Floor panel for forming a floor covering

Patent metadata

Field	Value
Publication number	US-11629508-B2
Application number	US-202117336793-A
Country	US
Kind code	B2
Filing date	Jun 2, 2021
Priority date	Jan 9, 2014
Publication date	Apr 18, 2023
Grant date	Apr 18, 2023

Abstract

A floor panel for forming a floor covering wherein the floor panel is substantially realized on the basis of synthetic material. The floor panel is rectangular and comprises a first pair of opposite edges and a second pair of opposite edges such that both pairs of opposite edges comprise coupling parts allowing for mutually coupling a plurality of such floor panels to each other. The coupling parts of at least the first pair of opposite edges are configured such that two of such panels can be coupled to each other at these edges by means of a turning movement and the coupling parts to this aim consist of a tongue and a groove as well as locking parts, which, in the coupled condition, prevent the shifting apart of the tongue and groove. The floor panel has a global thickness which is smaller than or equal to 4.5 millimeters.

First claim

The invention claimed is:

1. A floor panel for forming a floor covering,
wherein the floor panel comprises a substrate;
wherein the floor panel is rectangular, either oblong or square, and comprises a first pair of opposite edges;
wherein the first pair of opposite edges comprises coupling parts which allow mutually coupling a plurality of such floor panels to each other;
wherein said coupling parts, on the first pair of opposite edges, form a first locking system which, in a coupled condition of two of such floor panels, effects a locking in a plane of the floor panels and perpendicular to the respective edges, and said coupling parts, on the first pair of opposite edges also form a second locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels;
wherein the coupling parts on the first pair of opposite edges substantially are formed of a material of the floor panel itself and in said substrate;
wherein the coupling parts of the first pair of opposite edges are configured such that two of such panels can be coupled to each other at their first pair of opposite edges by means of a turning movement, and such that the coupling parts on the first pair of opposite edges include a tongue and a groove as well as locking parts which, in the coupled condition, prevent shifting apart of the tongue and groove; and
wherein, on the first pair of opposite edges, the groove is bordered by a lower lip and an upper lip, of which the lower lip extends laterally to beyond a distal end of the upper lip;
wherein an upper side of the lower lip at a height of a closing plane (S), in the coupled condition of two of such panels, is located on a first level (N 1 ) which is situated higher than a second level (N 2 ) which is determined by a lowermost point of the locking part located on an underside of the tongue; the closing plane (S) being defined as a vertical plane through the distal end of the upper lips;
wherein the locking parts of the first pair of opposite edges have a locking distance (A) which is greater than 0.6 times an overall thickness (T) of the floor panel, the locking distance (A) being formed by a horizontal distance between the closing plane (S) of two coupled floor panels and a vertical plane (VS) through the middle of a zone over which locking surfaces of the locking parts, in coupled condition, make contact with each other, as measured in horizontal direction.

2. The floor panel of claim 1 ,
wherein on the first pair of opposite edges an upper side of the tongue is provided with a contact surface intended for contacting a lower side of said upper lip over a certain contact zone, said contact zone viewed in a cross section of the tongue extending between a distal end point and a proximal end point, wherein a first horizontal distance is defined by a horizontal distance measured between said distal end point and said proximal end point;
wherein said contact surface at the upper side of the tongue in a distal direction of the tongue is inclined downwards;
wherein a second horizontal distance is defined as being a horizontal distance measured between said proximal end point and the most distal end of a tip of the tongue;
wherein the first horizontal distance in length covers a majority of the second horizontal distance.

3. The floor panel of claim 1 ,
wherein the floor panel comprises a second pair of opposite edges, wherein the second pair of opposite edges comprises coupling parts which allow mutually coupling a plurality of such floor panels to each other;
wherein said coupling parts, on the second pair of opposite edges, form a first 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, and said coupling parts, on the second pair of opposite edges also form a second locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels;
wherein the coupling parts on the second pair of opposite edges are configured such that two of such floor panels at the second pair of opposite edges can be coupled to each other by a downward movement of one panel in respect to the other panel in such a manner that a plurality of such panels can be coupled to each other by a “fold-down” technique.

4. The floor panel of claim 1 , wherein the height difference between the first and second levels (N 1 and N 2 ) is at least 0.05 times the overall thickness (T).

5. A floor panel for forming a floor covering,
wherein the floor panel comprises a substrate;
wherein the floor panel is rectangular, either oblong or square, and comprises a first pair of opposite edges;
wherein the first pair of opposite edges comprises coupling parts which allow mutually coupling a plurality of such floor panels to each other;
wherein said coupling parts, on the first pair of opposite edges, form a first 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, and said coupling parts, on the first pair of opposite edges also form a second locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the floor panels;
wherein the coupling parts on the first pair of opposite edges substantially are formed of the material of the floor panel itself and in said substrate;
wherein the coupling parts of the first pair of opposite edges are configured such that two of such panels can be coupled to each other at their first pair of opposite edges by means of a turning movement, and such that the coupling parts on the first pair of opposite edges include a tongue and a groove as well as locking parts which, in the coupled condition, prevent the shifting apart of the tongue and groove; and
wherein, on the first pair of opposite edges, the groove is bordered by a lower lip and an upper lip, of which the lower lip extends laterally to beyond the distal end of the upper lip;
wherein on the first pair of opposite edges said upper side of the tongue is provided with a contact surface intended for contacting said lower side of said upper lip over a certain contact zone, said contact zone viewed in a cross section of the tongue extending between a distal end point and a proximal end point, wherein a first horizontal distance is defined by a horizontal distance measured between said distal end point and said proximal end point;
wherein said contact surface at the upper side of the tongue in a distal direction of the tongue is inclined downwards;
wherein a second horizontal distance is defined as being a horizontal distance measured between said proximal end point and the most distal end of the tip of the tongue;
wherein the first horizontal distance in length covers the majority of the second horizontal distance.

6. The floor panel of claim 5 ,
wherein the upper side of the lower lip at a height of the closing plane, in the coupled condition of two of such panels, is located on a first level (N 1 ) which is situated higher than a second level (N 2 ).

7. The floor panel of claim 6 , wherein a height difference between the first and second levels (N 1 and N 2 ) is at least 0.05 times the overall thickness (T).

8. The floor panel of claim 5 ,
wherein the locking parts of the first pair of opposite edges have a locking distance (A) which is greater than 0.6 times an overall thickness (T) of the floor panel, the locking distance (A) being formed by a horizontal distance between a closing plane (S) of two coupled floor panels and a vertical plane (VS) through the middle of a zone

Assignees

• Flooring Ind Ltd Sarl

Inventors

• Cappelle Mark
• Devos Pieter

Classifications

• E04F15/105

  of organic plastics with or without reinforcements or filling materials · 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

• E04F15/02038 Primary

  characterised by tongue and groove connections between neighbouring flooring elements · 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

• E04F15/102

  of fibrous or chipped materials, e.g. bonded with synthetic resins · CPC title