Floor covering
09624676 ยท 2017-04-18
Assignee
Inventors
Cpc classification
B32B21/04
PERFORMING OPERATIONS; TRANSPORTING
E04F15/02
FIXED CONSTRUCTIONS
E04F15/02038
FIXED CONSTRUCTIONS
E04F2201/0153
FIXED CONSTRUCTIONS
B32B21/02
PERFORMING OPERATIONS; TRANSPORTING
E04C2/10
FIXED CONSTRUCTIONS
B32B21/14
PERFORMING OPERATIONS; TRANSPORTING
E04F15/107
FIXED CONSTRUCTIONS
E04F2201/043
FIXED CONSTRUCTIONS
E04F15/10
FIXED CONSTRUCTIONS
Y10T428/17
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
E04F15/102
FIXED CONSTRUCTIONS
E04F15/04
FIXED CONSTRUCTIONS
B32B2451/00
PERFORMING OPERATIONS; TRANSPORTING
B32B3/06
PERFORMING OPERATIONS; TRANSPORTING
International classification
E04B2/00
FIXED CONSTRUCTIONS
E04F15/04
FIXED CONSTRUCTIONS
E04F15/02
FIXED CONSTRUCTIONS
B32B3/06
PERFORMING OPERATIONS; TRANSPORTING
Abstract
Hard panels formed from a wood-based material and having a decorative layer for floor coverings are provided, at least on two opposite edges, with coupling devices made in one piece with the panels wherein similar panels may be coupled together to form a floor covering, wherein these coupling devices provide for an interlocking in a direction perpendicular to the plane of coupled panels, as well as in a direction perpendicular to the edges concerned and parallel to the plane of coupled panels. These coupling devices are constituted of a tongue and a groove. The top side of the tongue has a protrusion that cooperates with a meshing recess located in the lower side of the upper lip of the groove of the coupling devices, and a portion extending generally parallel with the plane of the panel to form a contact surface cooperating with the lower side of the upper lip of the groove.
Claims
1. A floor panel for forming a floor covering, wherein the floor panel is a laminate panel made of a board on the basis of wood, upon which one or several layers, including a decorative layer, are provided; wherein the floor panel is provided on at least two opposite edges with coupling parts made in one piece with the floor panel, as a result of which two of such floor panels can be mutually coupled to one another; wherein said coupling parts, in a coupled situation, provide for an interlocking in a direction perpendicular to a plane of the floor covering as well as in a direction perpendicular to the edges concerned and parallel to the plane of the floor covering; wherein said coupling parts comprise a tongue and a groove, said groove being bordered by an upper lip and a lower lip, the distal end of the upper lip defining a vertical plane that forms a closing plane between two of such coupled floor panels, said lower lip extending further than said vertical plane; wherein said coupling parts comprise first cooperating surfaces, on the top side of the tongue and the bottom side of the upper lip respectively, said first cooperating surfaces, in the coupled situation, working in conjunction with one another and forming a first cooperating zone, and second cooperating surfaces, on an interlocking part that is situated on the lower lip and on an opposite part of the other floor panel respectively, said second cooperating surfaces, in the coupled situation, working in conjunction with one another and forming a second cooperating zone; wherein said coupling parts are made such that two of such floor panels can be assembled by pushing towards one another by means of a movement mainly parallel to the plane of the floor covering; wherein the distal tip of said tongue, in the coupled situation, is situated in said groove past said vertical plane; wherein a distance between said vertical plane and the distal end of the lower lip is smaller than a thickness of the floor panel but larger than a distance between said vertical plane and the distal tip of the tongue in the coupled situation; wherein the distance between the distal tip of the tongue and said vertical plane in the coupled situation is smaller than the distance between a horizontal level defined by a height of said first cooperating zone and an intersection between said vertical plane and the top side of the lower lip; and wherein the floor panel shows one or both of the following characteristics: a thickness of the upper lip is larger than a thickness of the lower lip at said vertical plane; the distance between said vertical plane and the distal end of the lower lip is smaller than the distance between the upper side of the floor panel and the intersection between said vertical plane and the top side of the lower lip.
2. The floor panel of claim 1, wherein the uppermost point of the top side of said interlocking part defines a second horizontal level; wherein the lowermost point of the bottom side of the tongue defines a third horizontal level; and wherein the distance between said second and third horizontal level is smaller than of the distance between said first and third horizontal level.
3. The floor panel of claim 1, wherein the tongue and the groove are made such that when two of such floor panels are freely pushed towards one another, over a base or such, the tongue automatically ends up in the groove.
4. The floor panel of claim 1, wherein said interlocking part is situated on a part of the lower lip that is situated past said vertical plane.
5. The floor panel of claim 1, wherein said cooperating surfaces forming the second cooperating zone, or their tangent line, are directed slantingly in relation to the plane of the floor covering.
6. The floor panel of claim 1, wherein said coupling parts are made such that the coupling parts can be turned in and/or out one another by means of a movement of rotation.
7. The floor panel of claim 1, wherein said board is fiberboard of the type MDF or HDF.
8. The floor panel of claim 7, wherein said decorative layer is selected from the group consisting of: a printed paper layer, a layer of wood, a veneer layer and a cork layer.
9. The floor panel of claim 1, wherein said decorative layer is selected from the group consisting of: a layer of wood, a veneer layer and a cork layer.
10. The floor panel of claim 1, wherein the floor panel is rectangular, said floor panel comprising a first pair of opposite edges, formed by the aforementioned two opposite edges, and a second pair of opposite edges, which is also provided with coupling parts at least offering a locking in the horizontal direction.
11. A floor panel for forming a floor covering, wherein the floor panel is a laminate panel made of a board on the basis of wood, upon which one or several layers, including a decorative layer, are provided; wherein the floor panel is provided on at least two opposite edges with coupling parts made in one piece with the floor panel, as a result of which two of such floor panels can be mutually coupled to one another; wherein said coupling parts, in a coupled situation, provide for an interlocking in a direction perpendicular to a plane of the floor covering as well as in a direction perpendicular to the edges concerned and parallel to the plane of the floor covering; wherein said coupling parts comprise a tongue and a groove, said groove being bordered by an upper lip and a lower lip, the distal end of the upper lip defining a vertical plane that forms a closing plane between two of such coupled floor panels, said lower lip extending further than said vertical plane; wherein said coupling parts comprise first cooperating surfaces, on the top side of the tongue and the bottom side of the upper lip respectively, said first cooperating surfaces, in the coupled situation, working in conjunction with one another and forming a first cooperating zone, and second cooperating surfaces, on an interlocking part that is situated on the lower lip and on an opposite part of the other floor panel respectively, said second cooperating surfaces, in the coupled situation, working in conjunction with one another and forming a second cooperating zone; wherein said interlocking part is the only interlocking part being situated on the lower lip and taking part in said interlocking in the direction parallel to the plane of the floor covering and perpendicular to the edges; wherein said coupling parts are made such that two of such floor panels can be assembled by pushing towards one another by means of a movement mainly parallel to the plane of the floor covering; wherein the distal tip of said tongue, in the coupled situation, is situated in said groove past said vertical plane; wherein a distance between said vertical plane and the distal end of the lower lip is smaller than a thickness of the floor panel; wherein, in the coupled situation, there is a free space under the tongue, which extends from the distal tip of the tongue at least up to a point being situated further than a second vertical plane being defined by the most inwardly situated point of said first cooperating zone; and wherein the floor panel shows one or both of the following characteristics: a thickness of the upper lip is larger than a thickness of the lower lip at said vertical plane; the distance between said vertical plane and the distal end of the lower lip is smaller than the distance between the upper side of the floor panel and an intersection between said vertical plane and the top side of the lower lip.
12. The floor panel of claim 11, wherein the uppermost point of the top side of said interlocking part defines a second horizontal level; wherein the lowermost point of the bottom side of the tongue defines a third horizontal level; and wherein the distance between said second and third horizontal level is smaller than of the distance between said first and third horizontal level.
13. The floor panel of claim 11, wherein the tongue and the groove are made such that when two of such floor panels are freely pushed towards one another, over a base or such, the tongue automatically ends up in the groove.
14. The floor panel of claim 11, wherein said interlocking part is situated on a part of the lower lip that is situated past said vertical plane.
15. The floor panel of claim 11, wherein said cooperating surfaces forming the second cooperating zone, or their tangent line, are directed slantingly in relation to the plane of the floor covering.
16. The floor panel of claim 11, wherein said coupling parts are made such that they can be turned in and/or out one another by means of a movement of rotation.
17. The floor panel of claim 11, wherein said board is fiberboard of the type MDF or HDF.
18. The floor panel of claim 17, wherein said decorative layer is selected from the group consisting of: a printed paper layer, a layer of wood, a veneer layer and a cork layer.
19. The floor panel of claim 11, wherein said decorative layer is selected from the group consisting of: a layer of wood, a veneer layer and a cork layer.
20. The floor panel of claim 11, wherein the floor panel is rectangular, said floor panel comprising a first pair of opposite edges, formed by the aforementioned two opposite edges, and a second pair of opposite edges, which is also provided with coupling parts at least offering a locking in the horizontal direction.
21. A floor panel for forming a floor covering, wherein the floor panel is a laminate panel made of a board on the basis of wood, upon which one or several layers, including a decorative layer, are provided; wherein the floor panel is provided on at least two opposite edges with coupling parts made in one piece with the floor panel, as a result of which two of such floor panels can be mutually coupled to one another; wherein said coupling parts, in a coupled situation, provide for an interlocking in a direction perpendicular to a plane of the floor covering as well as in a direction perpendicular to the edges concerned and parallel to the plane of the floor covering; wherein said coupling parts comprise a tongue and a groove, said groove being bordered by an upper lip and a lower lip, the distal end of the upper lip defining a vertical plane that forms a closing plane between two of such coupled floor panels, said lower lip extending further than said vertical plane; wherein said coupling parts comprise first cooperating surfaces, on the top side of the tongue and the bottom side of the upper lip respectively, said first cooperating surfaces, in the coupled situation, working in conjunction with one another and forming a first cooperating zone, and second cooperating surfaces, on an interlocking part that is situated on the lower lip and on an opposite part of the other floor panel respectively, said second cooperating surfaces, in the coupled situation, working in conjunction with one another and forming a second cooperating zone; wherein said coupling parts are made such that two of such floor panels can be assembled by pushing towards one another by means of a movement mainly parallel to the plane of the floor covering; wherein the distal tip of said tongue, in the coupled situation, is situated in said groove past said vertical plane; wherein a distance between said vertical plane and the distal end of the lower lip is smaller than a thickness of the floor panel; and wherein an intersection between a second vertical plane defined by the most outwardly situated point of said first cooperating zone and the bottom side of the tongue is situated beneath a horizontal level defined by the uppermost point of the top side of said interlocking part.
22. The floor panel of claim 21, wherein the lowermost point of the bottom side of the tongue defines a second horizontal level; wherein said first and second horizontal level define a third horizontal level situated right in between; and wherein the intersection between said second vertical plane and the bottom side of the tongue is situated beneath said third horizontal level.
23. The floor panel of claim 21, wherein the tongue and the groove are made such that when two of such floor panels are freely pushed towards one another, over a base or such, the tongue automatically ends up in the groove.
24. The floor panel of claim 21, wherein said interlocking part is situated on a part of the lower lip that is situated past said vertical plane.
25. The floor panel of claim 21, wherein said cooperating surfaces forming the second cooperating zone, or their tangent line, are directed slantingly in relation to the plane of the floor covering.
26. The floor panel of claim 21, wherein said coupling parts are made such that they can be turned in and/or out one another by means of a movement of rotation.
27. The floor panel of claim 21, wherein said board is fiberboard of the type MDF or HDF.
28. The floor panel of claim 27, wherein said decorative layer is selected from the group consisting of: a printed paper layer, a layer of wood, a veneer layer and a cork layer.
29. The floor panel of claim 21, wherein said decorative layer is selected from the group consisting of: a layer of wood, a veneer layer and a cork layer.
30. The floor panel of claim 21, wherein the floor panel is rectangular, said floor panel comprising a first pair of opposite edges, formed by the aforementioned two opposite edges, and a second pair of opposite edges, which is also provided with coupling parts at least offering a locking in the horizontal direction.
Description
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:
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DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
(23) As represented in
(24) As described in U.S. Pat. No. 6,006,486, it is known that such panels 2 can be connected without any glue being required by making use of coupling means which, when the panels 2 are rectangular, provide for an interlocking in a direction R1, perpendicular to the plane of the floor covering 1, at least on one pair of opposite edges 3-4, and preferably on both pairs of edges 3-4, 5-6 respectively, 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.
(25) Coupling means can be used which allow for different coupling methods, but preferably coupling by rotating the panels relative to each other as well as by pushing the panels together while in a generally common plane. The latter makes it possible for such panels 2 to be coupled to one another in a known manner by first rotating them into one another on their edges 3-4, as represented by means of the panel 2A in
(26) Also, while a panel 2A is maintained in the rotated position, a following panel 2C can be coupled to the edges 5 and 6 concerned, either by means of a translation T3, or by means of a mutual rotation between the panels 2A and 2C, after which both panels 2A and 2C are then turned down so as to be locked to the preceding row of panels.
(27) As mentioned in the introduction, the present invention provides different new embodiments of coupling means to mutually connect such panels 2.
(28)
(29) Also, in this embodiment, the floor covering 1 comprises hard panels 2 which are provided with coupling means 7 made in one piece with the panels 2 on at least two opposite edges, in this case 5-6, so that several of such panels 2 can be mutually connected to one another. These coupling means 7 provide for an interlocking in the direction R1, as well as R2.
(30) Further, these coupling means 7 have a tongue 8 provided on the edge 5, and a groove 9 provided on the edge 6, in which the tongue 8 fits. The groove 9 is hereby bordered on the top side by means of a lip 10, hereafter called the upper lip. At the bottom, it is bordered by a lip 11, hereafter called the lower lip, which is longer than the upper lip 10, in other words, which extends further than the distal end 12 of the lip 10 in the horizontal direction away from groove 9.
(31) The interlocking in the direction R2 is obtained as the lower lip 11 forms an interlocking part 13 with an inwardly directed contact surface 14 which can co-operate with an opposite contact surface 15 formed on the edge 5 when being coupled.
(32) According to the invention, the panel edge 5 which is provided with the tongue 8 is made elastically flexible, whereas the lip 11 is preferably made rigid, the latter by making it relatively thick, as is clearly visible in
(33) The panel edge 5 is made such that it can elastically bend in several places. Thus, for example, the tongue 8 is flexible, but even more important is that this tongue 8 is preferably situated on a part 16, as represented, which is connected to the actual panel 2 via a flexible zone 17 in the shape of a local constriction or reduced cross-section.
(34) This flexible zone 17 is preferably situated on the place as indicated in
(35) If the panels 2 are made of fiberboard, of the type MDF or HDF, the thickness D1 is preferably even smaller than 3 mm, and better still smaller than 2 mm.
(36) The flexible zone 17 is situated against the top side 18 of the panel 2 concerned, which is particularly useful when MDF or HDF board is used, as such materials have a larger density on the outer surfaces, and thus the thickness on these places can be maximally reduced so as to obtain an optimal flexibility.
(37) Apart from the advantages already mentioned in the introduction, the invention according to the first aspect also offers the following advantageous characteristics: As the contact surface 14 is situated relatively high, said contact surface 14 can be provided in a more vertical position, without much deviation from the tangential directions B1 and B2 represented in
(38) According to a second aspect of the invention, which in the given example of
(39) The second coupling parts are preferably situated immediately next to the third coupling parts. The contact surface 21 is hereby formed of the top side of the above-mentioned interlocking part 13, whereas the contact surface 22 is situated precisely opposite to it.
(40) According to the embodiment of
(41) The coupling means 7 are mainly designed to be provided on one pair of edges 5-6, whereas coupling means 25 are preferably provided on the other edges 3-4, as represented in
(42) The above-described arrangement does not exclude, however, that the coupling means 7 may be provided on both pairs of edges 3-4 and 5-6, or on the longitudinal edges 3-4, whereas another connection is provided for on the short edges.
(43) Nor is it excluded to provide the panels 2 on merely one pair of edges with coupling means, in this case the coupling means 7.
(44) Further, the coupling means 7 are preferably made such that the panels 2 with their edges concerned, in this case the edges 5 and 6, can be connected to one another by pushing the panels 2 freely towards one another, as is represented step by step in
(45) The laying of the floor covering 1, with panels 2 containing coupling means 7, can then for example, yet not necessarily, be carried out as follows. In a situation as represented in
(46) Then, the panel 2A can be connected to the preceding panel with a translation T1, whereby the situations as represented in
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(48) As represented in
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(50) The coupling means 31 are hereby made such that the connection can be realized by pushing the panels 2 towards one another with the edges 5-6 concerned, for example over a base, whereby they systematically fit into one another, as represented in
(51) As shown in the figures, the tongue 8 has one end 24 which has been made thinner. There is also a free space 35 between the free end 36 of the lower lip 11 and the opposite part 37 under the tongue 8 of the other panel 2.
(52) The embodiment of
(53) The embodiment of
(54)
(55) Other particularities of this embodiment, which must not all be combined according to variants which are not represented, consist in that the top side 40 of the tongue 8, with the exception of the local protrusion 39, is mainly parallel to the surface of the floor covering 1, and in that the bottom side 42 of the tongue 8 is mainly formed of a smoothly bent surface which reaches up to the top side 40 of the tongue 8. Also this embodiment makes it possible for the panels 2 to be assembled by means of a mainly horizontal movement as well as rotational movement about the coupled edge.
(56) As seen in
(57)
(58) This floor covering 1 is special in that it provides at least the combination of the following characteristics: that the panels 2, and basically also the above-mentioned lips 10-11, are made of fiberboard of the type MDF or HDF; that the coupling means 43 are made such that the panels 2 can be assembled by pushing them towards one another; and that the above-mentioned space 44 extends to beneath the upper lip 10, such that this space 44 is in conformity with at least one of the following two characteristics: that the part of this space 44 which is situated under the level N3 extends inwardly to at least past the plane V1; that the part of this space 44 which is situated under the level N1 extends inwardly to at least past the plane V5.
(59) Thanks to this specific combination there is obtained a space 44 which acts as a depression in relation to the other dimensions extending over a relatively large distance in the direction R2, as a result of which the advantages mentioned in the introduction are obtained. In spite of the relatively large depression and, consequently, the fact that the lower lip 11 is relatively thin, the rigidity remains nevertheless sufficient thanks to the use of MDF or HDF as a base material, which has a layered fibrous structure.
(60) The distance between the levels N1 and N2 is preferably smaller than of the distance between the levels N2 and N4. Thus, the obstruction formed by the interlocking part 13 while the panels are being pushed together, is restricted to a minimum, as a result of which the panels 2 can smoothly slide into one another.
(61) Further, the intersection P4 between the plane V4 and the bottom side of the tongue 8 is situated beneath level N1, seen from a cross section, and better still beneath level N3. The tongue 8 thus obtains a relatively large thickness, which improves its rigidity. Further, it is even possible for the section P5 between the plane V5 and the bottom side of the tongue 8 to be situated beneath level N1, and better still beneath level N3.
(62) In particular, the section P3 between the plane V3 and the bottom side of the tongue 8 could be situated beneath level N1, and better still beneath level N3.
(63) According to a preferred characteristic of the invention, the part of the above-mentioned space 44 situated under the plane N3 would extend at least inwardly up to the vertical plane V6 which is determined by the tip 24 of the tongue 8.
(64) In the case where the panels 2 are rectangular and coupling means are formed on both pairs of edges 3-4 and 5-6 which provide for a vertical and a horizontal interlocking, whereby both edges 4 and 6 have a lower lip 11, 11A respectively, which is longer than the upper lip 10, at least the above-mentioned space 44 is preferably made continuous up to the end of the panel 2, as represented in
(65)
(66) It should be noted that in all the above-mentioned embodiments, the contact surfaces providing for the horizontal interlocking are preferably directed slantingly in relation to the plane of the floor covering 1. This does not exclude, however, that according to a variant, one or both contact surfaces can also be directed perpendicular to the plane of the floor covering. The contact surfaces can also be bent as such, whereby the tangent line in the middle of the contact zone determines the above-mentioned gradient.
(67) In the case where these contact surfaces, or their tangent line, are directed slantingly, they preferably extend in a direction which is tangential or almost tangential to a circle, whose center is situated on a point of rotation around which the panels 2 can be turned apart. As indicated in
(68) In order to provide for a snap-in effect, the direction B1 pertaining to the contact surfaces preferably does deviate from the direction of the above-mentioned tangent B2 and is directed inwardly, such that a snap-in effect is created when the panels are rotated into one another, whereby the above-mentioned direction B1 deviates 30 at the most from the above-mentioned tangential direction B2.
(69) What precedes can be applied in all the rotatable embodiments described above, also in the embodiments whereby the panels 2 are rotated apart by turning them down.
(70) The coupling means which are realized according to one or several of the first eight aspects of the invention are all particularly suitable to be provided on edges 3-4 and/or 5-6, whereby it must be possible to assemble the panels 2 by shifting them.
(71) In the case where the panels 2 are rectangular, in other words square or longitudinal, they are preferably provided with coupling parts on all four edges 3-4 and 5-6 which allow for a vertical and a horizontal interlocking, whereby coupling means as described in one or several of the above-mentioned first eight aspects are then provided on at least two opposite edges 3-4 or 5-6.
(72) In the case where the panels 2 are rectangular, the new coupling means are preferably provided at least on the short edges 5-6. Further, coupling means are then preferably provided on the long edges 3-4 which allow for an assembly, disassembly respectively by means of a movement of rotation, which can be of a known nature or which can also be made according to any of the above-mentioned eight aspects.
(73)
(74) Moreover, according to the embodiment of
(75)
(76) Both in the embodiment of
(77) Practically, the above-mentioned interlocking parts 13-47 are positioned such that a lateral play S is created during the above-mentioned further turning, as is schematically represented in
(78) In the embodiment of
(79) In particular, the distance Z1 between the tip of the tongue 8 and the interlocking part 47 situated on the same edge is smaller than or equal to the distance Z2 between the tip of the lip 10 bordering the top side of the groove 9 and the interlocking part 13 situated on the lip 11 bordering the bottom side of the groove 9.
(80) It should be noted that in the embodiments of
(81) As represented, coupling means are preferably provided both on the short edges and on the longitudinal edges which allow for an interlocking both in the vertical and in the horizontal direction, whereby they can all be made such that they allow for a connection and disconnection as described above with regard to
(82) The invention is by no means limited to the above-described embodiments represented in the accompanying drawings; on the contrary, such a floor covering can be made in different shapes and dimensions while still remaining within the scope of the invention.