FLOOR SYSTEM, A COUPLING INSERT AND A FLOOR COVERING COMPRISING SUCH A FLOOR SYSTEM
20250327312 ยท 2025-10-23
Inventors
Cpc classification
E04F15/02005
FIXED CONSTRUCTIONS
E04F2203/065
FIXED CONSTRUCTIONS
E04F2201/05
FIXED CONSTRUCTIONS
International classification
E04F15/02
FIXED CONSTRUCTIONS
Abstract
A floor system comprising a floor element, wherein said floor element comprises a top layer, preferably comprising a ceramic tile, and a support layer, wherein said support layer comprises edges provided with coupling elements, wherein the system comprises at least one coupling insert adapted to interact with one coupling element of the floor element.
Claims
1. A floor system comprising a floor element, wherein said floor element comprises a top layer, preferably comprising a ceramic tile, and a support layer, wherein said support layer comprises edges provided with coupling elements, wherein the system comprises at least one coupling insert adapted to interact with one coupling element of the floor element.
2. The floor system according to claim 1, wherein said coupling elements are the same on opposite edges of the support layer, and preferably on all the edges of the support layer.
3. The floor system according to claim 1, wherein the coupling elements are configured such that in a coupling condition with the coupling insert, relative movement between the coupling insert and the floor element in one or more vertical and/or horizontal direction is limited or prevented.
4. The floor system according to claim 1, wherein the coupling elements are disposed partially, preferably entirely, below said top layer.
5. The floor system according to claim 1, wherein said coupling element partially or entirely extend beyond a respective edge of the top layer.
6. The floor system according to claim 1, wherein the coupling element is present substantially continuously along the entire length of the respective edge.
7. The floor system according to claim 1, wherein said coupling elements are at least in part, preferably integrally, formed in support layer.
8. The floor system according to claim 7, wherein the coupling elements are milled in the support layer.
9. The floor system according to claim 1, wherein the coupling insert is adapted to interact with two or more floor elements, for example three floor elements or four floor elements.
10. The floor system according to claim 1, wherein the coupling insert comprises a central portion and two or more lateral portions extending laterally from said central portion wherein at least said lateral portions are adapted to interact with respective coupling elements of the floor elements.
11. The floor system according to claim 1, wherein said coupling insert is adapted to interact with a corner area of the floor elements.
12. The floor system according to claim 11, wherein the coupling insert is adapted to couple with two coupling elements on two different, preferably consecutive, edges of one floor element.
13. The floor system according to claim 9, wherein said coupling insert is, in a top view,; T-shaped or Y-shaped, for coupling together three floor elements; or -cross-shaped, for coupling together four floor elements.
14. The floor system according to claim 9, comprising multiple coupling inserts of different types.
15. The floor system according to claim 10, wherein said central portion is adapted, in an installed floor, to stay in between two or more floor elements so that its width can determine, or at least contribute to determine, a distance between the top layers of said floor elements.
16. The floor system according to claim 1, wherein said coupling insert comprises first and/or second contact surfaces adapted to contact respective first and/or second contact surfaces of the coupling elements.
17. The floor system according to claim 10, wherein one lateral portion is formed by an upper and/or a lower lip having one or more humps or protrusion adapted and to interact with respective recesses in the coupling elements of the support layer to define contact surfaces thereby defining contact surfaces that limit relative movement between the coupling insert and the floor element in one or more vertical and/or horizontal direction.
18. The floor system according to claim 1, wherein the support layer is in the form of a panel, or a board, attached, for example laminated, to a lower surface of the top layer.
19. A floor element comprising a top layer, preferably made of a ceramic material, and a support layer, wherein said support layer comprises edges provided with coupling elements adapted for being coupled with a coupling insert, wherein said coupling elements are the same on opposite edges of the support layer, more preferably on all the edges of the support layer.
20. A floor covering comprising a plurality of floor elements wherein the floor element comprising a top layer, preferably made of a ceramic material, and a support layer, wherein said support layer comprises edges provided with coupling elements; and a plurality or coupling inserts, wherein each of said coupling inserts is mechanically coupled with at least coupling element of at least two of said floor elements and comprising an adhesive material, preferably a grout, at least partially filling a space between the top layers of the floor elements.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0076] With the intention of better showing the characteristics of the invention, in the following, as an example without any limitative character, several preferred forms of embodiments are described with reference to the accompanying drawings, wherein
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DETAILED DESCRIPTION OF THE INVENTION
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[0085] As illustrated in
[0086] In the example, the top layer 5 is a ceramic tile and the support layer 6 is made of PVC, more particularly rigid PVC or PVC having 5 phr of plasticizer or less. The support layer further comprises calcium carbonate and form a so-called SPC.
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[0088] In accordance with the sixth independent aspect, a clearance 9 is available between adjacent edges 10-11 of support layers 6 of said floor elements 2. In the example of
[0089] Said gap 3 between the adjacent edges 7-8 of said top layers 5 and at least a part of said clearance 9 form a single void between said floor elements 2, in the absence of extraneous matter such as adhesive or an insert. In the case of the embodiment illustrated in
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[0092] Since the smallest width W9 of said clearance 9 is smaller than the width W3 of said gap 3, the insert 16 can be introduced through said gap 3 into said clearance 9 under the condition that the clearance 9 is at least partly available vertically below said gape between adjacent edges 7-8 of top layers 5, before said grout 4 is provided in the gap 3.
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[0096] In the examples of
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[0108] As shown, the coupling insert 17 further comprises means 41,42 for tightening said mechanical joining system 38, more particularly said second portion 37. In this example said means 41,42 comprise a knob 41 for turning a screw 42 that presses on the second portion 37. In this case the knob 41 extends above the horizontal plane defined by the floor covering 1, i.e. above the upper surface of the top layers 5.
[0109] By turning the knob 41 over the screw 42 the second portion 37 can be pressed down and its hooks 39 can engage with undercuts 40 located further down until the support layer 6 hinders further downward movement of said second portion 37. As the first portion 36 is placed below the edges 10-11 of said support layer 6, in this configuration the extending portions 10-11 of the support layer 6 are clamped between said first and second portion 36, 37 so that two couple of first contact surfaces 22 limiting the movement in opposite vertical directions. The screw 42 rotates over a threaded portion 43 of an upward directed stem 44 connected to the first portion 36 passing through an opening 26 in the second portion 37.
[0110] In the example, said means 41,42 are connected to said first portion 36 over a weakened material portion 45, for example in said upward directed stem 44. The weakened material portion 45 is available at a location below the horizontal plane defined by the floor covering, i.e. below the upper surface of the top layers 5. The weakened material portion 45 allows for easily removing the means 41, 42 for example with the blow of a hammer. After removal of these means 41,42 from the installed floor elements the gap 3 between the edges 7-8 of the top layers 5 can be filled with grout 4.
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[0114] It is remarked that, as illustrated in some of the figures, it is possible that an underlayment 50 is installed between the support layer 6 and the subfloor 51.
[0115] The present invention is in no way limited to the hereinabove described embodiments, but such floor system may be realized according to different variants without leaving the scope of the present invention.
[0116] Further, as is clear from the content of the description, the present invention relates to one or more of the items as listed below. [0117] 1. A floor system comprising a floor element 2, wherein said floor element 2 comprises a top layer 5, preferably comprising a ceramic tile, and a support layer 6, wherein said support layer 6 comprises edges 10-11 provided with coupling elements 18, wherein the system comprises at least one coupling insert 17 adapted to interact with one coupling element 18 of the floor element 2. [0118] 2. The floor system according to item 1, wherein said coupling elements 18 can be the same on opposite edges 10-11 of the support layer 6, and preferably on all the edges 10-11 of the support layer 6. [0119] 3. The floor system according to item 1 or 2, wherein the coupling elements 18 can be configured such that in a coupling condition with the coupling insert 17, relative movement between the coupling insert 17 and the floor element 2 in one or more vertical direction V and/or horizontal direction H is limited or prevented. [0120] 4. The floor system according to item 3, wherein said coupling elements 18 can comprise one or more first contact surfaces adapted to contact respective first contact surfaces of the insert to thereby preventing or limiting said movement in one or more vertical directions. [0121] 5. The floor system according to item 3 or 4, wherein said coupling elements can comprise one or more second contact surfaces adapted to contact respective second contact surfaces of the insert to thereby preventing or limiting said movement in one or more horizontal directions. [0122] 6. The floor system according to any of the preceding items, wherein a preferred embodiment of the invention, the coupling elements 18 are disposed partially, preferably entirely, below said top layer 5. [0123] 7. The floor system according to any items from 1 to 5, wherein said coupling elements 18 can partially or entirely extend beyond a respective edge 7-8 of the top layer 5. [0124] 8. The floor system according to any of the preceding items, wherein the coupling elements 18 are configured to allow coupling with the coupling insert 17 in an angling, horizontal and/or vertical movement. [0125] 9. The floor system according to any of the preceding items, wherein the coupling elements 18 can be present substantially continuously along the entire length of the respective edge 10,11 of the support layer 6. [0126] 10. The floor system according to any of the preceding items, wherein said coupling elements 18 are at least in part, preferably integrally, formed in the support layer 6. [0127] 11. The floor system according to item 10, wherein the coupling elements 18 are milled in the support layer 6. [0128] 12. The floor system according to any of the preceding items, wherein the coupling insert 17 can be adapted to interact with two or more floor elements 2, for example three floor elements 2 or four floor elements 2. [0129] 13. The floor system according to item 13, wherein the coupling insert can comprise a central portion and two or more lateral portions extending laterally from said central portion wherein at least said lateral portions are adapted to interact with respective coupling elements of the floor elements. [0130] 14. The floor system according to any of the preceding items, wherein said coupling insert 17 is adapted to interact with a corner area of the floor elements 2. [0131] 15. The floor system according to item 14, wherein the coupling insert 17 is adapted to interact with one coupling element 18 in an area at an extreme of the respective edge 10-11 of the support layer 6. [0132] 16. The floor system according to item 14 or 15, wherein the coupling insert 17 is adapted to couple with two coupling elements 18 on two different, preferably consecutive, edges 10-11 of one floor element 2. [0133] 17.The floor system according to any of the preceding items, wherein said coupling insert 17 is, in a top view, be T-shaped or Y-shaped, for coupling together three floor elements 2, for example the coupling insert 17 comprises three lateral portions 25 extend laterally from said central portion 24. [0134] 18. The floor system according to any of the items from 1 to 16, wherein said coupling insert 17 is, in a top view, cross-shaped, for coupling together four floor elements, for example the coupling insert 17 comprises four lateral portions 25 extend laterally from said central portion 25. [0135] 19. The floor system according to any of the preceding items, comprising multiple coupling inserts 17 of different types. [0136] 20. The floor system according to any of the items from 13 to 19, wherein said central portion 25 of the coupling item 17 can be formed by a body that extends substantially vertically from the lateral portions 25. [0137] 21. The floor system according to item, wherein said central portion 24 of the coupling insert 17 is adapted, in an installed floor covering 1, to stay in between two or more floor elements 2 so that its width W24 can determine, or at least contribute to determine, a gap 3 between the top layers 5 of said floor elements 2. [0138] 22. The floor system according to any of the preceding items, wherein said coupling insert 17 comprises first and/or second contact surfaces 22, 30 adapted to contact respective first and/or second contact surfaces 22, 30 of the coupling elements 18. [0139] 23. The floor system according to any of the items from 13 to 21 and item 22, wherein said first and/or second locking 22, 30 surfaces are formed in said lateral portion 25 and/or said central portion 24 of the coupling insert 17. [0140] 24. The floor system according to item 23, the coupling insert 17 can comprise one or more humps or protrusion 29, for example located in the lateral portion 25, adapted to define said contact surface 22, 30 and to interact with respective recesses 28 in the coupling elements 18 (or vice versa, coupling insert 17 can have one or more recesses 28 adapted to define said contact surface 22, 30 and to interact with respective humps or protrusion 29 in the coupling elements 18). [0141] 25. The floor system according to any of the preceding items, wherein the coupling insert 17 can be made of a material that is different from the material forming the support layer and/or the top layer. [0142] 26. The floor system according to any of the preceding items, wherein the coupling insert 17 can be mead of a material being more elastic (for example, having a lower Modulus of Young and/or a higher elongation at break under tension) than the material forming the support layer 6 and/or the top layer 5. [0143] 27. The floor system according to any of the preceding items, wherein the coupling insert 17 is made of a thermoplastic material, for example PE (poly ethylene), PP (poly propylene), PVC (poly vinyl chloride), PET (poly ethylene terephthalate). [0144] 28. The floor system according to any of the items from 1 to 28, wherein the coupling insert 18 is made of metal, for example steel or aluminum. [0145] 29. The floor system according to any of the items from 1 to 28, wherein the coupling insert 17 is made in a single body or in multiple separate bodies 36, 37. [0146] 30. The floor system according to any of the preceding items, wherein said floor elements 2 and/or said coupling insert 17 can comprise cavities, openings and/or hollow portions 26 adapted for being partially filled with an adhesive material, for example a grout 4, for example filling a gap 3 between the top layers 5 of two floor elements 2 in a floor covering 1. [0147] 31. The floor system according to any of the preceding items, wherein the support layer 6 is in the form of a panel, or a board, attached, for example laminated, to a lower surface of the top layer 5. [0148] 32. The floor system according to any of the preceding items, wherein said support layer 6 can be made of thermoplastic material, for example PE (poly ethylene), PP (poly propylene), PVC (poly vinyl chloride), PET (poly ethylene terephthalate). [0149] 33. The floor system according to any of the preceding items, wherein the top layer 5 of the floor element 2 is made of a ceramic tile, more preferably of the kind having a ceramic body and one or more glaze coating covering the upper surface of the tile. [0150] 34. The floor system according to any of the preceding items, wherein the floor element 2 comprises an intermediate layer between the top layer 5 and the support layer 6. [0151] 35. The floor system according to any of the preceding items, wherein intermediate layer comprises a resin material bonding together the top layer 5 and the support layer 6. [0152] 36. A floor element 2 comprising a top layer 5, preferably made of a ceramic material, and a support layer 6, wherein said support layer 6 comprises edges 10-11 provided with coupling elements 18 adapted for being coupled with a coupling insert 17, wherein said coupling elements 18 are the same on opposite edges 11-11 of the support layer 6, more preferably on all the edges 11-11 of the support layer 6. [0153] 37. A coupling insert 17 for installing floor elements 2 in a floor covering 1, configured for coupling with coupling element 18 of the floor element 2 for limiting movement in a vertical and/or horizontal direction of said coupling insert 17, for example comprising contact surfaces 22-30 adapted to cooperate with contact surfaces 22-30 of the coupling element 18 of the floor element 2, wherein the coupling inserts 17 comprises one or more of the following characteristics: [0154] the coupling insert 17 comprises a central portion 24 and one or more lateral portions 25, wherein said contact surfaces 22-30 are formed by one or more hump 29 and/or one or more recess 28 in said lateral portion 24 and/or central portion 25; and/or [0155] the coupling insert 17 is adapted to couple together two or more floor elements 2 together, preferably three or four floor elements 2; and/or [0156] said contact surfaces 22-30 are adapted to prevent movements in vertical and/or horizontal direction; and/or [0157] said coupling insert 17 is made in a single piece or in two or more separate pieces 36,37; and/or [0158] said coupling insert 17 comprises a lower portion 36 and a separate upper portion 37, wherein the lower portion 36 and the upper portion 37 are preferably connected over a tightened or tightenable mechanical joining system 38. [0159] 38. A floor covering 1 comprising a plurality of floor elements 2 wherein the floor element comprising a top layer 5, preferably made of a ceramic material, and a support layer 6, wherein said support layer 6 comprises edges 10-11 provided with coupling elements 18; and a plurality or coupling inserts 17, wherein each of said coupling inserts is mechanically coupled with at least coupling element of at least two of said floor elements. [0160] 39. The floor covering 1 according to item 38, wherein the floor element 2 and/or the coupling insert 17 are according to any of items from 1 to 37. [0161] 40. The floor covering according to item 38 or 39, comprising an adhesive material, preferably a grout 4, at least partially filling a gap 3 between the top layers 5 of the floor elements 2. [0162] 41. The floor covering according to item 38, 39 or 40, comprising an underlayer 50 between said floor elements 2 and a floor basement 51 to be covered, said underlayer 50 can be a sound insulating mat, a moisture insulating mat or a heat insulator. [0163] 42. A floor covering 1 comprising a plurality of floor elements 2, wherein the floor elements comprise a top layer 5, preferably made of a ceramic material, and a support layer 6, wherein said floor covering further comprises an adhesive material, preferably a grout 6, at least partially filling a gap 3 between adjacent edges 7-8 of top layers 5 of said floor elements 2, wherein at said gap 3 a clearance 9 is available between adjacent edges 10-11 of support layers 6 of said floor elements 2. [0164] 43. The floor covering 1 of item 42, wherein said clearance 9 is continuous over the entire thickness T2 of said adjacent edges 10-11 of support layers 6. [0165] 44. The floor covering 1 of item 42 or 43, wherein said adhesive material 4 fills said clearance 9 at least partially, preferably wholly. [0166] 45. The floor covering of any of items 42 to 44, wherein vertical and/or horizontal movement of said adjacent edges 10-11 of support layers 6 and/or top layers 5 is limited at least by means of a coupling insert 17 cooperating with said adjacent edges of support layers and/or top layers. [0167] 46. The floor covering 1 of any of items 42 to 45, wherein at least one of said adjacent edges of said support layers 6 and/or top layers 5 is profiled. [0168] 47. The floor covering of any of items 42 to 46, wherein at least one of said adjacent edges of said support layers 6 and/or top layers 5 defines a groove or an undercut. [0169] 48. A floor covering 1 comprising a plurality of floor elements 2, wherein the floor elements 2 comprise a top layer 5, preferably made of a ceramic material, and a support layer 6, wherein said floor covering 1 further comprises an adhesive material, preferably a grout 6, at least partially filling a gap 3 between adjacent edges 7-8 of top layers 5 of said floor elements 2, wherein vertical and/or horizontal movement of adjacent edges of support layers 6 of said floor elements 2 is limited at least by means of a coupling insert 17 cooperating with at least one, preferably with both, of said adjacent edges of said support layers 6 and/or said top layers 5. [0170] 49. The floor covering 1 of item 48, wherein at least one of said adjacent edges of said support layers 6 and/or top layers 5 is profiled. [0171] 50. The floor covering 1 of item 48 or 49, wherein at least one of said adjacent edges of said support layers 6 and/or top layers 5 defines at least a groove 19 and/or at least an undercut, and in that said coupling insert 17 cooperates at least with said groove 19 and/or said undercut. [0172] 51. The floor covering 1 of item 50, wherein said groove 19 is bordered by an upper lip and a lower lip, wherein an upper surface of said lower lip is formed in said support layer 6. [0173] 52. The floor covering 1 of item 51, wherein a bottom surface of said upper lip is formed by means of the bottom of said top layer 5, or, alternatively, is formed in said support layer 6. [0174] 53. The floor covering 1 of any of items 50 to 52, wherein said undercut is formed at the bottom of said support layer 6. [0175] 54. The floor covering 1 of any of items 48 to 53, wherein said coupling insert 17 is configured to be brought into engagement with at least one of said adjacent edges 10-11 by means of a substantially horizontal movement or a downward movement of said coupling insert 17 towards the respective edge. [0176] 55. The floor covering 1 of any of items 48 to 54, wherein said coupling insert 17 comprises one or more openings 26 filled with said adhesive material. [0177] 56. The floor covering 1 of any of items 48 to 55, wherein said coupling insert 17 comprises abutting surfaces in contact with said adjacent edges. [0178] 57. The floor covering 1 of any of items 48 to 56, wherein said floor elements 2 are installed in a checkerboard pattern, i.e. in parallel rows without offset between adjacent tiles, and in that said coupling insert 17 is at least available at the position where corners of four floor elements 2 are adjacent to each other. [0179] 58. The floor covering 1 of any of items 48 to 57, wherein said coupling insert 17 comprises a lower portion 36 and a separate upper portion 37, wherein the lower portion 36 and the upper portion 37 are preferably connected over a tightened or tightenable mechanical joining system 38. [0180] 59. The floor covering 1 of item 58, wherein said mechanical joining system 38 comprises a screw connection and/or a snapping connection, preferably comprising one or more hooks and undercuts, for example a linear ratchet. [0181] 60. A floor system comprising a floor element 2, wherein said floor element 2 comprises a top layer 5, preferably comprising a ceramic tile, and a support layer 6, wherein said support layer 6 comprises edges 10-11 provided with coupling elements 18, wherein the system comprises at least one coupling insert 17 adapted to interact with one coupling element 18 of the floor element 2, wherein said coupling insert 17 comprises a lower portion 36 and a separate upper portion 37, [0182] 61. The floor system of item 60, wherein the lower portion 36 and the upper portion 37 are connected over a tightened or tightenable mechanical joining system 38. [0183] 62. The floor system of item 61, wherein said mechanical joining system 38 comprises a screw connection and/or a snapping connection, preferably comprising one or more hooks and undercuts, for example a linear ratchet. [0184] 63. The floor system of item 61 or 62, wherein said coupling insert comprises a means for tightening said mechanical joining system, wherein said means preferably extends above the horizontal plane defined by the floor covering. [0185] 64. The floor system of item 63, wherein said means is connected to said first and/or second portion over a weakened material portion. [0186] 65. The floor system of item 64, wherein such weakened material portion is available below the horizontal plane defined by the floor covering. [0187] 66. The floor system according to any of item from 63 to 65, wherein said means may be formed as a knob, or a nut, such as a butterfly nut.