PANEL, COVERING AND METHOD FOR INSTALLING SUCH PANELS

• US 20170101785A1
• Filed: 12/22/2016
• Published: 04/13/2017
• Est. Priority Date: 12/22/2009
• 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 10,428,534 B2
• Time in Patent Office: Days
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 3/06 for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• CPC Class Codes: E04F 15/02033 Joints with beveled or recessed upper edges
• CPC Class Codes: E04F 15/02038 characterised by tongue and groove connections between neighbouring flooring elements
• CPC Class Codes: E04F 15/02194 Flooring consisting of a number of elements carried by a non-rollable common support plate or grid E04F15/022 takes precedence
• CPC Class Codes: E04F 15/105 of organic plastics with or without reinforcements or filling materials
• CPC Class Codes: E04F 15/107 composed of several layers, e.g. sandwich panels layered products in general B32B; producing decorative panels or veneers B44C5/04
• CPC Class Codes: E04F 2201/0123 by moving the sheets, plates or panels parallel to the abutting edges
• 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 2201/023 with a continuous tongue or groove

Abstract

A panel for forming a covering, more particularly a floor panel for forming a floor covering, which at least at two opposite edges, comprises coupling parts arranged to couple two of such panels to each other by means of a downward movement of one panel in respect to the other. The coupling parts form a first locking system arranged to lock in the plane of the panels and perpendicularly to the edges, as well as form a second locking system, which effects a locking perpendicularly to the plane of the panels. At least one of the coupling parts is formed at least partially in soft PVC (polyvinyl chloride), as well as at least partially formed from a milled profiled part of this soft PVC.

Claims

1. A panel for forming a floor covering, which, at least at two opposite edges comprises coupling parts of the type allowing to couple two of such panels to each other by means of a downward movement of one panel in respect to the other;

wherein these coupling parts form a first locking system, which effects a locking in the plane of the panels and perpendicularly to said edges, as well as form a second locking system, which effects a locking perpendicularly to the plane of the panels;

wherein the first locking system is formed at least of an upwardly directed lower hook-shaped portion which is situated at one of said two edges, as well as of a downwardly directed upper hook-shaped portion which is situated at the opposite edge;

wherein the lower hook-shaped portion consists of a lip with an upwardly directed locking element, whereas the upper hook-shaped portion consists of a lip with a downwardly directed locking element;

wherein the second locking system comprises locking parts consisting of only one single locking part situated next to the proximal end of the lower hook-shaped portion and a single locking part situated next to the distal end of the upper hook-shaped portion;

wherein at least one of said locking parts of the second locking system is made from soft PVC;

wherein said two opposite edges define respective upper panel edges; and

wherein the panel at each of said two respective upper panel edges is provided with a chamfered surface.

2. The panel of claim 1, wherein the panel substantially is formed of a substrate on the basis of soft PVC and wherein said coupling parts are integrally made in said substrate.

3. The panel of claim 1, wherein said locking parts define substantially horizontal locking surfaces.

4. The panel of claim 1, wherein the locking part that is situated next to the distal end of the upper hook-shaped portion, is placed somewhat towards the inside, such that this locking part is situated entirely underneath the upper side of the panel.

5. The panel of claim 1, wherein the distal end of the lower hook-shaped portion, in a coupled condition of two of such panels, is spaced from the opposite coupled panel.

6. The panel of claim 1, wherein this panel is rectangular, either oblong or square, and thus comprises a first pair of opposite edges and a second pair of opposite edges;

wherein both pairs of opposite edges comprise coupling parts allowing to mutually couple a plurality of such panels to each other;

wherein the coupling parts at the first pair of edges form a first locking system which effects a locking in the plane of the panels and perpendicular to the respective edges, as well as form a second locking system which effects a locking perpendicular to the plane of the panels;

wherein the coupling parts at the second pair of edges are formed by the aforementioned coupling parts that are of the type allowing to couple two of such panels to each other by means of a downward movement of one panel in respect to the other;

wherein the coupling parts at both pairs of edges substantially are realized from said substrate;

wherein the coupling parts at 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

wherein the coupling parts at the second pair of opposite edges are configured such that two of such floor panels as aforementioned can be coupled to each other by means of a downward movement, wherein this downward movement is obtained as a result of the turning movement at the first pair of edges.

7. The panel of claim 6, wherein at least said coupling parts which are of the type allowing to couple two of such panels to each other by means of a downward movement of one panel in respect to the other, are realized in soft PVC.

8. The panel of claim 7, wherein this panel comprises a substrate of a material on the basis of soft PVC;

and

wherein the coupling parts that are of the type allowing to couple two of such panels to each other by means of a downward movement of one panel in respect to another panel are integrally made from said substrate.

9. The panel of claim 8, wherein the coupling parts at both pairs of edges are realized substantially integrally from said substrate.

10. The panel of claim 1, wherein the panel comprises a substrate of soft PVC and a top layer above said substrate, said top layer having a material thickness,

wherein said chamfered surface forms a small bevel that is located within the material thickness of the top layer only and thus completely above said substrate.

11. The panel of claim 1, wherein the downwardly directed locking element, at the distal end of the upper hook-shaped portion, comprises a guiding surface, which is inclined with respect to the direction perpendicular to the plane of the panel.

12. The panel of claim 11, wherein said guiding surface extends upward from the lower side of the downwardly directed locking element.

13. A panel for forming a floor covering, wherein this panel is rectangular, either oblong or square, and thus comprises a first pair of opposite edges and a second pair of opposite edges;

wherein both pairs of opposite edges comprise coupling parts allowing to mutually couple a plurality of such panels to each other;

wherein the coupling parts at the first pair of edges form a first locking system which effects a locking in the plane of the panels and perpendicular to the respective edges, as well as form a second locking system which effects a locking perpendicular to the plane of the panels;

wherein also the coupling parts at the second pair of edges form a first locking system which effects a locking in the plane of the panels and perpendicular to the respective edges, as well as form a second locking system which effects a locking perpendicular to the plane of the panels;

wherein the coupling parts at the second pair of edges are of the type allowing to couple two of such panels to each other by means of a downward movement of one panel in respect to the other;

wherein the first locking system at the second pair of edges is formed at least of an upwardly directed lower hook-shaped portion which is situated at one of the two edges of said second pair of edges, as well as of a downwardly directed upper hook-shaped portion which is situated at the opposite edge;

wherein the lower hook-shaped portion consists of a lip with an upwardly directed locking element, whereas the upper hook-shaped portion consists of a lip with a downwardly directed locking element;

wherein the second locking system of said second pair of edges comprises locking parts consisting of only one single locking part situated next to the proximal end of the lower hook-shaped portion and a single locking part situated next to the distal end of the upper hook-shaped portion;

wherein at least one of said locking parts of the second locking system of the second pair of edges is made from soft PVC;

wherein at least the edges of the first pair of edges define respective upper panel edges; and

wherein the panel at said upper panel edges of the first pair of edges is provided with a chamfered surface.

14. The panel of claim 13, wherein the panel comprises a substrate on the basis of soft PVC and wherein said coupling parts of the first and second pairs of edges are integrally made in said substrate.

15. The panel of claim 13, wherein said locking parts define substantially horizontal locking surfaces.

16. The panel of claim 13, wherein the locking part that is situated next to the distal end of the upper hook-shaped portion, is placed somewhat towards the inside, such that this locking part is situated entirely underneath the upper side of the panel.

17. The panel of claim 13, wherein the distal end of the lower hook-shaped portion, in a coupled condition of two of such panels, is spaced from the opposite coupled panel.

18. The panel of claim 13, wherein the panel comprises a substrate on the basis of soft PVC and a top layer above said substrate, said top layer having a material thickness, wherein said chamfered surface forms a small bevel that is located within the material thickness of the top layer only and thus completely above said substrate.

19. A panel for forming a floor covering, which, at least at two opposite edges, comprises coupling parts of the type allowing to couple two of such panels to each other by means of a downward movement of one panel in respect to the other;

wherein these coupling parts form a first locking system, which effects a locking in the plane of the panels and perpendicularly to said edges, as well as form a second locking system, which effects a locking perpendicularly to the plane of the panels;

wherein the first locking system is formed at least of an upwardly directed lower hook-shaped portion which is situated at one of said two edges, as well as of a downwardly directed upper hook-shaped portion which is situated at the opposite edge;

wherein the lower hook-shaped portion consists of a lip with an upwardly directed locking element, whereas the upper hook-shaped portion consists of a lip with a downwardly directed locking element;

wherein the second locking system comprises locking parts consisting of a single locking part situated next to the proximal end of the lower hook-shaped portion and a single locking part situated next to the distal end of the upper hook-shaped portion;

wherein at least one of said locking parts of the second locking system is made from soft PVC;

wherein the downwardly directed locking element at the distal end of the upper hook-shaped portion comprises a guiding surface, which is inclined with respect to the direction perpendicular to the plane of the panel; and

wherein said guiding surface extends upward from the lower side of the downwardly directed locking element.

20. The panel of claim 19, wherein the panel comprises a substrate on the basis of soft PVC and wherein said coupling parts are integrally made in said substrate.

21. The panel of claim 19, wherein said guiding surface, when coupling two of such panels at the respective edges, guides the downwardly directed locking element through an opening between the upwardly directed locking element and the locking part situated next to the proximal end of the lower hook-shaped portion.

22. The panel of claim 19, wherein the locking parts define substantially horizontal locking surfaces.

23. The panel of claim 19, wherein the locking part that is situated next to the distal end of the upper hook-shaped portion is placed somewhat towards the inside, such that this locking part is situated entirely underneath the upper side of the panel.

24. The panel of claim 19, wherein the distal end of the lower hook-shaped portion, in a coupled condition of two of such panels, is spaced from the opposite coupled panel.