• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Floor panel for forming a floor covering, said floor panel (1) mainly consisting of plastic; wherein this floor panel (1) has a decorative top (36); wherein the floor panel (1) has at least one pair of opposite edges (4-5) coupling parts (8-9) which allow two such floor panels to be coupled together, said coupling parts (4-5) both having a lock in a first effect direction (V) perpendicular to the plane of the floor panels (1) as well as in a second direction (H) perpendicular to the respective edge (4-5) and in the plane of the floor panels (1), characterized in that at least one of the said coupling parts (9) comprises a separate locking element (28) which, when engaged, provides at least one locking in the said first direction (V).
    公开号:BE1021392B1
    申请号:E2012/0490
    申请日:2012-07-12
    公开日:2015-11-13
    发明作者:
    申请人:Flooring Industries Limited, Sarl；
    IPC主号:
    专利说明:

    Floor panel for forming a floor covering, floor covering formed from such floor panels and method for manufacturing such floor panels.
    This invention relates in the first place to a floor panel for forming a floor covering, as well as to a floor covering formed from such floor panels, as well as to a method for manufacturing such floor panels. More generally, it can also be used with panels other than floor panels, i.e. for forming coverings other than floor coverings.
    More specifically, the invention relates to a panel, more particularly a floor panel of the type which is mainly made of plastic, and more specifically of flexible or soft plastic, wherein these panels comprise coupling parts of at least two opposite edges of the type that allows two such panels can be coupled together.
    Floor panels which are designed as such are known, inter alia, from US 2002/0189183 and WO 2011/077311. The coupling parts employed herein are designed in one piece with the floor panels and provide for a locking in a first direction located in the plane of the floor panels and perpendicular to the relevant edges, as well as in a locking in a second direction perpendicular to the plane of the panels. It is also known from these documents that the coupling parts on at least two opposite edges can be designed such that they allow two such floor panels to be coupled to each other, by means of a downward movement, by which is meant that one floor panel at its edge by means of a Downward movement is squeezed or locked onto the edge of another floor panel. Such coupling parts are also known under the name "push lock".
    It is further known from WO 2011/077311 to use push lock coupling parts only on one pair of sides of floor panels of the above-mentioned type and to combine them with coupling parts on the other pair of sides which can be coupled by means of a turning movement. In this case it is called a "fold down" system. The above-mentioned "fold-down" system is particularly popular with panels consisting mainly of wood or wood-based plate materials, mainly due to the increased ease of installation that can be achieved with such a "fold-down" system. In the case of floor panels which are mainly made of plastic, and more specifically of flexible or soft plastic, they leave something to be desired. The flexible plastic of the panels can lead to insufficient tightness of the coupling. Moreover, floor panels of the above-mentioned type are considerably subject to expansion and / or shrinking under the influence of temperature changes. As a result of this expansion and / or shrinkage, the floor panels can open up at the level of their adjacent edges, in the event of shrinkage, or swivel upwards, in the case of expansion, so that especially in the case of so-called "push lock" connections or fold-down systems, the coupling parts can be pushed apart. The risk of bulging when expanded is related to the limited bending stiffness that such panels have.
    The invention aims in the first place at alternative panels, more particularly floor panels, which are mainly made up of plastic. According to various preferred embodiments, a solution is also sought for one or more of the aforementioned problems with plastic floor panels, known from the prior art.
    To this end, according to a first aspect, the invention relates to a floor panel for forming a floor covering, said floor panel mainly consisting of plastic; wherein this floor panel has a decorative top side; wherein the floor panel comprises coupling parts on at least one pair of opposite edges that allow two of such floor panels to be coupled to each other, said coupling parts both being locked in a first direction perpendicular to the plane of the floor panels and in a second direction perpendicular to the respective one edge and in the plane of the floor panels, characterized in that at least one of the aforementioned coupling parts comprises a separate element, more in particular a separate locking element, said locking element providing at least two of such floor panels at the respective edges in the coupled state permits or permits locking in the aforementioned first direction and / or a snap-fit of the respective coupling parts of two of such panels by means of a downward coupling movement. Preferably, the aforementioned coupling parts comprise integrated mechanical locking means that effect a locking in the aforementioned second direction, namely a horizontal direction. Because a separate locking element is used, the coupling parts of the floor panel can be further optimized. More particularly, the use of a separate locking element makes it possible to work with alternative materials, namely with materials different from the base material of the panel, wherein these materials can exhibit specific properties, such as compressive strength and / or elasticity, whereby possibly a more favorable locking of the floor panels can be obtained. Such individual locking elements of plastic or of metal can thus be realized, as a result of which relatively strong, yet still easily movable, locking parts can be realized which can for instance take up relatively large forces with a minimum contact surface.
    By "separate locking element" is meant a locking element that is produced separately and fitted in the panel, either factory or by the user or installer. The individual locking element can either be loosely arranged in a recess provided for this purpose or the like on the floor panel, or be fixedly attached to the floor panel, for example by mechanically locking the locking element in an adapted recess, or still by gluing it into a recess for that purpose. provided recess or by attaching it to the panel in any other way. The individual locking element is preferably inserted at the factory, preferably by machine. However, it is not excluded that, without departing from the scope of the present invention, the separate locking element will be provided by the user or installer.
    According to the invention, the "separate locking element" is to be understood in the first place as an element which is present relatively locally in the floor panel in question, more particularly in the edge of the floor panel, wherein this, preferably, only provides for a vertical locking this in contrast to locking elements as known from WO 2007/141605, wherein such locking element forms an essential part of the edge and provides both the locking in the horizontal and in the vertical direction. The aforementioned individual locking element therefore preferably relates to an element, more particularly a strip, which is located on one of the lateral sides of the edge profiles.
    It is noted that the use of a separate locking element which is arranged relatively locally in the edge of a floor panel is already known, inter alia, from the patent documents WO 2009/066153 and US 7,454,875, for locking relatively thick and / or rigid floor panels, more particularly laminate floor panels .
    Up to now it has not been obvious to use such individual locking elements with relatively thin floor panels, for example with floor panels of 5 mm or thinner, and certainly not with the flexible floor panels as described below, more particularly so-called LVT floor panels. On the one hand, it was assumed that, since plastic is flexible in itself, it is always possible to use the elasticity of the base material of the panels to form locking parts that engage elastically behind each other. In the case of push-lock coupling parts or fold-down systems, however, a balance had to be found in which the coupling parts are sufficiently elastic to press the respective locking parts to one behind the other, and these coupling parts, as well as the floor panel itself from which they are formed, are nevertheless sufficient be rigid to obtain a firm joint and a sufficiently pressure-resistant floor covering. The balance achieved has proved insufficient in many cases. On the other hand, it was assumed that a stable integration of an individual element into a thin panel, which moreover consists of a movable or flexible material, namely compressible plastic, was impossible. The inventor has unexpectedly determined that the integration of such individual locking elements is nevertheless possible and that good results can unexpectedly be achieved, in particular for push-lock coupling parts and / or fold-down systems.
    As already indicated above, the present invention is especially useful when applied to floor panels that are mainly made of flexible or soft plastic, or in other words to flexible panels.
    With flexible panels is meant panels which, in the case of a rectangular panel, for example of less than 50 centimeters wide, are clamped on one of both short sides of the panel and thereby protrude over a length of 100 centimeters and are not supported, the panels begin to bend under the influence of their own weight, whereby this bending at the free end relative to the clamped end is at least 10 centimeters. For this deflection, a deflection time of 10 seconds is considered and the panel starts from a flat horizontal position.
    A difficulty with floor panels that mainly consist of flexible or soft plastic is its possibly limited dimensional stability. When a plurality of such floor panels are in coupled condition, significant stresses or deformations of the floor panels can arise in the event of temperature fluctuations, and more particularly in the vicinity of the coupling parts of these floor panels. This can give rise to problems with a floor covering that is composed of such panels, and especially when this concerns a so-called floating floor covering, wherein the panels are coupled only at their edges with neighboring panels, and thus not via a possible glue connection or other connection. connected to the substrate. More specifically, these problems concern, among other things, the occurrence of gaps at the edges of the floor panels; upsetting the floor panels, more particularly at the edges of the floor panels; loosening or in other words breaking the connection of the floor panels; and such. It is known from the prior art, for example from US 2011/296780 or US 2012/135203, to slightly increase the dimensional stability of such floor panels by applying one or more fiberglass layers embedded in the soft plastic. However, such a glass fiber layer does not contribute to the strength of the mutual coupling between the panels themselves.
    The use of a separate locking element with flexible floor panels according to the invention makes it possible to achieve an even better mutual coupling of the panels. More specifically, by using a separate locking element, a stronger coupling of the floor panels can be obtained, wherein this stronger coupling is mainly speaking in the aforementioned first direction perpendicular to the plane of the floor panels. The invention therefore makes it possible to form floating floor coverings on the basis of flexible panels, which remain stable with a greater range of temperature fluctuations.
    The present invention furthermore comes into its own when applied to floor panels of the type generally indicated by the English term "Resilient floor panels". This type of floor panels includes a vinyl panel, more specifically a so-called vinyl tile, and in particular a panel of the so-called LVT-type ("Luxury Vinyl Tile") or VCT-type ("Vinyl Composite Tile", also called " Called Vinyl Composition Tile ”). This usually concerns panels made of so-called soft PVC (polyvinyl chloride), which is usually made of PVC in which plasticizers or the like are incorporated. Preferably at least 12 weight percent plasticizer is used in the PVC mix, any fillers, such as chalk, not taken into consideration.
    According to a preferred embodiment, it concerns a panel, more particularly a floor panel, wherein the coupling parts, on at least one pair of opposite sides, allow two of such floor panels to be coupled to each other by means of a downward movement of one floor panel relative to the other. . More specifically, seen in cross-section, by means of a downward translation movement. This type of link is sometimes referred to as a "push" or "fold-down" link. The present invention particularly comes into its own with panels which, on at least one pair of opposite sides, preferably on the short sides in the case of a rectangular panel, comprise coupling parts which, as mentioned above, can be joined to each other by means of a downward movement linked. Such a coupling can increase the ease of installation. It is noted here that both coupling parts are referred to which can themselves be fully fully coupled by means of a downward movement, and coupling parts which, in addition to the downward movement, require an additional operation to complete the coupling. Such additional operation may, for example, involve the coupling of a subsequent floor panel or a floor panel in an adjacent row. In the latter case, this is referred to as "side push", since a lateral pressing force is exerted on a separate locking element by means of the floor panel in the adjacent row, whereby this locking element comes into a position in which it effects the locking in the aforementioned first direction. Such side push systems are known per se for rigid panels, for example from WO 2008/004960.
    According to the invention, the floor panel has a decorative top. The floor panel is preferably composed primarily of a substrate and a top layer. It is clear that the aforementioned top layer does not necessarily have to consist of plastic. This top layer can, inter alia, serve as a decorative layer and / or as a wear layer. The top layer can itself consist of several layers, such as for example a decorative layer and a wear layer. According to a variant, the floor panel is free of a separate top layer, so that the floor panel per se forms or forms the substrate.
    Preferably, said top layer comprises at least one decorative layer in the form of a print. As a result, the appearance of the panel, or the appearance of the decorative surface, can be freely chosen and given any decorative character. For example, the aforementioned decorative layer may be a printed film, more particularly a printed thermoplastic film. Preferably, there is a wear layer above the printed film on the basis of thermoplastic material, for example on the basis of PVC or soft PVC. The use of a printed film, more particularly a printed thermoplastic film, together with a thermoplastic wear layer provides advantages with regard to the occurrence of wear on such panels. Namely, when coupling several of such panels, small differences in height can sometimes occur between the decorative tops of two coupled panels. In such cases, the top layer is particularly susceptible to wear in the peripheral areas. The use of a thermoplastic film and a similar wear layer leads to a limitation of this wear, since it can be made somewhat compressible, for example in itself it can consist of PVC or soft PVC.
    As mentioned, the top layer preferably comprises at least one translucent or transparent wear layer. According to a possible embodiment, the aforementioned wear layer is present in the form of a transparent thermoplastic wear layer. Preferably, the aforementioned wear layer is free of corundum particles or other wear-resistant particles.
    The top layer can be finished with a lacquer layer, which is applied as a liquid layer on the aforementioned wear layer and / or decorative layer and is subsequently cured. It is preferably a lacquer layer that can be cured by UV light. Preferably a lacquer layer is applied on top of the possible wear layer.
    The floor panel according to the invention preferably relates to a floor panel, wherein this floor panel, or at least at least the substrate of the floor panel, is mainly constructed from a thermoplastic material, preferably from a soft thermoplastic material. There are various options for constructing such a floor panel, two of which are explained below.
    According to a first and most preferred possibility, the floor panel, or at least at least the substrate of the floor panel, is made up of several layers of material, preferably layers of thermoplastic material, more particularly of soft thermoplastic material. The different layers of thermoplastic material of the substrate may optionally enclose one or more glass fiber layers, such as a glass fiber cloth or glass fiber fleece. According to the most preferred embodiment, the substrate consists of two soft PVC layers that mutually enclose a glass fiber layer, preferably a glass fiber fleece or so-called "non-woven". These layers of the substrate preferably further comprise fillers, such as a proportion of chalk. The panels preferably have a density between 1250 and 2250 kilograms per cubic meter.
    According to a second possibility, the substrate of the floor panel is made up of a single layer of thermoplastic material, more particularly soft thermoplastic material.
    According to a preferred embodiment, the floor panel, or at least at least the substrate of the floor panel, is mainly composed of polyvinyl chloride, more particularly of soft polyvinyl chloride, namely PVC containing plasticizers. Use is preferably made of PVC obtained from a PVC homopolymer of suspension quality with a K value between 50 and 80, or even better between 60 and 67.
    Mainly in the case of floor panels with a substrate of soft PVC, but also in the case of other floor panels, the possible blocking body of the individual locking element is preferably made of hard PVC, preferably PVC comprising cadmium or zinc stabilizers. The hard PVC of the locking element, more specifically the blocking body, thus offers an answer to the flexibility of the substrate. Moreover, the combination of soft PVC of the substrate and hard PVC of the blocking body can give rise to an optimum possibility for recycling. Moreover, extrusion techniques, or co-extrusion techniques, are very suitable for the realization of such locking elements.
    The optional fixing part preferably consists of the same or similar plastic as the blocking body.
    The plastic of the optional hinge part preferably consists of polyurethane.
    It is noted that the floor panel of the invention preferably has a substrate containing plasticizers. With such floor panels, the use of a separate locking element is particularly interesting. After all, temperature fluctuations in such floor panels lead to leaching of the plasticizers present, which may entail additional dimensional changes. Moreover, the flexibility of such panels can decrease over time, which could influence the quality of the coupling. By using a separate locking element, this aging can be at least partially avoided. According to a specific embodiment, it concerns a floor panel in which this floor panel has a substrate containing plasticizer of the DINP type, more particularly with a mass ratio of 20% to 40%, whereby any filler material is left out of consideration.
    According to a variant, it concerns a floor panel in which this floor panel is essentially free of plasticizers.
    As mentioned, the floor panel of the invention can, in addition to the plastic, also be a filling material, preferably lime or a lime-like material. The use of a filling material is primarily intended to reduce the amount of plastic required and / or to make the panel heavier. A heavier panel has the advantage in some cases that the panel is more stable and / or easier to stay in place during installation and / or after installation.
    The individual locking element is preferably embodied as an insert, preferably in the form of a strip, wherein this insert is present in a recess provided for this purpose in one of the aforementioned edges of the floor panel, and wherein this individual locking element comprises at least a portion which is movable laterally, and thus cooperates with a locking portion on an adjacent similar floor panel, this cooperation then preferably resulting in said locking in the first direction.
    Preferably, the aforementioned laterally movable part is elastically movable, such that during connecting two of such floor panels, this part is moved sideways against an elastic force, in order to subsequently return to a locking position. For example, the laterally movable portion may essentially consist of a rotatable blocking body. The individual locking element is preferably composed at least of a fastening part on the one hand and a rotatable blocking body on the other. The blocking body is preferably connected to the fixing part via a hinge part. The use of a hinge portion allows a relatively rigid blocking body to be elastically attached to a rigid attachment portion. In this way, elastic mobility of the blocking body can be combined with a good locking strength in the aforementioned first direction. Preferably, the aforementioned blocking body, when coupled, extends over a vertical distance that is less than 1.9 times the vertical distance defined by the mounting portion. This ratio represents a compromise between, on the one hand, obtaining a sufficiently strong lock, in particular a vertical lock, and on the other hand, a sufficiently strong connection of the individual locking element.
    The individual locking element preferably consists essentially of a strip of synthetic material. The use of synthetic material makes it possible to give the individual locking element the desired properties in terms of elasticity, compressive strength. Furthermore, the use of synthetic material offers virtually unlimited possibilities for the design of the individual locking element. This is particularly important when the thickness of the floor panel and therefore the dimensions of the individual locking element are very small, for example with floor panels with a thickness of 5 millimeters or less. Preferably, the individual locking element consists essentially of a co-extruded strip which, viewed in cross-section, has zones of synthetic material with different properties, more particularly materials of different flexibility. Preferably, the aforementioned optional hinge section is made of a more flexible material than the blocking section and / or the mounting section.
    The aforementioned coupling parts preferably comprise locking parts hooked one behind the other, respectively in the form of an upwardly directed locking part which is arranged on a first lip on a first of said two edges and a downwardly directed locking part which on a second lip on the second of said two edges two edges are provided, these locking parts hooked one behind the other cause a locking in the aforementioned horizontal direction. Preferably, the upwardly directed locking part, viewed in cross-section, extends over a height that is at least 24% of the total thickness of the floor panel. Preferably, the thickness of the first lip, viewed in cross-section, decreases in a direction from the center of the floor panel to the free end of the first lip, preferably mainly because the top of the first lip extends downwards or not in steps. .
    In the case of an upwardly directed locking part, this preferably still has one or more of the following properties: the property that the highest point of the upwardly directed locking part is in a horizontal plane, this horizontal plane extending between the lower surface and the upper surface of the recess in which the individual locking element is attached to the panel; the property that the highest point of the upwardly directed locking part is in a horizontal plane, said horizontal plane H2 intersecting the blocking body, if any, in the coupled state or in the uncoupled state, or in both; the property that the highest point of the upwardly directed locking part is in a horizontal plane, this horizontal plane extending above the locking part with which the possible blocking body cooperates.
    Each of these properties individually or in combination leads to a more firm connection of two such panels, both in the first and in the second direction.
    The panel of the invention preferably relates to a rectangular floor panel, either elongated or square; the aforementioned pair of opposite edges forming a first pair of edges, while the remaining two opposite edges forming a second pair of edges; wherein at the second pair of edges of the floor panel coupling parts are provided of the type that allows two such floor panels along the respective edges to be coupled to each other by means of a turning movement, said coupling parts providing a vertical and a horizontal locking and are preferably made in one piece with the floor panel. The coupling parts on the second pair of edges are preferably designed in the form of a tooth and a groove. The floor panels, in particular the coupling parts, are preferably configured such that the panels can be automatically joined to each other at the first pair of edges as a result of a downward rotation along the second pair of edges, more particularly such that several panels are systematically according to the so-called "Fold-down" principle can be installed.
    The present invention, although not limiting, is particularly suitable for thin floor panels, more particularly for floor panels that have a thickness of 3 millimeters to 6 millimeters and more particularly of 3 millimeters to 5 millimeters.
    According to a possible embodiment of the present invention, the floor panel has the following features: - the floor panel is essentially composed of, on the one hand, a core or a substrate, said core or substrate being made up of material forming the base material of the floor panel, and of on the other hand, a top layer, in other words a surface layer, which top layer is itself composed of several layers or not; - the aforementioned coupling parts of the respective pair of edges are mainly designed in the form of a tooth and a groove; and the aforementioned coupling parts comprise integrated mechanical locking means which effect a locking in the aforementioned second direction, namely a horizontal direction; - the aforementioned coupling parts, including the integrated mechanical locking means, are, as mentioned above, realized with a separate element which allows or enables a connection by snap-fastening of the respective coupling parts of two of such panels by means of a downward translation movement, namely in the vertical direction. ; - the base material of the floor panel from which the aforementioned core is composed contains mainly soft thermoplastic material and wherein this thermoplastic material optionally contains a filling material; and said top layer comprises a printed thermoplastic film and a transparent thermoplastic wear layer, wherein said transparent thermoplastic wear layer is thinner than 0.85 millimeters and is free of filler materials.
    It is clear that the invention also relates to a floor covering composed of floor panels as described above.
    The panel or floor panel of the invention preferably comprises at least one reinforcement layer, preferably formed from fibers, more particularly reinforcement fibers, such as glass fibers. The use of such a reinforcement layer, and in particular a reinforcement layer with fibers, increases the dimensional stability of the floor panels. This is particularly important with floor panels to be laid separately, because the use of fibers can considerably reduce the expansion and / or shrinkage of the panel under the influence of the temperature differences. As a result, the chance of the coupled floor floor panels becoming detached from each other as a result of expansion and / or shrinkage can be further minimized. It is noted that the aforementioned reinforcement fibers can occur in all sorts of forms, such as, for example, in the form of a cloth, a fleece or a net, more particularly, for example, a fiberglass cloth or a fiberglass fleece. Preferably, seen in cross-section of the panel, said fibers are used in one or more horizontal layers. Preferably, at least one of the aforementioned layers is located at the level of the aforementioned individual locking element. This creates the advantage that, from the viewpoint of connection properties, the floor panel is kept optimally stable at the most critical level, namely at the location of the locking element.
    In case one reinforcement layer, for example one layer with fibers, is used, this layer is preferably in the middle or substantially in the middle of the panel. A symmetrical structure of the floor panel is thus obtained, which offers advantages in terms of stability of the floor panel. According to a particularly preferred embodiment, two or more reinforcement layers are used, which are preferably spaced apart. In the case of two reinforcement layers, viewed in cross section, they are preferably situated on either side of the neutral line of the floor panel. This creates the advantage that bending forces can be counteracted in both directions. This is particularly advantageous with relatively flexible floor panels that are mainly made of soft PVC.
    The invention furthermore relates to a method for manufacturing floor panels as described above, wherein this method comprises at least the following steps: - forming the floor panel from a plastic; - applying profiles at the level of one or more edges of the floor panel; - applying glue in a recess, present in the relevant edge of the floor panel and provided for applying a separate locking element; - arranging a separate locking element in the above-mentioned recess. The step of arranging the separate locking element preferably takes place by means of a shaping wheel with which the recess provided for this purpose is arranged in the edge of the floor panel.
    With the insight to better demonstrate the features of the invention, a few preferred embodiments are described below as an example without any limiting character, with reference to the accompanying drawings, in which: Figure 1 shows a panel with the features of the invention; figures 2 and 3 represent a cross-section on a larger scale, respectively along the lines II-II and III-III shown in figure 1; Figure 4 shows how two floor panels can be connected to each other at the edges of Figure 3; figures 5 to 7 show how such floor panels can be connected to the edges shown in figure 2; Figure 8 shows on a larger scale the individual locking element which is arranged in the pair of edges of Figure 2; figures 9 and 10 represent in perspective how the long and the short edges of the floor panel of figure 1 can be coupled to similar floor panels, figure 10 giving a larger view of the area indicated in figure 9 by F10.
    Figures 1 to 7 show an embodiment of a panel 1 according to the invention, which is designed as a floor panel.
    In the example shown, the panel 1 is designed as an elongated rectangular strip, and thus has a first pair of opposite edges 2-3, which in this case form the long sides of the panel 1, and a second pair of opposite edges 4-5, which form the short sides of the panel 1.
    As is shown in more detail in Figures 2 and 3, both pairs of opposite edges 2-3 and 4-5 have coupling parts 6-7 and 8-9, respectively, which allow several of such panels 1 to be mutually coupled to each other.
    As specifically shown in Figs. 3 and 4, coupling parts 6-7 on the first pair of opposite edges 2-3 are configured such that two such panels on these edges 2-3 can be joined to each other in a locking manner by means of a turning movement W linked. The coupling parts 6-7 here form a first locking system which effects a locking in the plane of the panels 1 and perpendicular to the aforementioned edges 2-3, i.e. in this case in the horizontal direction H, as well as a second locking system which provides a locking transversely to effect the plane of the panels 1, in this case in the vertical V or the first direction mentioned in the introduction. To this end, the coupling parts 6-7 are constructed as a tooth 10 and a groove 11, which are provided with the vertical locking, and contain locking parts 12-13 which prevent the tongue and groove from sliding apart in the coupled condition.
    It is preferred here that, as shown, the groove 11 is bounded by a lower lip 14 and an upper lip 15, and that the locking parts 12 and 13 are in the form of cooperating projections, respectively on the underside of the tooth 10 and on the upper side of the lower lip 14. The cooperation takes place via locking surfaces 16 and 17 provided for this purpose. As shown, it is also preferred that the lower lip 14 extends laterally beyond the distal end of the upper lip 15, more especially such that the locking surface 17 is completely in the portion of the lower lip 14 that is located outside the upper lip 15.
    As schematically shown in Figures 5 to 7, the coupling parts 8-9 on the second pair of opposite edges 4-5 are configured such that two such panels 1 can be joined to each other by means of a downward movement M of one panel relative to the other. be linked. This downward movement M is explained in more detail below.
    As is clearly visible in Figure 7, the coupling parts 8-9 here form a first locking system which effects a locking transversely to the plane of the panels 1, in this case in the vertical direction V, as well as a second locking system which provides a locking in the plane of the panels 1 and perpendicular to the aforementioned edges 4-5, i.e. in this case in the horizontal direction H. Here, the vertical direction forms the first direction mentioned in the introduction, and the horizontal direction the second direction mentioned therein.
    The second locking system or the integrated mechanical locking means are mainly formed from an upwardly directed lower hook-shaped portion 18 located at the edge 5, as well as an downwardly directed upper hook-shaped portion 19 located at the opposite edge 4, which hook-shaped portions said downward movement M can be hooked in succession. The lower hook-shaped portion 18 consists of a lip 20 which extends laterally from the lower edge of the panel 1 and which is provided with an upwardly-facing locking element 21 with a locking surface 22, while the upper hook-shaped portion 19 consists of a lip 23 extending extends laterally from the upper edge of the panel 1 and which is provided with a locking element 24 directed downwards with a locking surface 25.
    The first locking system of the edges 4-5 on the short sides is formed by locking parts or locking parts 26-27. According to the invention, the coupling parts 8-9 comprise for this purpose a separate element or separate locking element 28 which in the coupled condition, as shown in Figure 7, provides for at least one locking in the aforementioned first direction, or vertical direction V. In the example, the separate element is located. locking element 28 located in the female coupling part 9, more particularly near the proximal end 29 of the lower hook-shaped part 18.
    As shown in Figures 5 to 8, the individual locking element 28 is designed as an insert in the form of a strip and is provided with a recess 30 in one of the edges 5. The individual locking element 28 comprises, in this case, a rotatable blocking body 31 which, as shown inter alia in figure 6, is movable laterally, and thus can cooperate with the locking part 26 of an adjacent floor panel 1. The blocking body 31 is elastically movable and enters a locking position towards the end of the downward movement M, as shown in Fig. 7. In the locking position, the blocking body 31 makes contact with the locking part 26 of an adjacent floor panel 1. This contact results in the aforementioned locking in the first direction V.
    The individual locking element 28 shown here further comprises a fastening part 32, the blocking body 31 being connected to the fastening part 32 via a hinge part 33. In this case, a clamp fit of the mounting portion 32 in the recess 30 is applied. According to an important alternative, the fixing portion 32 is connected to the panel 1 at least in that it is glued into such a recess 30.
    The individual locking element in the examples consists of a co-extruded strip which, viewed in the plane of Figures 5 to 8, has zones of synthetic material with different properties, the zone of the hinge part 33 being made of a more flexible material of the zone of the blocking body 31 and the zone of the mounting portion 32.
    It is noted that the coupling parts 8-9 can also be regarded essentially as a tongue and groove coupling, the locking part 26 acting as a tooth, while the groove in which this tooth takes place is defined by the locking part 27 which functions as an upper lip, and the first hook-shaped portion 18 which acts as a lower lip.
    It is noted that the space between the vertically active locking part 27 and the horizontally active locking element 21, which is also indicated with aperture H, functions as a female part, while the locking element 24 is designed as a male part that fits into the female part.
    The panel 1 from the examples is mainly formed on the basis of soft polyvinyl chloride (PVC). More specifically, it comprises a substrate realized on the basis of soft PVC, which substrate is designated by reference 34 in the figures. In these figures, this substrate is shown schematically as one layer. In reality, this can be either one layer or several layers, with not all having to consist of PVC. A top layer 35 is normally provided on the substrate, which top layer is also represented in the figures by only one layer, but which in reality can also consist of several layers. The top layer 35 is at least intended to provide a decorative top 36 on the panel 1, preferably in the form of a printed decor and, at least in the case of a floor panel, to ensure that a wear-resistant surface is provided.
    As indicated in Figure 7, the panels have a total thickness T. The thickness T preferably has a value between 3 and 10 mm. In a particularly practical embodiment, it will be between 3 and 6 mm.
    The example from the figures furthermore has the preferred feature that the upwardly directed locking part 21, viewed in cross-section, extends over a height H1 which is at least 24% of the total thickness T of the floor panel 1. The highest point of this upwardly directed locking part 21 is then situated in a horizontal plane H2 located between the lower surface 37 and the upper surface 38 of the recess 30 and / or in a horizontal plane H2 which intersects the blocking body 31, in this case both in coupled state as in non-coupled state. Moreover, the horizontal plane H2 extends above the locking portion 26 with which the blocking body 31 cooperates.
    It is noted that the aforementioned coupling parts, both 6-7 and 8-9, as shown, with the exception of the aforementioned individual locking element, are preferably formed in one piece from the material of the actual panel 1, more specifically from the substrate material. As a result, the coupling parts per se mainly consist of soft PVC. It is noted that these portions of the coupling parts 6-7 and 8-9 are preferably formed by means of a machining operation, more particularly milling operations. Milling techniques that allow for fitting locking parts to the edges of the panels are known, inter alia, from WO 97/47834. Provided that the choice of suitable milling cutters and a suitable adjustment thereof is achieved, suitable profiles, for example as shown in the figures, can also be realized.
    Figures 8 and 9 schematically show how the panels 1 can be installed. In order to explain the method, a number of the panels 1 are additionally distinguished again with references IA, 1B and IC. The panels 1 are laid row by row and linked to each other. In order to obtain that panels 1-1A-1B-1C are connected to both edges 2-3 and 4-5, the method comprises at least the following steps: - installing a first panel IA intended to form part of a first row of panels; - coupling a second panel 1B to said first panel 1A, such at first edges 2-3, wherein this second panel 1B is intended to form part of a second row, following said first row of panels; - coupling a third panel IC in the second row both to the aforementioned second panel 1B and to the first panel IA, wherein the third panel IC is coupled to the first panel IA by means of a turning movement in which the third panel IC from an upwardly rotated position is brought into substantially the same plane as the first and second panel, while as a result of this movement and the downward movement created thereby, the hook-shaped portions 18-19 between the third and second panel engage with each other.
    It is clear that normally between the installation of the first panel IA and the coupling of the second panel 1B, first all further panels of the row in which the first panel IA is located are also laid. The second panel 1B is coupled to the first panel 1A of course also by the panel 1B at its edge 2 via a winding movement W as shown in figure 4 at the edge 3 of the first panel IA, and any other panels from the row of to connect the panel IA.
    When connecting the panel IC to the panel IA, a winding movement W as in FIG. 4 is also applied. Hereby a downward movement M takes place at the short edges 4-5, whereby the coupling parts 8 and 9 are joined together.
    By this downward movement M is meant in a very broad sense any form of movement in which, in a section as seen in figures 5 to 7, one panel is lowered from a higher position with respect to the other. This movement M does not necessarily have to be a linear movement and during this movement deformations may occur temporarily in the panels and more particularly in the hook-shaped parts 18 and 19.
    Theoretically, a linear or almost linear downward movement M viewed in section can be used to insert a panel IC into a panel 1B, which means that the right-hand panel in Fig. 6, seen in section, is simply pressed straight down into the position of figure 7.
    It is further noted that the examples from the figures also show that the aforementioned lip 20 decreases in thickness from the lower hook-shaped part 18 from the center of the floor panel 1 to the free end of this lip, at least nevertheless at least over a part of this lip 20. In the example, this property has been obtained in that the upper side of the lip 20 extends stepwise downwards and thus a deeper part 39 of this lip 20 is formed, in this case just before the upwardly directed locking part 21.
    The present invention is by no means limited to the embodiments described above, but such floor panels, floor coverings and methods for manufacturing them can be realized according to different variants without departing from the scope of the present invention.
    权利要求:
    Claims (25)
    [1]
    Conclusions.
    1. - Floor panel for forming a floor covering, said floor panel (1) mainly consisting of plastic; said floor panel (1) having a decorative top (36); wherein the floor panel (1) at least one pair of opposite edges (4-5) coupling parts (8-9) allowing two of such floor panels to be coupled to each other, said coupling parts (4-5) both locking into a first direction (V) perpendicular to the plane of the floor panels (1) and in a second direction (H) perpendicular to the relevant edge (45) and in the plane of the floor panels (1), characterized in that at least one of the aforementioned coupling parts (9) comprises a separate locking element (28) which, when coupled, provides at least one locking in the aforementioned first direction (V).
    [2]
    Floor panel according to claim 1, characterized in that the floor panel (1) is of the flexible type.
    [3]
    Floor panel according to claim 1 or 2, characterized in that the floor panel (1) is a vinyl panel, more particularly a so-called vinyl tile, and in particular a panel of the so-called Luxury Vinyl Tile (LVT) type or VCT type ("Vinyl Composite Tile", also called "Vinyl Composition Tile").
    [4]
    Floor panel according to one of the preceding claims, characterized in that the floor panel (1) is essentially composed of a substrate (34) and a top layer (35).
    [5]
    Floor panel according to claim 4, characterized in that the top layer (35) contains at least one decorative layer, preferably in the form of a print.
    [6]
    Floor panel according to claim 4 or 5, characterized in that the top layer (35) comprises at least one transparent or transparent wear layer.
    [7]
    Floor panel according to one of the preceding claims, characterized in that the floor panel (1), or at least at least the substrate (34) (1) of the floor panel, is essentially made up of a thermoplastic material, preferably of a soft thermoplastic material .
    [8]
    Floor panel according to one of the preceding claims, characterized in that the floor panel (1), or at least at least the substrate (34) of the floor panel (1), is mainly made up of polyvinyl chloride, more particularly of soft polyvinyl chloride.
    [9]
    Floor panel according to one of the preceding claims, characterized in that the floor panel (1) has a substrate (34) containing plasticizers.
    [10]
    Floor panel according to one of claims 1 to 8, characterized in that the floor panel (1) is substantially free of plasticizers.
    [11]
    Floor panel according to one of the preceding claims, characterized in that the floor panel (1) comprises at least one reinforcement layer, preferably formed from fibers, more particularly reinforcement fibers, such as glass fibers.
    [12]
    Floor panel according to one of the preceding claims, characterized in that the coupling parts (8-9) are of the type that allows two of such floor panels to be moved by means of a downward movement (M) of one floor panel (1) relative to link the other to each other.
    [13]
    Floor panel according to one of the preceding claims, characterized in that the separate locking element (28) is designed as an insert, preferably in the form of a strip, wherein this insert is present in a recess (30) provided for this purpose in one of the aforementioned edges of the floor panel (1), and wherein this separate locking element comprises at least a portion (31) that is movable laterally, and thus can interact with a locking portion (32) on an adjacent similar floor panel.
    [14]
    Floor panel according to claim 13, characterized in that said laterally movable part (31) is elastically movable, such that this part is moved sideways against an elastic force during coupling of two of such floor panels (1) to subsequently move to return to a locking position.
    [15]
    Floor panel according to claim 13 or 14, characterized in that the aforementioned individual locking element (28) has one or a combination of two or more of the following features: - that the laterally movable part mainly consists of a rotatable blocking body (31); - that the individual locking element is at least composed of a fastening part on the one hand and a rotatable blocking body (31) on the other; - that the individual locking element is at least composed of a fastening part on the one hand and a rotatable blocking body (31) on the other, the blocking body being connected to the fastening part (32) via a hinge part (33); - that the individual locking element consists essentially of a strip of synthetic material; - that the individual locking element mainly consists of a co-extruded strip, which, viewed in cross-section, shows zones of synthetic material with different properties, more particularly materials of different flexibility; - that the individual locking element is composed at least of a fastening part on the one hand and a rotatable blocking body (31) on the other, wherein the blocking body (31) is connected to the fastening part (32) via a hinge part (33) and wherein the individual locking element consists essentially of a co-extruded strip, which, viewed in cross-section, shows areas of synthetic material with different properties, more specifically materials of different flexibility, the hinge portion (33) being made of a more flexible material than the blocking portion; - that the individual locking element (28) is arranged in a recess (30), wherein means are provided which hold the locking element (28) in the recess (30), said means being preferably formed by one or more of the following possibilities: a clamping fit of a portion of the locking element in the recess, an adhesive connection or the like, a mechanical locking between a portion of the locking element and the wall (38) of the recess (30).
    [16]
    Floor panel according to one of the preceding claims, characterized in that the individual locking element comprises at least one movable blocking body (31) and wherein said blocking body (31) in coupled condition extends over a vertical distance that is less than 1.9 times the vertical distance defined by the mounting arrangements for the individual locking element (28).
    [17]
    Floor panel according to one of the preceding claims, characterized in that the aforementioned coupling parts comprise locking parts (18-19) hooked one behind the other, respectively in the form of an upwardly directed locking part (21) which is attached to a first lip of a first of said two edges and a downwardly directed locking member (24) attached to a second lip on the second of said two edges, said locking members hooking one behind the other (18-19) locking in the aforementioned second or horizontal direction (H ).
    [18]
    Floor panel according to claim 17, characterized in that the upwardly directed locking part (21), viewed in cross section, extends over a height (H1) which is at least 24% of the total thickness (T1) of the floor panel (1) .
    [19]
    Floor panel according to claim 17 or 18, characterized in that the first lip, viewed in cross section, decreases in thickness from the center of the floor panel (1) towards the free end of the first lip, mainly because the upper side of the first lip lip, whether or not cascading downwards.
    [20]
    Floor panel according to one of the preceding claims, characterized in that the floor panel is rectangular, either elongated rectangular or square; wherein said pair of opposite edges (4-5) forms a first pair of edges, while the remaining two opposite edges (2-3) form a second pair of edges; wherein at the second pair of edges of the floor panel (1) coupling parts (6-7) are provided of the type that allows two of such floor panels (1) to be coupled along the respective edges by means of a turning movement (W) , wherein these coupling parts are provided with a vertical and a horizontal locking and are preferably made in one piece with the floor panel (1).
    [21]
    Floor panel according to one of the preceding claims, characterized in that the floor panel has a thickness (T1) of 3 millimeters to 6 millimeters and more particularly of 3 millimeters to 5 millimeters.
    [22]
    Floor panel according to claim 1, characterized in that - the floor panel is essentially composed of, on the one hand, a core or a substrate (34), said core or substrate being made up of material that forms the basic material of the floor panel (1) and from, on the other hand, a top layer, in other words a surface layer, which top layer per se is composed of several layers or not; - the aforementioned coupling parts (8-9) are mainly in the form of a tooth and a groove; - that the base material of the floor panel (1) from which the aforementioned core is constructed comprises mainly soft thermoplastic material, said thermoplastic material possibly containing a filling material; and - that said top layer contains a printed thermoplastic film and a transparent thermoplastic wear layer, said transparent thermoplastic wear layer being thinner than 0.85 millimeters and free of filler materials.
    [23]
    A panel displaying the features according to any of the preceding claims, wherein said panel is, instead of a floor panel, a panel intended for forming a covering other than a floor covering.
    [24]
    24. Cladding, more particularly a floor covering, characterized in that it is composed of panels, more particularly floor panels according to one of the preceding claims.
    [25]
    25. - Method for manufacturing panels, more especially floor panels, according to one of the preceding claims, wherein this method comprises at least the following steps: - forming the panel (1), more special floor panel, from a plastic; - applying profiles at the level of one or more edges (4-5) of the floor panel; - arranging the separate element, more specifically the separate locking element (28) on the panel, more particularly the floor panel, preferably factory-made, wherein this element, more specifically locking element, optionally is attached to the panel (1) by means of a glue joint or the like.
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    同族专利:
    公开号 | 公开日
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    DE202009004530U1|2009-01-16|2009-06-18|Flooring Industries Ltd.|floor panel|
    法律状态:
    2021-04-28| MM| Lapsed because of non-payment of the annual fee|Effective date: 20200731 |
    优先权:
    申请号 | 申请日 | 专利标题
    AZU20120003|2012-02-07|
    AZ20120003|2012-02-07|CN201380008098.9A| CN104160101B|2012-02-07|2013-01-30|Floor panel for forming floor covering, the floor covering formed by this floor panel and the method for manufacturing this floor panel|
    PCT/IB2013/050781| WO2013118030A2|2012-02-07|2013-01-30|Floor panel for forming a floor covering, floor covering formed from such floor panels and method for manufacturing such floor panels.|
    US14/377,292| US9771721B2|2012-02-07|2013-01-30|Floor panel for forming a floor covering, floor covering formed from such floor panels and method for manufacturing such floor panels|
    BR112014018892A| BR112014018892A8|2012-02-07|2013-01-30|floor panel to form a floor covering, a floor covering formed from these floor panels, and process for manufacturing these floor panels|
    EP13712906.0A| EP2812510B1|2012-02-07|2013-01-30|Floor panel for forming a floor covering, floor covering formed from such floor panels and method for manufacturing such floor panels|
    KR1020147025162A| KR102069909B1|2012-02-07|2013-01-30|Floor panel for forming a floor covering, floor covering formed from such floor panels and method for manufacturing such floor panels|
    RU2014136350A| RU2628345C2|2012-02-07|2013-01-30|Floor panel for forming floor boarding, floor boarding formed from such floor panels, and method for manufacturing such floor panels|
    US15/712,489| US10214918B2|2012-02-07|2017-09-22|Floor panel forming a floor covering, floor covering formed from such floor panels and methods for manufacturing such floor panels|
    US16/280,294| US10612249B2|2012-02-07|2019-02-20|Floor panel for forming a floor covering, floor covering formed from such floor panels and method for manufacturing such floor panels|
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