directed locking element is elastically tiltable; in coupled condition, a downward-directed support point is provided at the male part; underneath the male part, a space is present; in coupled condition, a space is present behind the distal end of the lower hook-shaped part; in coupled condition, a space is present above the upward-directed locking element, which space is made continuous with the space mentioned in the preceding paragraph; the previously mentioned angle of the tangent line at the first contact point is larger than 75 degrees; the previously mentioned angle of the tangent line at the first contact point is smaller than 90 degrees; the previously mentioned angle of the tangent line at the second contact point is more than 45 degrees; the previously mentioned angle of the tangent line at the second contact point is smaller than 75 degrees; the two contact surfaces of the second contact zone, including possible extensions thereof, seen in cross-section, extend to a first side and second side opposite to the first side of a respective closing surface, wherein the closing surface is defined as a vertical plane through upper edges of the coupled floor panels or at least the location where the floor panels come together at a top; the center point of the second contact zone is situated higher than the center point of the first contact zone; the second contact zone is a local contact zone, by which is meant that the second contact zone does not extend over the complete height of the male part; wherein this contact zone is situated with its upper end at a distance from an upper side of the floor panel and is situated with its lower end at a distance above a lower end of the male part; wherein the second contact zone, seen in height, is situated between and of the overall thickness of the male part, in other words, the vertical height measured between the lowest point of the male part and the upper side of the floor panel; the first and/or second coupling parts at the first pair of edges and/or at the second pair of edges are manufactured completely in one piece from the material of the floor panel, and from a substrate forming part of the floor panel; above said second contact zone, the distal end of the upper hook-shaped part is completely free from downwardly active support points, or anyhow at least free from support points which, in the coupled condition, define tangent lines forming an angle with the horizontal which is smaller than 45 degrees; at the male and/or female part, inclined and/or rounded portions are formed, which are configured such that the male part, during the downward movement thereof, automatically is guided into the female part, this during a joining according to the fold-down principle and/or during joining via a plane-parallel downward movement, the first and/or second coupling parts at the first pair and/or second pair of edges are configured such that in coupled condition a so-called pretension is existing, which forces the respective floor panels at the respective edges towards each other, wherein this is performed by applying overlapping contours, and wherein the pretension is the result of a deformation, either an elastic bending or an elastic compression, or a combination of both; the first and/or second coupling parts at the second pair of edges are free from hook and loop fasteners and/or adhesive connections; the floor panel is provided with chamfers on the first and/or second pair of edges; the floor panel has a top layer and/or decor layer which extends in one piece from the horizontal upper surface of the floor panel up to the chamfers; the chamfers are formed by impressions; the floor panel has a top layer with a decor; the floor panels comprise a substrate which is or is not consisting of multiple pieces and does or does not consist of a plurality of substrate layers, wherein the substrate, or, in the case of a plurality of layers, at least one of the substrate layers consists of a material fulfilling one or more, or any combination of the following characteristics, as far as such combination is not contradictory: synthetic material-based material, foamed or not foamed, resilient or hard, whether or not with plasticizer, and whether or not filled with wood-based or bamboo-based material, for example, in the form of fibers, chips, dust or sawdust, and/or filled with other substances, for example, chalk, lime, talcum, ground fillers based on stone species; synthetic material-based material, which is foamed with fine pores, such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm; synthetic material-based material, which is obtained by extruding synthetic material-based starting material in the form of plate material, wherein, in a preferred embodiment, this material is foamed, with fine pores which are such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm, synthetic material-based material, which is obtained by strewing synthetic material-based material, whether or not combined with other materials, by means of a strewing process and consolidating under the influence of pressure and possibly increased temperature in the form of plate material, wherein in a preferred embodiment the obtained material is foamed, this with fine pores, which are such that the majority of the synthetic material-based material comprises pores and/or gas inclusions having dimensions smaller than 1 mm; synthetic material consisting of, or on the basis of, or comprising one of the following materials: PP, PE, PET, PUR, PVC, PIR or other suitable synthetic materials; synthetic material-based material with plasticizers, wherein the synthetic material-based material is chosen from the materials listed in the preceding paragraph; wood-based material, for example, MDF, HDF, prefabricated wood panels, engineered wood panels, possibly with adapted core or end strips; the floor panel is made as one of the following kinds: as a laminate floor panel; as a so-called resilient floor panel; a LVT panel or CVT panel or comparable thereto panel on the basis of another synthetic material than vinyl; a floor panel with a first synthetic material-based, foamed, substrate layer, with thereon a thinner second substrate layer of or on the basis of vinyl or another synthetic material; as a floor panel with a hard synthetic material-based substrate.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) With the intention of better showing the characteristics of the invention, herein below, as an example without any limitative character, some preferred embodiments are described, with reference to the accompanying drawings, wherein:
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
(11) As represented in
(12) The represented floor panels 1 are configured such at their edges that they can be mutually coupled according to the so-called fold-down principle, which is a principle known as such and which consists in that such floor panels 1 can be coupled to each other at the first pair of edges 2-3 by means of a turning movement R and can be coupled to each other at the second pair of edges 4-5 by means of a downward movement M, wherein the downward movement M is the result of the turning movement R and thus substantially is realized simultaneously. Herein, the floor panels 1 also are configured such at their edges 2-3 and 4-5 that finally a locking in vertical direction V as well as horizontal direction H is obtained, this latter perpendicular to the respective edges.
(13) As represented in
(14) As can be seen in
(15) the coupling parts 6-7 comprise a horizontally active locking system HL, which, in a coupled condition of two of such floor panels 1, effects a locking in the plane of the floor panels 1 and perpendicular to the respective edges 2-3; the coupling parts 6-7 also comprise a vertically active locking system VL, which, in a coupled condition of two of such floor panels 1, effects a locking transverse to the plane of the floor panels, in other words, in vertical direction; the coupling parts 6-7 substantially are realized of the material of the floor panel 1 itself; and the coupling parts 6-7 are configured such that two of such floor panels 1 can be coupled to each other at these edges by means of a turning movement R.
(16) As can be seen in
(17) The embodiment of the edges 4 and 5 represented in
(18) It is noted that the coupling parts at the edges 2-3 and/or 4-5 preferably are configured such that in the coupled condition a so-called pretension is realized, which forces the coupled floor panels 1 towards each other, preferably with their upper edges towards and against each other. It is clear that the characteristic of the so-called pretension can be applied in all embodiments of floor panels according to the invention, as described herein above or herein below. Such pretension can be realized in various manners and preferably is based on a tension force which in coupled condition is generated by elastic bending and/or compression, wherein the retracting force created therein provides for that the floor panels are pressed towards each other. In
(19) In the larger view of
(20) The second and third aspect relate to alternative, examples of which are represented in
(21) A floor panel according to the second aspect shows the same basic characteristics at the edges 2-3 and 4-5 as defined herein above. Further, the second pair of edges 4-5 moreover shows the following characteristic: the second locking part 19, thus, of the male part 17, has a contact surface 23, which, in downward direction, by means of a bend 35, merges into a lower-situated distal surface 36, wherein this distal surface 36 in downward direction also extends further in distal direction, more particularly is made sloping in downward direction.
In other words, this means that underneath the bend 35 a portion with a surface 36 is present, which portion manifests itself in downward direction as a distal nose portion at the male part. It is clear that the bend 35 can be formed by an acute bending point as well as a rounded bending point. Intermediate surfaces can be provided as well.
(22) The aforementioned lower-situated distal surface 36 preferably is substantially flat.
(23) It is also preferred that said lower-situated distal surface 36 forms an angle, or, seen on average, forms an angle with the horizontal which is larger than 75 degrees and still better is larger than 80 degrees and still better is situated between 83 and 88 degrees, however, therein is inclined in a direction as in
(24) According to a preferred embodiment of the second aspect, below the contact surface 25 of the fourth locking part 21 a lower-situated proximal surface 37 is present on the female part 14, which surface, in the coupled condition of two of such floor panels, works in conjunction with the aforementioned lower-situated distal surface 36, or at least will work in conjunction therewith when the male part is moved out of the female part in upward direction. In
(25) A floor panel according to the third aspect also shows the same basic characteristics at the edges 2-3 and 4-5 as defined herein above. Further, the second pair of edges 4-5 moreover shows the following characteristic: on the proximal side of the female part, above the second contact zone C2 a proximal surface 38 is provided, which, in respect to the recess of the female part 14, is inwardly inclined in upward direction.
(26) In a preferred embodiment of a floor panel of the third aspect, this is further characterized in that the aforementioned proximal surface 38 substantially is flat and preferably extends up to the upper surface 39 of the floor panel 1, either up to the flat upper surface, as in
(27) According to preferred embodiments of floor panels 1 which are realized in accordance with the third aspect, such floor panel also shows one or more of the following characteristics: said proximal surface 38 forms an angle with the horizontal which is larger than 75 degrees and better is larger than 80 degrees and still better is situated between 83 and 88 degrees; above the contact surface of the second locking part a higher-situated distal surface 40 is present at the male part, which, in the coupled condition of two of such floor panels, works in conjunction with the aforementioned proximal surface 38, or anyway will at least work in conjunction therewith when the male part is moved out of the female part in upward direction.
(28) In
(29) In a particularly preferred embodiment of a floor panel according to the third aspect, the male part, so to speak, forms a dovetail with a formed thereon local locking portion halfway of the distal dovetail side, either in the form of a recess, or alternatively in the form of a protrusion. This then means, for example, that, with reference to
(30) A floor panel according to the fourth aspect also shows the same basic characteristics at the edges 2-3 and 4-5 as defined herein above. Further, the second pair of edges 4-5, as applied in the embodiment of
(31) In other words, this means that the closing surface S extends through the contact zone C2, or anyhow at least through the zone formed by the contact surfaces, inclusively the extensions thereof.
(32) Preferably, said closing surface intersects the second contact zone, possibly including extensions thereof, halfway or approximately halfway thereof, in other words, the middle of the contact zone C2, seen in cross-section, is situated in or approximately in the closing surface. Further, it is also preferred that said intersection is located at a height which is higher than the entire first contact zone C1 is situated.
(33) The embodiment of the second pair of edges 4-5 represented in
(34)
(35) In
(36) It is clear that the edges 4-5 represented in
(37) As represented in
(38) The embodiment represented in
(39) Regarding the seventh aspect, at the second pair of edges, apart from the already mentioned basic characteristics, the following characteristic is present as well: the lip 12 of the lower hook-shaped part 10, seen in a cross-section transverse to the respective edge, is characterized by a first longitudinal portion P1, being the portion extending from the proximal end of the lower hook-shaped part 10 up to the location where the upward-directed locking element 13 is starting, and by a second longitudinal portion P2, which is defined as being the most distal 75% of the first longitudinal portion P1, wherein the lip is reduced in thickness by at least 5%, and better at least 10% and still better at least 30% inside the aforementioned second longitudinal portion P2, such while preferably the distal side 33 of the distal end 34 of the lower hook-shaped part 10 is free from vertically active locking parts.
(40) In a preferred embodiment of the seventh aspect, the floor panel further is characterized in that it also shows one of the following characteristics: the thickness reduction is realized at least by means of providing a deeper-situated portion, namely the already mentioned portion 44, in the upper side of the lip 12 of the lower hook-shaped part 10; the thickness reduction is realized at least by means of providing a recess 45 at the lower side of the lip 12 of the lower hook-shaped part 10; the thickness reduction is realized at least by means of both measures mentioned in the preceding paragraphs, wherein preferably in cross-section and in a direction perpendicular to the respective edge there is an overlap between the aforementioned deeper-situated portion 44 and said recess 45.
(41) Further, it is also preferred that both angles A1 and A2, such as also applied in the example, are larger than 50 degrees.
(42) It is noted that the eighth aspect was also applied in all embodiments of
(43) Referring to
(44) In a preferred embodiment of the eighth aspect, the floor panel 1 preferably, as represented, is also characterized in that the recess 45 consists of a recessed portion 50, which is recessed in respect to the actual lower side of the floor panel, and a transition portion 51, which is situated between the actual lower side and the recessed portion 50 and which provides for a gradual transition.
(45) In
(46) Also, all combinations of two, three, four, five or all six of the characteristics listed herein above are possible according to the ninth aspect, wherein all mathematically possible combinations come into consideration, without thereby excluding certain combinations.
(47) According to preferred embodiments of a floor panel according to the ninth aspect, it further comprises one or more of the features listed herein below, wherein also all combinations are possible, as far as they do not comprise contradictory characteristics: said first substrate layer comprises at least a thermoplastic material; said first substrate layer is made at least on the basis of polyvinyl chloride, polyethylene, polyurethane, polypropylene or PIR, or a combination of the aforementioned; said first substrate layer is a filled synthetic material composite, wherein this filling preferably consists of one or a combination of the following materials: bamboo, cork and/or wood, and more particularly one or a combination of the aforementioned materials in the form of chips and/or fibers and/or dust or flour, such as sawdust; said first substrate layer is foamed; said first substrate layer is of the closed cell type; said first substrate layer comprises one or more plasticizers; said first substrate layer comprises fillers, such as chalk and/or lime and/or talcum; said first substrate layer is provided with at least one reinforcement layer, preferably of glass fiber or the like; said first substrate layer has a thickness of at least 3 mm, preferably at least 4 mm, and still more preferably at least 5 mm; said first and/or second substrate layer is made water-resistant; said second substrate layer is synthetic material-based; said second substrate layer comprises at least a thermoplastic material, which preferably is of the soft type; said second substrate layer is made at least on the basis of vinyl, such as polyvinyl chloride, more particularly soft polyvinyl chloride, polyethylene, more particularly soft polyethylene, polyurethane, polypropylene, PIR or a combination of the aforementioned; said second substrate layer substantially consists of one or a combination of the following materials: wood veneer, rubber, linoleum, a paper-based or foil-based laminate sheet, or alternatively any material, more particularly cork, bamboo or wood veneer, which is encased by vinyl or resin; said second substrate layer comprises one or more plasticizers; said second substrate layers comprises fillers, such as chalk and/or lime; said second substrate layer is provided with at least one reinforcement layer, preferably of glass fiber or the like; the floor panel comprises a backing layer, which preferably is situated directly underneath the first substrate layer, which backing layer, for example, is made on the basis of one or more of the following materials: cork, rubber and/or a soft foamed layer; the floor panel comprises a top layer, whether or not consisting of a plurality of layers, which top layer preferably is situated directly above the second substrate layer, and/or the second substrate layer is provided with a backing layer at the underside of this second substrate layer; top layer comprises at least a decorative layer, preferably in the form of a print, preferably provided on a foil or film; said top layer comprises at least a translucent or transparent wear layer and/or is provided with hard particles for increasing the wear resistance, such as corundum; the floor panel has an overall thickness which is smaller than 10 mm, still better in the order of magnitude of 8 mm or possibly thinner; said first substrate layer is foamed gradually, wherein the degree of foaming increases in downward or in upward direction.
(48)
(49) As mentioned in the introduction, the tenth aspect provides a floor panel for forming a floor covering, wherein this floor panel 1 comprises a first pair of opposite edges 2-3, as well as a second pair of opposite edges 4-5, analogous to the illustration in
(50) Also according to the tenth aspect, the first pair of opposite edges 2-3 comprises coupling parts 6-7, which, for example, analogous to
(51) Also according to the tenth aspect, the second pair of opposite edges 4-5 also comprises coupling parts 8-9 on both edges, which allow that two of such floor panels 1 mutually can be coupled to each other, and wherein these coupling parts 8-9 show the following characteristics: the coupling parts 8-9 comprise a horizontally active locking system, which, in a coupled condition of two of such floor panels 1, effects a locking in the plane of the floor panels 1 and perpendicular to the respective edges 4-5; the coupling parts 8-9 also comprise a vertically active locking system, which, in a coupled condition of two of such floor panels 1, effects a locking transverse to the plane of the floor panels 1; the coupling parts 8-9 substantially are realized from the material of the floor panel 1 itself; the horizontally active locking system of the second pair of edges 4-5 is formed at least of an upward-directed lower hook-shaped part 10 which is situated on one of said two edges 4, as well as a downward-directed upper hook-shaped part 11, which is situated on the opposite edge 5, wherein the lower hook-shaped part 10 consists of a lip 12 with an upward-directed locking element 13, which proximally thereof defines a female part 14 in the form of a recess, whereas the upper hook-shaped part 11 consists of a lip 15 with a downward-directed locking element 16 forming a male part 17; the coupling parts 8-9 are configured such that two of such floor panels 1 can be coupled to each other at their respective edges 4-5 by means of a downward movement of the one floor panel in respect to the other; the vertically active locking system comprises vertically active locking parts 18-19-20-21, which, by means of respective contact surfaces 22-23-24-25, define at least a first contact zone C1 and a second contact zone C2, which are situated at opposite sides of the male part 17 and female part 14; the aforementioned vertically active locking parts comprise a first locking part 18 and a second locking part 19 at the respective opposite sides 26-27 of the male part 17, as well as a third locking part 20 and a fourth locking part 21 at the respective opposite sides 28-29 of the female part 14; the first and third locking part 18, 20, respectively, in the coupled condition of two of such floor panels 1, define said first contact zone C1, while having contact surfaces 22 and 24, which, in coupled condition, define at least one inclined tangent line T1; the second and fourth locking part 19, 21, respectively, in the coupled condition of two of such floor panels 1, define said second contact zone C2, while having contact surfaces 23 and 25, which, in the coupled condition, also define at least one inclined tangent line T2; said male part 17 has a distal side 27 and a proximal side 26, wherein the second locking part 19 is situated at the distal side 27; and said two tangent lines T1-T2 are upwardly inclined towards each other from their respective contact zones C1-C2.
(52) According to the tenth aspect, the floor panel is characterized in that the upward-directed locking element 13, the downward-directed locking element 16 and the pertaining contact surfaces of the first contact zone C1 are configured such that the upward-directed locking element 13 with its pertaining contact surface, in the coupled condition, adopts a somewhat tilted position in respect to the position adopted by this contact surface in the free condition; and that both contact surfaces of the first contact zone, in the not coupled condition, are oriented mutually deviating in such a manner that in the coupled condition mutually a less deviating or not deviating orientation is obtained. This is clearly illustrated in
(53) According to
(54) As represented, it is preferred that said contact surfaces substantially are flat and that, when for their free condition the contours of the coupling parts are presented over each other, the respective contact surfaces show an angle difference AD of 2 to 10 degrees.
(55) According to another preferred characteristic of the tenth aspect, the tangent line T2, which is determined by the aforementioned second contact zone C2, forms an angle A2 with the horizontal which is smaller than 60, and still better smaller than 55, and still better is 45 to 52 degrees, or alternatively is 45 degrees, and also alternatively is even less than 45 degrees. Such smaller angle provides for a better engagement. In combination with the main characteristic of the tenth aspect, this moreover offers a synergetic effect. The inventor in fact has found that in such couplings, which are critical because joining them must not be too difficult, but at the same time also must be able to offer sufficient locking, the combination of certain characteristics sometimes offers unexpectedly good results.
(56) The use of such values for the angle A2 can also be applied in combination with the other aspects of the invention, as far as not being contradictory.
(57) It is clear that the locking element 13, or at least the respective contact surface thereof, according to the tenth aspect must be tillable. This tiltability may be realized in any manner. Preferably, to this aim a recess 45 is provided at the lower side of the floor panel, however, other techniques are not excluded. The tiltability can also be achieved, for example, as a result of elasticity in the material.
(58) The tenth aspect generally does not comprise any requirements in respect to the fact whether the lower hook-shaped part 10 at the distal side 33 is free from vertically active mechanical locking parts or not. Thus, there are three different possibilities, which each are interesting. According to a first possibility, for which the embodiment of
(59) It is noted that the characterizing part of the tenth aspect can also be applied in a broader sense. Thus, the invention provides for a deviating aspect, according to which the characterizing part of the tenth aspect in any so-called push-lock or fold-down coupling is applied, thus, with the only requirement that at the first contact zone inward-directed contact surfaces are present, which have to fulfill the characterizing part of the tenth aspect, whereas at the location where usually the second contact zone is present, then a vertical locking is or is not present, wherein in the case of a locking this can be of any kind.
(60) The floor panels of the invention may also comprise one or more of the herein below listed features. These features may be mutually combined at choice, wherein all possible combinations come into consideration, as far as they do not comprise contradictory characteristics and thus are feasible. Also, any of these features or any feasible combination of features can be applied to a floor panel of any of the aforementioned aspects or combination of aspects, of course also as far as such combination does not comprise contradictory characteristics. The intended features are the following: the coupling parts 6-7 and 8-9 are realized such at the floor panel 1 that a plurality of such floor panels 1 can be installed according to the fold-down principle; the floor panel 1 is oblong rectangular and the first pair of opposite edges 2-3 forms the long sides of the floor panel 1, whereas the second pair of opposite edges 4-5 forms the short sides of the floor panel 1; the coupling parts 8-9 at the second pair of edges 4-5 can be joined into each other by means of a downward snap movement; the coupling parts at the first and/or second pair of edges are made substantially as profiled parts in the material of the floor panel, preferably substantially or entirely by means of a machining treatment, preferably by means of one or more milling treatments, for example, with milling cutters which are active under different operative angles, and still more particularly milling cutters of which the rotation axis during use is located external to the floor panel; the coupling parts at the first and/or second pair of edges are made as millable profiled parts, which can be milled by means of milling cutters with a rotational axis which during milling is situated external to the floor panels; the aforementioned male part 17 is or is not split; preferably, the male part is a solid part, which thus, for example, as in
(61) It is noted that said vertically active locking system VL and horizontally active locking system HL of the first pair of edges 2-3 can be realized in any manner. Preferably, however, to this aim, as represented in
(62) Further, it is noted that in the embodiment of
(63) It is noted that according to a deviating alternative embodiment, the coupling parts at the first pair of edges do not necessarily have to be able to be coupled by a turning movement, however, indeed are configured at least such that they can be coupled to each other by a downward movement. In that case, on the first pair of edges, too, coupling parts can be applied with characteristics such as those claimed in the preceding claims for the second pair of edges. The coupling parts at both pairs of edges then possibly can be made identical to each other. Such floor panel then can be coupled by downward movement, plane-parallel to the floor, to surrounding floor panels. It is noted that this is a deviating embodiment, however, that the invention shows its advantages best with floor panels which can be installed according to the fold-down principle.
(64) According to another, then indeed clearly deviating alternative embodiment, which preferably indeed is applied in combination with the fold-down principle, there is no vertical locking in the first contact zone, which means that there is no mechanical vertically active locking and solely a horizontal locking is present. This then means that the contact surfaces in the first contact zone C1 are vertical or, seen from the male locking part, are inclined from the bottom towards the top in outward direction. Such deviation can be integrated in each of the aforementioned embodiments according to preceding aspects, by which then new aspects are obtained. Then, too, at least a number of the obtained combinations remain new and inventive.
(65) According to the invention, the term tangent line can be interpreted in a number of different ways. In general, hereby a line has to be understood which is tangential between two cooperating contact surfaces; the location where this tangent line is considered can be random; however, usually this has to be considered in an average position, or thus the global tangent line has to be considered, unless this is defined otherwise. Alternatively, according to this application the term tangent line may also be replaced by the direction of the cooperating contact surfaces or the average or global direction or global tangent line thereof.
(66) Deviating or more specific definitions for the tangent line, which can be applied according to alternatives, are the following: when the second and fourth locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the second contact zone is taken, which forms the smallest angle with the horizontal; when the second and fourth locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the second contact zone is taken, which is determined by the middle of the second contact zone; when the first and third locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the first contact zone is taken, which forms the largest angle with the horizontal; when the first and third locking part define a plurality of tangent lines, for example, because the cooperating contact surfaces are not flat, then the tangent line from the first contact zone is taken, which is determined by the middle of the first contact zone.
(67) Further, it is noted that the terms distal side of the male part and proximal side of the female part usually also comprise the extensions of these sides up to the upper side of the floor panel.
(68) By contact surfaces and contact zones, also a line contact may be understood; a contact surface or contact zone basically is the location where, in coupled condition and with a possible load, the actual contact is brought about. When speaking about extensions of contact surfaces, by this the real extensions of the surfaces have to be understood, next to the specific location where the actual contact is existing. In this case, this does not relate to a theoretical, not-present extension.
(69) By substrate layers situated directly above each other, it is not excluded that possibly glue is present between these layers, or a thin layer, such as a reinforcement fleece, for example, glass fleece or the like.
(70) By coupling parts which are substantially manufactured from the material of the floor panel is meant that at least the substantial components thereof are formed in one piece from the material of the floor panel and that at least all locking parts and locking elements are realized in one piece from the material of the floor panel. In other words, this means that no separate locking strips are applied, such as elastically bendable locking strips (for example, as known under the denominations Multifit, 5G and the like). The above does not exclude, for example, that the coupling parts applied according to the invention can be provided with a coating or the like. The above also does not exclude that the coupling parts are formed in one piece in edge strips which consist of a special material choice and which are taken up in the edges of the substrate of the floor panel, such as known, for example, from the manufacture of so-called engineered wood panels.
(71) References V and H represent the vertical and horizontal directions.
(72) According to a particular characteristic, the middle of the contact zone C2 is situated at a vertical distance VD2 underneath the upper side of the floor panel, which is at least 0.25, and better at least 0.28 and still better at least 0.30 times the overall thickness THP of the floor panel. Subordinate thereto is preferred that the middle of the contact zone C2 is situated at a distance VD1 from the lower side which is at least 0.35 and still better at least 0.40 times the thickness THP. This is particularly useful with thin floor panels of 5 mm or less and/or with floor panels of the resilient type, more particularly LVT and the like. This idea can also be applied independently, only making use of the aforementioned basic characteristics of the edges.
(73) It is clear that with the aforementioned term that the tangent lines T1 and T2 are inclined towards each other from their respective contact zones, it is not only meant that they meet each other in an intersection in upward direction, but also that this intersection is located between a vertical through the first contact zone and a vertical through the second contact zone. In other words, this means that in one and the same cross-section one of the tangent lines from the top to the bottom is tilted to the left, whereas the other tangent line then is tilted to the right.
(74) It is clear that the invention can be applied at least with oblong rectangular as well as square floor panels, with classic installation patterns as well as with special installation patterns, for example, herringbone patterns.
(75) It is clear that, when it is stated that the lower hook-shaped part at the distal side of its distal end is free from vertically active mechanical locking parts, by this is meant that there no mechanical parts engage or sit behind each other which counteract a taking apart in upward direction. Herein, a frictional contact is possible indeed, anyhow, as illustrated in the respective embodiments, however, preferably no contact at all will exist.
(76) The invention can be applied to relatively thin floor panels for forming a floor covering, for example of 4 mm or thinner, as well as to thicker floor panels.
(77) As can be derived from all embodiments, this always relates to embodiments wherein the coupling parts at the second pair of edges in resting position define contours which, when presented to each other, come to sit vertically behind each other at the first and third locking part, and thus this does not relate to locking parts which first have to be brought into the position by means of an actuator, such as known, for example, from U.S. Pat. No. 9,260,870 B2.
(78) In other words, the first and third locking part define contours at their contact surfaces, which contours engage behind each other solely by an own snap effect of the lower hook-shaped part.
(79) In still other words, a lower hook-shaped part is applied, of which the upward-directed locking element 13 performs an elastic to- and fro-movement during coupling, wherein more particularly the female part first is pressed open in order to subsequently close in an elastic manner.
(80) However, this does not exclude that an extra support portion, such as 33B, can be applied, additionally to the locking element 13 which closes by its own elasticity, in order to additionally counteract, in the final closed condition, an elastic backward movement. Such support portion 33B then does not function as an actuator, but only as an extra locking.
(81) The present invention is in no way limited to the embodiments described herein above and represented in the figures, on the contrary may such floor panels be realized according to various variants, without leaving the scope of the present invention.