Floor Panel for Producing a Covering

Abstract

A floor panel includes male and female coupling means that are formed by at least one proximal groove that opens onto a lower face or upper face, respectively, of the panel and by a distal flexible tongue that extends from the end of the edge of the panel towards the lower face or upper face, respectively. The tongue has a proximal wall inclined at an angle with respect to a vertical plane towards the bottom and the outside of the panel and towards the top and the outside of the panel, respectively. The tongue of at least one of the male coupling means or female coupling means has a distal wall that includes, at least, a protrusion or a notch that is able to engage with a notch or a protrusion formed in or on a proximal wall of the proximal groove of the corresponding female coupling means or male coupling means so as to form an end stop, avoiding vertical movement of a panel with respect to an adjacent panel. The flexible tongue of the female coupling means comprises a chamfered part that forms an angle of between 2° and 20° with respect to the main plane of the panel.

Claims

1. Male-female coupling means for a floor panel having the form of a plank and/or tile and being made of a plastic material for producing a floor covering or similar, comprising: the male coupling means being formed of at least one so-called proximal groove intended to open onto a lower face of the panel and of a flexible distal tongue intended to extend from one end of one edge of the panel towards the lower face of said panel, the female coupling means are formed of at least one proximal groove intended to open onto an upper face of the panel and of a flexible tongue intended to extend from one end of an opposite edge of the panel, towards the upper face of said panel, the deformable flexible distal tongue of the male coupling means has a proximal wall inclined at an angle β with respect to a vertical plane towards the bottom and towards the outside, the flexible tongue of the female coupling means has a proximal wall inclined at an angle α with respect to a vertical plane towards the top and towards the outside, the distal tongue of at least one of the male coupling means or female coupling means has a distal wall comprising, at least, a protrusion or a notch that is able to engage with a notch or a protrusion formed in or on a proximal wall of the proximal groove of the corresponding female coupling means or male coupling means of an adjacent panel so as to form an end stop, avoiding vertical movement of the panel with respect to an adjacent panel, wherein the flexible tongue of the female coupling means comprises a chamfered part intended to form an angle of between 2° and 20° with respect to the main plane of the panel, wherein said chamfered part gives rise to a reduction in the clipping force and to a deformation of the flexible tongue such that it is easier to assemble two adjacent panels.

2. The male-female coupling means according to claim 1, wherein the distal walls of the deformable flexible tongues of the male coupling means and female coupling means comprise, respectively, a protrusion and a notch that are able to engage with a notch and a protrusion, respectively, formed in or on the proximal walls of the proximal grooves of the corresponding female coupling means and male coupling means so as to form an end stop, avoiding vertical movement of a panel with respect to an adjacent panel.

3. The male-female coupling means according to claim 1, wherein the angles α and β are between 1° and 45°, and preferably between 5° and 15°.

4. The male-female coupling means according to claim 3, wherein angle α is equal to angle β.

5. The male-female coupling means according to claim 1, wherein the proximal walls of the proximal grooves of the male coupling means and female coupling means are respectively inclined at an angle of between 1° and 45°, and preferably between 5° and 15° with respect to a vertical plane.

6. The male-female coupling means according to claim 1, wherein the deformable flexible distal tongue and the proximal groove of the male coupling means, and the deformable flexible tongue and the proximal groove of the female coupling means are inclined towards the outside of the panel.

7. The male-female coupling means according to claim 6, wherein the distal walls and proximal walls of the deformable flexible tongues of the male coupling means and female coupling means are parallel and inclined, respectively, at an angle β and an angle α with respect to a vertical plane, and the proximal walls of the proximal grooves of the male coupling means and female coupling means are parallel to the proximal walls, respectively, of the deformable flexible tongues of the male coupling means and female coupling means.

8. The male-female coupling means according to claim 1, wherein the chamfered part forms an angle of 10° with respect to the main plane of the panel.

9. A floor panel having the form of a plank and/or tile and being made of a plastic material for producing a floor covering or similar, said panel comprising at least two pairs of opposing sides defining two adjacent edges comprising male coupling means and two opposing adjacent edges comprising female coupling means, the kinematic assembly of two adjacent panels being vertical, wherein the male-female coupling means comprise: the male coupling means being formed of at least one so-called proximal groove intended to open onto a lower face of the panel and of a flexible distal tongue intended to extend from one end of one edge of the panel towards the lower face of said panel, the female coupling means are formed of at least one proximal groove intended to open onto an upper face of the panel and of a flexible tongue intended to extend from one end of an opposite edge of the panel, towards the upper face of said panel, the deformable flexible distal tongue of the male coupling means has a proximal wall inclined at an angle β with respect to a vertical plane towards the bottom and towards the outside, the flexible tongue of the female coupling means has a proximal wall inclined at an angle α with respect to a vertical plane towards the top and towards the outside, the distal tongue of at least one of the male coupling means or female coupling means has a distal wall comprising, at least, a protrusion or a notch that is able to engage with a notch or a protrusion formed in or on a proximal wall of the proximal groove of the corresponding female coupling means or male coupling means of an adjacent panel so as to form an end stop, avoiding vertical movement of the panel with respect to an adjacent panel, wherein the flexible tongue of the female coupling means comprises a chamfered part intended to form an angle of between 2° and 20° with respect to the main plane of the panel, wherein said chamfered part gives rise to a reduction in the clipping force and to a deformation of the flexible tongue such that it is easier to assemble two adjacent panels.

10. The floor panel according to claim 9, wherein the lower face of the floor panel comprises a chamfered part that opens onto the proximal groove, and forms an angle of between 2° and 20° with respect to the main plane of the panel, said chamfered part allowing for the lowering of the panel when clipping, in order to come into contact, by deformation, with the floor and thus promote the viability of said clipping.

11. The floor panel according to claim 10, wherein the chamfered part forms an angle of 10° with respect to the main plane of the panel.

Description

BRIEF DESCRIPTION OF FIGURES

[0033] Further advantages and features will become clearer from the following description of several alternative embodiments, given by way of non-limiting examples, of a floor panel, with reference to the accompanying drawings wherein:

[0034] FIG. 1 is a schematic view of two adjacent panels,

[0035] FIG. 2 is a partial cross-sectional view of an embodiment of the male coupling means and of the female coupling means of two panels, before clipping,

[0036] FIG. 3 is a view corresponding to FIG. 2 showing the pre-clipping of the panels,

[0037] FIG. 4 is a view corresponding to FIG. 2 during clipping of the panels,

[0038] FIG. 5 is a view corresponding to FIG. 2 in the clipped position of the panels,

[0039] FIG. 6 is a cross-sectional view of a further embodiment of the male coupling means and of the female coupling means of two panels, the panels being shown before clipping,

[0040] FIG. 7 is a view corresponding to FIG. 6 showing the pre-clipping of the panels,

[0041] FIG. 8 is a view corresponding to FIG. 6 during clipping of the panels,

[0042] FIG. 9 is a view corresponding to FIG. 6, the panels being shown in the clipped position,

[0043] FIG. 10 is a cross-sectional view of a further embodiment of the male coupling means and of the female coupling means of two panels in the case of panels of small thicknesses, the panels being shown before clipping,

[0044] FIG. 11 is a view corresponding to FIG. 10 showing the pre-clipping of the panels,

[0045] FIG. 12 is a view corresponding to FIG. 10 during clipping of the panels,

[0046] FIG. 13 is a view corresponding to FIG. 10 in the clipped position of the panels,

[0047] FIG. 14 is a cross-sectional view of an embodiment of the male coupling means and of the female coupling means of two panels, showing the protrusion arranged only on the female coupling means and the notch arranged only in the male coupling means,

[0048] FIG. 15 is a cross-sectional view similar to that of FIG. 14, this time showing the protrusion arranged only on the male coupling means, and the notch arranged only in the female coupling means,

[0049] FIG. 16 is a graph showing the difference between the clipping forces for the same version of coupling means, with and without the chamfered part on the lower part of said coupling means,

[0050] FIG. 17 is a graph showing the reduction in clipping force,

[0051] FIG. 18 is a graph showing the increase in unclipping force.

DETAILED DESCRIPTION

[0052] In the continuation of the description of the floor panel, the same reference numbers designate the same items. Furthermore, the views are not necessarily drawn to scale. In addition, the floor panels described below are preferably made of plasticized PVC and contain an inorganic filler; however, it is clear that the floor panels may be obtained of any plastic material.

[0053] Each floor panel (1) comprises two pairs of opposing sides defining the edges of the panel. Two adjacent edges comprise male coupling means (2) while adjacent two opposing edges comprise female coupling means (3). The kinematic assembly of two panels (1) is vertical according to a force (F). Said male coupling means (2) are formed of at least one so-called proximal groove (4) opening onto a lower face of the panel (1) and of a distal tongue (5) extending from the end of the edge of the panel (1) towards the lower face of said panel (1). The distal tongue (5) has a substantially rectangular cross-section. Said female coupling means (3) are formed of at least one proximal groove (6) of a substantially rectangular cross section, opening onto an upper face of the panel (1) and of a deformable flexible tongue (7) extending from the end of the edge of the panel (1), towards the upper face of said panel (1). The deformable flexible tongue (7) has a proximal wall inclined towards the top and towards the outside of the panel (1) at an angle (α) with respect to the vertical plane, such that the distal tongue (5) of the male coupling means (2) is introduced into the proximal groove (6) of the female coupling means (3) at an angle, by bearing against the deformable flexible tongue (7) which deforms in order to allow for the introduction of the distal tongue (5) into the proximal groove (6). The distal tongue (5) also deforms when introduced into the proximal groove (6).

[0054] The proximal wall of the deformable flexible tongue (7) is inclined towards the top and towards the outside of the panel (1) at an angle (α) of between 1° and 45° with respect to the vertical, and preferably at an angle (α) of between 5° and 15° with respect to the vertical. Moreover, the proximal groove (4) of the male coupling means (2) has a proximal wall inclined towards the bottom and towards the outside of the panel (1) at an angle (β) with respect to the vertical plane of said panel (1). Said angle (β) is between 1° and 45° and preferably between 5° and 15°. In this particular embodiment, angle (α) is substantially equal to angle (β). It is clear that angle (α) can be different from angle (β) without departing from the scope of the present disclosure.

[0055] Furthermore, the distal tongue (5) of the male coupling means (2) has a distal wall comprising at least one protrusion (11) that is able to engage with a notch (12) formed in a proximal wall of the proximal groove (6) so as to form an end stop, avoiding vertical movement of a panel (1) with respect to an adjacent panel.

[0056] According to the disclosed embodiments, and for example with reference to FIG. 9, the deformable flexible tongue (7) has a lower wall comprising a chamfered part (13) that forms an angle of between 2° and 20°, and preferably 10° with respect to the main plane of the panel (1). This chamfered part (13) gives rise to a reduction in the clipping force such that it is easier to assemble two adjacent panels. Accordingly, with reference to FIG. 16, it should be noted that the clipping force of the floor panel is significantly less than the clipping force of a floor panel with no chamfered part. This chamfered part (13) limits the clipping forces and allows for a design that is more suited to the protrusion (11). This range of values for the angle of the chamfered part (13) makes it possible to implement a material recess over substantially the entire width of the deformable flexible tongue (7). Thus, before clipping together two adjacent panels, the chamfered part (13) of the deformable flexible tongue (7) is not in contact with the floor such that, during clipping, the tongue (7) pivots until the chamfered part (13) comes to rest on the floor thus limiting those forces that oppose clipping. In this way, it is easier to assemble two adjacent panels, and the risks of damaging the protrusion (11) are reduced.

[0057] According to the embodiment shown in FIGS. 2 to 5, the deformable flexible tongue (7) has a distal wall comprising two parts, namely, an upper part inclined with respect to the vertical at an angle of between 1° and 45°, and preferably between 1° and 20° and a lower part extending vertically. The proximal wall of the proximal groove (4) also comprises two parts, namely, an upper part inclined with respect to the vertical at an angle of between 1° and 45°, and preferably between 1° and 20° in order to improve unclipping, and a lower part extending vertically, in order to improve clipping.

[0058] According to the embodiment shown in FIGS. 6 to 9, the lower face of the floor panel (1) may also comprise a chamfered part (14) that opens onto the proximal groove (4) and forms an angle of between 2° and 20°, ideally 10° with respect to the main plane of the panel (1). This chamfered part (14) allows for the lowering of the panel (1) when clipping, in order to come into contact, by deformation, with the floor and thus promote the viability of said clipping,

[0059] In this embodiment, the distal wall of the deformable flexible tongue (7) also comprises an upper part inclined at an angle of between 1° and 20° with respect to the vertical and a lower part that is also inclined at an angle of between 1° and 20° with respect to the vertical. The upper and lower parts extend parallel on either side of a notch (15). The proximal wall of the proximal groove (4) also comprises two parts, an upper part inclined at an angle of between 1° and 20° with respect to the vertical, and a lower part that is inclined at an angle of between 1° and 20° with respect to the vertical. The upper and lower parts extend parallel on either side of a shoulder forming a protrusion (16) that is able to engage with the notch (15), in order to improve clipping.

[0060] It should be noted that the clipping force of the floor panels is slightly less than the clipping force of floors panels of the prior art during the first millimeters of engagement of the male and female parts, and that the unclipping force is clearly greater than that of the panels of the prior art.

[0061] Moreover, it will be observed that the orientation at an angle of between 1° and 45°, and preferably between 5° and 15° with respect to the vertical of the proximal walls of the tongues (5, 7) of the male coupling means (2) and the female coupling means (3) provides an opening for the male coupling means (2) and the female coupling means (3) during clipping such that the protrusion (11) does not rub against the proximal groove (6) thus safeguarding the protrusion (11) and reducing the clipping forces. Moreover, this orientation at an angle of between 1° and 45°, and preferably between 5° and 15° with respect to the vertical of the proximal walls of the tongues (5, 7) of the male coupling means (2) and the female coupling means (3) makes it possible to transfer the shear force of the protrusion to torsion/compression forces in all the profiles of the male parts (2) and female parts (3), thus increasing the unclipping forces.

[0062] Advantageously, the deformable flexible distal tongue (5) and the proximal groove (4) of the male coupling means (2), and the deformable flexible tongue (7) and the proximal groove (6) of the female coupling means (3) are inclined towards the outside of the panel (1). In other words, the deformable flexible distal tongues (5, 7) comprise distal walls that are substantially parallel to their proximal walls and that are notably inclined, respectively, at an angle (β, α) with respect to a vertical plane towards the outside of the panel. In the same way, the proximal grooves (4, 6) comprise proximal walls that are substantially parallel to the proximal walls, respectively, of the deformable flexible tongues (5, 7).

[0063] In this way, the inclinations promote the deformation of the deformable flexible distal tongue (5) of the male coupling means (2) and of the deformable flexible tongue (7) of the female coupling means (3), limiting, during vertical clipping, the friction of the protrusion (11) of the male coupling means (2) against the proximal wall of the proximal groove (6) of the female coupling means (3) and the friction of the protrusion (16) of the male coupling means (2) against the distal wall of the tongue (7) of the female coupling means (3) thus making it possible to have better sized protrusions, in order to safeguard said protrusions against friction, and therefore to reduce the clipping forces, as shown in FIG. 17.

[0064] In addition, said inclinations promote, during unclipping, the transfer of shear forces imposed upon the protrusions to torsion/compression forces in all the profiles of the male parts (2) and female parts (3), thus increasing the unclipping forces, as illustrated in FIG. 18.

[0065] The alternative embodiment in reference to FIGS. 10 to 13 is particularly intended for floor panels of small thicknesses. As already indicated, each floor panel (1) comprises two pairs of opposing sides defining the edges of the panel, two adjacent edges comprising male coupling means (2) and two opposing adjacent edges comprising female coupling means (3). Said male coupling means (2) are formed of at least one so-called proximal groove (4) opening onto the lower face of the panel (1) and of a distal tongue (5) extending from the end of the edge of the panel (1) towards the lower face of said panel (1). The distal tongue (5) has a substantially rectangular cross-section. Said female coupling means (3) are formed of at least one proximal groove (6) of a substantially rectangular cross section, opening onto the upper face of the panel (1) and of a deformable flexible tongue (7) extending from the end of the edge of the panel (1), towards the upper face of said panel (1). The proximal wall of the deformable flexible tongue (7) extends at an angle of between 1° and 45°, and preferably between 5° and 15° with respect to the vertical, towards the top and towards the outside of the panel (1). Furthermore, the proximal wall of the deformable flexible tongue (5) of the male coupling means (2) also extends at an angle of between 1° and 45°, and preferably between 5° and 15° with respect to the vertical, towards the bottom and towards the outside of the panel (1).

[0066] In the same way as for the embodiment shown in FIG. 6, the distal wall of the distal tongue (5) of the male coupling means (2) comprises a protrusion (11) that is able to engage with a notch (12) formed in the proximal wall of the proximal groove (6) in order to form an end stop, avoiding vertical movement of a panel (1) relative to an adjacent panel (1).

[0067] Similarly, as already indicated, the bottom wall of the deformable flexible tongue (7) comprises a chamfered part (13) which gives rise to a reduction in the clipping force such that it is easier to assemble two adjacent panels.

[0068] The distal wall of the deformable flexible groove (7) comprises two parts, an upper part inclined at an angle of between 1° and 20° with respect to the vertical, and a lower part that is also inclined at an angle of between 1° and 20° with respect to the vertical. The upper and lower parts extend parallel on either side of a notch (15). The proximal wall of the proximal groove (4) also comprises two parts, an upper part inclined at an angle of between 1° and 20° with respect to the vertical, and a lower part that is inclined at an angle of between 1° and 20° with respect to the vertical. Said upper and lower parts extend parallel on either side of a shoulder forming a protrusion (16) that is able to engage with the notch (15), in order to improve clipping.

[0069] Lastly, it is clear that the examples that have just been given are only specific illustrations and by no means limiting as concerns the scope of the claims.

[0070] For example, and in reference to FIGS. 14 and 15 it is clear that the protrusion (11, 16) and the notch (12, 15) can be provided only on one of the coupling means (2, 3), or on both without departing from the scope of the contemplated embodiments.

[0071] The advantages clearly emerge from the description, and in particular, it should particularly be pointed out and recalled that:

[0072] the clipping action has vertical kinematics but the fact that the proximal walls of the deformable flexible tongues are oriented makes it possible to limit the clipping forces and to promote the transfer of force for the unclipping action,

[0073] the orientation causes the clipping to be opened such that the protrusion of the tongue does not rub during descent, safeguarding said protrusion and reducing the clipping forces,

[0074] the lower chamfered part on the lower profile limits the clipping forces and allows for better sizing of the protrusion,

[0075] the chamfered part on the upper profile makes it possible to descend lower during clipping and therefore, to promote the clipping viability.

[0076] The features of the contemplated embodiments give rise to the following technical effects and results:

[0077] When a vertical force is applied in order to assemble two panels (1) together, the deformable flexible distal tongue (5) of the male coupling means (2) comes into contact with the deformable flexible tongue (7) of the female coupling means (3); this contact causes deformation of the deformable flexible distal tongue (5) of the male coupling means (2) as well as deformation of the deformable flexible tongue (7) of the female coupling means (3); this deformation allows for the introduction of the deformable flexible distal tongue (5) of the male coupling means (2) into the proximal groove (6) of the female coupling means (3) and the introduction of the deformable flexible tongue (7) of the female coupling means (3) into the proximal groove (4) of the male coupling means (2).

[0078] When no more vertical force is applied, the deformable flexible distal tongue (5) of the male coupling means (2) resumes its original form thus allowing the protrusion (11) of the male coupling means (2) to engage with the notch (12) of the female coupling means (3), and the deformable flexible tongue (7) of the female coupling means (3) resumes its original form thus allowing the protrusion (16) of the male coupling means (2) to engage with the notch (15) of the female coupling means (3).

[0079] When a force is applied in order to disassemble two panels (1), the engagement of the protrusion (11) of the male coupling means (2) with the notch (12) of the female coupling means (3) and that of the protrusion (16) of the male coupling means (2) with the notch (15) of the female coupling means (3) gives rise to a shear force between the protrusion (11) of the male coupling means (2) and the notch (12) of the female coupling means (3) and between the protrusion (16) of the male coupling means (2) and the notch (15) of the female coupling means (3). The shear force between the protrusion (11) of the male coupling means (2) and the notch (12) of the female coupling means (3) gives rise to deformation of the deformable flexible distal tongue (5) of the male coupling means (2); the shear force between the protrusion (16) of the male coupling means (2) and the notch (15) of the female coupling means (3) gives rise to deformation of the deformable flexible tongue (7) of the female coupling means (3). The combined deformation of the deformable flexible distal tongue (5) of the male coupling means (2) and of the deformable flexible tongue (7) of the female coupling means (3) gives rise to leading/wedging contact between the deformable flexible distal tongue (5) of the male coupling means (2) and the deformable flexible tongue (7) of the female coupling means (3). This leading contact makes it possible to transfer the shear force between the protrusion (11) of the male coupling means (2) and the notch (12) of the female coupling means (3), as well as the shear force between the protrusion (16) of the male coupling means (2) and the notch (15) of the female coupling means (3) to torsion/compression forces in all the profiles of the male parts (2) and female parts (3), thus increasing the unclipping forces.