Floor Panel and Floor

Abstract

The present invention relates to a floor panel and to a floor. The floor panel according to the invention includes a core provided with an upper and lower surface, and a first and second core flank at a first and second side of the core, respectively. The floor panel includes a first coupling part and a second coupling part provided at the first side and the second side of the core, respectively. Each of the coupling parts includes an inner side flank, an outer side flank, and an upper portion flank connecting the inner side flank to the outer side flank. According to the invention, a portion of the first core flank and an upper portion of the outer side flank of the second coupling part are inclined such that when the floor panel is coupled to an adjacently arranged further floor panel these upper portions lie against each other for the purpose of providing a locking in a vertical direction. In addition, a first upper portion flank of the tongue of the first coupling part includes a curved recess and the groove of the second coupling part may include a bulge complimentary to the curved recess.

Claims

1. A floor panel,. comprising: a core provided with an upper surface, a lower surface, a first core flank at a first side of the core, and a second core flank at a second side of the core, wherein the first core flank comprises a first core flank upper portion that connects to the upper surface; a first coupling part and a second coupling part provided at the first side and the second side of the core, respectively; wherein the first coupling part comprises: a first tongue having a first inner side flank, a first outer side flank, and a first upper portion flank connccting the first inner side flank to the first outer side flank; a first bridging part connecting the first tongue to the core; wherein the second coupling part comprises: a second tongue shaving a second inner side flank, a second outer side flank, and a second upper portion flank connecting the second inner side flank to the second outer side flank, wherein the second outer side flank comprises a second outer side flank upper portion that connects to the upper surface; a second bridging part connccting the second tongue to the core; wherein the first inner side flank, the first bridging part, and the first core flank define a first groove and wherein the second inner side flank, the second bridging part, and the second core flank define a second groove; wherein the floor panel is configured to be coupled to an adjacently arranged further floor panel that is identical to said floor panel in such a manner that the first tongue of the floor panel is received in the second groove of the adjacently arranged further floor panel and that the second tongue of the adjacently arranged further floor panel is received in the first groove of the floor panel thereby providing a first locking in a first direction substantially parallel to the upper surface; wherein at least a part of the first core flank upper portion of the first core flank and at least a part of the second outer side flank upper portion of the second outer side flank are inclined such that when the floor panel is coupled to the adjacently arranged further floor panel these upper portions lie against each other for the purpose of providing a second locking in a second direction substantially perpendicular to the upper surface; and in that the first upper portion flank of the first tongue comprises a curved recess that connects to the first inner side flank at a first angle (α) in between 90° and 150° , wherein the first inner side flank extends from the curved recess towards the first bridging part and towards the core, and wherein the second groove comprises a bulge that is shaped substantially complementarily to the curved recess and is configured such that it is received in the curved recess when the floor panel is coupled to the adjacently arranged further floor panel.

2. The floor panel according to claim 1, wherein the inclined part of the second outer side flank upper portion of the second outer side flank comprises a first outer point that is arranged farthest away from a central part of the core in the first direction, and wherein the inclined part of the first core flank upper portion of the first core flank comprises an inner point, and a second outer point that is arranged farthest away from a central part of the core in a third direction, wherein the third direction is substantially opposite to the first direction; wherein the floor panel is configured such that when the second upper portion flank of the second tongue of the adjacently arranged further floor panel is arranged in the curved recess of the floor panel prior to coupling said floor panel to said adjacently arranged further floor panel and is moved in the first direction, the first outer point of the adjacently arranged further floor panel slides underneath the second outer point of the floor panel towards the inner point of the floor panel.

3. The floor panel according to claim 2, wherein during the sliding movement of the first outer point of the adjacently arranged further floor panel towards the inner point of the floor panel, the second upper portion flank of the adjacently arranged further floor panel is guided by the first inner side flank of the floor panel, and wherein the floor panel is configured such that when the second upper portion flank of the second tongue of the adjacently arranged further floor panel is arranged in the curved recess of the floor panel just before or at the moment the second upper portion flank will be guided by the first inner side flank of the floor panel, the bulge of the adjacently arranged further floor panel is guided by the curved recess of the floor panel.

4. The floor panel according to claim 1, wherein the first inner side flank extends from the curved recess towards the first bridging part and towards the core at a second angle relative to a normal of the lower surface that is in between 0° and 45° , more preferably between 10° and 30° .

5. The floor panel according to claim 1, wherein the first outer side flank comprises a first locking element and the second core flank comprises a second locking element, wherein the first locking element and the second locking element are configured such that when the floor panel is coupled to the adjacently arranged further floor panel the first locking element of the floor panel cooperates with the second locking element of the adjacently arranged further floor panel for the purpose of providing a third locking in the second direction.

6. The floor panel according to claim 5, wherein the second locking element extends in the second direction from a second locking element start part up to a second locking element end part; wherein the second inner side flank comprises a second inner side flank end at which the second inner side flank is coupled to the second upper portion flank; wherein the second locking element end part and the second inner side flank end are at a substantially equal distance to the upper surface; and/or wherein the second core flank further comprises an inclined sub second core flank arranged in between the lower surface and the second locking element start part and extending under a fifth angle relative to a normal of the lower surface, wherein the fifth angle is in between 0° and 60° .

7. The floor panel according to claim 1, wherein the first core flank upper portion extends under a third angle relative to a normal of the lower surface and wherein the second outer side flank upper portion extends under a fourth angle relative to said normal of the lower surface, wherein both the third and fourth angles are in between 0° and 30° .

8. The floor panel according to claim 7, wherein the third angle is at least substantially equal to the fourth angle, and preferably larger than the fourth angle by an angle in between 0° and 5° .

9. The floor panel according to claim 6, wherein the third angle at least substantially equal to the second angle, and preferably larger than the second angle by an angle in between 0° and 5° .

10. The floor panel according to claim 1, wherein the lengths of the first core flank upper portion, the first inner side flank, the second inner side flank, and the second outer side flank upper portion are substantially equal.

11. The floor panel according to claim 1, wherein the first bridging part comprises at least a first bridging flank and a second bridging flank.

12. The floor panel according to claim 11, wherein the first bridging flank is coupled with the first inner side flank and the second bridging flank, and wherein the second bridging flank is coupled with the first core flank.

13. The floor panel according to claim 1, wherein the second upper portion flank comprises a first flank segment and a second flank segment, wherein the first flank segment is coupled with the second inner side flank and the second flank segment, and wherein the second flank segment is coupled with the second outer side flank.

14. The floor panel according to claim 11, wherein the first bridging flank and the first flank segment substantially flat and/or wherein the second bridging flank and the second flank segment are substantially flat.

15. The floor panel according to claim 11, wherein the first bridging flank and the first flank segment are curved and/or wherein the second bridging flank and the second flank segment are curved.

16. The floor panel according to claim 11, wherein the first bridging flank and the first flank segment are complementarily shaped and/or wherein the second bridging flank and the second flank segment are complementarily shaped.

17. The floor panel according to claim 1, wherein the curved recess occupies at most half of an entire surface of the first upper portion flank of the first upper tongue.

18. The floor panel according to claim 1, wherein the curved recess occupies at most half of an entire surface of the first upper portion flank of the first upper tongue.

19. The floor panel according to claim 18, wherein the second groove further comprises a recess and/or a substantially flat flank segment.

20. The floor panel according to claim 19, wherein the bulge and/or substantially flat flank segment of the first upper portion flank and the recess and/or substantially flat flank segment of the second groove are complementarily shaped.

21. The floor panel according to claim 1, wherein the first locking element extends in the second direction from a first locking element start part up to a second locking element end part, wherein the first outer side flank further comprises an inclined sub first outer side flank that is arranged in between the first locking element start part and the lower surface and extends under a sixth angle relative to a normal of the lower surface, wherein the sixth angle is in between 0° and 60° .

22. The floor panel according to claim 1, wherein the first core flank comprises a third locking element and wherein the second outer side flank comprises a fourth locking element, wherein the third locking element and the fourth locking element are configured such that when the floor panel is coupled to the adjacently arranged further floor panel the third locking element of the floor panel cooperates with the fourth locking element of the adjacently arranged further floor panel for the purpose of providing a fourth locking in the second direction.

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

24. A floor comprising a plurality of adjacently arranged and coupled floor panels as defined in claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Further advantages, features and details of the invention are elucidated on the basis of preferred embodiments thereof, wherein reference is made to the accompanying drawings, in which:

[0039] FIG. 1A presents a cross sectional view of a first embodiment of a floor panel in accordance with the present invention arranged next to an identical floor panel in an uncoupled state and FIGS. 1B-1D show the process of coupling these floor panels;

[0040] FIGS. 2A and 2B illustrate a second embodiment of a floor panel in accordance with the present invention in an uncoupled and coupled state, respectively;

[0041] FIGS. 3A and 3B illustrate a third embodiment of a floor panel in accordance with the present invention in an uncoupled and coupled state, respectively;

[0042] FIGS. 4A and 4B illustrate a fourth embodiment of a floor panel in accordance with the present invention in an uncoupled and coupled state, respectively;

[0043] FIGS. 5A and 5B illustrate a fifth embodiment of a floor panel in accordance with the present invention in an uncoupled and coupled state, respectively;

[0044] FIGS. 6A and 6B illustrate a sixth embodiment of a floor panel in accordance with the present invention in an uncoupled and coupled state, respectively; and

[0045] FIG. 7 illustrates a floor in accordance with the invention.

DESCRIPTION OF THE INVENTION

[0046] FIG. 1 illustrates two identical floor panels 2 arranged side by side. In this manner, both sides of a single panel can be illustrates in detail. Moreover, both floor panels will be referred to using the same reference number 2.

[0047] Floor panel 2 comprises a core 4, a first coupling part 20 and a second coupling part 22, wherein first coupling part 20 is provided at a first side 12 of core 4 and wherein second coupling part 22 is provided at a second side 16 of core 4.

[0048] Core 4 of floor panel 2 comprises an upper surface 6, a lower surface 8, a first core flank 10 at first side 12 of core 4, and a second core flank 14 at second side 16 of core 4. First core flank 10 comprises a first core flank upper portion 18 that connects to upper surface 6. Furthermore, first coupling part 20 of floor panel 2 comprises a first tongue 24 and a first bridging part 32, wherein first tongue 24 has a first inner side flank 26, a first outer side flank 28, and a first upper portion flank 30 connecting first inner side flank 26 to first outer side flank 28. First bridging part 32 connects first tongue 24 to core 4.

[0049] Second coupling part 22 of floor panel 2 comprises a second tongue 34 and a second bridging part 44, wherein second tongue 34 has a second inner side flank 36, a second outer side flank 38, and a second upper portion flank 40 connecting second inner side flank 36 to second outer side flank 38. Second outer side flank 38 comprises a second outer side flank upper portion 42 that connects to upper surface 6. Furthermore, second bridging part 44 connects second tongue 34 to core 4.

[0050] Typically, lower surface 8 and upper surface 6 are substantially flat surfaces. Moreover, upper surface 6 may be provided with decorations that are protected by a protective layer. Floor panel 2 may be arranged on an underlay instead of being arranged on a subfloor directly. Such underlay may improve the thermal insulation of the floor and/or may improve sound isolation.

[0051] In the illustrated embodiment, first upper portion flank 30 is curved. Furthermore, second core flank 14 comprises an inclined sub second core flank 80 that extends from second core flank 14 towards lower surface 8 at a fourth angle δ relative to a normal N1 of lower surface 8, wherein the fourth angle is between 0° and 60° . Similarly, first outer side flank 28 comprises an inclined sub first outer side flank 82 that extends from first outer side flank 28 towards lower surface 8 at a fifth angle ε relative to normal N1, wherein the fifth angle is between 0° and 60° .

[0052] First bridging part 32 comprises a first bridging flank 72 and a second bridging flank 74. Second upper portion flank 40 comprises a first flank segment 76 and a second flank segment 78. First flank segment 76 is coupled with second inner side flank 36 and second flank segment 78, whereas second flank segment 78 is coupled with second outer side flank 38.

[0053] In the illustrated embodiment, first inner side flank 26, first bridging part 32, and first core flank 10 define a first groove 46 and second inner side flank 36, second bridging part 44, and second core flank 14 define a second groove 48. Floor panel 2 is configured to be coupled to an adjacently arranged identical further floor panel in such a manner that first tongue 24 of floor panel 2 is received in second groove 48 of the adjacently arranged further floor panel and that second tongue 34 of the adjacently arranged further floor panel is received in first groove 46 of the floor panel thereby providing a first locking in first direction 50 substantially parallel to upper surface 6. As shown, at least a part of first core flank upper portion 18 of first core flank 10 and at least a part of second outer side flank upper portion 42 of second outer side flank 38 are inclined such that when floor panel 2 is coupled to the adjacently arranged further floor panel, upper portions 18 and 42 lie against each other for the purpose of providing a second locking in a second direction 51 substantially perpendicular to the upper surface;

[0054] In order to couple and lock first coupling part 20 and second coupling part 22, first upper portion flank 30 comprises a curved recess 52 that connects to first inner side flank 26 at a first angle a in between 90° and 150° . First inner side flank 26 extends from curved recess 52 towards first bridging part 32 and towards core 4. Second groove 48 comprises a bulge 54 that is shaped substantially complementarily to curved recess 52 and that is configured such that it is received in curved recess 52 when floor panel 2 is coupled to the adjacently arranged further floor panel. It should be noted that bulge 54 may be omitted or may be shaped to be not or not fully complementary to curved recess 52.

[0055] In the illustrated embodiment of floor panel 2, the inclined part of second outer side flank upper portion 42 of second outer side flank 38 comprises a first outer point 56 that is arranged farthest away from a central part of core 4 in first direction 50. The inclined part of first core flank upper portion 18 of first core flank 10 comprises a second outer point 58 that is arranged farthest away from a central part of core 4 in a third direction 60 that is substantially opposite to first direction 50. The inclined part may further comprise an inner point 62 that generally corresponds to that part of the inclined part that is arranged closest to a central part of core 4 when viewed along first direction 50.

[0056] First core flank upper portion 18 extends under a third angle γ1 relative to normal N1 of lower surface 8 and second outer side flank upper portion 42 extends under a fourth angle γ2 relative to normal N1 of the lower surface 8. Both these angles (γ1, γ2) are in between 0° and 30° .

[0057] However, it is preferred that third angle γ1 is at least substantially equal to fourth angle γ2, and is preferably larger than fourth angle γ2 by an angle in between 0° and 5° . In this manner, a clamping action will occur when the adjacently arranged further floor panel 2 is coupled to floor panel 2.

[0058] In floor panel 2 of FIG. 1, first inner side flank 26 extends from curved recess 52 towards first bridging part 32 and towards core 4 at a second angle β relative to normal N1 of lower surface 8 that is between 0° and 30° . It is preferred that third angle γ1 is at least substantially equal to second angle β, and preferably larger than the second angle β by an angle in between 0° and 5° .

[0059] To facilitate the abovementioned clamping action, it is preferred that at least part of coupling parts 20, 22 is resilient and/or deformable. For example, first bridging part 32 may be configured to deform slightly to allow first tongue 30 to move away from core 4 to allow second tongue 40 to be inserted into first groove 46.

[0060] First outer side flank 28 comprises a first locking element 64 and second core flank 14 comprises a second locking element 66. Locking elements 64, 66 are configured such that when floor panel 2 is coupled to adjacently arranged further floor panel 2, first locking element 64 of floor panel 2 cooperates with second locking element 66 of adjacently arranged further floor panel 2 for the purpose of providing a third locking in second direction 51.

[0061] Furthermore, floor panel 2 is configured such that when second upper portion flank 40 of the second tongue 34 of adjacently arranged further floor panel 2 is arranged in curved recess 52 of the floor panel 2 prior to coupling floor panel 2 to adjacently arranged further floor panel 2 and is moved in first direction 50, first outer point 56 of adjacently arranged further floor panel 2 slides underneath the second outer point 58 of floor panel 2 towards inner point 62 of floor panel 2. This is illustrated in FIGS. 1B-1D. As illustrated, first outer point 56 is guided by first core flank upper portion 18 during the final stage of coupling floor panel 2 to further floor panel 2.

[0062] First locking element 64 extends in second direction 51 from a first locking element start part 63 up to a second locking element end part 65. Similarly, second locking element 66 extends in second direction 51 from a second locking element start part 71 up to a second locking element end part 70. Second inner side flank 36 comprises a second inner side flank end 68 at which second inner side flank 36 is coupled to second upper portion flank 40.

[0063] Second locking element end part 70 and second inner side flank end 68 are preferably at a substantially equal distance to upper surface 6.

[0064] As shown in FIG. 1C, during the abovementioned sliding movement, second inner side flank 36 is guided by first inner side flank 26. Moreover, prior to pushing further floor panel 2 downward to enable it to be coupled to floor panel 2, second inner side flank end 68 rests on curved recess 52. This is illustrated in FIG. 1C. This resting position can be identified by the user as he will notice a slight vertical drop when aligning floor panel 2 and further floor panel 2. At this moment, first outer point 56 is or has already moved underneath second outer point 58. Consequently, when the user uses increased force, for example to enable the clamping action, damage to points 56, 58 can be avoided. Hence, the present invention allows delicate structures of floor panel 2, such as points 56, 58, to be protected during the final stages of floor panel coupling.

[0065] FIG. 2A illustrates a further embodiment of a floor panel 90 in accordance with the present invention, and FIG. 2B illustrates how floor panel 90 can be coupled to an identical further floor panel 90. In this alternative embodiment, first inner side flank 26 is configured at an angle η, wherein angle η is between 90° and 120° . In this embodiment angle θ is 90° and angle θ is complement to angle η. In other embodiments, angle θ is larger than second angle η by an angle in between 0° and 5° . Also in this manner, a clamping action can be obtained.

[0066] First inner side flank 26 is connected to curved recess 52 by curved recess end 92. The illustrative embodiment shows that curved recess end 92 can be slightly curved. Bulge end 94 may have a shape that is complementary to the shape of curved recess end 92.

[0067] FIG. 3A illustrates a floor panel 106 in which second groove 48 comprises a curved portion 110. Furthermore, first upper portion flank 30 comprises a flat flank 108 that is coupled to curved recess 52 and first outer side flank 28. In the coupled state, shown in FIG. 3B, a space 114 can be identified between curved portion 110 and flat flank 108. Space 114 could for example be used to collect debris that would otherwise disturb the coupling between floor panels 2. However, as shown in FIGS. 4A and 4B that illustrate a further embodiment of a floor panel 116, curved portion 110 can be replaced by a flat flank 118 such that a space between flat flanks 118, 108 cannot or hardly be identified when the floor panels 2 are coupled.

[0068] In some cases, a reduced vertical locking would suffice. In such cases, first core flank upper portion 18 and second outer side flank upper portion 42 can be configured substantially parallel to normal N1 as with floor panel 122 shown in FIGS. 5A and 5B. Such embodiment would still benefit from the improved manner in which the floor panels can be aligned prior to providing the relatively strong force to allow the panel to be coupled.

[0069] To improve vertical locking, first core flank 10 may comprise a recess 124, wherein recess 124 is preferably a curved recess. Furthermore, second outer side flank 38 may comprise a bulge 126, wherein bulge 126 and recess 124 are complementary with each other. Recess 124 and bulge 126 are examples of cooperating locking elements. The skilled person will readily understand that other locking elements are equally possible.

[0070] FIG. 6A illustrates a floor panel 130 in which second upper portion flank 40 comprises a first flank segment 132 and a second flank segment 134, wherein first flank segment 132 is substantially parallel to upper surface 6 and second flank segment 134 is substantially flat and configured at an angle compared to flank segment 132. Furthermore, first bridging part 32 comprises a first bridging flank 72 and a second bridging flank 74, wherein first bridging flank 72 is substantially parallel to lower surface 8 and second bridging flank 74 is substantially flat and configured at an angle compared to first bridging flank 72. In the coupled state, shown in FIG. 6B, it can be seen that at least a part of first bridging flank 72, second bridge flank 74 and second flank segment 134 define a space 138 that could for example be used to collect debris that would otherwise disturb the coupling between floor panels 2.

[0071] FIG. 7 illustrates a floor 152 comprising coupled identical floor panels 154, 164, 166, 168, 170, 172, 174, 176, wherein each of said floor panels comprises four sides. Each short side 156, 158 is coupled to a short side of an adjacent panel, whereas each long side 160, 162 is coupled to the long sides of two adjacent panels. The coupling between shorts sides and/or the coupling between long sides can be obtained using the first coupling part and second coupling part as described above.

[0072] The present invention has been described using detailed embodiments thereof. However, the skilled person will readily understand that the present invention is not limited to these embodiments and that various modifications can be made without departing from the scope of the invention, which is limited by the appended claims and their equivalents.