Floor covering panel

Abstract

Floor covering hard panels having at least on two opposite edges, coupling elements made in one piece with the panels, so that several ones of such panels can be mutually coupled, whereby these coupling elements provide for an interlocking in a direction perpendicular to the plane of the panels, as well as in a direction perpendicular to the edges and parallel to the plane of the panels, and whereby these coupling elements are made such that the panels can be rotated into and/or out of one another at least along the above-mentioned edges. The panels are provided, at least on the above-mentioned edges, near the top side, with a part from which has been removed an amount of material such as by a bevel.

Claims

1. A method for assembling a floor covering; said method comprising at least the step of interlocking a plurality of rectangular panels; said plurality of rectangular panels having an elongated design and being provided with a pair of opposite long sides and a pair of opposite short sides; both said pair of opposite long sides and said pair of opposite short sides being provided with edges having coupling means; said coupling means allowing said interlocking in a direction perpendicular to the plane of the floor covering as well as in a direction perpendicular to said edges and parallel to the plane of the floor covering; said pair of opposite long sides being provided with a bevel at both edges of said pair, each of the long side bevels being located at an upper side edge of the long sides and extending downwardly from a top surface of the panel; wherein said step of interlocking a plurality of rectangular panels comprises forming a first row of panels by at least interlocking a number of said panels at said edges of said pair of short sides; forming a second row of panels including rotating a first panel of said second row into the panels of said first row at the long sides; rotating a second panel of the second row into the panels of said first row at the long sides; and coupling said first panel and said second panel at the edges of their short sides; wherein co-operating panels of the first and second rows define upper contact surfaces located below the bevels and lower contact surfaces located below the upper contact surfaces, the lower contact surfaces of the first and second rows having inclined surfaces which are configured to cooperate with each other; wherein the upper contact surfaces of the panels of the second and first rows rotate against each other as the panels of the second row are coupled to the panels of the first row, wherein the bevels of the panels avoid contact with one another during the rotating of the panels of the second row into the panels of the first row, wherein the lower contact surfaces are brought against each other as the first and second panels are coupled; wherein the coupling means at the long sides include a tongue and a groove, such tongue fitting in the groove when interlocking two of such panels, said groove being bordered by an upper lip and a lower lip; wherein a V-shaped width is defined by the coupled panels, a recess is formed on each panel such that when the panels are coupled at their long edges, a clearance is formed by the recesses of the opposed panels below the upper contact surfaces and above the tongue, said clearance, measured in horizontal direction, having a maximal width, and said clearance in horizontal direction being completely confined with its maximal width within the V-shaped width by not extending beyond the V-shaped width in the horizontal direction; wherein a first panel of the panels defines a groove below the upper contact surface, said groove being bordered by an upper lip and a lower lip, the recess of the first panel is located between the groove and the upper contact surface and has a first width, a second panel of the panels defines a tongue below the upper contact surface, the recess of the second panel is located between the tongue and the upper contact surface and has a second width such that the first and second widths form the clearance, a perimeter of the clearance, seen from a cross section along a direction perpendicular to said edges, at least partially being defined by a bevelled lower edge of the upper lip, the bevelled lower edge of the upper lip being at a lowermost portion of the recess of the first panel, the recess of the first panel terminates at the tongue when the tongue is inserted into the groove, the first width, when measured in a direction perpendicular to the long edges of the first and the second panels and parallel to the plane of the floor covering, is larger than the second width, and wherein the height of the long side bevels is smaller than the average height difference, seen in coupled condition, between a contact point formed between the long side bevels and a contact zone formed between an upper side of the tongue and an underside of the upper lip.

2. The method of claim 1, wherein said coupling of said first panel and said second panel at said edges of said pair of short sides is performed by means of a translation in the plane of the floor covering.

3. The method of claim 1, wherein said coupling of said first panel and said second panel at said edges of said pair of short sides is performed while holding said first panel in a rotated position.

4. The method of claim 3, wherein said coupling of said first panel and said second panel at said edges of said pair of short sides is performed by means of a translation of the respective edges alongside each other.

5. The method of claim 4, wherein said first panel and said second panel are subsequently rotated down.

6. The method of claim 3, wherein said coupling of said first panel and said second panel at said edges of said pair of short sides is performed by means of mutual rotation between said first panel and said second panel.

7. The method of claim 6, wherein said first panel and said second panel are subsequently rotated down.

8. The method of claim 1, wherein said pair of opposite short sides is provided with a bevel at both edges of said pair.

9. The method of claim 1, wherein said panels comprise a core and a decorative upper surface.

10. The method of claim 9, wherein said rotating of said first panel is performed along a contact zone being obtained at said edges concerned and being situated completely below said decorative upper surface.

11. The method of claim 9, wherein said decorative upper surface represents a single wood pattern.

12. The method of claim 1, wherein said panels are assembled into said floor covering by mutual interlocking said panels practically free of play.

13. The method of claim 1, wherein said panels have a width and a length; said width being smaller than 16 cm.

14. The method of claim 13, wherein said length amounts to at least eight times said width.

15. The method of claim 13, wherein the coupling means of each panel extends along the entirety of the length of the long and short sides the panel.

16. The method of claim 1, wherein the recess of the first panel includes an upper recessed portion extending inwardly relative to and below from the contact surface, and a bevel following from the upper recessed portion in a downward direction toward the groove.

17. The method of claim 1, wherein the contact surfaces are located at the same height relative to one another, the recesses are defined at the same height relative to one another downwardly adjacent from the contact surfaces.

18. A method for assembling a floor covering; said method comprising at least the step of interlocking a plurality of rectangular panels; said plurality of rectangular panels being provided with a pair of opposite long sides and a pair of opposite short sides; both said pair of opposite long sides and said pair of opposite short sides being provided with edges having coupling means; said coupling means allowing said interlocking in a direction perpendicular to the plane of the floor covering as well as in a direction perpendicular to said edges and parallel to the plane of the floor covering; said pair of opposite long sides being provided with a bevel at both edges of said pair, each of the long side bevels being located at an upper side edge of the long sides and extending downwardly from a top surface of the panel to an upper contact surface formed below the bevel and above a recess formed on each panel such that when opposed panels are coupled, a clearance is formed by the recesses of said opposed panels, wherein said step of interlocking a plurality of rectangular panels comprises forming a row of panels by at least interlocking said panels at said edges of said pair of short sides; coupling a first panel into a panel of said row at said edges of said pair of long sides by means of a translation in said plane of the floor covering; and coupling a second panel into a panel of said row at said edges of said pair of long sides; coupling said first panel and said second panel at said edges of said pair of short sides; at said long sides maintaining the clearance as the upper contact surfaces are brought against one another while the coupling means are engaged; wherein the coupling means at the long sides include a tongue and a groove, such tongue fitting in the groove when interlocking two of such panels; wherein a V-shaped width is defined by the bevels of the first and second panels, and said clearance, measured in horizontal direction, having a maximal width, and said clearance in horizontal direction being completely confined with its maximal width within the V-shaped width by not extending beyond the V-shaped width in the horizontal direction; wherein a first panel of the panels defines the groove below the upper contact surface, said groove being bordered by an upper lip and a lower lip, the recess of the first panel is located between the groove and the upper contact surface and has a first width, a second panel of the panels defines the tongue below the upper contact surface, the recess of the second panel is located between the tongue and the upper contact surface and has a second width such that the first and second widths form the clearance, a perimeter of the clearance, seen from a cross section along a direction perpendicular to said edges, at least partially being defined by a bevelled lower edge of the upper lip, the bevelled lower edge of the upper lip being at a lowermost portion of the recess of the first panel, the recess of the first panel terminates at the tongue when the tongue is inserted into the groove, the first width, when measured in a direction perpendicular to the long edges of the first and the second panels and parallel to the plane of the floor covering, is larger than the second width; and wherein the height of the long side bevels is smaller than the average height difference, seen in coupled condition, between a contact point formed between the long side bevels and a contact zone formed between an upper side of the tongue and an underside of the upper lip.

19. The method of claim 18, wherein said panels have a width and a length; said width being smaller than 16 cm.

20. The method of claim 19, wherein the coupling means of each panel extends along the entirety of the length of the long and short sides the panel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In order to better explain the characteristics of the invention, the following preferred embodiments are described as an example only without being limitative in any way, with reference to the accompanying drawings, in which:

(2) FIG. 1 schematically represents a part of a floor covering which is built up of panels according to the invention;

(3) FIG. 2 represents a top view of a panel from the floor covering of FIG. 1;

(4) FIGS. 3 and 4 represent sections, according to lines III-III and IV-IV respectively in FIG. 2;

(5) FIG. 5 represents a section according to line V-V in FIG. 1 to a larger scale;

(6) FIG. 6 represents a section according to line VI-VI in FIG. 1 to a larger scale;

(7) FIG. 7 represents the part indicated by F7 in FIG. 6 to a larger scale;

(8) FIG. 8 shows a view analogous to that in FIG. 7, but whereby the panels are mainly shifted towards one another in one and the same plane;

(9) FIG. 9 shows a section of another panel according to the invention, with bevels which are provided with a print;

(10) FIG. 10 schematically represents how the print can be provided in the embodiment of FIG. 9;

(11) FIG. 11 schematically represents a section according to line XI-XI in FIG. 10; and

(12) FIG. 12 represents a section of another panel according to the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

(13) As represented in FIGS. 1 and 2, the invention concerns a floor covering 1 as well as hard panels 2 from which such a floor covering 1 is built up.

(14) According to a first aspect of the invention, a floor covering 1 is formed of hard laminate panels 2, wherein these panels 2 are provided at least on two opposite edges 3-4, and preferably, as represented in the FIGS. 2 to 8, on both pairs of edges 3-4, 5-6 respectively, with coupling means or elements 7 made in one piece out of the core material of the panels 2, so that several of such panels 2 can be mutually coupled to one another, whereby these coupling means 7 provide for an interlocking in a direction R1 perpendicular to the plane of the floor covering 1, as well as in, a direction R2 perpendicular to the edges 3-4 or 5-6 concerned and parallel to the plane of the floor covering 1 or panels 2, and whereby these coupling means 7 are made such that the panels 2 can be assembled and/or disassembled at least along the above-mentioned edges 3-4, 5-6 respectively, by means of a rotation.

(15) Such coupling means 7, which make it possible to couple the panels 2 without any glue being required, at least on two sides and preferably on all sides, and whereby the panels 2 are uncoupled by rotating them out of one another, are known as such from international patent Publication No. WO 97/47834.

(16) From WO 97/47834 it is also known that the above-mentioned coupling means 7, as represented in FIGS. 3 to 8 of the present application, may consist of a tongue 8 and a groove 9 on the one hand, and of locking device 10 on the other hand which at least ensure a specific interlocking in a direction perpendicular to the edges 3-4, 5-6 respectively, of the coupled panels 2 and parallel to the plane of these panels 2. As is further represented, these coupling means 7 are moreover preferably made such that the lip 11 which limits or defined the bottom side of the groove 9, seen from a cross section, extends past the upper lip 12, while the locking means 10 are formed of interlocking parts 13-14 working in conjunction, on the above-mentioned lip 11 which limits the bottom side of the groove 9 and on the bottom side of the coupled panel 2 respectively, in particular the bottom side of the tongue 8 or the extension of this bottom side.

(17) As explained in WO 97/47834, such coupling means 7, depending on their embodiment, allow for different couplings. According to the most preferred embodiment, they are, as will be described hereafter by means of FIG. 1, made such that they allow for a coupling by rotating into one another as well as by shifting towards one another in a generally common plane. The latter allows such panels to be coupled by first rotating them into one another on their edges 3-4, as represented by the panel 2A in FIG. 1, with a rotation W1, and by subsequently snapping them together on their edges 5-6 by means of a translation T1. According to a variant, the connection on the edges 3-4 of the panels concerned can also be realized by starting from a position as is schematically indicated with reference 2B, and by coupling the panel concerned by means of a translation or sliding motion T2.

(18) The above-mentioned rotation is further illustrated in FIGS. 6 and 7, whereas the sliding motion is represented in FIG. 8. It should be noted that the tongue 8 and groove 9 are preferably made such that, as is also represented in FIG. 8, when two such panels 2 are freely shifted towards one another over a bottom or support, the tongue 8 automatically is introduced into and ends up in the groove 9.

(19) It is also possible, while holding a panel 2A in a rotated position, to couple a following panel 2C onto it on the edges 5 and 6 respectively, either by means of a generally co-planar translation T3, or by a mutual rotation between the panels 2A and after which both panels 2A and 2C are then rotated down to be interlocked with the preceding row of panels.

(20) Another advantage consists in that a glueless coupling without any play or practically without any play remains possible, also with thicker panels which can be rotated into and/or out of one another, without any extreme compression forces being created on the edge parts during the rotation. The bevels according to this invention ensure that such forces are excluded and/or remain limited, so that the risk of damages, among others to the top layer or to the surface of the bevels, are excluded, if not restricted.

(21) What makes the first aspect of the invention special is that the above-mentioned panels 2 are provided, at least on two of their edges 3-4 or 5-6 and preferably on all four edges 3 to 6, near the top side, with a part from which an amount of material has been cut-away and removed (a cut-away portion), which part preferably each time is in the form of a bevel 15.

(22) As represented in FIGS. 6 and 7, these bevels 15 among others offer the advantage that the panels 2 can be easily rotated in relation to one another, as the material parts 16 and 17 which are otherwise present no longer press onto one another, and a contact zone 18 is obtained which is situated relatively low in the panel thickness.

(23) Another advantage is that when it is required for the above-mentioned interlocking parts 13 and 14, in particular the accompanying lower contact surfaces 19 and 20, to extend tangentially or almost tangentially around a circle having the contact zone 18 as its centre, the average gradient A of the contact surfaces can be kept relatively large for a same distance E of the protruding part of the lower lip 11, as indicated in FIG. 5, as a result of which a solid interlocking can be ensured, even with thicker panels 2.

(24) Another advantage consists in that, irrespective of the thickness D of the panels 2, the contact zone 18 can always be situated at a certain height H above the bottom side of the panels 2; provided the bevels 15 are realized over an appropriate height H1. Thus it is possible, if required, to always work with similar cutting tools to form the tongue 8 and groove 9 for thinner as well as for thicker 5 panels 2.

(25) Although the above-mentioned advantages are particularly felt with embodiments of the type whereby the uncoupling of the panels 2 can be realized by means of a rotation around the above-mentioned contact zone 18, it should be noted that the above-mentioned bevels 15 also offer advantages which do not necessarily coincide with the fact whether it is either or not possible for the panels 2 to be disassembled by means of rotation. Such bevels 15 offer the advantage that the panels 2 never press directly onto one another on their top surface, so that damage of the top layer resulting from mutual contact between the panels 2 is excluded, which is particularly important in the case of laminate parquet, as well as for floor coverings which are connected without any glue and whereby the panels are driven one another laterally in a generally common plane by means of a hammer and a stop block.

(26) Also, according to a different embodiment, the first aspect of the invention no longer merely applies to panels 2 which can be disassembled by means of a rotation, but it also applies to all sorts of panels 2 which are provided with coupling means 7 which make it possible for the panels 2 to be interlocked both vertically and horizontal on their edges 3-4, 5-6 respectively, irrespective of whether the assembly and/or disassembly has to be or can be realized by means of a rotation or sliding motion.

(27) The above-mentioned bevels 15 preferably extend at an angle X of 45 in relation to the plane which is determined by or includes the panels 2. However, other gradients are not excluded.

(28) Practically, the bevels 15 will extend in a horizontal direction over a distance Z in the order of magnitude of 2 millimeter, although other dimensions are not excluded here either.

(29) As is further represented in FIG. 5, lateral surfaces, in particular upper contact surfaces 21, 22 are present under the above-mentioned bevels 15, which fit up to one another at least at the top when the panels 2 are coupled, and thus form a mutual stop. A recess 38, 39 is formed on each panel below the upper contact surfaces 21, 22 such that when opposed panels 2 are coupled, and a clearance 40 is formed by the recesses 38, 39 between the opposed panels below the upper contact surfaces 21, 22 and above the tongue 8 and the groove 9 of the opposed panels 2. And as shown in FIGS. 7 and 8, at a lowermost portion of the upper lip 12, recess 39 is further formed by a bevelled lower edge 71.

(30) A V-shaped width (50) is defined by the bevels (15) of the first and second panels (2). The width (52) of the clearance (40) is less than the V-shaped width (50).

(31) It is clear that the first aspect of the invention can be applied with panels 2 having an elongated design, as represented in FIG. 2, as well as with panels 2 having a square design.

(32) According to the above-mentioned second aspect of the invention, which the given example of FIGS. 1 and 2 is combined with the above-mentioned first aspect, but which can also be realized as separate from the first aspect, the invention concerns a floor covering 1, consisting of laminated hard panels 2 having a core 23 and a panel decorative upper surface 24, whereby these panels 2 are rectangular and elongated and are provided with coupling means 7 on at least two opposite longitudinal edges 3-4 and/or 5-6, as a result of which several of such panels 2 can be mutually coupled to one another, whereby these coupling means 7 are provided with an interlocking in a direction perpendicular to the plane of the floor covering 1, as well as in a direction perpendicular to the edges 3-4-5-6 concerned and parallel to the plane of the floor covering, and whereby these coupling means 7 are made such that the panels 2 can be coupled and/or uncoupled by means of a rotation along their longitudinal edges 3-4 and/or 5-6, such that the useful width B of the panels 2 is smaller than 17 cm, and preferably amounts to 15.5 cm.

(33) Such a narrow width B, combined with coupling means 7 of the type whereby the uncoupling has to be carried out by rotating the panels 2 in relation to one another, as represented in FIG. 6, offers the advantage that the height H2 over which the panel 2 to be uncoupled has to be rotated before it is detached, also remains relatively small, as a result of which the disadvantage mentioned in the introduction is minimised.

(34) Moreover, the panels 2, according to the second aspect of the invention, preferably also have a length L which amounts to at least eight times the width B.

(35) Preferably, the panels 2 made according to the second aspect of the invention, also have a single pattern which is repeated over the entire top surface, in particular a wood pattern.

(36) FIG. 9 illustrates the third aspect of the invention. According to this third aspect, the invention concerns a floor covering 1 consisting of hard panels 2 with a laminated structure, having a panel decorative layer 25 on the top surface, wherein cut-away bevels 15 or such are formed on one or several edges 3 to 6 of the panels 2, near the top side, and in that the exposed surface of these bevels 15 or such is also provided with a bevel decorative layer, in this case a print 26, which is preferably obtained as a print layer that has been provided on this surface by means of transfer printing.

(37) As shown in FIG. 8, the cut-away bevels 15 extend through the core 23 of each panel as well as the panel decorative layer 25, thereby exposing edges of the respective layers 23 and 25. The print layer 26 (FIGS. 9, 10) covers or masks the exposed core and panel decorative edges, preferably matching the pattern of the panel decorative layer so that, when viewed from the top surface, the exposed bevel area is covered by the bevel decorative layer.

(38) The panel decorative layer 25 may as such consist of several layers, but it preferably contains at least one film or coating-like layer imprinted with a pattern, for example a wood pattern printed on a paper layer. In this case, the print 26 can be realized on the bevels 15 or such with a similar pattern. As a printing technique is applied for the decorative layer as well as for the print 26, it is very easy to match both patterns as far as colour and/or design are concerned.

(39) As mentioned in the introduction, the print 26 is preferably moisture-proof and impermeable. Thus is obtained a sealing on the bevels 15, which is particularly useful when the panels have a porous core, for example made of MDF or HDF.

(40) FIGS. 10 and 11 schematically represent how the print 26 can be provided on the surface 27 by means of transfer printing. A support 28 which is provided with a printing layer 29 is put into contact with the surface 27 and is applied with a preferably heated press-on roller 30, as a result of which the printing layer 29 adheres to the material of the panel 2 and comes off the support 28, so that the above-mentioned print 26 is created. The support 28 with the printing layer 29 is hereby supplied as of a roller 31, whereas said support 28, after the printing layer 29 has been transferred to the surface 27, is rolled up on a roller 32.

(41) Other transfer printing techniques which are known as such are not excluded, however.

(42) It should be noted that, both as far as the above-mentioned first aspect and the third aspect are concerned, according to a preferred embodiment, one or several, and preferably all bevels 15 extend at such an angle that the plane including the bevel 15, does not intersect the contour of the panel 2 or at most just touches it, as indicated by the lines W in FIGS. 3, 4 and 10 outside the bevel area. This is advantageous in that, both when the bevels 15 are formed and when the print 26 is applied, these bevels 15 are easily accessible to the machine parts used in the manufacturing procedures.

(43) According to a fourth aspect of the invention, it concerns a floor covering consisting of laminated hard panels 2 with a core 23 based on MDF or HDF, or a similar material, wherein the panels 2 are each separately provided with an underlayer 36 made of synthetic material or another dampening or insulating material provided on the bottom side and fixed onto it, preferably made of polyethylene or polyethylene base material, as represented in FIG. 12. The combination of these materials offers the advantage that little sound is produced when these panels 2 are walked on.

(44) The above-mentioned underlayer 36 can be fixed to the bottom side of the panel 2 in any way whatsoever, for example by means of gluing or by melting it onto the panel. In the case of a conventional laminate construction, the structure thus consists of the decorative layer 25, the core 23, usually based on MDF or HDF, a counterlayer 37, and the above-mentioned underlayer 36.

(45) It is clear that the fourth aspect of the invention can be used in combination with floor panels which are provided with a conventional tongue and groove on their edges, as well as in combination with floor panels with coupling means which provide for a horizontal and a vertical interlocking, for example coupling means 7 as described above.

(46) The invention is by no means limited to the above-described embodiments represented on the accompanying drawings; on the contrary, such a floor and in particular the above-mentioned panels, can be made in all shapes and dimensions while still remaining within the scope of the invention.