Floor panel for forming a floor covering

Patent metadata

Field	Value
Publication number	US-10309113-B2
Application number	US-201615543908-A
Country	US
Kind code	B2
Filing date	Jan 13, 2016
Priority date	Jan 16, 2015
Publication date	Jun 4, 2019
Grant date	Jun 4, 2019

Abstract

Floor panel for forming a floor covering, wherein this floor panel is at least composed of a substrate; wherein the floor panel, on at least one pair of opposite edges, comprises coupling parts, which coupling parts allow that two of such floor panels can be coupled to each other by means of a downward movement of one 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 perpendicular to the plane of the floor panels, and form a second locking system, which effects a locking in a second direction perpendicular to the edges and in the plane of the floor panels.

First claim

The invention claimed is:

1. A floor panel for forming a floor covering in a plane, wherein this floor panel is at least composed of a substrate;
wherein the floor panel comprises coupling parts on at least one pair of opposite edges, said coupling parts allowing that two of such floor panels can be coupled to each other by means of a downward movement of one floor panel in respect to the other floor panel;
wherein these coupling parts, in the coupled condition of said two of such floor panels, form a first locking system which effects a locking in a first direction perpendicular to the plane of the floor panels, and form a second locking system which effects a locking in a second direction perpendicular to the edges and in the plane of the floor panels;
wherein said coupling parts substantially are formed of the material of said substrate and are realized in one piece therewith;
wherein the second locking system includes hook-shaped parts including at least a downward-directed upper hook-shaped part situated on a first edge of said pair of opposite edges, and an upward-directed lower hook-shaped part situated on a second edge of said pair of opposite edges, the second edge being opposite from the first edge of said pair of opposite edges, said hook-shaped parts being configured to be engaged behind each other by means of said downward movement when coupling said two of such floor panels;
wherein said upper hook-shaped part consists of a lip with a downward-directed locking element, whereas said lower hook-shaped part consists of a lip with an upward-directed locking element;
wherein said first locking system comprises locking parts in the form of one or more protrusions, which, in the coupled condition of said two of such floor panels, respectively cooperate with one or more undercuts, said one or more protrusions being situated in the proximity of the distal extremity of the upper hook-shaped part and said one or more undercuts being situated in the proximity of the proximal extremity of the lower hook-shaped part;
wherein said lip of the upper hook-shaped part is provided with a support surface with which this upper hook-shaped part, in the coupled condition of said two of such floor panels, rests on the lip of the lower hook-shaped part;
wherein said lip of the upper hook-shaped part is provided with an upward-directed recess in which said upward-directed locking element, in the coupled condition of said two of such floor panels, is situated at least partially;
wherein said support surface is situated closer to the distal extremity of the upper hook-shaped part than said downward-directed locking element which in its turn is situated closer to said distal extremity than said upward-directed recess;
wherein the most upward-situated point of the upward-directed recess is situated higher than said support surface, which in its turn is situated higher than the most downward-situated point of said downward-directed locking element;
wherein the distal extremity of at least one of said one or more protrusions is situated farther distal than a vertical closing surface which is formed between said two of such floor panels in the coupled condition;
wherein said downward movement seen in a cross-section is substantially parallel to a plane of the vertical closing surface; and
wherein the distance between an upper side of the floor panel and the most downward-situated point of said downward-directed locking element is at least 1.1 times larger than the distance between the upper side of the floor panel and the most downward-situated point of said support surface.

2. The floor panel of claim 1 , wherein the distance between an upper side of the floor panel and the most downward-situated point of said support surface is at least 1.2 times larger than the distance between the upper side of the floor panel and the most upward-situated point of said upward-directed recess.

3. The floor panel of claim 1 , wherein the distance between an upper side of the floor panel and the most upward-situated point of said upward-directed recess is less than half of the overall thickness of the floor panel.

4. The floor panel of claim 1 , wherein the floor panel is a vinyl panel, wherein the vinyl panel is a LVT (“Luxury Vinyl Tile”) or VCT (“Vinyl Composite Tile” or “Vinyl composition Tile”).

5. The floor panel of claim 1 , wherein the floor panel, or at least the substrate thereof, substantially is formed on the basis of polyurethane or polypropylene.

6. The floor panel of claim 1 , wherein the floor panel substantially consists of a laminate panel with the substrate being of MDF or HDF or of an engineered wood panel.

7. The floor panel of claim 1 , wherein the floor panel is rectangular, either oblong or square, wherein said pair of opposite edges forms a first pair of opposite edges, and moreover 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, and in a second direction perpendicular to the plane of the floor panel.

8. The floor panel of claim 7 , wherein the coupling parts on the second pair of opposite edges are configured such that two of such floor panels, on this second pair of opposite edges, can be coupled 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.

9. A floor panel for forming a floor covering in a plane, wherein said floor panel is at least composed of a substrate;
wherein the floor panel comprises coupling parts on at least one pair of opposite edges, said coupling parts allowing that two of such floor panels can be coupled to each other by means of a downward movement of one floor panel in respect to the other floor panel;
wherein these coupling parts, in the coupled condition of said two of such floor panels, form a first locking system which effects a locking in a first direction perpendicular to the plane of the floor panels, and form a second locking system which effects a locking in a second direction perpendicular to the edges and in the plane of the floor panels;
wherein said coupling parts substantially are formed of the material of said substrate and are realized in one piece therewith;
wherein the second locking system includes hook-shaped parts including at least of a downward-directed upper hook-shaped part situated on a first edge of said pair of opposite edges, and an upward-directed lower hook-shaped part situated on a second edge of said pair of opposite edges, the second edge being opposite from the first edge of said pair of opposite edges, said hook-shaped parts being configured to be engaged behind each other by means of said downward movement when coupling said two of such floor panels;
wherein said upper hook-shaped part consists of a lip with a downward-directed locking element, whereas said lower hook-shaped part consists of a lip with an upward-directed locking element;
wherein said first locking system comprises locking parts in the form of one or more protrusions, which, in the coupled condition of said two of such floor panels, respectively cooperate with one or more undercuts, said one or more protrusions being situated in the proximity of the distal extremity of the upper hook-shaped part and said one or more undercuts being situated in the proximity of the proximal extremity of the lower hook-shaped part;
wherein said lip of the lower hook-shaped part is provided with a support surface on which the lip of the upper hook-shaped part rests in the coupled

Assignees

• Flooring Ind Ltd Sarl

Inventors

• Devos Pieter

Classifications

• E04F2201/023

  with a continuous tongue or groove · CPC title

• E04F2201/0146

  with snap action of the edge connectors · CPC title

• E04F2201/0169

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

• E04F2201/03

  Undercut connections, e.g. using undercut tongues or grooves · CPC title

• E04F2201/041

  Tongues or grooves with slits or cuts for expansion or flexibility · CPC title