Floor panel for forming a floor covering

Patent metadata

Field	Value
Publication number	US-10060140-B2
Application number	US-201515110268-A
Country	US
Kind code	B2
Filing date	Jan 9, 2015
Priority date	Jan 9, 2014
Publication date	Aug 28, 2018
Grant date	Aug 28, 2018

Abstract

A floor panel for forming a floor covering wherein the floor panel is substantially realized on the basis of synthetic material. The floor panel is rectangular and comprises a first pair of opposite edges and a second pair of opposite edges such that both pairs of opposite edges comprise coupling parts allowing for mutually coupling a plurality of such floor panels to each other. The coupling parts of at least the first pair of opposite edges are configured such that two of such panels can be coupled to each other at these edges by means of a turning movement and the coupling parts to this aim consist of a tongue and a groove as well as locking parts, which, in the coupled condition, prevent the shifting apart of tongue and groove. The floor panel has a global thickness which is smaller than or equal to 4.5 millimeters.

First claim

The invention claimed is:

1. A floor panel for forming a floor covering,
wherein the floor panel comprises a substrate based on a synthetic material formed as one or more base layers;
wherein the floor panel is of the supple type and is rectangular, either oblong or square, and thus comprises a first pair of opposite edges and a second pair of opposite edges;
wherein both pairs of opposite edges comprise coupling parts which allow mutually coupling a plurality of such floor panels to each other;
wherein said coupling parts, on both pairs of edges, form a first locking system which, in a coupled condition of two of such floor panels, effects a locking in the plane of the floor panels and perpendicular to the respective edges, as well as form a second locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels;
wherein these coupling parts on the first pair of opposite edges substantially are formed of the material of the floor panel itself and in said substrate;
wherein the coupling parts of at least the first pair of opposite edges are configured such that two of such panels can be coupled to each other at these edges by means of a turning movement, and to this aim these coupling parts on the first pair of opposite edges consist of a tongue and a groove as well as of locking parts which, in the coupled condition, prevent the shifting apart of the tongue and groove;
wherein, on the first pair of opposite edges, the groove is bordered by a lower lip having an upper side and an upper lip, of which the lower lip extends laterally to beyond the most distal end of the upper lip;
wherein the floor panel has a global thickness (T) which is smaller than or equal to 4.5 millimeters;
wherein the locking parts of the first pair of opposite edges have a locking distance (A) which is greater than 0.6 times the value of the overall thickness (T) of the floor panel, the locking distance (A) being formed by the horizontal distance between a vertical closing plane (S) of two coupled floor panels and a vertical plane (VS) through the middle of the zone over which the locking surfaces of the locking parts, in coupled condition, make contact with each other, as measured in horizontal direction, and the closing plane (S) being defined as a vertical plane through the most distal end of the upper lip;
wherein the upper side of the lower lip at the height of said closing plane, in the coupled condition of two of such panels, is located on a level (N 1 ) which is situated higher than a level (N 2 ) which is determined by a lowermost point of the locking part located on the underside of the tongue, wherein the height difference between the two levels (N 1 and N 2 ) is at least 0.05 times the overall thickness (T);
wherein, seen in a cross section perpendicular to coupled edges of said first pairs of edges, the tongue has a tongue portion extending from the closing plane to the tip of the tongue, said tongue portion having an underside, wherein the underside of said tongue portion defines one or more portions that, from a proximal position to a distal position, are upwardly inclined, wherein seen in said cross section said one or more portions define a majority of said underside of said tongue portion; and
wherein in the coupled condition of two of such floor panels, a space is present on the aforementioned first pair of edges underneath the tongue, which space extends from the tip of the tongue at least to beyond a vertical center plane (M) through the zone over which the contact between the upper side of the tongue and the underside of the upper lip extends.

2. The floor panel of claim 1 , wherein the floor panel substantially is composed of a soft thermoplastic material, or that at least one or more base layers of the floor panel consist of such a material.

3. The floor panel of claim 1 , wherein the floor panel includes polyvinyl chloride, soft polyvinyl chloride, or at least one or more base layers which include polyvinyl chloride or soft polyvinyl chloride.

4. The floor panel of claim 1 , wherein the floor panel is a vinyl panel.

5. The floor panel of claim 1 , wherein the floor panel or one or more base layers of the floor panel are formed of polyurethane or polypropylene.

6. The floor panel of claim 1 , wherein the substrate, in one or more base layers thereof, comprises plasticizers.

7. The floor panel of claim 1 , wherein the substrate, in one or more layers thereof, is provided with one or more fillers.

8. The floor panel of claim 1 , wherein it is provided with at least one reinforcement layer of glass fiber.

9. The floor panel of claim 1 , wherein the floor panel comprises a locking groove and that the floor panel, at the location of the locking groove, has a minimum thickness which is greater than 0.4 times the overall thickness of the floor panel.

10. The floor panel of claim 1 , wherein on the first pair of opposite edges, an underside of the upper lip is provided with a contact surface for an upper side of the tongue and that the contact surface is horizontal or alternatively runs slightly inclined at an angle with a plane in which the floor panel extends, wherein the angle is less than 7 degrees.

11. The floor panel of claim 1 , wherein on the first pair of edges locking surfaces are formed which, in coupled condition, define a tangent line which extends at an angle of more than 50 degrees and still better more than 60 degrees to the horizontal.

12. The floor panel of claim 1 , wherein the first pair of opposite edges is configured such that, when two of such floor panels are coupled to each other, a contact, herein below named first contact (C 1 ), is present between the underside of the tongue and the upper side of the lower lip, wherein a contact point or contact zone defined by such first contact (C 1 ), seen in cross-section, is situated entirely within two planes (V 1 and V 2 ) which are located parallel to the closing plane (S), this respectively on both sides of the closing plane, each time one millimeter or half a millimeter remote from the closing plane (S), such that the first contact (C 1 ) is locally present between said planes (V 1 and V 2 ) and thus does not continue beyond these borders.

13. The floor panel of claim 1 , wherein in the coupled condition of two of such panels, on said first pair of edges, a first space is present underneath the tongue, the first space extending from the tip of the tongue at least to beyond a vertical center plane (M) through the zone over which the contact between the upper side of the tongue and the underside of the upper lip extends;
wherein the first space ends at a contact, herein after named first contact (C 1 ), formed by a contact point or a contact zone, between the underside of the tongue and the upper side of the lower lip;
wherein the first contact (C 1 ), in distal direction of the groove, ends at a second space, wherein the transition, in respect to the groove side, is situated proximally to a theoretical vertical plane (V 3 ), which, in respect to the groove side, is situated distally at a distance (E) from the closing plane (S) of the floor panel, which distance is smaller than 0.5 times the overall thickness (T) or smaller than 0.25 times the overall thickness (T); and
wherein the closing plane is defined as being a vertical plane through the most distal end of the upper lip.

14. The floor panel of claim 12 , wherein the respective coupling means are configured such that in coupled condition there is a second contact (C 2 ) which, in respect to the groove side, is located proximally from the locking surf

Assignees

• Flooring Ind Ltd Sarl

Inventors

• Cappelle Mark
• Devos Pieter

Classifications

• E04F15/02038 Primary

  characterised by tongue and groove connections between neighbouring flooring elements · CPC title

• E04F2201/0153

  by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement · CPC title

• E04F15/102

  of fibrous or chipped materials, e.g. bonded with synthetic resins · CPC title

• E04F15/105

  of organic plastics with or without reinforcements or filling materials · CPC title

• E04F15/107

  composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04) · CPC title