FLOOR PANEL

• US 20110271632A1
• Filed: 01/14/2010
• Published: 11/10/2011
• Est. Priority Date: 01/16/2009
• Status: Active Grant

• Current Assignee: Flooring Industries Limited Sarl (Mohawk Industries Incorporated)
• Original Assignee: Flooring Industries Limited Sarl (Mohawk Industries Incorporated)
• Inventors: Cappelle, Mark, Van Hooydonck, Guy
• Granted Patent: US 9,290,948 B2
• Time in Patent Office: Days
• US Class Current: 52/582.2
• CPC Class Codes: E04F 15/02 Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: E04F 15/02038 characterised by tongue and groove connections between neighbouring flooring elements
• CPC Class Codes: E04F 15/04 only of wood or with a top layer of wood, e.g. with wooden or metal connecting members rollable parquet E04F15/16
• CPC Class Codes: E04F 2201/0115 with snap action of the edge connectors
• CPC Class Codes: E04F 2201/0138 by moving the sheets, plates or panels perpendicular to the main plane
• CPC Class Codes: E04F 2201/0153 by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
• CPC Class Codes: E04F 2201/0176 with snap action of the edge connectors
• CPC Class Codes: E04F 2201/049 wherein the elements are made of organic plastics with or without reinforcements or filling materials
• CPC Class Codes: E04F 2201/0523 Separate tongues; Interlocking keys, e.g. joining mouldings of circular, square or rectangular shape
• CPC Class Codes: E04F 2201/0535 adapted for snap locking
• CPC Class Codes: E04F 2201/0552 adapted to be rotated around an axis parallel to the joint edge
• CPC Class Codes: E04F 2201/0588 of organic plastics with or without reinforcements or filling materials
• CPC Class Codes: F16B 5/0056 by moving the sheets, plates or panels or the interlocking key perpendicular to the main plane

Abstract

Floor panel, which, at least at two opposite sides, includes coupling parts with which two of such floor panels can be coupled to each other; wherein these coupling parts form a horizontally active locking system and a vertically active locking system; wherein the horizontally active locking system comprises a male part in the form of a downwardly directed projection and a female part with a seat open towards the top, which have horizontally active locking surfaces; and wherein the vertically active locking system includes a vertically active locking element, which forms part of an insertion piece provided in the female part; wherein the insertion piece is formed at least of the combination of a bottom part; a back part adjoining thereto and an elastically movable lock-up body directed downward with a free extremity, which lock-up body, by means of a hinge portion, is connected directly or indirectly to the back part.

Claims

1-46. -46. (canceled)

47. Floor panel, having a top and comprising at least at two opposite sides, coupling parts enabling two of such floor panels to be coupled to each other;

wherein said coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the horizontally active locking system comprises a male part in the form of a downwardly directed projection and a female part with a seat open towards the top, said male and female parts having horizontally active locking surfaces;

wherein said male part and female part enable two of such floor panels to be connected to each other at said sides by locating on one of the floor panels the pertaining male part, by means of a downward movement, in the female part of the other floor panel;

wherein the vertically active locking system comprises a vertically active locking element, which forms part of an insertion piece provided in the female part;

wherein said insertion piece comprises at least the combination of a bottom part, which, in the coupled condition of two of such floor panels, is situated at least partially underneath said projection, a back part adjoining thereto and an elastically movable lock-up body directed downward with a free extremity;

said lock-up body, by means of a hinge portion, being connected directly or indirectly to the back part, and wherein said lock-up body forms a stop-forming locking portion at said extremity, said locking portion capable of cooperation with a locking portion of a similar coupled floor panel.

58. The floor panel of claim 47, wherein the distance, measured in horizontal direction between the upper edge of the floor panel at the location of the female part up to the beginning of the locking surface situated at said lip-shaped part, is larger than the distance, measured in vertical direction, between the upper side of the floor panel and the lower side of the projection of the male part.

59. The floor panel of claim 47, wherein the locking element comprises a lock-up body which is pivotable by means of a hinge portion and wherein the pivotable lock-up body is rotatable against a support surface pertaining to the respective floor panel concerned.

60. The floor panel of claim 47 or 48, wherein the locking element comprises a rigid pivotable lock-up body, which is rigid.

61. The floor panel of claim 47 or 48, comprising a locking element which is connected to the upper side of a back part, wherein this back part is taken up in a lateral recess.

62. The floor panel of claim 47 or 48, comprising a locking element which is connected to the upper side of a back part;

wherein the locking element comprises a pivotable lock-up body; and

wherein in the back part, a recess is provided which provides room for the lock-up body.

63. The floor panel of claim 47 or 48, wherein the insertion piece comprises a back part, a bottom part, and a lip-shaped part, wherein the lip-shaped part is made with different inclinations on both sides.

64. The floor panel of claim 47 or 48, comprising a locking element and a tensioning system, with which, by means of the lock-up body, in coupled condition a permanent tension force is exerted.

48. Floor panel, having a top and comprising at least at two opposite sides, coupling parts enabling two of such floor panels to be coupled to each other;

wherein said coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the horizontally active locking system comprises a male part in the form of a downwardly directed projection and a female part with a seat open towards the top, said male and female parts having horizontally active locking surfaces;

wherein said male part and female part enable two of such floor panels to be connected to each other at said sides by locating one of the floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel;

wherein the vertically active locking system comprises a vertically active locking element, which forms part of an insertion piece provided in the female part;

wherein the insertion piece comprises at least, on the one hand, a lock-up body and, on the other hand, a bottom part wherein this bottom part, in the coupled condition of two of such floor panels, is situated at least partially underneath said projection, and wherein said insertion piece comprises a co-extruded synthetic material strip with, seen in cross-section, zones of synthetic material with different properties.

49. Floor panel, having a top and comprising at least at two opposite sides, coupling parts enabling two of such floor panels to be coupled to each other;

wherein said coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the horizontally active locking system comprises a male part in the form of a downwardly directed projection and a female part with a seat open towards the top, said male and female parts having horizontally active locking surfaces;

wherein said male part and female part enable two of such floor panels to be connected to each other at said sides by locating one of the floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel;

wherein the vertically active locking system comprises a vertically active locking element, which forms part of an insertion piece provided in the female part;

wherein the insertion piece comprises at least, on the one hand, a lock-up body and, on the other hand, a bottom part;

wherein the bottom part, in the coupled condition of two of such floor panels, is situated at least partially underneath said projection, wherein at the lower side of the projection of the male part and at the upper side of said bottom part, mutually parallel contact surfaces are provided which, in the coupled condition of two of such floor panels, cooperate with each other so that the contact surface which is present at the lower side of the projection, seen in cross-section, rests on the contact surface of the bottom part over a certain distance; and

wherein the vertically active locking system is configured such that, in the coupled condition, such floor panel, at its side comprising the male part, in downward direction is exclusively held back by contact surfaces being present between the walls of said projection and said seat.

50. Floor panel, having a top and comprising at least at two opposite sides, coupling parts enabling two of such floor panels to be coupled to each other;

wherein the coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the horizontally active locking system comprises a male part in the form of a downwardly directed projection and a female part with a seat open towards the top, said male and female parts having horizontally active locking surfaces;

wherein said male part and female part enable two of such floor panels to be connected to each other at said sides by locating one of the floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel;

wherein the vertically active locking system comprises a vertically active locking element, which forms part of an insertion piece provided in the female part;

wherein this insertion piece comprises at least, on the one hand, a lock-up body and, on the other hand, a bottom part;

wherein the bottom part, in the coupled condition of two of such floor panels, is situated at least partially underneath said projection; and

wherein the vertically active locking system comprises a tensioning system with which the male part, in the coupled condition, is pressed on in said seat with a downward-directed tension force.

51. Floor panel, having a top and comprising at least at two opposite sides, coupling parts enabling two of such floor panels to be coupled to each other;

wherein the coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the horizontally active locking system comprises a male part in the form of a downwardly directed projection and a female part with a seat open towards the top, said male and female parts having horizontally active locking surfaces;

wherein said male part and female part enable two of such floor panels to be connected to each other at said sides by locating one of these floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel;

wherein the vertically active locking system comprises a vertically active locking element, which forms part of an insertion piece provided in the female part;

wherein the insertion piece, apart from the locking element, also comprises at least a bottom part which, in the coupled condition of two of such floor panels, is situated at least partially underneath said projection, as well as an upwardly directed lip-shaped part forming the horizontally active locking surface pertaining to the female part; and

wherein said lip-shaped part is made single-walled.

52. Floor panel, having a top and comprising at least at two opposite sides, coupling parts enabling two of such floor panels to be coupled to each other;

wherein the coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the horizontally active locking system comprises a male part in the form of a downwardly directed projection and a female part with a seat open towards the top, said male and female parts having horizontally active locking surfaces;

wherein said male part and female part enable two of such floor panels to be connected to each other at said sides by locating one of these floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel;

wherein the vertically active locking system comprises a vertically active locking element, which forms part of an insertion piece provided in the female part;

wherein said insertion piece also comprises at least a bottom part which, in the coupled condition of two of such floor panels, is situated at least partially underneath said projection, as well as a back part extending upwardly from the bottom part, to which back part the locking element is connected, either directly or indirectly; and

wherein said bottom part is made thinner than said back part and is thinner than the average thickness of the back part.

53. Floor panel, having a top and comprising at least at two opposite sides, coupling parts enabling two of such floor panels to be coupled to each other;

wherein the coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the horizontally active locking system comprises a male part in the form of a downwardly directed projection and a female part with a seat open towards the top, said male and female parts having horizontally active locking surfaces;

wherein said male part and female part enable two of such floor panels to be connected to each other at said sides by locating one of these floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel;

wherein the vertically active locking system comprises a locking element, which forms part of an insertion piece provided in the female part;

wherein this insertion piece also comprises at least a bottom part which, in the coupled condition of two of such floor panels, is situated at least partially underneath said projection; and

wherein the male part, in the coupled condition of two of such floor panels, rests on the bottom part; and

said insertion piece comprises an extruded synthetic material strip having, at the height of the bottom part, a configuration which contributes to minimizing tolerance deviations in the thickness of the bottom part.

54. Floor panel, having a top and comprising at least at two opposite sides, coupling parts enabling two of such floor panels to be coupled to each other;

wherein the coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the horizontally active locking system comprises a male part in the form of a downwardly directed projection and a female part with a seat open towards the top, said male and female parts having horizontally active locking surfaces;

wherein said male part and female part define hook-shaped parts that enable two of such floor panels to be connected to each other at said sides by locating one of these floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel;

wherein the vertically active locking system comprises a vertically active locking element, which forms part of an insertion piece provided in the female part;

wherein the insertion piece also comprises at least a bottom part which, in the coupled condition of two of such floor panels, is situated at least partially underneath said projection, as well as an upwardly-directed lip-shaped part which forms the horizontally active locking surface pertaining to the female part; and

wherein the male part in horizontal direction cooperates with and laterally is held back by the lip-shaped part and in vertical direction is supported exclusively by means of one or more support points, which are active between the actual basic materials from which the hook-shaped parts are formed.

55. Floor panel, having a top and comprising at least at two opposite sides, coupling parts enabling two of such floor panels to be coupled to each other;

wherein the coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the horizontally active locking system comprises a male part in the form of a downwardly directed projection and a female part with a seat open towards the top, said male and female parts having horizontally active locking surfaces;

wherein said male part and female part define hook-shaped parts that enable two of such floor panels to be connected to each other at said sides by locating one of these floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel;

wherein the vertically active locking system comprises a vertically active locking element, which forms part of an insertion piece provided in the female part;

wherein this insertion piece also comprises at least a bottom part which, in the coupled condition of two of such floor panels, is situated at least partially underneath said projection; and

wherein the locking surfaces, which provide for the horizontal locking, are formed in the basic material of the floor panels, whereas the male part in downward direction actually is supported on the insertion piece.

56. Floor panel, having a top and comprising at least at two opposite sides, coupling parts enabling two of such floor panels to be coupled to each other;

wherein the coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the horizontally active locking system comprises a male part in the form of a downwardly directed projection and a female part with a seat open towards the top, said male and female parts having horizontally active locking surfaces;

wherein said male part and female part enable two of such floor panels to be connected to each other at said sides by locating one of the floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel;

wherein the vertically active locking system comprises a vertically active locking element in the form of a lock-up body directed downward with a free extremity, which forms part of an insertion piece provided in the female part; and

wherein the distance over which the lock-up body extends in height in the coupled condition, is smaller than the height of the back part, and is larger than ⅓

of the height of the back part.

57. Floor panel, having a top and comprising at least at two opposite sides, coupling parts enabling two of such floor panels to be coupled to each other;

wherein the coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the horizontally active locking system comprises a male part in the form of a downwardly directed projection and a female part with a seat open towards the top, said male and female parts having horizontally active locking surfaces;

wherein said male part and female part enable two of such floor panels to be connected to each other at said sides by locating one of the floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel;

wherein the vertically active locking system comprises a vertically active locking element, which forms part of an insertion piece provided in the female part;

wherein the insertion piece, apart from the locking element, also comprises at least a bottom part which, in the coupled condition of two of such floor panels, is situated at least partially underneath said projection, as well as an upwardly directed lip-shaped part forming the horizontally active locking surface pertaining to the female part;

wherein the coupling parts are configured such that two of such floor panels can be turned into each other and/or out of each other by means of a turning movement of the one floor panel with respect to the other floor panel.

65. Floor panel, comprising at least at two opposite sides, coupling parts enabling two of such floor panels to be coupled to each other;

wherein the coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the coupling parts comprise a male part and a female part;

wherein said male part and female part enable two of such floor panels to be connected to each other at said sides by locating one of these floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel; and

wherein at least one of said locking systems comprises an insertion piece of synthetic material, said insertion piece being provided with one or more lips which are deformable, said lips being located laterally on a wall of the insertion piece and which, in the coupled condition of two of such floor panels, exert a tension force which presses the coupling parts against one or more contact surfaces.

66. Floor panel, comprising at least at two opposite sides, coupling parts enabling two of such floor panels to be coupled to each other;

wherein the coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the horizontally active locking system comprises a male part and a female part, which enable two of such floor panels to be connected to each other at said sides by locating one of the floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel;

wherein the vertically active locking system comprises a locking element, which forms part of an insertion piece provided in one of the respective sides; and

wherein the locking element comprises at least a pivotable lock-up body;

wherein the lock-up body, by means of a hinge portion, is connected to a basic part pertaining to the insertion piece, and wherein the pivotable lock-up body and the basic part are provided with surfaces which, when the lock-up body is pivoted inwards, form guiding surfaces for each other and thereby determine the movement of the lock-up body.

67. The floor panel of claim 66, wherein the insertion piece is provided in a recess in the female part.

68. The floor panel of claim 66, wherein the cooperation between the pivotable lock-up body and the basic part is obtained in two steps, wherein in the first step the lock-up body is pushed aside with a smaller force than in the second step.

69. The floor panel of claim 66, wherein the lock-up body comprises a rigid element.

70. The floor panel of claim 66, wherein the insertion piece is configured such that in the free condition a distance is present between the basic part and the lock-up body, said distance being bridged over by the material portion.

71. Floor panel, comprising at least at two opposite sides, coupling parts enable of such floor panels to be coupled to each other;

wherein the coupling parts form a horizontally active locking system and a vertically active locking system, which enable two of such floor panels to be connected to each other at said sides by locating one of these floor panels, by means of a downward movement, in the other floor panel;

wherein the vertically active locking system comprises locking parts engaging one after the other, of which at least one locking part is situated on a lip-shaped bendable part which extends in the height; and

wherein at least said bendable part comprises of a pressed fiber material, said material showing a predominant fiber direction and/or predominant fiber planes, wherein this fiber material is positioned such that the predominant fiber direction and/or predominant fiber planes also extend in the height.

72. The floor panel of claim 71, wherein the pressed fiber material comprises of a wood-based material.

73. Floor panel, having a top and comprising at least at two opposite sides, coupling parts enable two of such floor panels to be coupled to each other;

wherein the coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the horizontally active locking system comprises a male part in the form of a downwardly directed projection and a female part with a seat open towards the top, said male and female parts having horizontally active locking surfaces;

wherein said male part and female part enable two of such floor panels to be connected to each other at said sides by locating one of these floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel;

wherein the vertically active locking system comprises a vertically active locking element, which forms part of an insertion piece provided in the female part;

wherein said insertion piece, apart from the locking element, also comprises at least a bottom part, which, in the coupled condition of two of such floor panels, is situated at least partially underneath said projection; and

wherein said bottom part, during said downward movement, is elastically deformed and, towards the end of the downward movement, relaxes again at least partially.

74. Floor panel, in rectangular and/or oblong form, having a top and comprising at a first pair and a second pair of two opposite sides, coupling parts enabling two of such floor panels to be coupled to each other;

wherein the coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the horizontally active locking system comprises a male part in the form of a downwardly directed projection and a female part with a seat open towards the top, said male and female parts having horizontally active locking surfaces;

wherein said male part and female part enable two of such floor panels, on the one hand, to be connected to each other at said first pair of sides by locating one of the floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel, and, on the other hand, to be connected to each other at said second pair of sides by providing one of these floor panels with the pertaining male coupling part, by means of a turning movement about the respective sides, in the female coupling part of the other floor panel; and

wherein, at the first pair as well as at the second pair of sides, the vertically active locking system comprises a vertically active locking element, which forms part of an insertion piece, wherein the insertion piece at the first pair of sides is provided in the female coupling part, and at the second pair of sides is situated at the male coupling part.

75. Floor panel, having a top, and comprising at least at two opposite sides, coupling parts enabling two of such floor panels to be coupled to each other;

wherein the coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the horizontally active locking system comprises a male part in the form of a downwardly directed projection and a female part with a seat open towards the top, said male and female parts having horizontally active locking surfaces;

wherein said male part and female part enable two of such floor panels to be connected to each other at said sides by locating one of the floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel;

wherein the vertically active locking system comprises a vertically active locking element which is integrally made with an insertion piece which is provided in the female part or forms a portion of the female part;

wherein the insertion piece, apart from the locking element, also comprises at least a bottom part, which, in the coupled condition of two of such floor panels, is situated at least partially underneath said projection; and

wherein the insertion piece projects in horizontal direction beyond the upper edge of the respective floor panel over a distance which is larger than the distance over which the portion of the female coupling part made in one piece with the floor panel projects beyond this upper edge.

76. Floor panel, having a top and comprising at least at two opposite sides, coupling parts enabling two of such floor panels to be coupled to each other;

wherein the coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the horizontally active locking system comprises a male part in the form of a downwardly directed projection and a female part with a seat open towards the top, said male and female parts having horizontally active locking surfaces;

wherein said male part and female part enable two of such floor panels to be connected to each other at said sides by locating one of the floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel;

wherein the vertically active locking system comprises a vertically active locking element, which forms part of an insertion piece which is provided at one of said two sides;

wherein the locking element, during said downward movement, is configured to perform a lateral to- and fro-movement, so that first the locking element is pushed aside in an elastic manner and subsequently moves back in an elastic manner to arrive in a locking position; and

wherein the insertion piece comprises, on the one hand, a movable hook-shaped portion with a portion extending laterally substantially in horizontal direction and forming said locking element, and an attachment portion with which the insertion piece is provided in a recess provided for this purpose.

77. Floor panel, having a top and comprising at least at two opposite sides, coupling parts enabling two of such floor panels to be coupled to each other;

wherein the coupling parts form a horizontally active locking system and a vertically active locking system;

wherein the horizontally active locking system comprises a male part in the form of a downwardly directed projection and a female part with a seat open towards the top, said male and female parts having horizontally active locking surfaces;

wherein said male part and female part enable two of such floor panels to be connected to each other at said sides by providing one of these floor panels with the pertaining male part, by means of a downward movement, in the female part of the other floor panel;

wherein the vertically active locking system comprises a vertically active locking element, which forms part of an insertion piece which is provided at one of said two sides;

wherein the locking element, during said downward movement, is configured to perform a lateral to- and fro-movement, so that first the locking element is pushed aside in an elastic manner and subsequently moves back in an elastic manner to arrive in a locking position; and

wherein the insertion piece comprises, on the one hand, a movable portion extending laterally substantially in horizontal direction and forming said locking element, and an attachment portion with which the insertion piece is provided in a recess provided for this purpose, wherein the locking element, viewed in height, as such occupies less than half of the height of the insertion piece.