Floor panel for forming a floor covering

Patent metadata

Field	Value
Publication number	US-10697184-B2
Application number	US-201816100436-A
Country	US
Kind code	B2
Filing date	Aug 10, 2018
Priority date	Aug 23, 2017
Publication date	Jun 30, 2020
Grant date	Jun 30, 2020

Abstract

A floor panel comprises coupling parts in the form of a tongue and groove connection with locking elements; wherein the groove is bordered by an upper lip and a lower lip; and wherein the one locking element is provided on the lower side of the tongue and the other locking element is provided on the upper side of the lower lip; characterized in that the most upward-situated point of the locking element on the lower lip is situated at a distance of at least ⅓ times the thickness of the floor panel from the underside of the floor panel; and that the minimum thickness of the lower lip is maximum ¼ times the thickness of the floor panel.

First claim

The invention claimed is:

1. A floor panel for forming a floor covering, comprising a first edge with a first coupling part and a second, opposite edge with a second coupling part, wherein the aforementioned coupling parts are configured such that they allow coupling two of such floor panels to each other and realizing a coupled condition of two of such floor panels on the respective edge;
wherein the first coupling part is realized in the form of a tongue and the second coupling part is realized in the form of a groove, wherein said groove is bordered by an upper lip and a lower lip, wherein said tongue and groove, in coupled condition, form a tongue and groove connection which, at the respective edge, forms a locking between the coupled panels in a first direction perpendicular to the plane of the panels;
wherein the lower lip protrudes beyond the free end of the upper lip and the portion of the lower lip, which protrudes beyond the free end of the upper lip, has a length, as measured according to the direction in the plane of the panel and perpendicular to the edge, which is smaller than the thickness of the floor panel;
wherein the coupling parts each comprise a locking element, wherein said locking elements, in the coupled condition, counteract the moving apart of the tongue and groove in a second direction in the plane of the panels and perpendicular to the coupled edges and thus realize a locking between the coupled panels in the second direction;
wherein the locking element of the first coupling part is provided on the lower side of the tongue and the locking element of the second coupling part is provided on the upper side of the lower lip and beyond the free end of the upper lip;
wherein the coupling parts are configured such that the locking elements of two of such panels can be brought one behind the other by means of a turning movement of the one panel in respect to the other;
wherein the most upward-situated point of the locking element on the lower lip is situated at a distance, measured according to the direction perpendicular to the plane of the floor panel, of at least ⅓ times the thickness of the floor panel from the underside of the floor panel;
and wherein the minimum thickness of the lower lip is maximum ¼ times the thickness of the floor panel, wherein the lower lip reaches its minimum thickness between the free end of the upper lip and the locking element on the lower lip;
wherein in the coupled condition a space is arranged to be formed between the upper surface of the lower lip and the lower side of the tongue, at least at the location of the aforementioned minimum thickness of the lower lip;
wherein said space has a maximum height, as measured according to the direction perpendicular to the plane of the panel, which is larger as the height over which horizontally active locking surfaces extend;
wherein the maximum height of the space, as measured according to the direction perpendicular to the plane of the panel, is situated between 0.75 and 1.5 times the minimum thickness of the lower lip.

2. The floor panel of claim 1 , wherein the minimum thickness of the lower lip is approximately ⅕ of the thickness of the floor panel.

3. The floor panel of claim 1 , wherein the floor panel has a thickness situated between 9 and 15 millimeters.

4. The floor panel of claim 1 , wherein the locking elements are manufactured from the material of and in one piece with the actual floor panel.

5. The floor panel of claim 1 , wherein the floor panel comprises a core and a decorative top layer situated above the core.

6. The floor panel of claim 5 , wherein the core of the floor panel comprises one of the following materials: wood fiberboard or a thermoplastic synthetic material; or consists of a core composed of a plurality of wooden slats; or consists of a plywood core.

7. The floor panel of claim 5 , wherein the floor panel shows one or a combination of two or more of the following characteristics:
the characteristic that one or more pairs of vertically active locking surfaces are formed at least partially from the material of the core;
the characteristic that the aforementioned coupling parts consist of milled profiles which, for at least 70 percent of their contour, are provided in the material of the core;
the characteristic that the first pair of opposite edges as well as the second pair of opposite edges is provided with coupling parts;
the characteristic that the aforementioned coupling parts further allow a coupling by means of a horizontal shifting movement of the edges towards each other and/or by means of a downward-directed movement of the first coupling part with said tongue up into the second coupling part with said groove;
the characteristic that in a coupled condition of two of such floor panels a tension force is obtained between the upper edges of the respective floor panels;
the characteristic that the lower lip in a coupled condition is bent;
the characteristic that the aforementioned coupling parts comprise support portions, which, in the coupled condition of two of such floor panels, cause a fixation in the mutual position of the aforementioned locking elements;
the characteristic that the support portions are situated immediately next to cooperating portions or horizontally active locking surfaces of the locking elements without an intermediate space;
the characteristic that the support portions, in respect to the floor panel with the groove, are situated proximally from the aforementioned cooperating portions or horizontally active locking surfaces of the locking elements.

8. The floor panel of claim 1 , wherein the lower lip, in a coupled condition, is bent and wherein the aforementioned coupling parts comprise support portions, which, in the coupled condition of two of such floor panels, cause a fixation in the mutual position of the aforementioned locking elements.

9. The floor panel of claim 1 , wherein the maximum height of the space, is at least twice as large as the height of the horizontally active locking surfaces.

10. The floor panel of claim 1 , wherein the maximum height of the space, as measured according to the direction perpendicular to the plane of the panel, is larger than 0.1 times the thickness of the floor panel.

11. The floor panel of claim 1 , wherein the locking angle formed by the locking elements is situated between 45 and 90 degrees.

12. The floor panel of claim 1 , wherein the coupling parts are formed such that, when performing the turning movement, a click or snap effect occurs.

13. First and second floor panels for forming a floor covering, each of said first and second floor panels comprising a first edge with a first coupling part and a second, opposite edge with a second coupling part, wherein the coupling parts are configured such that they allow coupling of the first and second floor panels with the first coupling part of the first panel to the second coupling part of the second panel;
wherein the first coupling part is realized in the form of a tongue and the second coupling part is realized in the form of a groove, wherein said groove is bordered by an upper lip and a lower lip, wherein said tongue and groove, in coupled condition, form a tongue and groove connection which, at the respective edge, forms a locking between the coupled panels in a first direction perpendicular to the plane of the panels;
wherein the lower lip protrudes beyond the free end of the upper lip and the portion of the lower lip, which protrudes beyond the free end of the upper lip, has a length, as measured according to the direction in the plane of the panel and perpendicular to the edge, which is smaller

Assignees

• Flooring Ind Ltd Sarl

Inventors

• De Rick Jan

Classifications

• E04F2201/043

  with tongues and grooves being formed by projecting or recessed parts of the panel layers · CPC title

• E04F2201/042

  with grooves positioned on the rear-side of the panel · CPC title

• E04F15/04

  only of wood {or with a top layer of wood}, e.g. with wooden {or metal} connecting members (rollable parquet E04F15/16) · 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