Floor panel for forming a floor covering

Patent metadata

Field	Value
Publication number	US-10072428-B2
Application number	US-201615543746-A
Country	US
Kind code	B2
Filing date	Jan 13, 2016
Priority date	Jan 15, 2015
Publication date	Sep 11, 2018
Grant date	Sep 11, 2018

Abstract

A floor panel for forming a floor covering comprises a substrate consisting of at least two substrate layers differing in density and, on at least one pair of opposite edges, is provided with coupling parts of the so-called push-lock type. Vertically active locking surfaces, where they cooperate in the coupled condition of two of such floor panels, define a tangent line which is horizontal or does not deviate more than 50 degrees from the horizontal. The locking surfaces are situated closer to the upper side of the first substrate layer than to the lower side of the first substrate layer.

First claim

The invention claimed is:

1. A floor panel for forming a floor covering, wherein said floor panel comprises:
a composed substrate;
wherein said floor panel comprises coupling parts on at least two opposite edges, which coupling parts allow that said floor panel can be coupled to another of said floor panel by means of a downward movement of said floor panel in respect to the other floor panel;
wherein these coupling parts, in the coupled condition of two of such floor panels, form a first locking system which effects a locking in a first direction in a plane of the floor panels and perpendicular to said edges, as well as form a second locking system which effects a locking in a second direction transverse to the plane of the floor panels;
wherein the first locking system is formed at least of an upward-directed lower hook-shaped part which is situated on one of said two opposite edges, as well as a downward-directed upper hook-shaped part which is situated on the other, opposite edge of said two opposite edges, the upward-directed lower hook-shaped part and the downward-directed upper hook-shaped part being configured to be engaged behind each other by means of said downward movement;
wherein the lower hook-shaped part includes a lip with an upward-directed locking element, whereas the upper hook-shaped part includes a lip with a downward-directed locking element;
wherein the second locking system comprises locking parts, which respectively are situated in the proximity of the proximal extremity of the lower hook-shaped part and the distal extremity of the upper hook-shaped part;
wherein said composed substrate includes at least of two substrate layers, including a synthetic material-based first substrate layer and a second substrate layer situated directly there above, which second substrate layer has a thickness of at least 0.5 mm;
wherein the first substrate layer constitutes more than half of the thickness of the floor panel;
wherein the first substrate layer is foamed and is of the closed cell-type and of a hard foam-type, and the second substrate layer is not foamed or is less foamed than the first substrate layer;
wherein the first substrate layer comprises polyvinyl chloride and is of a rigid type and thus comprises no plasticizers or plasticizers in an amount of less than 20 phr;
wherein the second substrate layer comprises polyvinyl chloride and plasticizers in an amount of more than 15 phr;
wherein said locking parts are provided with locking surfaces that are configured to cooperate in the coupled condition of two of such floor panels and that define a tangent line which is horizontal or does not deviate more than 50 degrees from the horizontal; and
wherein said locking surfaces are situated closer to the upper side of the first substrate layer than to the lower side of the first substrate layer, irrespective whether these are situated in or not in said second substrate layer.

2. The floor panel of claim 1 , wherein said first substrate layer comprises at least a thermoplastic material.

3. The floor panel of claim 1 , wherein said first substrate layer is a filled synthetic material composite
that includes one or more of bamboo, cork, and wood.

4. The floor panel of claim 3 , wherein said filled synthetic material composite includes one or more of bamboo, cork, and wood in the form of fiber or dust, or both fiber and dust.

5. The floor panel of claim 3 , wherein said first substrate layer is foamed.

6. The floor panel of claim 5 , wherein said first substrate layer is of the closed cell-type.

7. The floor panel of claim 1 , wherein said first substrate layer comprises a filler.

8. The floor panel of claim 7 , wherein said filler of said first substrate layer includes chalk or limestone, or both chalk and limestone.

9. The floor panel of claim 7 , wherein said filler of said second substrate layer includes chalk or limestone, or both chalk and limestone.

10. The floor panel of claim 1 , wherein said first substrate layer has a thickness of at least 3 mm.

11. The floor panel of claim 1 , wherein said second substrate layer comprises at least a thermoplastic material, which is of the soft type.

12. The floor panel of claim 1 , wherein said second substrate layer comprises a filler.

13. The floor panel of claim 1 , wherein the floor panel comprises a top layer, which comprises one or a combination of the following characteristics:
the top layer comprises at least a decorative layer, in the form of a print, and provided on a foil or film;
the top layer comprises at least a translucent or transparent wear layer.

14. The floor panel of claim 1 , wherein said coupling parts substantially are realized in the material of the floor panel itself.

15. The floor panel of claim 14 , wherein said coupling parts substantially are realized in said composed substrate.

16. The floor panel of claim 15 , wherein said coupling parts substantially are realized entirely in one piece of said composed substrate.

17. The floor panel of claim 1 , wherein the floor panel is rectangular, either oblong or square,
wherein said two opposite edges form a first pair of opposite edges and apart therefrom the floor panel comprises a second pair of opposite edges;
wherein the second pair of opposite edges also comprises coupling parts, which coupling parts allow a locking in a first direction perpendicular to the respective edges and in the plane of the floor panel, as well as in a second direction perpendicular to the plane of the floor panel.

18. The floor panel of claim 17 , wherein the coupling parts on the second pair of opposite edges are configured such that two of such floor panels can be coupled at this second pair of opposite edges by means of a turning movement of one floor panel in respect to the other floor panel, in such a manner that a plurality of such floor panels can be coupled by means of a “fold-down” technique.

19. A floor panel for forming a floor covering, wherein this floor panel comprises a composed substrate;
wherein said floor panel comprises coupling parts on at least two opposite edges, which coupling parts allow that said floor panel can be coupled to another of said floor panel by means of a downward movement of said floor panel in respect to the other floor panel;
wherein these coupling parts, in the coupled condition of two of such floor panels, form a first locking system which effects a locking in a first direction in a plane of the floor panels and perpendicular to said edges, as well as form a second locking system which effects a locking in a second direction transverse to the plane of the floor panels;
wherein the first locking system is formed at least of an upward-directed lower hook-shaped part which is situated on one of said two opposite edges, as well as a downward-directed upper hook-shaped part which is situated on the other, opposite edge of said two opposite edges, the upward-directed lower hook-shaped part and the downward-directed upper hook-shaped part being configured to be engaged behind each other by means of said downward movement;
wherein the lower hook-shaped part includes a lip with an upward-directed locking element, whereas the upper hook-shaped part includes a lip with a downward-directed locking element;
wherein the second locking system comprises locking parts, which respectively are situated in the proximity of the proximal extremity of the lower hook-shaped part and the distal extremity of the upper hook-shaped part;
wherein said composed substrate includes at least of two sub

Assignees

• Flooring Ind Ltd Sarl

Inventors

• Devos Pieter

Classifications

• E04F2201/0146

  with snap action of the edge connectors · CPC title

• B32B2471/00

  Floor coverings (B32B2419/04 takes precedence) · 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

• E04F15/105 Primary

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

• E04F2201/045

  wherein the elements are made of wood · CPC title