Glue-Down Decorative Floor Covering System

Abstract

The invention relates to a glue-down decorative floor covering system. The invention also relates to a glue-down floor covering realized by a plurality of tiles of the glue-down floor covering system according to the invention. The invention further relates to a tile for use in a glue-down floor covering system according to the invention.

Claims

1. A glue-down decorative floor covering system, comprising: a plurality of interlockable decorative flexible floor tiles, wherein each floor tile has a substrate layer and is rectangular, either oblong or square, and thus comprises a first pair of opposite edges and a second pair of opposite edges; wherein the first pair of opposite edges comprise mechanical coupling parts allowing to mutually mechanically couple a plurality of such tiles to each other, wherein said coupling parts form a first locking system which effects a locking of mutually coupled tiles in the plane of the tiles and perpendicular to the respective edges, as well as form a second locking system which effects a locking of mutually coupled tiles perpendicular to the plane of the tiles, wherein these coupling parts are realized from said substrate layer; wherein the coupling parts of the first pair of opposite edges comprise (i) at a first edge a first coupling part comprising a sideward tongue extending in a direction substantially parallel to the plane of the tile, the bottom front region of said sideward tongue at least partially being rounded or being flat, the bottom back region of said tongue being configured as bearing region, wherein the bottom back region is located closer to the level of the upper side of the tile than a lowest part of the bottom front region, and wherein the coupling parts of the first pair of opposite edges comprise (ii) at an opposite second edge a second coupling part comprising a recess for accommodating at least a part of the sideward tongue of a further tile, said recess being defined by an upper lip and a lower lip, said lower lip being provided with a upwardly protruding shoulder for supporting the bearing region of the sideward tongue, the sideward tongue being designed such that locking takes place by an introduction movement into the recess of the sideward tongue a further tile and a angling down movement about an axis parallel to the first edge, as a result of which a top side of the sideward tongue will engage the upper lip and the bearing region of the sideward tongue will be supported by and/or facing the shoulder of the lower lip, leading to interlocking of adjacent tiles at the first and second edges, wherein the bearing region is connected to a substantially vertical second end surface of the tile, in particular of the substrate layer, and wherein, in coupled condition of adjacent tiles, the first end surface faces the second end surface, such that the first end surface and the second end surface mutually enclose a lower glue chamber, and wherein the second pair of opposite edges comprises further mechanical coupling parts allowing to mutually mechanically couple a plurality of such tiles to each other, wherein these coupling parts are configured to form a first locking system which effects a locking of mutually coupled tiles in the plane of the tiles and perpendicular to the respective edges, as well as to form a second locking system which effects a locking of mutually coupled tiles perpendicular to the plane of the tiles, wherein these coupling parts of the second pair of edges are realized from said substrate layer, wherein the coupling parts of the second pair of opposite edges comprise (iii) at a third edge a lower bridge to which an upward tongue is connected, wherein the upward tongue comprises an inner side which faces an upward flank of said coupling part, wherein said inner side of the upward tongue and the upward flank enclose an upward groove, and wherein an outer side of the upward tongue is provided with a first locking element, and wherein the coupling parts of the second pair of opposite edges comprise (iv) at an opposite fourth edge an upper bridge to which a downward tongue is connected, wherein the downward tongue insertable into the upward groove of another floor tile, wherein a downward groove is enclosed by said downward tongue and a downward flank, wherein the upward tongue of another floor tile is insertable in said downward groove, wherein the downward flank is provided with a second locking element configured to co-act, in a coupled position, with the first locking element of an adjacent floor tile, and wherein, in coupled position, a gap is present in between the outer side of the upward tongue and the downward flank allowing glue to flow into said gap.

2. The floor covering system according to claim 1, wherein the coupling parts of the first pair of opposite edges are designed to snap or click together during mutual coupling.

3. The floor covering system according to claim 1, wherein at least one coupling part of the coupling parts of the first pair of opposite edges is designed to resiliently deform during mutual coupling.

4. The floor covering system according to claim 1, wherein, in coupled condition of the coupling parts, the sideward tongue and the recess mutually enclose a plurality of gaps.

5. The floor covering system according to claim 1, wherein a lower surface of the bearing region, which is configured to be supported by and/or to face the shoulder of the lower lip, is upwardly inclined in the direction of the bottom front region of the sideward tongue.

6. The floor covering system according to claim 1, wherein an upper surface of the shoulder of the lower lip is upwardly inclined in the direction of the upper lip.

7. The floor covering system according to claim 1, wherein the distance between the upper surface of the tile and a lower surface of the bearing region, which is configured to be supported by and/or to face the shoulder of the lower lip, is smaller than the distance between the upper surface of the tile and the shoulder of the lower lip.

8. The floor covering system according to claim 1, wherein, in coupled condition of adjacent tiles, the bearing region and the shoulder of the lower lip mutually enclose an upper glue chamber.

9. The floor covering system according to claim 8, wherein the upper glue chamber is connected to the lower glue chamber.

10. The floor covering system according to claim 1, wherein the lower lip is provided with a substantially vertical first end surface.

11. The floor covering system according to claim 1, wherein the bearing region is connected to a substantially vertical second end surface of the tile, in particular of the substrate layer.

12. The floor covering system according to claim 11, wherein, in coupled condition of adjacent tiles, the first end surface faces the second end surface, such that the first end surface and the second end surface mutually enclose a lower glue chamber, wherein preferably the lower glue chamber is arranged at a distance from the bottom of the tiles and/or wherein the first end surface and the second end surface are located at a distance from each other, preferably a distance of at least 0.2 mm, to allow sufficient glue to enter between the faces.

13. The floor covering system according to claim 1, wherein the first locking element is a bulge, and wherein the second locking element is a recess, wherein in coupled condition of adjacent floor tiles the first locking element is positioned at a distance from the second locking element.

14. The floor covering system according to claim 1, wherein each tile comprises at least one printed decorative layer affixed, either directly or indirectly, to an upper surface of the substrate layer, at least one wear layer affixed, either directly or indirectly, to an upper surface of the decorative layer.

15. The floor covering system according to claim 1, wherein each floor tile has a thickness of less than 4.7 mm.

16. The floor covering system according to claim 1, wherein each floor tile comprises at least one flexible substrate layer at least partially composed of polyvinyl chloride (PVC).

17. The floor covering system according to claim 1, wherein the substrate layer comprises at least one inert filler, such as calcium carbonate.

18. The glue-down floor covering realized by interlocking a plurality of tiles of the glue-down floor covering system according to claim 1.

19. The glue-down floor covering according to claim 18, wherein the floor covering is glued onto a subfloor.

20. A glue-down decorative floor covering system, comprising a plurality of interlockable decorative flexible floor tiles, wherein each floor tile is rectangular, either oblong or square, and comprises a first pair of opposite edges and a second pair of opposite edges; wherein the first pair of opposite edges comprise mechanical coupling parts allowing to mutually mechanically couple a plurality of such tiles to each other, wherein said coupling parts form a first locking system that effects a locking of mutually coupled tiles in a plane of the tiles and perpendicular to the respective edges, as well as form a second locking system that effects a locking of mutually coupled tiles perpendicular to the plane of the tiles, wherein the coupling parts substantially are realized from said substrate layer; wherein the coupling parts at said first pair of opposite edges are configured such that two of such tiles can be coupled to each other at said edges by a turning movement and/or vertical movement, and wherein the second pair of opposite edges is free of any mechanical coupling parts, wherein the second pair of opposite edges consists of a third edge and an opposite fourth edge, wherein the third edge is provided with a substantially vertical third end surface and wherein the fourth edge is provided with a substantially vertical fourth end surface, wherein, in coupled condition of adjacent tiles, a top section of the third end surface and the fourth end surface face and engage to each other, or are in contact with each other, over at least half the thickness of the tiles.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The invention will be elucidated on the basis of non-limitative exemplary embodiments shown in the following figures, wherein:

[0029] FIG. 1 shows a perspective view of a glue-down tile of a glue-down floor covering system according to the invention,

[0030] FIG. 2 a lateral cross-section of the tile according to FIG. 1,

[0031] FIG. 3 a longitudinal cross-section of the tile according to FIG. 1,

[0032] FIG. 4 a glue-down floor covering consisting of a plurality of interlocked glue-down tiles according to FIG. 1,

[0033] FIG. 5 a detailed view of a part A of the floor covering according to FIG. 4,

[0034] FIG. 6 a cross-section according to line B-B of the floor covering according to FIG. 4,

[0035] FIG. 7 a top view of a glue-down floor covering consisting of a plurality of interlocked glue-down tiles according to FIG. 1 installed according to a first installation pattern, and

[0036] FIG. 8 a top view of a glue-down floor covering consisting of a plurality of interlocked glue-down tiles according to FIG. 1 installed according to a second installation pattern, and

[0037] FIG. 9 shows a cross section of (a part of) two identical panels according to the invention, in coupled condition.

DESCRIPTION OF THE INVENTION

[0038] FIG. 1 shows a perspective view of a rectangular glue-down tile 1 of a glue-down floor covering system 2 (see FIGS. 4-8) according to the invention, FIG. 2 shows a lateral cross-section of the tile according to FIG. 1, and FIG. 3 a longitudinal cross-section of the tile according to FIG. 1. The tile 1 is mechanically interconnectable with two similar tiles for forming said covering 2. The tile 1 comprises a first pair of opposing long edges 1a, 1b, identified as the first edge 1a and the second edge 1b, and second pair of opposing short edges 1c, 1d, identified as the third edge 1c and the fourth edge 1d. The first pair of opposing edges 1a, 1b comprises complementary mechanical coupling parts 3, 4, identified as the male coupling part 3, and the female coupling part 4 to allow the tile 1 to be mechanically coupled with two other tiles 1. The second pair of opposing edges 1c, 1d is free of any mechanical coupling parts, which makes the tile 1 suitable to be mechanically coupled to two tiles only. Each edge 1a, 1b, 1c, 1d is provided with a longitudinal groove 5a, 5b, 5c, 5d extending in a direction parallel to the corresponding edge. Grooves 5a, 5b, 5c, 5d of adjacent edges 1a, 1b, 1c, 1d are mutually connect and together form a circumferential groove 5. The circumferential groove 5 is intended to receive glue during gluing down of the tile 1 onto a subfloor 6 to intensify the connection between the tile 1 and the subfloor 6 and between the tile 1 and adjacent tiles. The male coupling part 3 comprises a sideward tongue 7 which is integrally connected to a central body 8 of the tile 1. A front region 7a of the sideward tongue 7 is provided with a flat bottom surface 9. An outer end (a tip) of the front region 7a of the sideward tongue 7 is provided at an upper side with an inclined locking surface 10. A back region 7b of the sideward tongue 7 is situated in between the front region 7a and the central body and connects the front region 7a to the central body 8. An lower side of the back region 7b could be identified as a bearing surface 11. This bearing surface 11 is inclined in the direction of the front region 7a of the sideward tongue 7. The bearing surface 11 connects to a substantially vertical first end surface 12 of the central body 8. The female coupling part 4 comprises an upper lip 13 and a lower lip 14 defining a recess 15. Both lips 13, 14 are integrally connected to the central body 8. As shown in FIG. 1, the width of the upper lip 13 is substantially smaller than the width of the lower lip 14. The recess 15 has a shape which is complementary to the shape of the sideward tongue 7. More in particular, a top surface 16 of a back region 14a of the lower lip 14 has a (complementary) flat shape, configured to co-act with the flat bottom surface of the front region 7a of the sideward tongue 7, while a front region 14b of the lower lip 14 is provided with a upwardly protruding shoulder 17, configured to face the bearing surface 11 of the sideward tongue 7 of another tile, at a distance from said bearing surface 11. The space created this way, in coupled condition, is defined as upper glue chamber 21. A lower surface 18 of the upper lip 13 is inclined and corresponds to the locking surface 10 of the sideward tongue 7. A substantially vertical distal end surface 19 of the lower lip 14 is connected to a lower surface 20 of the tile 1, and in coupled condition with another tile, will face the end surface 12 of the central body 8, and will be positioned at a distance from said end surface 12 of the central body 8. The space created this way, in coupled condition, is defined as lower glue chamber 22, which is connected to the upper glue chamber 21 as visualized in more detail in FIGS. 4 and 5. In FIGS. 4-8 a floor covering system according to the invention is shown, and more in particular a floor covering realized by said floor covering system, wherein a plurality of tiles 1 are interconnected, and wherein the tiles 1 are glued down to the subfloor 6 by using solidified glue 23. As shown in FIG. 5, the glue has flown (and solidified) in the upper and lower glue chambers 21, 22. As shown in FIG. 6, the groove 5c of the third edge 1c and the groove 5d of the fourth edge 1d are facing each other and together form a (small) further glue chamber 24. To allow glue 23 to flow into this glue chamber 24 during installation, a glue inlet 25 is created at the bottom in between the tiles 1. This glue inlet 25 is actually formed by cut-away portions of the bottom parts of the third edge 1c and the fourth edge 1d. The top sections of the outer surfaces of the third edge 1c and the fourth edge 1d are typically positioned against each other, wherein (uncoupled, loose) direct contact is present between these top sections. Optionally, during installation a thin film of glue may flow in between these top sections. The aforementioned further glue chamber 24 formed in between the grooves 5c and 5d contributes to further stabilization of the floor covering once the glue has been solidified. As shown by arrow C in FIG. 4, two tiles 1 can be mechanically connected by angling down (turning down) a tile 1 be coupled while the male coupling part 3 of the tile 1 is inserted into the female coupling 4 of an already installed tile 1. During this angling down movement, wherein the coupling parts 3, 4 co-act with each other, the tile 1 to be installed will automatically be installed and aligned in a proper manner, while prevent that glue will flow in between the coupling parts 3, 4 up to the top surfaces of the tiles 1 (which would foul the tiles 1). During this angling down movement at least coupling parts 3, 4 will have to be deformed temporarily in order to be able to insert the sideward tongue 7 into the complementary recess 15. In the installed state, the coupling parts 3, 4 will normally return to their initial shape to the complementary shapes of both coupling parts 3, 4. This temporary deformation of one of more coupling parts 3, 4 will lead to a click-type or snap-type connection, whereas the male coupling part 3 will have to be clicked or snapped into the female coupling part 4. This interconnection will lead to locking of two tiles 1 in both horizontal direction and vertical direction. As shown in FIGS. 5 and 6, the tiles 1 have a layered structure, wherein a substrate layer 26 (core layer) is normally the thickest layer and comprises PVC, plasticizer, and preferably at least one filler. The plasticizer softens the PVC which typically provides the tile 1 as such a flexible character. A backing layer 27, also referred to as balancing layer is affixed to a lower side of the substrate layer 26, and typically has the function to balance the tile 1 as such. On top of the substrate layer 26 successively a decorative printed layer 28, a wear layer 29, and a UV hardened lacquer layer 30 are applied. The thickness of this panel is preferably between 2.8 and 4.7 mm. As shown in FIGS. 4 and 7 the rectangular tiles 1 can be installed in a horizontal grid, but as shown in FIG. 8 it is also imaginable to install the tiles for example in an offset or staggered brickwork pattern.

[0039] FIG. 9 shows a cross section of (a part of) two identical panels 31 according to the invention, in coupled condition. In this figure only the first pair of complementary opposite edges are shown, in particular complementary coupling parts thereof. The panels 31 are typically square or rectangular (oblong), wherein a second pair of opposite edges is preferably free of any coupling parts. The thickness of the shown panels 31 is 4.7 mm or less, and is preferably situated within the range of 3.2-3.5 mm. In this cross-section, not all panel layers are shown, but typically these panels 31 comprise a core 32 and a layer top structure, typically with a decorative character, affixed on top of said core 32. The core 32 is typically PVC based, although, alternatively, mineral based and/or wood based and/or polymer based compositions could be used to compose the core 32 A back layer affixed to a bottom side of the core 32 may also be applied. The coupling parts make integral part of said core. One of the coupling parts, which make part of the panel 31, depicted on the left-hand side, comprises a lower bridge 33 to which an upward tongue 34 is connected. The upward tongue 34 comprises an inner side 34a which faces an upward flank 32a of the first coupling part. Said inner side 34a of the upward tongue 34 and the upward flank 32a enclose an upward groove. An outer side 34b of the upward tongue 34 is provided with a locking element, such as a bulge 35. The second coupling part which is depicted makes part of the right-hand side panel 31 and comprises an upper bridge 36 to which a downward tongue 37 is connected. The lower bridge 33 and/or the upper bridge 36 is/are preferably resilient (to some extent) to facilitate coupling. The downward tongue 37 is inserted in the upward groove. The upward tongue 34 is inserted in a downward groove enclosed by said downward tongue 37 and a downward flank 32b. The downward flank 32b is provided with a second locking element, such as a recess 37 configured to co-act, in a coupled position, preferably a coupled offset position (wherein the panels are slightly tilted with respect to each other). A gap 38 is present in between the outer side 34b of the upward tongue 34 and the downward flank 32b, which allows glue to flow into said gap 38 to increase a bond between the panels 32 and a subfloor (not shown). Optionally, additional, mutually co-acting locking elements 39a, 39b, e.g. a bulge and co-acting recess, shown with dashed lines, are applied near a top seam in between the two panels 32. Various spaces are present in between the panels 32 to allow expansion of the panels, and/or to receive glue. A part of the inner side 34a of the upward tongue 34 is inclined towards the upward flank 32, and, preferably, a part of the inner side 37a of the downward tongue 37 is inclined towards the downward flank 32b, in order to realize an (additional) vertical locking effect (i.e. perpendicular to a plane defined by the panels 31). As will be evident, the shown coupling parts are configured to be coupled by means of a vertical movement, also referred to as a drop-down movement or lowering movement or drop-lock movement.

[0040] The above-described inventive concepts are illustrated by several illustrative embodiments. It is conceivable that individual inventive concepts may be applied without, in so doing, also applying other details of the described example. It is not necessary to elaborate on examples of all conceivable combinations of the above-described inventive concepts, as a person skilled in the art will understand numerous inventive concepts can be (re) combined in order to arrive at a specific application.

[0041] It will be apparent that the invention is not limited to the working examples shown and described herein, but that numerous variants are possible within the scope of the attached claims that will be obvious to a person skilled in the art.

[0042] The verb comprise and conjugations thereof used in this patent publication are understood to mean not only comprise, but are also understood to mean the phrases contain, substantially consist of, formed by and conjugations thereof.