Panel, covering and method for installing such panels

• US 9,670,682 B2
• Filed: 07/12/2016
• Issued: 06/06/2017
• 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
• Primary Examiner(s): Chapman, Jeanette E
• Application Number:
  US15/207,685
• Publication Number:
  US 20160356047A1
• Time in Patent Office: 329 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 floor panel for forming a floor covering;

wherein the panel comprises a substrate of a material on the basis of soft PVC;

wherein the panel is rectangular, either oblong or square, and 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 couple a plurality of such panels to each other;

wherein the coupling parts, at both pairs of edges, form a first locking system effecting a locking in the plane of the panels and perpendicular to the respective edges, and form a second locking system effecting a locking transverse to the plane of the panels;

wherein the coupling parts, at least at one of said two pairs of edges, substantially are realized from said substrate and in one piece of said material on the basis of soft PVC;

wherein the coupling parts, at least at said one of said two pairs of edges, consist of a tongue and a groove, as well as locking parts, which, in the coupled condition, prevent the drifting apart of the tongue and groove, said locking parts defining cooperating locking surfaces;

wherein said groove is bordered by a lower lip and an upper lip, wherein the lower lip extends laterally up to beyond the distal end of the upper lip and wherein the lower lip comprises one of said cooperating locking surfaces;

wherein said tongue and groove have a shape which provides for that, in the coupled condition of two of such panels, a space is present underneath the tongue, said space extending from the tip of the tongue continuously underneath the tongue up to a location situated beyond the distal end of the upper lip, said location measured in horizontal direction being closer to said locking surface at said lower lip than to the distal end of the upper lip;

wherein a contacting portion at the underside of the upper lip, which, in the coupled condition of two of such panels, cooperates with the upper side of the tongue at the respective opposite edge, forms a downward inclination, more particularly a slight downward inclination, in proximal direction; and

wherein in the coupled condition said lower lip located distally from the corresponding locking surface is free from vertically active support surfaces.

2. The floor panel of claim 1, wherein the tongue and groove, including the locking parts, are arranged for allowing interconnecting two of such panels at the respective edges by means of a turning movement.

3. The floor panel of claim 2, wherein, when two of such floor panels, at the respective edges, are presented to each other in a plane-parallel manner, the tongue, at least with its tip, already comes to sit at least partially underneath the lip bordering the upper side of the groove, without any bending being necessary already.

4. The floor panel of claim 3, wherein the tongue is beveled or rounded at its upper side, next to the tip;

and wherein, distally from the contacting portion, a beveled and/or rounded portion is present at the underside of the upper lip.

5. The floor panel of claim 1, wherein the distance from the tip of the tongue up to the distal end of the upper lip, is larger than 1.2 times and still better is larger than 1.3 times the average thickness of the portion of the tongue situated in coupled condition underneath said contacting portion at the underside of the upper lip.

6. The floor panel of claim 1, wherein the smallest thickness of the portion of the lower lip situated beyond the distal end of the upper lip, is at least 0.7 times the average thickness of the upper lip at the location of said contacting portion at the underside of the upper lip.

7. A floor panel for forming a floor covering;

wherein the panel comprises a substrate of a material on the basis of synthetic material;

wherein the panel is rectangular, either oblong or square, and 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 couple a plurality of such panels to each other;

wherein the coupling parts, at both pairs of edges, form a first locking system effecting a locking in the plane of the panels and perpendicular to the respective edges, as well as form a second locking system effecting a locking transverse to the plane of the panels;

wherein the coupling parts at least at one of said two pairs of edges substantially are realized from said substrate;

wherein said coupling parts, at least at said one of said two pairs of edges, consist of a tongue and a groove, as well as locking parts, which, in the coupled condition, prevent the drifting apart of the tongue and groove;

wherein said groove is bordered by a lower lip and an upper lip, whereby the lower lip extends laterally up to beyond the distal end of the upper lip;

wherein said tongue and groove have a shape which provides for that, in the coupled condition of two of such panels, a space is present underneath the tongue, said space extending from the tip of the tongue continuously underneath the tongue at least up to a location situated beyond the distal end of the upper lip;

wherein a contacting portion at the underside of the upper lip, which, in coupled condition of two of such panels, cooperates with the upper side of the tongue at the respective opposite edge, forms a downward inclination, more particularly a slight downward inclination, in proximal direction;

wherein the tongue is in connection with the remainder of the panel by means of a narrowed portion;

wherein the smallest vertical thickness of the portion of the lower lip situated beyond the distal end of the upper lip, is smaller than the smallest vertical thickness of said narrowed portion; and

wherein the tongue, in downward direction, is supported on the groove by means of the locking surfaces and/or by means of a support point situated proximally from the locking surfaces.

8. The floor panel of claim 7, wherein the tongue and groove, including the locking parts, are arranged for allowing interconnecting two of such panels at the respective edges by means of a turning movement.

9. The floor panel of claim 8, wherein said tongue and groove are realized such that, when two of such panels, at the respective edges, are presented to each other in a plane-parallel manner, the tongue, at least with its tip, already comes to sit at least partially underneath the lip bordering the upper side of the groove, without any bending being necessary already.

10. The floor panel of claim 9, wherein the tongue is beveled or rounded at its upper side, next to the tip;

and wherein, distally from the contacting portion, a beveled and/or rounded portion is present at the underside of the upper lip.

11. The floor panel of claim 7, wherein the distance from the tip of the tongue up to the distal end of the upper lip, is larger than 1.2 times the average thickness of the portion of the tongue situated in coupled condition underneath said contacting portion at the underside of the upper lip.

12. The floor panel of claim 7, wherein the smallest vertical thickness of the portion of the lower lip situated beyond the distal end of the upper lip, is at least 0.7 times the average thickness of the upper lip at the location of said contacting portion at the underside of the upper lip.