PANEL, MORE PARTICULARLY FLOOR PANEL

• US 20120096801A1
• Filed: 06/22/2010
• Published: 04/26/2012
• Est. Priority Date: 06/29/2009
• Status: Active Grant

• Current Assignee: Flooring Industries Limited Sarl (Mohawk Industries Incorporated)
• Original Assignee: Flooring Industries Limited Sarl (Mohawk Industries Incorporated)
• Inventors: Cappelle, Mark
• Granted Patent: US 8,615,953 B2
• Time in Patent Office: Days
• US Class Current: 52/592.1
• CPC Class Codes: E04F 15/02038 characterised by tongue and groove connections between neighbouring flooring elements
• CPC Class Codes: E04F 15/102 of fibrous or chipped materials, e.g. bonded with synthetic resins
• 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 2201/0146 with snap action of the edge connectors
• 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 2201/041 Tongues or grooves with slits or cuts for expansion or flexibility

Abstract

A panel having a core and at least two opposite edges with coupling parts at two opposite edges. The coupling parts of the panels can be coupled to each other by means of a downward movement, such that a locking is obtained in the plane of the panels and perpendicular to the edges, as well as perpendicular to the plane of the panels. The coupling parts at the two edges comprise locking parts ensuring locking in the direction perpendicular to the plane of the panels, and at least one of these locking parts forms part of a flexible portion made in one piece with the core. The flexible portion is bendable at least in the plane of the panel. The panel includes at least one support portion which forms a support against bending of the flexible portion in a direction transverse to the plane of the coupled panels.

Claims

1-23. -23. (canceled)

24. A floor panel comprising a core, an upper side, a bottom side and at least two opposite edges, the panel having coupling parts provided at said two opposite edges and having a configuration such that two of such panels can be coupled to each other by means of a downward movement of one of the panels in respect to the other, such that a locking is obtained in the plane of the panels and perpendicular to said edges, as well as perpendicular to the plane of the panels, the coupling parts at said two edges including locking parts ensuring said locking in the direction perpendicular to the plane of the panels and at least one of the locking parts forms part of a flexible portion made in one piece with said core, said flexible portion extending along the respective edge and being bendable at least in the plane of the panel, as a result of connecting two of such panels, wherein the panel includes at least one support portion, which, with two of such coupled panels, when exerting a force in a direction opposed to said downward movement, forms a support against bending of the flexible portion in a direction transverse to the plane of the coupled panels.

25. The panel of claim 24, wherein said locking parts are formed from parts which engage behind each other by means of a snap movement.

26. The panel of claim 24, wherein said flexible portion defines a lip, whereas another locking part, which is intended to work in conjunction therewith, defines a tongue-shaped portion, which, during joining two of such panels, causes an elastic bending in the lip, such that the tongue-shaped portion can take place behind the lip by means of a snap movement.

27. The panel of claim 24, wherein the support portion is a portion of the core supporting the flexible portion, said support portion preventing the flexible portion in a coupled condition from bending out in a direction transverse to the plane of the panels.

28. The panel of claim 24, wherein the flexible portion and the support portion cooperate with each other by means of a releasable and/or deformable connection.

29. The panel of claim 24, wherein said flexible portion is suspended such that, apart from a bending in the plane of the panel, it performs a tilting and/or torsion movement.

30. The panel of claim 24, wherein the support portion is formed by a fixed portion of the panel, with a contact surface along which the flexible portion can be displaced.

31. The panel of claim 24, wherein the flexible portion extends substantially in the plane of the floor panel and has a contact surface which is intended for cooperating with a locking part of a coupled floor panel;

the flexible portion, at least at the rear side and at the contact surface, is free in respect to said core; and

that, in the direction of the lateral sides thereof, at least at one of its two extremities, is in connection with the core.

32. The panel of claim 31, wherein the flexible portion is at both extremities in connection with the core.

33. The panel of claim 24, wherein the coupling parts comprise locking parts, which ensure said locking in the plane of the panels and perpendicular to said edges, and that these locking parts comprise hook-shaped parts, which, in the coupled condition of two of such panels, engage behind each other.

34. The panel of claim 24, wherein said hook-shaped parts are performed as a lower hook-shaped part with a flange which protrudes laterally next to the underside of the panel and which is provided with an upwardly directed portion, and an upper hook-shaped part with a flange which protrudes laterally next to the upper side of the panel and which is provided with a downwardly directed portion, wherein said flexible portion is formed at the edge which comprises the lower hook-shaped part, in a material portion of the core situated above this hook-shaped part.

35. The panel of claim 24, wherein it comprises a plurality of said flexible portions along the same edge.

36. The panel of claim 24, wherein the core, at least at the edge comprising the flexible portion and/or at said two edges, consists of a wood composite in the form of a board extending according to the plane of the panel and which is formed by pressing together a mat of wood components, which are adhered to each other by means of a binding agent.

37. The panel of claim 24, wherein the core, at least at the edge comprising the flexible portion and/or at said two edges, consists of wood fiberboard.

38. The panel of claim 24, wherein the core, at least at the edge comprising the flexible portion, and/or at said two edges, is selected from the group consisting of MDF and HDF.

39. The panel of claim 24, wherein the core thereof is made monolithic, and is made from a material selected from the group consisting of MDF and HDF.

40. The panel of claim 24, wherein the panel has a shape selected from the group consisting of rectangular, oblong or square, and wherein the panel is provided with coupling parts on all four edges, the coupling parts allow performing a mechanical locking with adjacent panels, such that at all four edges a locking is obtained in the plane of the panels and perpendicular to said edges as well as perpendicular to the plane of the panels.

41. The panel of claim 40, wherein the panel is provided at two edges with coupling parts which allow coupling two of such panels to each other by means of a downward movement of one of the panels in respect to the other, whereas the other two edges are provided with coupling parts which allow joining together two of such panels by means of a turning movement.

42. A floor panel, the panel comprising a core, an upper side, a bottom side and at least two opposite edges, the panel having coupling parts provided at said two opposite edges and having a configuration such that two of such panels can be coupled to each other by means of a downward movement of one of the panels in respect to the other, such that a locking in the plane of the panels and perpendicular to said edges, as well as perpendicular to the plane of the panels is obtained, the coupling parts at said two edges including locking parts ensuring said locking in the direction perpendicular to the plane of the panels, and at least one of these locking parts forms part of a flexible portion, made in one piece with said core, the portion extending along the respective edge and bendable at least in the plane of the panel, as a result of joining together two of such panels, the coupling parts including locking parts which ensure said locking in the plane of the panels and perpendicular to the aforementioned edges, and that these locking parts define hook-shaped parts which, in the coupled condition of two of such panels, engage one behind the other, the hook-shaped parts are performed as a lower hook-shaped part with a flange protruding laterally next to the underside of the panel and provided with an upwardly directed portion, and an upper hook-shaped part with a flange protruding laterally next to the upper side of the panel and provided with a downwardly directed portion, wherein said flexible portion is formed at the edge comprising the lower hook-shaped part in a material portion of the core situated above the hook-shaped part.

43. A floor panel comprising a core, an upper side, a bottom side and at least two opposite edges, the panel having coupling parts provided at said two opposite edges, and having a configuration such that two of such panels can be coupled to each other by means of a downward movement of one of the panels with respect to the other, such that a locking in the plane of the panels and perpendicular to said edges, as well as perpendicular to the plane of the panels is obtained, the coupling parts at said two edges including locking parts ensuring said locking in the direction perpendicular to the plane of the panels, and at least one of these locking parts forms part of a flexible portion made in one piece with said core, and extending along the respective edge and bendable at least in the plane of the panel, as a result of joining together two of such panels, and wherein the flexible portion, with the exception of possible cuts forming a substantial part of a profile formed at the coupling parts, is cut free substantially by only one cut, the cut extending only over a portion of the thickness of the panel at the location where the cut is situated.

44. A floor panel comprising a core, an upper side, a bottom side and at least two opposite edges, the panel having coupling parts provided at said two opposite edges and having a configuration such that two of such panels can be coupled to each other by means of a downward movement of one of the panels in respect to the other, such that a locking in the plane of the panels and perpendicular to said edges, as well as perpendicular to the plane of the panels is obtained, the coupling parts at said two edges including locking parts ensuring said locking in the direction perpendicular to the plane of the panels, at least one of these locking parts forms part of a flexible portion made in one piece with said core, and extending along the respective edge and bendable at least in the plane of the panel, as a result of joining together two of such panels, wherein the flexible portion is bordered at its rear side by a cut, wherein said cut has an open end and a closed end and/or bottom and the flexible portion globally diminishes in cross-section in the direction from the open end towards the closed end and/or the bottom.

45. A floor panel comprising a core, an upper side, a bottom side and at least two opposite edges, the panel having coupling parts provided at said two opposite edges, the coupling parts having a configuration such that two of such panels can be coupled to each other by means of a downward movement of one of the panels in respect to the other, such that a locking in the plane of the panels and perpendicular to said edges, as well as perpendicular to the plane of the panels is obtained, the coupling parts at said two edges comprising locking parts ensuring said locking in the direction perpendicular to the plane of the panels, at least one of these locking parts forms part of a flexible portion made in one piece with said core, and extending along the respective edge and bendable at least in the plane of the panel, as a result of joining together two of such panels, wherein the flexible portion is attached such that it performs only a rotational and/or torsion movement during coupling.

46. A floor panel comprising a core, an upper side, a bottom side and at least two opposite edges, the panel having coupling parts provided at said two opposite edges, the coupling parts having a configuration such that two of such panels can be coupled to each other by means of a downward movement of one of the panels in respect to the other, such that a locking in the plane of the panels and perpendicular to said edges, as well as perpendicular to the plane of the panels is obtained, the coupling parts at said two edges including locking parts ensuring said locking in the direction perpendicular to the plane of the panels, at least one of these locking parts forms part of a flexible portion, made in one piece with said core, and extending along the respective edge and bendable at least in the plane of the panel, as a result of joining together two of such panels, wherein the panel has a core comprising a plurality of crosswise-directed elements, and said flexible portion is realized along the edge of such crosswise-directed element, the crosswise-directed element is selected from the group consisting of MDF, HDF, and synthetic material.