Floor panel made of plastic having mechanical locking edges

Patent metadata

Field	Value
Publication number	US-11002020-B2
Application number	US-201715660363-A
Country	US
Kind code	B2
Filing date	Jul 26, 2017
Priority date	Sep 1, 2008
Publication date	May 11, 2021
Grant date	May 11, 2021

Abstract

A floor panel has a carrier layer which is a plastic material that is pliable and elastic at an application temperature of the flooring. A decorative layer is disposed above the carrier layer. Complementary mechanical locking profiles provided on at least two panel edges. The locking profiles cooperating in the locked state of two floor panels and counter-acting a moving apart of the floor panels. At least one panel edge has an edge break-away point at the edge of the decorative layer.

First claim

I claim:

1. A floor panel comprising:
a carrier layer comprising a plastic material that is pliable and elastic at an application temperature of the floor panel;
a decorative layer being disposed above the carrier layer;
a first complementary mechanical locking means provided on a first two panel edges of the floor panel such that the floor panel is capable of being coupled together with a second floor panel of the same configuration as the floor panel to form a first locked state to counteract a moving apart of the floor panel and the second floor panel in a horizontal plane and a vertical plane;
a second complementary mechanical locking means provided on a second two panel edges such that the floor panel is capable of being coupled together with a third floor panel of the same configuration as the floor panel to form a second locked state to counteract a moving apart of the floor panel and the third floor panel in the horizontal plane and the vertical plane, wherein at least one edge of the first two panel edges or the second two panel edges has an edge break-away point at an edge of the decorative layer;
the second complementary locking means being complementary hook elements, the complementary hook elements forming the second locked state through a vertical movement between one of the complementary hook elements on one of the second two panel edges of the floor panel and another of the complementary hook elements on an opposite panel edge of the second two panel edges of the third floor panel;
each of the hook elements includes an inward facing vertical undercut surface, the inward facing vertical undercut surface of the one of the complementary hook elements of the floor panel and the inward facing vertical undercut surface of the other complementary hook element of the third floor panel cooperate in the second locked state to counteract a moving apart of the floor panel and the third floor panel in the horizontal plane; and
each of the complementary hook elements has an outward facing vertical surface, each of the complementary hook elements has a locking projection on the outward facing vertical surface and each of the complementary hook elements has a locking recess on the outward facing vertical surface, the locking projections on each of the hook elements being at a distance from the surface of the panel, the locking projections on the outward facing vertical surface of the complementary hook elements fit in the locking recesses on the outward facing vertical surface of the complementary hook elements in the second locked state to counteract a moving apart of the floor panel and the third floor panel in the vertical plane, wherein the carrier layer is a split carrier layer, and further comprising a reinforcement layer arranged as at least one intermediate layer in the split carrier layer.

2. The floor panel according to claim 1 , wherein the edge break-away point is designed as a chamfer, radius or stepped mortise.

3. The floor panel according to claim 1 , wherein above the decorative layer a transparent wear protection layer is disposed.

4. The floor panel according to claim 1 , wherein below the carrier layer a counteracting layer is provided.

5. The floor panel according to claim 1 , wherein the plastic material of the carrier layer is a thermoplastic elastomer.

6. The floor panel according to claim 1 , wherein the plastic material of the carrier layer is an amorphous elastomer, wherein plasticizers are added to the amorphous elastomer.

7. The floor panel according to claim 1 , wherein the thickness of the floor panel amounts to 1.5 mm to 6 mm.

8. The floor panel according to claim 1 , wherein the floor panel includes four panel edges.

9. The floor panel according to claim 8 , wherein at least one of two mutually opposite panel edges of the first complementary mechanical locking means is provided with a groove and the opposite panel edge of the first complementary mechanical locking means is provided with a tongue formed complementary to the groove.

10. The floor panel according to claim 9 , wherein the tongue and the groove each include an undercut, that the undercut of the tongue and the undercut of the groove are designed in such a manner that in the locked state they counteract a moving apart of the floor panels in their plane and vertically to the locked panel edge.

11. The floor panel according to claim 1 , further comprising the reinforcement layer that includes fiber-reinforced material.

12. The floor panel according to claim 1 , wherein an upwardly facing surface of one of the locking projections is in close contact with a downwardly facing surface of one of the locking recesses in the second locked state.

Assignees

• Akzenta Paneele Profile Gmbh
• Akzenta Paneele & Profile Gmbh

Inventors

• Hannig Hans-Jürgen

Classifications

• E04F2201/0146

  with snap action of the edge connectors · 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

• E04F15/02 Primary

  Flooring or floor layers composed of a number of similar elements (of webs E04F15/16) · CPC title

• E04F15/02038 Primary

  characterised by tongue and groove connections between neighbouring flooring elements · 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