U.S. patent application number 17/427806 was filed with the patent office on 2022-05-05 for panel and covering formed with such panels.
The applicant listed for this patent is FLOORING INDUSTRIES LIMITED, SARL. Invention is credited to Mark CAPPELLE.
Application Number | 20220136257 17/427806 |
Document ID | / |
Family ID | 1000006139411 |
Filed Date | 2022-05-05 |
United States Patent
Application |
20220136257 |
Kind Code |
A1 |
CAPPELLE; Mark |
May 5, 2022 |
PANEL AND COVERING FORMED WITH SUCH PANELS
Abstract
A panel includes a top side, a bottom side and a first edge
extending between the top and bottom side and having a first
coupling part; and a second edge extending between the top and
bottom side and having a second coupling part. The coupling parts
make it possible to produce a horizontal and vertical lock between
two such panels by means of a vertical movement of the one panel
with respect to the other panel.
Inventors: |
CAPPELLE; Mark; (Staden,
BE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FLOORING INDUSTRIES LIMITED, SARL |
Bertrange |
|
LU |
|
|
Family ID: |
1000006139411 |
Appl. No.: |
17/427806 |
Filed: |
February 5, 2020 |
PCT Filed: |
February 5, 2020 |
PCT NO: |
PCT/IB2020/050904 |
371 Date: |
August 2, 2021 |
Current U.S.
Class: |
52/588.1 |
Current CPC
Class: |
E04F 2201/043 20130101;
E04F 15/04 20130101; E04F 15/02038 20130101; E04F 13/10 20130101;
E04F 2201/042 20130101; E04F 2201/049 20130101; E04F 2201/0153
20130101; E04F 2201/0535 20130101; E04F 2201/0552 20130101; E04F
2201/023 20130101; E04F 13/0894 20130101; E04F 2201/0146
20130101 |
International
Class: |
E04F 15/02 20060101
E04F015/02; E04F 15/04 20060101 E04F015/04 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 7, 2019 |
BE |
2019/5073 |
Claims
1.-26. (canceled)
27. A panel, comprising a top side, a bottom side and a first edge
extending between the top and bottom side and having a first
coupling part, and a second edge extending between the top and
bottom side and having a second coupling part, which coupling parts
make it possible to produce a horizontal and vertical lock between
two such panels by means of a vertical movement of the one panel
with respect to the other panel, wherein the first coupling part
comprises a lip which is situated on the bottom side of the panel
and has a first, upwardly directed locking element which forms a
first locking surface, which first locking surface, in the coupled
position, cooperates with a second locking surface which is formed
in a first, downwardly directed locking groove of the second
coupling part, in order to partly or completely produce the
horizontal lock, wherein the coupling parts comprise a second,
separate locking element which, in the coupled position, cooperates
with a second locking groove of the coupling parts in order to
partly or completely produce the vertical lock and wherein the
first coupling part comprises a first closure surface which, in the
coupled position, cooperates with a second closure surface of the
second coupling part, in this case defining a vertical closure
face, wherein the separate locking element is part of the first
coupling part, wherein the lip is elastically bent in the coupled
position, in such a way that a reactive force is generated which
pushes the coupled panels against each other at the location of the
cooperating closure surfaces, and wherein the upwardly directed
locking element, viewed in the disengaged position, has an
uppermost point which is situated at a vertical distance from the
bottom side of the panel of at least 0.35 times the thickness of
the panel.
28. The panel of claim 27, wherein, in the coupled position, the
cooperating locking surfaces define a central point which is
situated at a horizontal distance from the vertical closure face
which is at most once the thickness of the panel.
29. The panel of claim 27, wherein, in the coupled position, the
cooperating locking surfaces define a tangent which forms an angle
with the horizontal from 45 to 85 degrees, but less than 90
degrees.
30. The panel of claim 27, wherein, viewed in the disengaged
position, the lip has a most distal point which is situated at a
horizontal distance from the vertical closure face which is at
least once the thickness of the panel.
31. The panel of claim 27, wherein the lip is bent over a maximum
vertical distance of 0.0025 to 0.015 times the thickness of the
panel.
32. The panel of claim 27, wherein the upwardly directed locking
element is connected to another portion of the lip via a stepped
portion of a top side of the lip, which stepped portion runs
upwards in the direction towards the upwardly directed locking
element.
33. The panel of claim 27, wherein the lip has a minimum thickness
which is at least 0.175 times the thickness of the panel.
34. The panel of claim 27, wherein the downwardly directed locking
groove has a bottom which runs substantially obliquely downwards in
a direction away from the second locking surface.
35. The panel of claim 27, wherein the first and second coupling
part are configured in such a way that they make it possible to
disengage the respective edges by means of a turning movement.
36. The panel of claim 27, wherein the panel comprises a core or
core layer made of wood or wood-based material, such as MDF or HDF,
and wherein the first and/or second coupling part is at least
partly made of this wood or wood-based material.
37. The panel of claim 27, wherein the thickness of the panel
ranges from 3 to 20 millimeters.
38. The panel of claim 27, wherein the top side of the panel is
free from chamfers or bevels on the first and/or second edge.
39. The panel of claim 27, wherein the panel is rectangular and the
first and second edges form the short edges of the panel.
40. The panel of claim 39, wherein the panel comprises coupling
parts on the long edges, which coupling parts make it possible to
produce a horizontal and vertical lock between two such panels by
means of a turning movement of the one panel with respect to the
other panel.
41. A panel, comprising a top side, a bottom side and a first edge
extending between the top and bottom side and having a first
coupling part, and a second edge extending between the top and
bottom side and having a second coupling part, which coupling parts
make it possible to produce a horizontal and vertical lock between
two such panels by means of a vertical movement of the one panel
with respect to the other panel, wherein the first coupling part
comprises a lip which is situated on the bottom side of the panel
and has a first, upwardly directed locking element which forms a
first locking surface, which first locking surface, in the coupled
position, cooperates with a second locking surface which is formed
in a first, downwardly directed locking groove of the second
coupling part, in order to partly or completely produce the
horizontal lock, wherein the coupling parts comprise a second,
separate locking element which, in the coupled position, cooperates
with a second locking groove of the coupling parts in order to
partly or completely produce the vertical lock and wherein the
first coupling part comprises a first closure surface which, in the
coupled position, cooperates with a second closure surface of the
second coupling part, in this case defining a vertical closure
face, wherein the separate locking element is part of the first
coupling part, wherein the lip is elastically bent in the coupled
position, in such a way that a reactive force is generated which
pushes the coupled panels against each other at the location of the
cooperating closure surfaces, and wherein the upwardly directed
locking element, viewed in the disengaged and/or coupled position,
has an uppermost point which defines a horizontal level, which
horizontal level is situated above at least a portion of the
separate locking element.
42. The panel of claim 41, wherein, in the coupled position, the
cooperating locking surfaces define a central point which is
situated at a horizontal distance from the vertical closure face
which is at most once the thickness of the panel.
43. The panel of claim 41, wherein, viewed in the disengaged
position, the lip has a most distal point which is situated at a
horizontal distance from the vertical closure face which is at
least once the thickness of the panel.
Description
[0001] The present invention relates to a panel and to a covering
produced using such panels.
[0002] More particularly, the invention relates to a panel which
comprises a top side, a bottom side, a first edge extending between
the top and bottom side and having a first coupling part and a
second edge extending between the top and bottom side and having a
second coupling part. The term "top side" of the panel is here
generally understood to mean the side of the panel which is visible
in the installed position of the panel, whereas the term "bottom
side" of the panel is understood to mean the opposite side.
[0003] The coupling parts are of the so-called push-lock type. This
means that they make it possible to bring about a horizontal and
vertical lock between two such panels by means of a vertical
movement of the one panel with respect to the other panel. This
means that that the first edge can be coupled to the second edge by
means of a movement of the first edge relative to the second edge
substantially along the vertical direction or the direction at
right angles to the surface to be produced by coupled or installed
panels. The result of the coupling movement is a horizontal and
vertical lock which has been produced between the mutually coupled
edges. In the context of the present invention, the term
"horizontal lock" is understood to mean in the horizontal direction
or in the direction in the plane of the coupled panels and at right
angles to the coupled edges, whereas the term a "vertical lock" is
understood to mean a lock in the vertical direction or in the
direction at right angles to the plane of the coupled panels.
[0004] The first coupling part comprises a lip which is preferably
situated on the bottom side of the panel and has a first, upwardly
directed locking element which forms a first locking surface. In
the coupled position, this locking surface cooperates with a second
locking surface which is formed in a first, downwardly directed
locking groove of the second coupling part. The terms "upwardly" or
"upward" are here understood to mean in a direction towards the top
side of the panel, whereas the terms "downwardly" or "downward" are
understood to mean in a direction towards the bottom side of the
panel. The cooperation between the first and second locking surface
is aimed at partly or completely producing the horizontal lock.
[0005] The first coupling part furthermore comprises a first
closure surface, which closure surface, in the coupled position,
cooperates with a second closure surface of the second coupling
part, as a result of which a vertical closure face is defined. The
vertical closure face is situated at the location of a connecting
joint which is formed between the coupled panels and which is
visible from above, i.e. from a top view of the coupled panels.
[0006] Panels of the above-described push-lock type are known per
se. Essentially, there are two types of such push-lock systems,
i.e. a single-part and two-part type. With push-lock systems of the
single-part type, the coupling parts are designed to form a single
entity with the actual panel. In other words, no separate insert or
the like is used. Such single-part push-lock systems are described,
for example, in the documents WO 01/02669 and WO 01/75247. An
advantage of these push-lock systems is the fact that, due to the
lack of a separate insert, they are easy to produce and relatively
inexpensive. However, often a compromise has to be found with such
systems between the strength of the lock on the one hand and the
speed of installation on the other hand due to the limited
properties of the actual material from which the panels are
constructed. This is certainly the case with panels which are made
of wood or wood-based material, such as MDF or HDF, which materials
only have a limited elasticity.
[0007] With the two-part variant, a separate locking element is
used to partly or completely produce the horizontal and/or vertical
lock. In this case, the term "separate" is understood to mean that
the locking element is not formed as a single entity with the
actual panel, but involves a separate element which may, for
example, be fitted by an installer of the panels or in the factory,
i.e. during the production process of the panels. Such two-part
systems are also known per se and are described, for example, in
documents WO 2006/043893 and WO 2009/066153. An advantage of the
two-part push-lock systems is the fact that they are less dependent
on the actual material from which the panels are constructed. The
material of the separate insert may be chosen in such a manner and
irrespective from the material of the actual panels, that both the
strength of the lock and the speed of installation result in a
positive experience. It is thus no longer so important to find a
compromise between these two elements. The use of the separate
element may, however, result in a slightly more complicated
production process and slightly increases the price of the
push-lock system.
[0008] A drawback of the systems disclosed in the document WO
2009/066153, is the fact that, for some applications, the risk of
gaps forming between the coupled panels is too great. Such
formation of gaps may result in water or moisture penetrating into
the coupling, which may be disastrous in spaces where large
quantities of water are used, such as a bathroom or the like, in
particular with moisture-sensitive panels, such as panels which are
made of wood or wood-based material, such as MDF or HDF.
[0009] Document WO 2017/068523 describes different two-part
push-lock systems, in which the principle of "pretension" is
applied. In this case, a lip which is bent in the coupled position
generates a force which pushes the panels towards each other and
thus prevents the formation of gaps. However, it turns out that the
vertical lock which is provided by the systems described is not
satisfactory for some applications. With some applications, the
occurrence of differences in height between the coupled panels is
not counteracted to a sufficient degree.
[0010] The object of the present invention is firstly to alleviate
one or several of the drawbacks mentioned in connection with
two-part push-lock systems.
[0011] For this purpose, the invention, according to a first
aspect, relates to a panel, comprising a top side, a bottom side
and a first edge extending between the top and bottom side and
having a first coupling part, and a second edge extending between
the top and bottom side and having a second coupling part, which
coupling parts make it possible to produce a horizontal and
vertical lock between two such panels by means of a vertical
movement of the one panel with respect to the other panel, wherein
the first coupling part comprises a lip which is preferably
situated on the bottom side of the panel and has a first, upwardly
directed locking element which forms a first locking surface, which
first locking surface, in the coupled position, cooperates with a
second locking surface which is formed in a first, downwardly
directed locking groove of the second coupling part, in order to
partly or completely produce the horizontal lock, wherein the
coupling parts comprise a second, separate locking element which,
in the coupled position, cooperates with a second locking groove of
the coupling parts in order to partly or completely produce the
vertical lock and wherein the first coupling part comprises a first
closure surface which, in the coupled position, cooperates with a
second closure surface of the second coupling part, in this case
defining a vertical closure face, characterized in that the
separate locking element is part of the first coupling part, in
that the lip is elastically bent in the coupled position, in such a
way that a reactive force is generated which pushes the coupled
panels against each other at the location of the cooperating
closure surfaces, and in that the upwardly directed locking
element, in the disengaged position, has an uppermost point which
is situated at a vertical distance from the bottom side of the
panel of at least 0.35 times, preferably at least 0.4 times and
more preferably at least 0.45 times the thickness of the panel. In
this case, the thickness of the panel is defined as being the
vertical distance between the bottom side and the top side of the
panel. The measures according to this first aspect offer the
advantage that both the formation of gaps and the occurrence of
differences in height are counteracted in an optimum manner. The
risk of the formation of gaps is minimized due to the fact that
pretension is provided in the coupling without this leading to a
significant risk of disengagement of the coupling parts. The latter
is achieved through the relatively high design of the upwardly
directed locking element, as a result of which this locking element
can be arranged relatively deeply in the downwardly directed
locking groove, so that it can only be removed from the locking
groove with difficulty, even in the bent position of the lip.
Furthermore, the risk of differences in height can be kept under
control more reliably, due to the fact that the separate locking
element is provided in the first coupling part. The separate
element can be made more robust in this location, thus providing a
more reliable vertical lock, without this resulting in problems
during installation, such as, for example, this separate element
becoming trapped between the edges to be coupled, which is a
significant risk with a separate locking element which is too
robust and is provided in the second coupling part.
[0012] In the coupled position, the cooperating locking surfaces
may define a central point which is situated at a horizontal
distance from the vertical closure face which is at most once the
thickness of the panel. This relatively short locking distance
ensures that in particular the horizontal lock is reinforced
further, which has a positive effect on counteracting the formation
of gaps.
[0013] In the coupled position, the cooperating locking surfaces
may define a tangent which forms an angle with the horizontal of 45
to 90 degrees, preferably from 65 to 90 degrees, but less than 90
degrees. Such an oblique orientation of the locking surfaces
ensures efficient transmission of the force generated by the bent
lip to the cooperating closure surfaces, which results in an
optimum action of the pretension.
[0014] Viewed in the disengaged position, the lip may have a most
distal point which is situated at a horizontal distance from the
vertical closure face which is at least once the thickness of the
panel. Such relatively long lip enhances the elastic properties
thereof and thus ensures that it can easily be bent.
[0015] The lip may be bent over a maximum vertical distance of
0.0025 to 0.015 times, preferably of 0.005 to 0.0125 times the
thickness of the panel. This ensures that the force generated by
the bent lip is sufficiently large to counteract the formation of
gaps efficiently without the ease of installation suffering any
detrimental effect.
[0016] The upwardly directed locking element may be connected to
another portion of the lip via a stepped portion of a top side of
the lip, which stepped portion preferably runs upwards in the
direction towards the upwardly directed locking element. Such a
stepped portion ensures a stable connection of the upwardly
directed locking element to the remaining portion of the lip, which
improves the strength of the connection.
[0017] The lip may have a minimum thickness of at least 0.175 times
the thickness of the panel, which ensures a stable design of the
lip and thus has a positive effect on the strength of the
connection.
[0018] The downwardly directed locking groove may have a bottom
which runs substantially obliquely downwards in a direction away
from the second locking surface. This ensures that the upwardly
directed locking element can be made relatively high and can be
inserted relatively deeply into the downwardly directed locking
groove, whereas the connection of the second coupling part to the
actual panel remains stable. The top side of the upwardly directed
locking element may be adapted hereto and also run substantially
obliquely downwards in a direction away from the first locking
surface.
[0019] The first coupling part may have an upward side which
comprises the closure surface, in which upward side a recess is
provided which houses the separate locking element. This location
of the separate locking element is ideal with a view to minimizing
possible installation problems. In this case, the second locking
groove is preferably provided in a distal side of the second
coupling part, which distal side comprises the second closure
surface.
[0020] The separate locking element may be deformable and/or
movable and this preferably in an elastic way, the deformability
and/or mobility of the separate element making it possible to reach
the locked or coupled position between the respective edges. Such a
separate element is known per se and described, for example, in
documents WO 2006/043893 and WO 2009/066153.
[0021] The separate locking element is preferably made of one or
several plastics, such as polyvinyl chloride (PVC) or acrylonitrile
butadiene styrene (ABS).
[0022] The separate locking element may comprise a rotatable,
preferably elastically rotatable, locking leg which, in the coupled
position, cooperates with the second locking groove in order to
partly or completely produce the vertical lock. Such rotatable
locking leg is advantageous with a view to a quick installation
procedure. When performing the coupling movement, the rotatable
locking leg may initially be swung away, for example because the
second coupling part pushes it away, in such a way that the
respective edges can be coupled to each other, in order to then
rebound, either completely or not, in order to reach the locking
position. In this case, the locking leg thus actually performs a
reciprocating movement.
[0023] The rotatable locking leg may be directed downwards, which
is an advantageous configuration if the separate locking element is
provided in the first coupling part.
[0024] The separate locking element may comprise a more flexible
material part which makes a rotary movement of the locking leg
possible. In this case, the expression "more flexible" is
understood to mean that the material part is more flexible than the
locking leg, for example due to the fact that it is made from a
softer plastic. The more flexible material part makes it possible
for the locking leg to be readily rotatable, which improves the
ease of installation, despite the rotatable locking leg being of a
robust design. The rotatable locking leg may be formed as a single
entity with the more flexible material part. To this end, a
co-extrusion technique may be used, for example. The rotatable
locking leg may be made from, for example, rigid or semi-rigid
polyvinyl chloride (PVC) or acrylonitrile butadiene styrene (ABS),
whereas the more flexible material part may be made from, for
example, soft PVC.
[0025] The separate locking element may comprise a securing part
for securing the separate locking element in a recess provided for
the purpose. The securing part may be designed in such a manner
that this securing part fits into the recess in a clamping manner.
The securing part may be formed as a single entity with the
rotatable locking leg. If the separate locking element also
comprises a more flexible material part, the rotatable locking leg,
the more flexible material part and the securing part are
preferably formed as a single entity with each other, for example
by means of co-extrusion. The securing part is preferably made from
the same material as the rotatable locking leg.
[0026] The first and second coupling part may be configured in such
a way that they make it possible to disengage the respective edges
by means of a turning movement. This results in a simple way of
uninstalling the panels, for example in case an error occurred
during installation or when replacing installed panels. The
bendability of the lip and the optionally oblique orientation of
the locking surfaces can contribute to a quick disengagement of the
coupled edges by turning.
[0027] The lip and the upwardly directed locking element may be
formed as a single entity with the panel. To this end, cutting
and/or milling tools may be used.
[0028] The first coupling part may be formed entirely as a single
entity with the actual panel except for the separate locking
element.
[0029] The second coupling part may be formed entirely as a single
entity with the actual panel.
[0030] The invention is used particularly advantageously with
panels made of wood or wood-based material or with panels which
comprise a core or core layer made of wood or wood-based material,
wherein the first and/or second coupling part is at least partly
made of and forms a single entity with this wood or wood-based
material. Examples of such materials are solid wood, chipboard and
fiberboard, such as MDF (Medium Density Fiberboard) and HDF (High
Density Fiberboard). Such materials are water- and/or
moisture-sensitive, hence the importance of avoiding water or
moisture from penetrating in the coupling and keeping the
connecting joint between coupled panels tight, thus preventing the
formation of gaps. The measures according to the invention see to
this and are thus particularly advantageous with this type of
panels. A waterproof coating may be provided in the coupling in
order to be able to keep infiltrating water or moisture out still
more effectively. Such a coating may be provided, for example, at
least at the location of the first and/or second closure
surface.
[0031] The invention is extremely suitable for use with panels
comprising an MDF or HDF core, in which the first and/or second
coupling part is at least partly, and preferably substantially, in
the case of the first coupling part except for the separate locking
element, formed as a single part with the material of the MDF or
HDF core. In this case, the term "substantially" is intended to
indicate that the respective coupling parts may partly be composed
of a possible top and/or counter layer which would be situated
above and below the MDF or HDF core, respectively.
[0032] It is not excluded that the invention is used with panels
made of a material other than a wood or wood-based material, such
as panels made of or panels containing a core or core layer made of
an optionally filled thermosetting material, for example
thermosetting polyurethane, a filled or a non-filled thermoplastic
material, for example polyvinyl chloride, polyethylene,
polypropylene, polyethylene terephthalate or thermoplastic
polyurethane, a mineral or ceramic material, cement fiber plate or
magnesium oxide plate. Other materials are not excluded.
[0033] The thickness of the panels may range from 3 to 20
millimeters. However, panels which are thinner or thicker are not
excluded. A typical thickness of panels having an MDF or HDF core
ranges from 6 to 12 millimeters and is typically around 8
millimeters.
[0034] The panel may be a decorative panel, i.e. a panel which has
a decor on its top side, such as a wood or stone decor. This decor
can be effectuated by a wooden top layer which is applied to a core
of the panel or by a carrier sheet which is applied to a core of
the panel and which is printed thereon, such as a paper sheet
printed with a decor or a plastic film printed with a decor.
[0035] The invention makes it possible to design the top side of
the panel so as to be free from chamfers or bevels on the first
and/or second edge. Such chamfers or bevels are sometimes provided
in order to mask any differences in height between the coupled
panels. Due to the fact that the invention makes it possible to
minimize the risk of such differences in height, it makes it
possible to omit chamfers or bevels, in such a way that the top
side of the final covering produced by means of such panels may be
flat. However, it is not excluded that the top side of the panel
may be provided with a chamfer or a bevel on the first and/or
second edge in order, for example, to mask a possible difference in
height which would occur nevertheless or to produce, for example, a
plank effect in the final covering.
[0036] The invention may be used with rectangular panels which, in
practice, are the most common panels. Preferably, the short edges
are provided with the first and second coupling part, but it is not
excluded that the first and second coupling part are used on the
long edges.
[0037] When using the first and second coupling part on the short
edges, the long edges may also be provided with coupling parts, but
this does not necessarily have to be the case. The coupling parts
on the long edges may be of the push type, i.e. of the type which
makes it possible to produce a horizontal and vertical lock between
two such panels by means of a vertical movement of the one panel
with respect to the other panel, and may thus be of the same type
as the coupling parts on the short edges. However, to this end, the
coupling parts on the long edges do not have to be identical to the
coupling parts on the short edges and do not even have to have the
measures of the invention. In case the coupling parts on the long
edges are also of the push type, the coupling parts on the long and
short edges may be configured in such a manner that they allow the
panel to be coupled by both a long edge and a short edge to
adjacent panels in one and the same vertical movement.
[0038] In an alternative, the coupling parts on the long edges may
be of the turning type, i.e. of the type which makes it possible to
produce a horizontal and vertical lock between two such panels by
means of a turning movement of the one panel with respect to the
other panel. To this end, the coupling parts on the long edges may,
for example, be in the form of a locking tongue and groove
connection, as is known per se, for example, from document WO
97/47834. If the coupling parts on the long edges are of the
turning type, the coupling parts on the long and short edges may be
configured in such a way that they make it possible to couple the
panel by both a long edge and a short edge to the adjacent panels
in one and the same turning movement. In the field, such turning
movement is also referred to as "fold-down movement" and is known
per se, for example from document WO 01/75247.
[0039] It is not excluded that the invention is used with panels
other than rectangular panels. Using coupling parts of the push
type on both pairs of edges may be useful, for example, with square
panels. Panels other than rectangular or square panels are not
excluded.
[0040] The panel is preferably a floor panel, but it is not
excluded that the invention is used with other types of panels,
such as for example wall, ceiling or door panels.
[0041] With the same object and according to a second aspect, the
invention relates to a panel, comprising a top side, a bottom side
and a first edge extending between the top and bottom side and
having a first coupling part and a second edge extending between
the top and bottom side and having a second coupling part, which
coupling parts make it possible to produce a horizontal and
vertical lock between two such panels by means of a vertical
movement of the one panel with respect to the other panel, wherein
the first coupling part comprises a lip which is preferably
situated on the bottom side of the panel and has a first, upwardly
directed locking element which forms a first locking surface, which
first locking surface, in the coupled position, cooperates with a
second locking surface which is formed in a first, downwardly
directed locking groove of the second coupling part, in order to
partly or completely produce the horizontal lock, wherein the
coupling parts comprise a second, separate locking element which,
in the coupled position, cooperates with a second locking groove of
the coupling parts in order to partly or completely produce the
vertical lock and wherein the first coupling part comprises a first
closure surface which, in the coupled position, cooperates with a
second closure surface of the second coupling part, thus defining a
vertical closure face, characterized in that the separate locking
element is part of the first coupling part, in that the lip is
elastically bent in the coupled position, in such a way that a
reactive force is generated which pushes the coupled panels against
each other at the location of the closure surfaces, and in that the
upwardly directed locking element, in the disengaged and/or coupled
position has an uppermost point, which uppermost point defines a
horizontal level which is situated above at least a portion of the
separate locking element. As with the first aspect, the measures
according to this second aspect offer the advantage that both the
formation of gaps and the occurrence of differences in height are
counteracted in an optimum manner.
[0042] The panel according to the second aspect may have one or
several of the features which are described in connection with the
first aspect, without the upwardly directed locking element, viewed
in the disengaged position, having to have an uppermost point which
is situated at a vertical distance from the bottom side of the
panel of at least 0.35 times the thickness of the panel, although
it is not excluded that the panel also has this feature.
[0043] The invention also relates to a covering which is produced
using panels which are configured according to the first and/or
second aspect. The covering is preferably a decorative covering,
such as a decorative floor or wall covering.
[0044] In order to show the features of the invention in more
detail, some preferred embodiments are described below by way of
example and without being limited thereto, with reference to the
accompanying drawings, in which:
[0045] FIG. 1 shows a panel according to the invention in top
view;
[0046] FIG. 2 shows an enlarged cross section along line II-II in
FIG. 1;
[0047] FIG. 3 shows an enlarged cross section along line in FIG. 1;
and
[0048] FIG. 4 shows an enlarged view of the coupling parts from
FIG. 3, however in the coupled position.
[0049] FIG. 1 shows a panel 1 according to the invention in top
view. The panel 1 is a floor panel of the decorative type. However,
the decor is not shown in FIG. 1. By means of several such panels
1, a decorative floor covering can be produced.
[0050] The panel 1 has a top side 2 and a bottom side 3. The panel
1 is rectangular and thus has a pair of long edges 4-5 and a pair
of short edges 6-7, which long and short edges 4-5-6-7 extend
between the top side 2 and the bottom side 3. On the long edges
4-5, the panel 1 comprises coupling parts 8-9 and on the short
edges 6-7 coupling parts 10-11.
[0051] FIG. 2 shows the coupling parts 8-9 on the long edges 4-5
and also shows how these edges 4-5 can be coupled to each other.
The coupling parts 8-9 are configured in such a way that they make
it possible to produce a horizontal and vertical lock between two
such panels 1 by means of a turning movement W of the one panel 1
and the other panel 1. The coupling parts 8-9 also make it possible
to couple two such panels 1 by means of a substantially horizontal
movement S of the one panel 1 relative with respect to the other
panel 1. When carrying out this horizontal movement S, the lip 12
is bent elastically, as is indicated by the arrow, and a so-called
click-fit or snap-fit effect occurs.
[0052] The coupling parts 8-9 are designed in the form of a locking
tongue and groove connection, i.e. a tongue and groove connection
which not only produces a vertical but also a horizontal lock. The
coupling part 8 comprises a groove 12 which is configured to
receive the tooth 13 of the coupling part 9 in order thus to
produce the vertical lock. More particularly, the top side of the
tooth 13, in the coupled position, cooperates with the bottom side
of a top lip 14 which delimits the groove along the top in order to
produce the vertical lock. The groove 12 is delimited along the
bottom by a bottom lip 15 which is provided with an upwardly
directed locking element 16. In the coupled position, this locking
element 16 cooperates with a downwardly directed locking groove 17
on the tooth 13 in order to produce the horizontal lock. The bottom
lip 15 extends beyond the distal or free end of the top lip 14 in
the horizontal direction.
[0053] The coupling parts 8-9 are made of and formed as a single
entity with the material of the actual panel 1.
[0054] The panel 1 has a thickness T of 3 to 20 millimeters, more
particularly approximately 8 millimeters.
[0055] FIG. 3 shows the coupling parts 10-11 on the short edges 6-7
and also shows how these edges 6-7 can be coupled to each other.
The coupling parts 10-11 make it possible to produce a horizontal
and vertical lock between two such panels 1 by means of a vertical
movement M of the one panel 1 with respect to the other panel 1.
The coupling parts 8-9 and 10-11 are designed in such a way that
they make it possible to couple the panel 1 in one and the same
turning movement by both a long edge and a short edge to adjacent
such panels 1. This thus involves a panel 1 of the so-called
fold-down type.
[0056] The coupling part 10 comprises a lip 18 which is situated on
the bottom side 3 of the panel 1 and has an upwardly directed
locking element 19 which forms a locking surface 20. In the coupled
position, this locking surface 20 cooperates with a locking surface
21 which is formed in a downwardly directed locking groove 22 of
the coupling part 11 in order to produce the horizontal lock.
[0057] The coupling part 10 comprises a first closure surface 23
which, in the coupled position, cooperates with a second closure
surface 24 of the second coupling part 11, which cooperating
closure surfaces, in the coupled position, define a vertical
closure face V1.
[0058] Viewed in the disengaged position, the lip 18 has a most
distal point P which is situated at a horizontal distance D from
the vertical closure face V1 of at least once the thickness T of
the panel 1.
[0059] The locking element 19 is connected to another portion of
the lip 18 via a stepped portion 25 of a top side of the lip 18.
The stepped portion 25 runs upwards in the direction towards the
locking element 19.
[0060] The lip 18 has a minimum thickness T2 which is at least
0.175 times the thickness T of the panel 1.
[0061] The locking groove 22 has a bottom 26 which runs
substantially obliquely downwards, in a direction away from the
second locking surface 21. The locking element has a top side 27
which is adapted thereto and runs substantially obliquely
downwards, in the direction away from the first locking surface
20.
[0062] The coupling part 10 is provided with a separate locking
element 28. This locking element is arranged in a recess 29 which
is provided in an upward side 30 of the first coupling part 10. The
upward side 30 comprises or forms the closure surface 23. In the
coupled position, the separate element 28 cooperates with a locking
groove 31 which is provided in a distal side 32 of the coupling
part 11 in order to produce the vertical lock.
[0063] The separate locking element 28 is elastically deformable
and comprises a rotatable locking leg 33 which, in the coupled
position, cooperates with the locking groove 31. The separate
locking element 28 comprises a more flexible material part 34 which
makes a rotary movement of the locking leg possible, and a securing
part 35, by means of which securing part 35 the separate element 28
is secured in the recess 29. The separate element 28 is formed as a
single entity by means of co-extrusion. The more flexible material
part 34 is more flexible than the locking leg 33 and than the
securing part 35, which elements 33 and 35 are made from the same
material.
[0064] Viewed in the disengaged position, the locking element 19
has an uppermost point P1, which is situated at a vertical distance
H1 from the bottom side 3 of the panel 1 of at least 0.45 times the
thickness T of the panel 1. This uppermost point P1 defines a
horizontal level N, which horizontal level N is situated above at
least a portion of the separate locking element 28.
[0065] FIG. 4 shows an enlarged view of the coupling parts 10-11
from FIG. 3, however in the coupled position.
[0066] In the coupled position, the lip 18 is elastically bent in
such a way that a reactive force is generated which pushes the
coupled panels 1 against each other at the location of the
cooperating closure surfaces 23-24. The lip 18 is bent over a
maximum vertical distance D2.
[0067] Viewed in the coupled position, the upwardly directed
locking element 19 has an uppermost point P2 which defines a
horizontal level N1 which horizontal level N1 is situated above at
least a portion of the separate locking element 28.
[0068] In the coupled position, the cooperating locking surfaces
20-21 define a central point P3 which is situated at a horizontal
distance D1 from the vertical closure face V1 of at most once the
thickness T of the panel 1.
[0069] In the coupled position, the cooperating locking surfaces
20-21 define a tangent T1 which forms an angle A with the
horizontal of 45 to 85 degrees, preferably of 65 to 85 degrees, but
is smaller than 90 degrees.
[0070] The coupling parts 10-11 are configured in such a way that
they make it possible to disengage the respective edges 6-7 by
means of a turning movement W1. To this end, the lip 18 is able to
bend as indicated by the arrow.
[0071] The panel 1 comprises an HDF core 36, a top layer 37
situated on top of the HDF core 36 and a counter layer 38 arranged
under the HDF core 36. The top layer 37 comprises at least one
paper sheet which is printed with a decor and impregnated and a
wear layer which is arranged over the printed paper sheet,
comprising an impregnated paper sheet, optionally provided with
wear-resistant particles, such as corundum particles. The counter
layer 38 comprises at least one impregnated paper sheet. The
detailed structure of the top and counter layer is not shown.
[0072] Except for the separate locking element 28, the coupling
part 10 is made of and formed as a single entity with the material
of the actual panel 1. The coupling part 11 is completely made of
and formed as a single entity with the material of the actual panel
1.
[0073] The top side 2 of the panels 1 is free from bevels or
chamfers on the edges 6-7. However, it is not excluded that such
bevels are provided, for example as indicated by a dashed line.
[0074] For the sake of clarity, the horizontal and vertical
direction are indicated by the arrows H and V, respectively, in
FIG. 4.
[0075] The present invention is by no means limited to the
above-described embodiments, but such panels and coverings may be
produced according to different variants without departing from the
scope of the present invention.
* * * * *