Coated panel

Patent metadata

Field	Value
Publication number	US-12480315-B2
Application number	US-202118016268-A
Country	US
Kind code	B2
Filing date	Jun 21, 2021
Priority date	Jul 17, 2020
Publication date	Nov 25, 2025
Grant date	Nov 25, 2025

Abstract

A coated panel with a substrate and a decorative top layer. The substrate includes an, optionally filled, plastic composite. The coated panel is provided on at least a first pair of two opposite edges with mechanical coupling means that allow two such panels to be coupled to each other on the first pair of edges in question. Locking is obtained both in a vertical direction perpendicular to the plane of the coupled panels, and in a horizontal direction perpendicular to the respective edges and in the plane of the coupled panels. The mechanical coupling means or coupling parts allow a displacement in the direction along the coupled edges.

First claim

The invention claimed is:

1 . A floor covering comprising a plurality of coated panels, each of said coated panels comprising a substrate and a decorative top layer superjacent to the substrate,
wherein the substrate comprises a plastic layer, wherein the coated panel is provided on at least a first pair of two opposite edges with mechanical coupling parts that allow two of the coated panels to be coupled to each other on the first pair of edges, wherein locking of two of said coated panels is obtained both in a vertical direction perpendicular to a plane of the coupled coated panels, and in a horizontal direction perpendicular to the first pair of edges and in the plane of the coupled coated panels, wherein the mechanical coupling parts allow a displacement in a direction along the coupled edges, and wherein in a coupled condition of two or more of said coated panels on the first pair and/or on a second pair of opposite edges of the coated panels, a horizontally acting locking and/or a contact surface is formed, directly under a position where upper surfaces of the coupled coated panels abut against each other, and in that the contact surface is formed mainly on a compressible portion of the substrate and/or the decorative top layer; wherein the mechanical coupling parts of the first pair of edges of the coated panels are configured as a tongue and a groove that is delimited by an upper lip and a lower lip; wherein the tongue and groove are provided with locking parts that counteract a moving apart of the tongue and groove in the horizontal direction; wherein the lower lip in a coupled state is unloaded or displays a maximum deflection of less than 0.07 millimeter.

2 . The floor covering of claim 1 , wherein the horizontally acting locking or contact surface is formed on a first layer of the substrate and the decorative top layer,
wherein the first layer is more flexible than an underlying second layer of the substrate, wherein both the first layer and the second layer comprise PVC and the first layer of the substrate comprises a higher proportion of plasticizer than the second layer located thereunder.

3 . The floor covering of claim 1 , wherein the mechanical coupling parts of the first pair of opposite edges are configured with a clearance, fitting or with a clamping.

4 . The floor covering of claim 1 , wherein the panel is rectangular, wherein the panel is provided both on the pair of long edges and on the pair of short edges with coupling parts,
wherein the coupling parts on the pair of long edges allow two of the coated panels to be coupled to each other by a rolling motion, and the coupling parts on the pair of short edges allow two of the coated panels to be coupled to each other by a downward motion, wherein the pair of long edges form the first pair of edges, and the pair of short edges form the second pair of edges.

5 . The floor covering of claim 1 , wherein at least one portion of the coupling parts is provided on the first pair of edges with a water-repellent substance.

6 . The floor covering of claim 1 , wherein the decorative top layer comprises a print and a thermoplastic wearing layer applied thereon.

7 . The floor covering of claim 6 , wherein the panel has a lowered edge region at least on one edge,
wherein both the print and the wearing layer extend continuously from on a central area of the panel over the lowered edge region.

8 . The floor covering of claim 7 , wherein the lowered edge region relates to a chamfer.

9 . The floor covering of claim 7 , wherein the surface of the lowered edge region is formed essentially by the wearing layer.

10 . The floor covering of claim 9 , wherein in the coupled state of two of the coated panels, contact surface arises directly under a join of the respective upper surfaces of the coupled coated panels,
wherein this contact surface mainly, or even exclusively, is formed on a material of a first layer and the superjacent layers of the decorative top layer.

11 . The floor covering of claim 7 , wherein the print extends at a location of the lowered edge region in one and the same plane as at a location of the central area.

12 . The floor covering of claim 6 , wherein the wearing layer has, at the location of a central area, a thickness of 0.3 mm or more, but less than 0.75 mm.

13 . The floor covering of claim 6 , wherein the wearing layer consists mainly of a thermoplastic, such as polyvinyl chloride.

14 . The floor covering of claim 6 , wherein the print is applied on a thermoplastic carrier film.

15 . The floor covering of claim 6 , wherein the substrate comprises several layers,
wherein a first layer with a first hardness is located between the print and a second layer with a second hardness that is greater than the first hardness.

16 . The floor covering of claim 15 , wherein both the first layer and the second layer contain polyvinyl chloride,
wherein a content of plasticizer in the first layer is higher than in the second layer.

Assignees

• Flooring Ind Ltd Sarl
• Unilin Bv

Inventors

• Brouckaert Dries
• Naeyaert Christophe
• Rollier Bryan

Classifications

• 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

• E04F2201/0153

  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

• E04F15/107

  composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04) · CPC title