Floor panel for forming a floor covering

Patent metadata

Field	Value
Publication number	US-11834846-B2
Application number	US-202218087529-A
Country	US
Kind code	B2
Filing date	Dec 22, 2022
Priority date	Jan 9, 2014
Publication date	Dec 5, 2023
Grant date	Dec 5, 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 having one or more base layers comprising thermoplastic material and fillers, and at least one top layer;
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, and 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 a distal end of the upper lip;
wherein, at least one locking part is provided with a locking surface which is located at least partially in the portion of said lower lip which is situated beyond said distal end of said upper lip;
wherein an upper side of the lower lip at a height of a 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 ) which is determined by a lowermost point of the locking part located on the underside of the tongue; the closing plane (S) being defined as a first vertical plane through said distal end of the upper lip;
wherein on the first pair of opposite edges the upper side of the tongue is provided with a contact surface intended for contacting the 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, the proximal end point being the end point of the contact zone located closest to the distal end of the upper lip, wherein said proximal end point is distanced from said distal end of the upper lip at least by means of a chamfered surface portion of the lower side of said upper lip;
wherein a contact is present between the underside of said tongue and the upper side of said lower lip, wherein the contact is situated entirely between the closing plane (S) and a second vertical plane extending through said upper lip and located parallel to the closing plane (S) and at most spaced half a millimeter remote from the closing plane (S).

2. The floor panel of claim 1 ,
wherein a first horizontal distance is defined by a horizontal distance measured between said distal end point and said proximal end point;
wherein a second horizontal distance is defined as being a horizontal distance measured between said proximal end point and a most distal end of the 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 2 , wherein said contact surface at the upper side of the tongue is horizontal or inclined with an angle less than 7 degrees.

4. The floor panel of claim 3 , wherein said contact surface at the upper side of the tongue in a distal direction of the tongue is inclined downwards.

5. 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.

6. The floor panel of claim 5 , wherein the coupling parts on the second pair of opposite edges are substantially identical to the coupling parts applied on the first pair of edges.

7. The floor panel of claim 5 , wherein the height difference between the two levels (N 1 and N 2 ) is at least 0.05 times an overall thickness (T) of the floor panel.

8. The floor panel of claim 7 , wherein the locking parts of the first pair of opposite edges have a locking distance (A) which is greater than 0.6 times a value of the 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 a middle of a zone over which locking surfaces of the locking parts, in coupled condition, make contact with each other, as measured in a horizontal direction of the floor panel.

9. The floor panel of claim 5 , wherein said floor panel has a global thickness which is smaller than or equal to 4.5 millimeter.

10. The floor panel of claim 9 , wherein said at least one locking part in a coupled condition cooperates with a locking groove at the bottom of said tongue, wherein said floor panel, at the location of said locking groove, has a minimum thickness which is greater than 0.4 times the overall thickness of the floor panel.

11. The floor panel of claim 5 , wherein said locking surface defines a tangent line which extends at an angle of more than 50 degrees to the horizontal.

12. The floor panel of claim 1 , wherein said contact between the underside of said tongue and the upper side of said lower lip is formed by cooperating curved surfaces on the underside of said tongue and the upper side of said lower lip.

13. The floor panel of claim 12 , wherein a space is present underneath the tongue, which space extends from the tip of said tongue to said contact between the underside of said tongue and the upper side of said lower lip.

14. A floor panel for forming a floor covering,
wherein the floor panel comprises a substrate having one or more base layers comprising thermoplastic material and fillers, and at least one top layer;
wherein the floor panel is rectangular, either oblong or square, and comprises a first and a second pair of opposite edges;
wherein the first and second pair of opposite edges comprise coupling parts which allow mutually coupling a plurality of such floor panels to each other;
wherein said coupling parts, on the first and 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 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 th

Assignees

• Flooring Ind Ltd Sarl

Inventors

• Cappelle Mark
• Devos Pieter

Classifications

• E04F15/02038 Primary

  characterised by tongue and groove connections between neighbouring flooring elements · CPC title

• E04F15/102

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

• 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