Source: https://patents.google.com/patent/US10100532B2/en
Timestamp: 2019-06-26 22:21:48
Document Index: 663637715

Matched Legal Cases: ['art 30', 'art 31', 'art 31', 'art 30', 'art 34', 'art 31', 'art 30', 'art 31', 'art 31', 'art 30']

US10100532B2 - Floor element, locking system for floor elements, floor covering and method for composing such floor elements to a floor covering - Google Patents
Floor element, locking system for floor elements, floor covering and method for composing such floor elements to a floor covering Download PDF
US10100532B2
US10100532B2 US15/372,735 US201615372735A US10100532B2 US 10100532 B2 US10100532 B2 US 10100532B2 US 201615372735 A US201615372735 A US 201615372735A US 10100532 B2 US10100532 B2 US 10100532B2
US15/372,735
US20170089078A1 (en
2006-12-21 Priority to BE2006/0641A priority Critical patent/BE1017403A5/en
2006-12-21 Priority to BE2006/0641 priority
2007-09-18 Priority to DE202007013059 priority
2007-09-18 Priority to DE202007013059U priority patent/DE202007013059U1/en
2007-09-18 Priority to DE202007013059U priority
2007-12-17 Priority to PCT/IB2007/004153 priority patent/WO2008078183A2/en
2009-06-16 Priority to US51945609A priority
2014-07-11 Priority to US14/329,157 priority patent/US9534400B2/en
2016-12-08 Priority to US15/372,735 priority patent/US10100532B2/en
2016-12-08 Assigned to FLOORING INDUSTRIES LIMITED, SARL reassignment FLOORING INDUSTRIES LIMITED, SARL ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CAPPELLE, MARK, VANHASTEL, LUC, SCHACHT, BENNY
2016-12-08 Application filed by Flooring Industries Ltd Sarl filed Critical Flooring Industries Ltd Sarl
2017-03-30 Publication of US20170089078A1 publication Critical patent/US20170089078A1/en
2018-10-16 Publication of US10100532B2 publication Critical patent/US10100532B2/en
In order to increase the installation comfort of such floor elements, one mostly strives to implement them with relatively large dimensions. To wit, large floor elements are more practical to be applied by the user, and composing a floor covering requires less time when the user can start from large floor elements. In connection with the shorter installation time, also the installation cost of such floor covering is lower. By “large floor elements”, substantially floor elements with such a size are meant that they still can easily be handled by a single person. Typical dimensions of such floor elements are, for example, 1200 by 200 millimeters.
As aforementioned, by “entity-forming means”, means or portions are meant which allow forming an entity, starting from said components. These are means which are particularly provided for forming such entity, wherein by an entity the smallest possible group of parts is understood, which, as a floor element, can cooperate with equal or similar entities or floor elements, with the intention of forming a floor covering. It is clear that within the scope of the present invention, the respective entities always must comprise two or more of such components. It is also clear that the term entity does not relate to two or more floor panels, which are coupled to each other solely in a manner known as such, for example, from WO 97/47834, or which, more particularly, are coupled solely by means of an identical pair of complementary coupling means present at least at two opposite sides of each floor panel. The entity-forming means of the invention rather relate to provisions which are made separately from the identical pairs of complementary coupling means present at the floor elements and/or at each of the respective components. It is clear that according to the present invention, it is not excluded that, apart from the presence of such identical pairs of complementary coupling means or coupling parts at each component, also a separate entity-forming means is provided at the floor element. For examples of such embodiments, reference is made to the further introduction and the detailed description.
It is noted that each of said components preferably at least at a first pair and still better at both pairs of opposite sides is provided with mechanical coupling means, which allow a mutual coupling, wherein preferably at all sides a vertical and horizontal coupling is provided for. However, a combination of coupling means may also be opted for, which provides for a vertical and horizontal locking solely at one pair of opposite sides, whereas at a second pair of sides, preferably at the short sides of oblong components, one works with coupling means allowing either solely a vertical locking, or solely a horizontal locking. It is evident that in the case that solely a vertical locking is desired, one may work with a simple tongue-in-groove connection, and that in the case that solely a horizontal locking is desired, one may work with a so-called “drop” connection, further examples of which will be discussed in the following.
In a first possible embodiment, said entity-forming means consist at least of mechanical coupling means situated at least at one side of each of said components, wherein these mechanical coupling means allow that the respective sides of said components can cooperate with each other. Such mechanical coupling means or coupling parts preferably are made differently in respect to the mechanical coupling means shown by the floor element as such at two opposite edges thereof. Herein, “differently” is to be interpreted in the broadest sense, however, preferably relates to different dimensions, geometry, material and/or functionality of the coupling means themselves or at least a portion thereof. In respect to the functionality of the coupling means, which form part of the entity-forming means, it is preferred that they can effect at the respective sides a locking in a vertical direction perpendicular to the plane of the floor element and/or in a horizontal direction perpendicular to said sides and in the plane of the floor element. Thus, it is possible that these coupling means are made such that they allow to couple the respective components to each other and/or release them from each other by moving a first of said components at the respective side into one, out of one, respectively, of the other of said components by means of an angling movement around the respective side. It is noted that by means of coupling means, such as described by means of this first possibility, an entity of the first as well as of the second kind can be effected.
As a material for the basic board or basic layer, for example, wood-based material or synthetic material can be chosen. Thus, the basic structure may comprise, for example, a layer of softwood of the type usually applied with so-called “engineered wood”, or may comprise wood fiber material, such as, for example, softboard, MDF or HDF (medium density fiberboard or high density fiberboard). Possibly, the basic structure may also be composed of a plurality of parts or of a plurality of layers, whether or not consisting of different materials.
Apart from the fact whether said means effect an entity of the first, the second or another kind, it is noted that the entity of said components preferably is such, that it is maintained under the influence of solely the own weight of the components, independent from the orientation of the floor element. Still better, it is also maintained when the floor elements undergo normal handling. By “normal handling”, amongst others, taking the floor elements out of the package and bringing them to the location of their installation is understood. Further, it is noted that, although this is preferred, according to the invention said components do not necessarily have to be in the package in a mutual position in which said entity is existing. According to another embodiment, said components may even be packaged separately and one can only speak of an entity after the components have been taken from the package and said entity-forming means have been applied by the user for effecting the entity. In the above, it is clear that “maintaining the entity independently from the orientation” means that the floor element allows that it can be held at least to a limited extent out of its normal flat position without destroying said entity. The extent to which said entity is maintained preferably is such that the entity also is maintained during normal handling of the floor element. It is clear that such stable entity enhances the smoothness with which the entities can be installed.
In an important application for so-called “engineered wood”, i.e., floor elements having a top layer of a noble and/or hardwood species, beneath which a layer or structure of a cheaper kind of wood is provided, as known, for example, from said EP 1 589 160 or DE 203 10 959 U1, the components of the floor element of the invention substantially or solely are made of the noble and/or hardwood species, whereas the basic structure then is realized at least of the cheaper wood species, wherein this basic structure then possibly is composed in a similar manner as in one of the manners already applied to known embodiments of “engineered wood”.
FIG. 4 shows another possibility for the embodiment of the entity-forming means 14. Here, they consist at least of mechanical coupling means 9A-10A allowing that the components 2-3 of the same floor element 1 can cooperate with each other. These coupling means 9A-10A are made differently than the mechanical coupling means 9-10, which the floor element 1 as such is having at least at two opposite edges 5-6 and which allow that two of such floor elements 1 as such can be coupled to each other. In the example, the being “different” of the coupling means 9A-10A, which form a part of the entity-forming means 14, becomes evident from the difference in geometry between the coupling means 9-10 and the entity-forming coupling means 9A-10A. For example, the entity-forming means 14 at the groove side 6A thereof form an upright-standing locking element 23A, which effects the horizontal locking among the components 2-3 and has a highest point, which is situated in a horizontal plane H2, wherein this plane H2 extends above the upright-standing locking element 23, situated at the groove side 6, of the coupling means 10 of the floor element 1. In this case, the being “different” of the entity-forming means 14 is also emphasized by a difference in functionality. While the coupling means 9-10 of the floor element 1 allow that these floor elements can be coupled with a horizontal shifting movement S towards each other as well as with an angling movement W along their upper edges 24, the entity-forming means 14 from the example solely allow a coupling by means of an angling movement W. From the above, it is clear that the illustrated entity-forming coupling means 9A-10A, when coupling the respective components 2-3, effect a locking in horizontal H1 as well as in vertical direction V1 of the components 2-3.
FIG. 17 shows another important embodiment of a floor elements 1 according to the invention, wherein the entity-forming means 14, apart from a basic structure 28, also comprise mechanical coupling means 9A-10A, which are differing from the coupling means 9-10, which latter allow to couple such floor elements 1 as such. In the depicted entity-forming means 14, the being “different” of the entity-forming coupling means 9A-10A substantially can be reduced to the fact that they are made smaller. Amongst others, the difference in the distance D between the locking surface at the upright-standing locking element 23-23A of the groove 10-10A and the upper edge 24 of the respective component 2, floor element 1, respectively, can be regarded as relevant for the difference in the dimensions between the coupling means 9-10 and 9A-10A. These distances may have a ratio of, for example, 5 to 4. Preferably, this ratio is larger than 3 or still better is larger than 2 or even larger than one and a half.
Further, it is noted that there, where a component lying freely on a basic structure is mentioned, by “freely” in these cases is meant that this component 3 can be displaced or shifted in respect to the basic structure 28, and thus possible temporary attachment means, such as a releasable glue connection, between the component 3 and the basic structure 28 are not excluded. Also, it is not excluded that components 3, which can be shifted in respect to a basic structure 28, such as a board, in their final position are fixedly connected to the basic structure, for example, by means of a glue connection.
According to another, not represented variant of the first aspect of the invention, the components of one and the same floor element comprise at least one pair of coupling means allowing for a coupling in horizontal and vertical direction by means of a downward movement. Such coupling is known better as a “pushlock” and is known as such, for example, from WO 00/47841.
Still another variant is represented in FIG. 50. In this example, the components 2-3 of the same floor element 1 comprise at least one pair of coupling means allowing a coupling in horizontal direction H1 by means of a downward movement N, without any vertical connection. Such coupling is known better as a “drop” connection and, in the floor elements 1 of the present invention, preferably can be applied to the short sides 7A-8A of the components 2-3. The example of such drop connection represented here also has the particular feature that the male coupling part 30A can be provided in the female coupling part 31A not only with a downward movement N, but also with a substantially horizontal shifting movement S. This feature allows that the components 2-3, preferably at their short sides 7A-8A, can be engaged into each other in a simple manner even at difficult to reach places, such as beneath overhanging cabinets and radiators. Preferably, in such case the respective component 2-3 is guided at its long sides 5-6 in that it is already connected with adjacent components 2-3.
FIG. 51 represents another possible locking system 38 which can be applied in the same circumstances as the locking system from FIG. 49, for example, at the long sides 5-6 of the components 2-3 of a floor element 1 according to the invention, and to this aim also is constructed substantially similar to this locking system from FIG. 49. The particularity of the locking system 38 shown here lies in the fact that in a coupled condition of the components 2-3 the lower lip 39 of the groove 10 adopts a bent position, in which it actively counteracts the occurrence of gaps at the upper edges 24 of the components 2-3 by means of its elastic resilience. Locking systems 38 having in coupled condition a bent groove lip 39 are as such better known as locking systems with so-called “pretension”. The principle of pretension in floor elements is known as such, for example, from WO 97/47834. FIG. 51 clearly shows that it is possible that the basic structure 28 is made of a compressible material, which can offer space for the bending-out of the lower lip 39.
FIG. 52 shows another locking system 38, which is constructed similar to that of FIG. 50 and which, as the locking system 38 of FIG. 50, preferably is applied at the short sides 7A-8A of the components 3 of the floor elements 1 of the present invention, however, can also be applied in other floor elements 1. The particular characteristics of the locking system 38 represented here relate to, on the one hand, the presence of so-called “pretension” and, on the other hand, the presence of a vertically active support surface 66 by which, despite a bendable female coupling part 31A, it can be avoided that the male coupling part 30A moves too far downward when the surface or decorative side 11 of the floor covering 54 is loaded. By means of this latter characteristic, a stable floor covering 54 can be obtained, wherein the risk that the female coupling part 34A fails can be limited. It is clear that the vertical position of said support surface 66 preferably is little or not at all influenced by a possible bending of the female coupling part 31A. Also, it is clear that both aforementioned particular characteristics also can be separately present in the locking system 38. When they are combined, as represented here, one will work preferably with relatively straight horizontally active locking surfaces 44-45 between the male coupling part 30A and the female coupling part 31A. In particular, one can work with locking surfaces 44-45 forming an angle A4 of more than 70° and even more than 80° with the upper side or decorative side 11 of the respective floor element 1 or component 3. Hereby, it is obtained that the elastic resilience of the female coupling part 31A has only a small or even practically no vertical effect on the female coupling part 30A, such that the risk of the creation of height differences between the respective components 3 or floor elements 1 is minimized; on the contrary, it is obtained that this resilience substantially results in a pretension force by which the components 3 or floor elements 1 are actively forced towards each other in horizontal direction H1.
Of course, it is possible, and moreover preferred, that the respective components 2-3-52 also are provided with coupling means at opposite short sides 7-8. Herein, this preferably relates to coupling means allowing at least a locking by means of a downward movement N, such as those represented in FIGS. 50 and 52, or as it is the case in a so-called “pushlock” coupling. In the downward-angled condition, a locking can also be obtained at the short sides 7-8 by means of a component 2A already present in the floor covering 54, such that the respective component 2 can adopt its final position in the floor covering 54 by means of the angling movement W represented in FIG. 53. The remaining components 3-52 then can be brought into their final position, starting from the obtained angled-down position, by means of a shifting movement S performed in an either inclined or not inclined position P2. It is not excluded that for the installation of one and the same component 2-3-52, one alternates between inclined and not inclined positions. So, for example, may a certain component 3 be shifted in an inclined position P2 and thereafter be shifted in the not-inclined position or vice versa. For example, it may be useful to bridge-over the largest distance in the inclined condition P2 and afterwards effect the final connection at the short sides 7-8 by means of a short horizontal shifting movement, for example, with the aid of a hammer and a tapping block.
1. A floor panel, wherein the floor panel is rectangular and comprises a pair of opposite long sides and a pair of opposite short sides,
wherein the long sides are provided with coupling parts for mutually coupling the floor panel to a similar floor panel by an angling movement,
wherein the long side coupling parts, in a coupled condition of the floor panel with the similar floor panel, effect a locking in a first direction that is perpendicular to a plane of the coupled panels, as well as in a second direction that is in the plane of the coupled panels and perpendicular to the respective coupled sides,
wherein the long side coupling parts include a tongue, at one of the long sides, and a groove, at the other of the long sides, the groove being bordered by an upper lip and a lower lip, and the long side coupling parts further include locking parts,
wherein the locking parts comprise a first locking part at the lower lip and a second locking part at an underside of the tongue,
wherein the long side coupling parts allow the coupled panels to adopt at least two mutual orientations at the respective coupled sides, including
a first mutual orientation in which upper surfaces of the panels are situated substantially in a same plane, and
a second mutual orientation in which the upper surfaces of the panels enclose an angle (A2) and in which the panels are still locked in both said first direction and said second direction, and
wherein said second mutual orientation can be adopted up to the angle (A2) enclosed by the upper surfaces of the panels of 175 degrees or less,
wherein the panels are configured to be brought from the first mutual orientation to the second mutual orientation by a relative angling movement around the coupled sides, and
wherein the panels are configured such that
when coupled in said first mutual orientation, a pretension is provided by a bending of the lower lip, and
when in said second mutual orientation, said pretension is absent.
5. The floor panel of claim 1, wherein the short sides are provided with coupling parts for mutually coupling the floor panel to a second similar floor panel by a movement substantially perpendicular to the plane of the panels,
wherein the short side coupling parts, in the coupled condition of the floor panel with the second similar floor panel, effect a locking in a direction in the plane of the panels and perpendicular to the respective coupled sides, the short side coupling parts being free from locking parts which effect a locking in a direction perpendicular to the plane of the coupled panels and,
wherein the short side coupling parts comprise a male coupling part at one of the short sides, and a female coupling part at the other of the short sides.
10. The floor panel of claim 1, wherein the first locking part includes a first locking surface having a first contacting portion, and the second locking part includes a second locking surface having a second contacting portion, and
wherein, in the first mutual orientation, the first contact portion of the first locking part directly contacts the corresponding second contacting portion of the second locking part between a lower horizontal plane and an upper horizontal plane, the lower horizontal plane and the upper horizontal plane extending in a direction parallel to the upper surface of the panels in the coupled panels.
13. The floor panel of claim 1, wherein the first locking part includes a first locking surface having a first contacting portion, and the second locking part includes a second locking surface having a second contacting portion, and
wherein, in the second mutual orientation, the first locking surface is free from contact with the second locking surface.
14. The floor panel of claim 1, wherein the first locking part includes a first locking surface having a first contacting portion, and the second locking part includes a second locking surface having a second contacting portion, and
wherein, in the second mutual orientation, a clearance is provided between the first locking surface and the second locking surface such that movement of the floor panel with respect to the similar floor panel is provided in a limited distance in a direction parallel to the upper surface of the floor panel while locking in both the first direction and the second direction is maintained.
US15/372,735 2006-12-21 2016-12-08 Floor element, locking system for floor elements, floor covering and method for composing such floor elements to a floor covering Active US10100532B2 (en)
BE2006/0641A BE1017403A5 (en) 2006-12-21 2006-12-21 Floor element, locking system for floor elements, floor covering and method for composing such floor elements to form a floor covering.
BE2006/0641 2006-12-21
DE202007013059U DE202007013059U1 (en) 2006-12-21 2007-09-18 Floor element and from such floor elements of existing flooring
DE202007013059U 2007-09-18
DE202007013059 2007-09-18
PCT/IB2007/004153 WO2008078183A2 (en) 2006-12-21 2007-12-17 Floor element, locking system for floor elements, floor covering and method for composing such floor elements to a floor covering
US51945609A true 2009-06-16 2009-06-16
US14/329,157 US9534400B2 (en) 2006-12-21 2014-07-11 Floor element, locking system for floor elements, floor covering and method for composing such floor elements to a floor covering
US15/372,735 US10100532B2 (en) 2006-12-21 2016-12-08 Floor element, locking system for floor elements, floor covering and method for composing such floor elements to a floor covering
US14/329,157 Continuation US9534400B2 (en) 2006-12-21 2014-07-11 Floor element, locking system for floor elements, floor covering and method for composing such floor elements to a floor covering
US20170089078A1 US20170089078A1 (en) 2017-03-30
US10100532B2 true US10100532B2 (en) 2018-10-16
ID=38197801
US12/519,456 Expired - Fee Related US8806830B2 (en) 2006-12-21 2007-12-17 Floor element, locking system for floor elements, floor covering and method for composing such floor elements to a floor covering
US14/329,157 Active US9534400B2 (en) 2006-12-21 2014-07-11 Floor element, locking system for floor elements, floor covering and method for composing such floor elements to a floor covering
US15/372,735 Active US10100532B2 (en) 2006-12-21 2016-12-08 Floor element, locking system for floor elements, floor covering and method for composing such floor elements to a floor covering
US (3) US8806830B2 (en)
EP (1) EP2099987A2 (en)
CN (1) CN101563511A (en)
BE (1) BE1017403A5 (en)
DE (1) DE202007013059U1 (en)
RU (1) RU2009128081A (en)
WO (1) WO2008078183A2 (en)
GB2085357A (en) 1980-08-27 1982-04-28 Tarkett Ab Laminated block and method of manufacturing parquet boards or squares by means of such blocks
WO1999001629A1 (en) 1997-07-04 1999-01-14 Perstorp Flooring Ab Flooring method and use of a compression arrangement
EP1103672A2 (en) 1999-11-24 2001-05-30 Manfred Deisl Parquet from massive wood strips
DE10204991C1 (en) 2002-02-06 2003-10-09 Ehp Holzprodukte Gmbh Parquet element made of wood for flooring comprises an upward-protruding tongue having on its outer long side an outward-opening locking groove into which is inserted a locking tongue
EP1437456A1 (en) 2003-01-09 2004-07-14 Flooring Industries Ltd. Floor covering, floor panel and set of floor panels for forming such floor covering, and methods for packaging and manufacturing such floor panels
WO2005061191A1 (en) 2003-12-24 2005-07-07 Kabushikikaisha Takahashishinkichi Kenchikukenkyusho Solid wood laminated panel and narrow board for use therein
EP1589160A2 (en) 2004-04-15 2005-10-26 tilo GmbH Panel for dual layer parquet
2006-12-21 BE BE2006/0641A patent/BE1017403A5/en active
2007-09-18 DE DE202007013059U patent/DE202007013059U1/en not_active Expired - Lifetime
2007-12-17 US US12/519,456 patent/US8806830B2/en not_active Expired - Fee Related
2007-12-17 RU RU2009128081/03A patent/RU2009128081A/en not_active Application Discontinuation
2007-12-17 EP EP07859222A patent/EP2099987A2/en not_active Withdrawn
2007-12-17 CN CNA2007800470556A patent/CN101563511A/en not_active Application Discontinuation
2007-12-17 WO PCT/IB2007/004153 patent/WO2008078183A2/en active Application Filing
2014-07-11 US US14/329,157 patent/US9534400B2/en active Active
2016-12-08 US US15/372,735 patent/US10100532B2/en active Active
International Search Report from corresponding PCT Application No. PCT/IB2007/004153, dated Jul. 17, 2008.
RU2009128081A (en) 2011-01-27
US20170089078A1 (en) 2017-03-30
US9534400B2 (en) 2017-01-03
US20090320402A1 (en) 2009-12-31
DE202007013059U1 (en) 2007-11-15
CN101563511A (en) 2009-10-21
WO2008078183A3 (en) 2008-09-12
WO2008078183A2 (en) 2008-07-03
BE1017403A5 (en) 2008-08-05
EP2099987A2 (en) 2009-09-16
US20140318070A1 (en) 2014-10-30
US8806830B2 (en) 2014-08-19
EP1497510B2 (en) 2008-12-24 Flooring
US20140090331A1 (en) 2014-04-03 Locking system, floorboard comprising such a locking system, as well as method for making floorboards
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:SCHACHT, BENNY;VANHASTEL, LUC;CAPPELLE, MARK;SIGNING DATES FROM 20140702 TO 20140704;REEL/FRAME:040600/0352