Floor panel for forming a floor covering

Patent metadata

Field	Value
Publication number	US-11225800-B2
Application number	US-202016802879-A
Country	US
Kind code	B2
Filing date	Feb 27, 2020
Priority date	Dec 31, 2015
Publication date	Jan 18, 2022
Grant date	Jan 18, 2022

Abstract

A floor panel for forming a floor covering, wherein the floor covering consists of floor panels, which, on at least one pair of edges, are provided with coupling parts. The coupling parts substantially are manufactured from the material of the floor panel, and the coupling parts are configured such that two such floor panels, at the pair of edges, can be installed and locked to each other by means of a downward movement and/or by means of the fold-down principle.

First claim

The invention claimed is:

1. A floor panel for forming a floor covering,
wherein this floor panel comprises a first pair of opposite edges, and a second pair of opposite edges;
wherein the first pair of opposite edges comprises first coupling parts, which allow that two of such floor panels mutually can be coupled to each other, and wherein said first coupling parts show the following characteristics:
the first coupling parts comprise a first horizontally active 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;
the first coupling parts comprise a first vertically active locking system, which, in the coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels;
the first coupling parts substantially are realized from the material of the floor panel itself; and
the first coupling parts are configured such that two of such panels can be coupled to each other at first pair of opposite edges by means of a turning movement;

wherein the second pair of opposite edges comprises second coupling parts, which allow that two of such floor panels mutually can be coupled to each other, wherein said second coupling parts show the following characteristics:
the second coupling parts comprise a second horizontally active locking system, which, in the coupled condition of two of such floor panels, effects a locking in the plane of the floor panels and perpendicular to the respective edges;
the second coupling parts comprise a second vertically active locking system, which, in the coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels;
the second coupling parts substantially are realized from the material of the floor panel itself;
the second horizontally active locking system of the second pair of opposite edges is formed at least of an upward-directed lower hook-shaped part which is situated at a first edge of the second pair of edges, and a downward-directed upper hook-shaped part, which is situated on a second edge of the second pair of edges, wherein the lower hook-shaped part defines a lip with an upward-directed locking element, which proximally thereof defines a female part in a form of a recess, whereas the upper hook-shaped part has a lip with a downward-directed locking element forming a male part;
the second coupling parts are configured such that two of such floor panels can be coupled to each other at the first and second edges by means of a downward movement of the one floor panel in respect to the other;
the second horizontally active locking system comprises horizontally active locking parts, which by means of respective contact surfaces, define at least a first contact zone, the horizontally active locking parts comprise a first locking part at a proximal side of the downward-directed locking element and a third locking part at a proximal side of the upward-directed locking element;
the first and third locking parts, in the coupled condition of two of such floor panels, define said first contact zone, while having contact surfaces which, in the coupled condition, define and are arranged along a first inclined tangent line;
there is a horizontal locking but no vertical locking in the first contact zone;
the second vertically active locking system comprises vertically active locking parts, which, by means of respective contact surfaces, define at least a second contact zone, the vertically active locking parts comprise a second locking part at a distal side of the male part, and a fourth locking part at a proximal end of the upward-directed lower hook-shaped part;
the second and fourth locking parts, in the coupled condition of two of such floor panels, define said second contact zone, while having contact surfaces, which, in the coupled condition, define and are arranged along a second inclined tangent line;
the lower hook-shaped part comprises at a distal side of a distal end a fifth locking part, wherein a sixth locking part is provided at a proximal end of the downward-directed upper hook-shaped part;
wherein in the coupled condition of the second pair of opposite edges of two such panels, the second vertically active locking comprises the engagement of the fifth locking part at the distal side of the distal end of the lower hook-shaped part with the sixth locking part at the proximal end of the downward-directed upper hook-shaped part.

2. The floor panel of claim 1 , wherein at the male and at the female part, rounded portions are formed, which are configured such that the male part, during the downward movement thereof, automatically is guided into the female part, this during a joining according to the fold-down principle or during a joining via a plane-parallel downward movement.

3. The floor panel of claim 1 , wherein the sixth locking part provided at the proximal end of the downward-directed upper hook-shaped part comprises or is provided by a protrusion.

4. The floor panel of claim 1 , wherein the fifth locking part at the distal side of the distal end of the lower-hook-shaped part comprises or is provided by a recess or an undercut.

5. The floor panel of claim 1 , wherein at the lower side of the lower hook-shaped part, a recess is present which extends from a certain location at the lower side up to an end of the lower hook-shaped part.

6. The floor panel of claim 5 , wherein seen in cross-section, said certain location is situated proximally from the upward-directed locking element.

7. The floor panel of claim 5 , wherein the recess consists of a recessed portion, which is recessed in respect to an actual lower side of the floor panel, and a transition portion, which is situated between the actual lower side and the recessed portion and which provides for a gradual transition.

8. The floor panel of claim 5 , wherein the recess allows a bending of the lip of the lower hook-shaped part in downward direction.

9. The floor panel of claim 1 , wherein the second pair of edges also shows the following characteristics:
at the male part, at a height lower than the second contact zone, a contact surface is provided, which, in the coupled condition, together with a contact surface on the coupled floor panel, forms a support point which limits the movement of the male part in downward direction; and
the contact surfaces forming said support point are situated on a lower side of the male part and on the upper side of the lip of the lower hook-shaped part, respectively, wherein in the coupled condition, distally from this support point a space is present between the lower side of the male part and the upper side of said lip, wherein this space is formed in that a portion of the upper side of the lip is situated deeper than the support point.

10. The floor panel of claim 1 , wherein the second locking part comprises of a recess at the distal side of the male part.

11. The floor panel of claim 1 , wherein the fourth locking part comprises a protrusion at the proximal end of the upward-directed lower hook-shaped part.

12. The floor panel of claim 1 , wherein the upward-directed locking element, the downward-directed locking element and the contact surfaces of the first contact zone are configured such that the upward-directed locking element with a first contact surface in the coupled condition adopts a tilted position in respect to a position which the first contact surface adopts in a free condition; and that the contact surfaces of the first contact zone in a not-coupled condition mutually are oriented deviating in such a manner that in the coupled

Assignees

• Flooring Ind Ltd Sarl

Inventors

• De Rick Jan Eddy
• Devos Pieter

Classifications

• E04F2201/0146

  with snap action of the edge connectors · 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

• E04F2201/043

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

• E04F2201/023

  with a continuous tongue or groove · CPC title

• E04F2201/0176

  with snap action of the edge connectors · CPC title