Floor panel for forming a floor covering

Patent metadata

Field	Value
Publication number	US-12203274-B2
Application number	US-202017781997-A
Country	US
Kind code	B2
Filing date	Nov 3, 2020
Priority date	Dec 3, 2019
Publication date	Jan 21, 2025
Grant date	Jan 21, 2025

Abstract

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

First claim

The invention claimed is:

1. A floor panel for forming a floor covering,
wherein the floor panel comprises a first pair of opposite edges, and a second pair of opposite edges;
wherein the first pair of opposite edges comprises coupling parts arranged so that two of said floor panels mutually can be coupled to each other;
wherein the coupling parts comprise a horizontally active locking system, wherein in a coupled condition of the two of said floor panels, effects a locking in a plane of the two of said floor panels and perpendicular to respective edges;
wherein the coupling parts also comprise a vertically active locking system, wherein in a coupled condition of the two of said floor panels, effects a locking transverse to the plane of the two of said floor panels;
wherein the coupling parts substantially are realized from a material of the floor panel; and wherein the second pair of opposite edges also comprises coupling parts on both of said opposite edges, arranged that the two of said floor panels mutually can be coupled to each other,
wherein said coupling parts comprise the following characteristics:
wherein the coupling parts comprise a horizontally active locking system, wherein in a coupled condition of the two of said floor panels, effects a locking in the plane of the two of said floor panels and perpendicular to the respective edges;
wherein the coupling parts also comprise a vertically active locking system, wherein in a coupled condition of the two of said floor panels, effects a locking transverse to the plane of the two of said floor panels;
wherein the coupling parts substantially are realized from the material of the floor panel;
wherein the horizontally active locking system of the second pair of edges is formed at least of an upward-directed lower hook-shaped part situated on one of said two edges, and a downward-directed upper hook-shaped part situated on the opposite edge,
wherein the upward-directed lower hook-shaped part consists of a lip with an upward-directed locking element, wherein proximally of the upward-ward directed locking element, a female part is defined as a recess, whereas the downward-directed upper hook-shaped part consists of another lip with a downward-directed locking element forming a male part;
wherein the coupling parts of the second pair of opposing edges are configured such that the two of said floor panels can be coupled to each other at the respective edges by a downward movement involving a downward snapping movement of a first floor panel of the two of said floor panels in respect to a second floor panel of the two of said floor panels;
wherein the vertically active locking system of the second pair of opposing edges comprises vertically active locking parts by respective locking surfaces, define at least a first vertical locking zone and a second vertical locking zone, wherein in coupled condition of two of said panels the first vertical locking zone is located at a distal end of the upward-directed locking element and
wherein in coupled condition of two of said panels the second vertical locking zone is situated at a distal end of the downward-directed locking element;
wherein the vertically active locking parts comprise a first locking part at the edge of the panel at a proximal end of the lip of the upper hook-shaped part, a second locking part at the distal end of the downward-directed locking element, and a third locking part at a distal end of the lip of the lower hook-shaped part and a fourth locking part at a proximal end of the female part;
wherein the first and third locking part, in the coupled condition of the two of said floor panels, define said first vertical locking zone;
wherein the second and fourth locking part, in the coupled condition of the two of said floor panels, define said second vertical locking zone.

2. The floor panel according to claim 1 , wherein in coupled condition at the second pair of edges of two of said floor panels, no vertical locking is provided between a proximal end of the downward-directed locking element and a proximal end of the upward-directed locking element and/or
wherein the floor panel is configured such that the first vertical locking zone and the second vertical locking zone are the only zones where a vertical locking is provided in coupled condition of two of said floor panels between the edges of the second pair of opposite edges.

3. The floor panel according to claim 1 , wherein the first vertical locking zone is provided at least at ⅔ of a thickness of the floor panel from the surface of the floor panel.

4. The floor panel according to claim 1 , wherein an angle between a proximal end of the downward-directed locking element and the horizontal direction in a proximal direction of the upper hook-shaped part is less than 90 and/or
wherein an angle between the proximal end of the upward-directed locking element and the horizontal direction in a distal direction of the lower hook-shaped part is less than 90°.

5. The floor panel according to claim 1 , wherein in coupled condition at the second pair of edges of two of said floor panels, a proximal end of the downward-directed locking element contacts a proximal end of the upward-directed locking element.

6. The floor panel according to claim 1 , wherein the second locking part is provided by a first undercut at the distal end of the downward-directed locking element; and
wherein the fourth locking part is provided by a first protrusion at the proximal end of the female part.

7. The floor panel according to claim 6 , wherein an included angle of the first protrusion is larger than an included angle of the first undercut.

8. The floor panel according to claim 6 , wherein the first undercut has a triangular shape with rounded corner points.

9. The floor panel according to claim 6 , wherein the first protrusion comprises two inclined outer surfaces with in between the two inclined outer surfaces a vertical surface, where an upper inclined surface is more inclined with respect to the surface of the floor panel than a lower inclined surface.

10. The floor panel according to claim 6 , wherein a bottom of the first protrusion has an angle between 25° and 35° with the surface of the floor panel.

11. The floor panel according to claim 6 , wherein a bottom of the first undercut has an angle between 25° and 35° with the surface of the floor panel.

12. The floor panel according to claim 6 , wherein in coupled condition of two of said floor panels at the second pair of opposite edges a first space is present between the coupled opposite edges below a contact between a bottom of the first protrusion and a bottom of the first undercut and on the distal to the distal end of the downward-directed locking element and
wherein the first space continues into a second space between a bottom part of the downward-directed locking element and an upper part of the lip of the lower hook-shaped part.

13. The floor panel according to claim 1 , wherein the first locking part is provided by a second protrusion at the proximal end of the downward directed upper hook-shaped part; and
wherein the third locking part is provided by a third undercut at the distal end of the upward-directed locking element.

14. The floor panel as in claim 13 , wherein an upper surface of the second protrusion has an angle between 1° and 20° with the surface of the floor panel.

15. The floor panel as in claim 13 , wherein an angle with the surface of the floor panel of an upper surface of the third undercut is between 5 and 15°.

16. The floor panel as in claim 13 , wherein a firs

Assignees

• Flooring Ind Ltd Sarl
• Unilin Bv

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

• E04F2201/023

  with a continuous tongue or groove · 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

• E04F2201/0146

  with snap action of the edge connectors · CPC title