FLOOR PANEL FOR FORMING A FLOOR COVERING

Abstract

A floor panel contains opposite edges that contain coupling parts to link two floor panels. These coupling parts contain locking planes: first and second locking planes on the first edge with an enclosed angle between 90° and 175°; and third and fourth locking planes on the second edge with an enclosed angle between 90° and 175°. The first locking plane is closer to the top of the floor panel than the second locking plane. The angle with the surface of the floor panel of the first locking plane is smaller than the second locking plane. The angle with the floor plane surfaces of the third locking plane is smaller than that of the fourth locking plane. The second locking plane is provided for interaction with the fourth locking plane of a coupled panel. The first locking plane is provided for interaction with the third locking plane of a coupled panel.

Claims

1.-44. (canceled)

45. A floor panel for forming a floor covering, wherein this floor panel contains a substrate and a decorative layer; wherein this floor panel is rectangular, either oblong or square, and thus contains a first pair of opposite edges and a second pair of opposite edges; wherein the first pair of opposite edges contain first coupling parts allowing several of these floor panels to be coupled together; wherein these first coupling parts constitute a first locking system which, in a coupled condition of two such floor panels, creates a locking system in the plane of the floor panels and perpendicular to the relevant edges, and a second locking system which, in a coupled condition of two of such floor panels, creates a transverse lock at the panel plane; wherein these first coupling parts are realized mainly in the material of the floor panel itself, and in said substrate; wherein for the purpose of the first locking system, these first coupling parts contain locking parts which, in the coupled condition, prevent the first coupling parts from being moved apart; said locking parts are fitted with locking planes; wherein the locking part of the coupling part on the first edge of the first pair of opposite edges contains a first and a second locking plane, wherein the first and second locking planes are adjacent, separated by a bending line or a curved bending plane, wherein the first locking plane and the second locking plane form a convex part of the coupling part to which these locking planes belong; wherein there is an enclosed angle between the first and second locking planes between 90° and 175; wherein the locking part of the coupling part on the second edge of the first pair of opposite edges contains a third and a fourth locking plane, wherein the third and fourth locking planes are adjacent, separated by a bending line or a curved bending plane, wherein the third locking plane and the fourth locking plane form a concave part of the coupling part to which these locking planes belong; between the third and fourth locking planes there is an enclosed angle between 90° and 175°; wherein the first locking plane is closer to the top of the floor panel than the second locking plane; wherein the angle between the first locking plane and the floor panel surface is less than the angle between the second locking plane and the surface of the floor panel; wherein the angle between the third locking plane and the floor panel surface is less than the angle between the fourth locking plane and the surface of the floor panel; wherein the second locking plane is provided for interaction with the fourth locking plane of a coupled similar panel; wherein the first locking plane is provided for interaction with the third locking plane of a coupled similar panel.

46. The floor panel according to claim 45, wherein the angle between the first locking plane and the surface of the floor panel is at least 10° smaller than the angle between the second locking plane and the surface of the floor panel.

47. The floor panel according to claim 45, wherein the angle between the third locking plane and the surface of the floor panel is at least 10° smaller than the angle between the fourth locking plane and the surface of the floor panel.

48. The floor panel according to claim 45, wherein the first, the second, the third and the fourth locking planes are all located in the lower half of the floor panel thickness.

49. The floor panel according to claim 45, wherein the area of the first boundary plane is larger than the area of the second boundary plane.

50. The floor panel according to claim 45, wherein the area of the third boundary plane is larger than the area of the fourth boundary plane.

51. The floor panel according to claim 45, wherein the enclosed angle between the first and second locking planes is smaller than the enclosed angle between the third and fourth locking planes.

52. The floor panel according to claim 45, wherein the difference between on the one hand the angle between the first locking plane and the surface of the floor panel and on the other hand the angle between the third locking plane and the surface of the floor panel is greater than the difference between on the one hand the angle between the second locking plane and the surface of the floor panel and on the other hand the angle between the fourth locking plane and the floor panel surface.

53. The floor panel according to claim 52, wherein the difference between on the one hand the angle between the second locking plane and the surface of the floor panel and on the other hand the angle between the fourth locking plane and the surface of the floor panel is less than 3° in absolute value.

54. The floor panel according to claim 45, wherein the coupling part on the first edge of the first pair of opposite edges contains a horizontal-facing lip, at the bottom of the floor panel, and an upward-facing hook at the distal end of the lip; wherein the first and the second locking planes are located on the inside of this upward-facing hook.

55. The floor panel according to claim 54, wherein the horizontal line situated vertically in the center between the first and second locking planes is located in the lower half of the distance between the highest point of the upward-facing hook and the lowest point of the top of the lip; this line is in the lower 40% of the distance between the highest point of the upward-facing hook and the lowest point of the top of the lip.

56. The floor panel according to claim 45, wherein the angle between the second locking plane and the floor panel surface is between 48° and 72.

57. The floor panel according to claim 45, wherein the first coupling parts comprise a tongue and a groove containing the locking parts, the first coupling parts configured to allow two of such floor panels to be mechanically connected at these edges by means of horizontal sliding and/or by means tilting.

58. The floor panel according to claim 57, wherein at the first pair of opposite edges the groove is bounded by a lower lip and an upper lip, the lower lip extending sideways beyond the distal end of the upper lip; and where the lower lip contains an upward-facing hook at the distal end of the lower lip, wherein the first and the second locking planes are located at the inside of this upward-facing hook.

59. The floor panel according to claim 58, wherein the lower lip in coupled condition is at least partially elastically bent and thus provides a clamping force which ensures that the coupled panels are forced together, while the floor panels are pressed together at or close to the surface of the floor panels.

60. The floor panel according to claim 45, wherein the first coupling parts are configured so that in coupled condition the horizontal distance between on the one hand the vertical line through the center in a vertical direction between the first and second locking planes and on the other hand the plane at or close to the surface of the coupled panels where the coupled panels are sealed together is less than 5.5 mm.

61. The floor panel according to claim 45, wherein the second pair of opposite edges contain second coupling parts allowing several such floor panels to be coupled together, wherein these second coupling parts at the second pair of opposite edges form a third locking system which, in a coupled condition of two such floor panels, creates a lock in the plane of the floor panels and perpendicular to the relevant edges, as well as form a fourth locking system which, in a coupled condition of two such floor panels, creates a lock across the panel planes; wherein these second coupling parts at the second pair of opposite edges are substantially created in the material of the floor panel itself and more specifically in said substrate.

62. The floor panel according to claim 45, wherein the second coupling parts at the second pair of edges are configured to allow two such floor panels to be coupled at these edges by a downward motion of one panel relative to the other.

63. The floor panel according to claim 62, wherein said second coupling parts are substantially made up of the material of said substrate and are created as one whole with it, wherein the third locking system is at least formed of a downward-facing upper hook-shaped section located on one edge of said pair of opposite edges, and an upward-facing lower hook-shaped section located on the other opposite edge of said pair of opposite edges, which hook-shaped parts may be hooked together by means of said downward motion; wherein said upper hook-shaped comprises a lip with a downward-facing locking element, while said lower hook-shaped part consists of a lip with an upward-facing locking element.

64. The floor panel according to claim 63, wherein in the fourth locking system at least one of the second coupling parts comprises one or more projections that engage in one or more undercuts in the other of the second coupling parts of the coupled floor panel.

Description

[0055] In order to show the characteristics according to the invention, some embodiments are described below, with reference to the accompanying figures, in which

[0056] FIG. 1 schematically shows a top view of a floor panel according to the invention;

[0057] FIG. 2 shows the cross-section according to line II-II of the floor panel according to the invention of FIG. 1;

[0058] FIGS. 3 and 4 show details of coupling parts of the floor panel of FIGS. 1 and 2;

[0059] FIG. 5 shows two floor panels in coupled condition according to FIGS. 1 and 2;

[0060] FIG. 6 shows a detail of the coupling of FIG. 5;

[0061] FIG. 7 shows the coupling at the short side of two floor panels as shown in FIG. 1; and

[0062] FIG. 8 illustrates how floor panels can be installed to form a floor covering in an embodiment of the invention through a so-called “fold down” motion.

[0063] Equal elements are shown in the various figures with the same reference number.

[0064] FIG. 1 schematically shows a top view of a floor panel according to the invention. FIG. 2 shows the cross-section according to line II-II of the floor panel according to the invention of FIG. 1. FIGS. 3 and 4 show details of the coupling parts of the floor panel of FIGS. 1 and 2. FIG. 5 shows two floor panels according to FIGS. 1 and 2 in coupled condition. FIG. 6 shows a detail of the coupling of FIG. 5.

[0065] The floor panel (1) illustrated in FIGS. 1-8 is a floor panel for the forming of the floor covering. The floor panel has a thickness T. This floor panel (1) contains a substrate (10)— for example of HDF (High Density Fiberboard) and a decorative layer (12). The floor panel (1) in the example is rectangular. It has a first pair of opposite edges (2, 3) and a second pair of opposite edges (4, 5). The first pair of opposite edges (2, 3) contains first coupling parts (6, 7) which allow several of these floor panels (1) to be coupled together, as shown in FIG. 5, by means of tilting motion or by means of horizontal sliding the coupling parts into each other.

[0066] These first coupling parts (6, 7) constitute a first locking system which, in a coupled condition of two such floor panels, creates a locking in the plane of the floor panels and perpendicular to the relevant edges, and also a second locking system which, in a coupled condition of two such floor panels, creates a locking across the panel face. These first coupling parts (6, 7) are created in the substrate (10).

[0067] For the first locking system to be achieved, these first coupling parts (6, 7) contain locking parts which, in the coupled condition, prevent the first coupling parts from sliding apart. The first coupling parts consist of a tongue (40) and a groove (42) containing the locking parts. These first coupling parts (tongue 40 and groove 42) are configured to allow two of such floor panels to be mechanically coupled to these edges by means of horizontal sliding and also by means of tilting. The groove (42) is bounded at the first pair of opposite edges by a lower lip (33) and an upper lip (44). The lower lip (33) extends sideways beyond the distal end of the upper lip (44). The lower lip (33) has an upward-facing hook (34) at its distal end.

[0068] The locking parts are fitted with locking planes (21, 22, 23, 24). The locking part of the coupling part (6) at the first edge (2) of the first pair of opposite edges contains a first (21) and a second (22) locking plane. The first (21) and second (22) locking planes are located on the inside of the upward-facing hook (34). The first locking plane is closer to the top of the floor panel than the second locking plane. In the example, the first and second locking planes are adjacent, separated by a bending line (27). The first locking plane and the second locking plane form a concave section (30) of the coupling part to which these locking planes belong.

[0069] The locking part of the coupling part (7) on the second edge (3) of the first pair of opposite edges contains a third (23) and a fourth (24) locking plane. In the example, the third (23) and fourth (24) locking planes are adjacent, separated by a bend (29). The third locking plane (23) and the fourth locking plane (24) form a concave section (28) of the coupling part to which these locking planes belong. The first, second, third and fourth locking planes are all located in the lower half of the floor panel thickness (T).

[0070] The angle γ.sub.1 (in the example 47°) between the first locking plane (21) and the surface (15) of the floor panel is smaller than the angle γ.sub.2 (in the example 60°) between the second locking plane (22) and the surface (15) of the floor panel. The angle γ.sub.3 (in the example 50°) between the third locking plane (23) and the surface (15) of the floor panel is smaller than the angle γ.sub.4 (in the example 60°) between the fourth locking plane (24) and the surface (15) of the floor panel. The second locking plane is provided for interaction with the fourth locking plane of a coupled similar panel. The first locking plane is provided for interaction with the third locking plane of a coupled similar panel. Between the first and second locking planes there is an enclosed angle α of 165°. Between the third and fourth locking planes there is an enclosed angle β of 172°.

[0071] Preferably, the area of the first boundary plane is larger than the area of the second boundary area. In the example, the area of the second boundary plane is 42% of the area of the first boundary plane. The area of the third boundary plane is larger than the area of the fourth boundary plane.

[0072] As shown in FIG. 5, the lower lip in coupled condition is partially elastically bent downward, resulting in a clamping force (F) that forces the linked floor panels together. this results in a tension force (F) which ensures that the floor panels are pressed together at or close to the surface of the floor panels.

[0073] The first coupling parts of the example are configured so that in coupled condition (see FIG. 5) the horizontal distance (A) between on the one hand the vertical line (V.sub.1) through the center in a vertical direction between the first and second locking planes and on the other hand the plane at or near the surface of the coupled panels where the connected panels are sealed together is 5 mm.

[0074] When coupling two such floor panels by a tilting motion, the boundary surfaces of the tongue (40) must push against the boundary surfaces on the inside of the upward-facing hook (34). Because the first boundary plane has a lower angle to the surface of the floor panel than the second boundary plane, and because the third boundary plane has a lower angle to the surface of the floor panel than the fourth boundary plane, the contact between the boundary planes of the tongue and boundary planes of the hook is effected later during the coupling process. This reduces the force required to realize this coupling by means of the tilting motion of the tongue (40) in the groove (42). Because of the selection made in the example of the angles between the locking planes and the floor panel surface, in coupled condition there is contact between the second and the fourth locking planes and only just no contact between the first and third locking planes. In the event of a load on the coupling that wants to move the coupled panels apart, distortion of the coupling parts will also cause contact between the first and third locking planes, thus creating the strength of the horizontal coupling.

[0075] FIG. 7 shows the coupling of two floor panels on their short sides according to the example of FIG. 1. For the reference values, please refer to FIGS. 1 and 7. The second pair of opposite edges (4, 5) of floor panel 1 contains second coupling parts (8, 9) that allow several of such floor panels (1) to be coupled together. These second coupling parts (8, 9) constitute a third locking system on the second pair of opposite edges (4, 5) which, in coupled condition of two such floor panels, creates a locking in the plane of the floor panels and perpendicular to the relevant edges, and also a fourth locking system which, in coupled condition of two such floor panels, creates a locking perpendicular to the panels plane. These second coupling parts on the second pair of opposite edges are mainly realized in the material of the floor panel itself, and more in particular in said substrate. The second coupling parts on the second pair of edges are configured to allow two such floor panels to be coupled together on these edges by means of a downward motion of one panel relative to the other.

[0076] The third locking system consists of a downward-facing upper hook-shaped section (49) located on one edge of the said pair of opposite edges, and of an upward-facing lower hook-shaped (50) section located on the other opposite edge of said pair of opposite edges. The hook-shaped sections can be hooked together by means of a downward motion (M). The upper hook-shaped part (49) consists of a lip (52) with a downward-facing locking element (54). The lower hook-shaped part consists of a lip (56) with an upward-facing locking element (57).

[0077] The downward-facing locking element contains projections (60, 61) that engage in undercuts (63, 64) in the upward-facing locking element of the coupled floor panel.

[0078] FIG. 8 illustrates how, according to the example of invention described above, floor panels can be installed through a so-called “fold down” (FD) motion into a floor covering. A floor panel 1 has coupling parts at the long side as explained in FIGS. 2, 6 and it has coupling parts at the short side as explained in FIG. 7. At the long side, the floor panel can be coupled by tilting at the long side of floor panels already installed. This floor panel can then be folded down further, while the hooks of the short edges are coupled together by this downward motion. This is referred to as coupling by means of “fold down”.

[0079] The present invention is by no means limited to the embodiments described above and shown in the figures, but such a floor panel may be implemented in several shapes and dimensions without exceeding the scope of the invention.

[0080] For instance, it should be noted that although an oblong panel is shown in FIG. 1, the invention can also be applied in square floor panels. Also, the edges of the first pair of opposite edges in FIG. 1 are identified as the edges 2, 3 of the long sides, but it is clear that by definition the first pair of edges might also be present on the short sides, while the second pair of edges is then present on the long sides.