Patent Description:
More particularly, it relates to floor panel which can be coupled to each other at least on certain edges.

The aim of the invention is that such floor covering is easy to install, this as a result of the claimed combination of characteristics of the floor panels, and/or that, in comparison with existing floor panels, advantageous characteristics after installation are obtained and/or that the floor panels can be realized in a simple manner, for example, by applying less complex profiled edge parts on at least one pair of the edges. The invention primarily aims at offering compromises between coupling systems on a first pair of edges and a second pair of edges, whereby a user-friendly product is achieved which, however, remains effective in its use.

To this aim, the invention relates to floor panels such as described herein below, wherein various advantageous embodiments are offered.

The invention relates to a floor panel for forming a floor covering, wherein this floor panel is realized substantially on the basis of synthetic material and preferably as a layer-shaped, either single-layer or multi-layer, substrate; wherein this floor panel is rectangular, either oblong or square, and thus comprises a first pair of opposite edges and a second pair of opposite edges; wherein the first pair of opposite edges comprises coupling parts, which allow that a plurality of such floor panels mutually can be coupled to each other; wherein these coupling parts form a first mechanical locking system, which, in a coupled condition of two of such floor panels, effects a locking in the plane of the floor panels and perpendicular to the respective edges, as well as form a second mechanical locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the panels; wherein these coupling parts, on the first pair of opposite edges, preferably are realized substantially in the material of the floor panel itself, and more particularly in said substrate; with the characteristic that the floor panel, on the second pair of edges, is provided with an edge configuration which allows that two of such floor panels can be positioned with their respective edges alongside each other, wherein the configuration of the edges is free from mechanical horizontally active locking systems. This offers the advantage that the motion in the material during shrinkage and expansion of the floor panel can easily be accommodated, and there are no horizontally active locking means which might be pushed out of each other.

The second pair of edges is also free from mechanical vertically active locking systems.

The floor panel, on the second pair of edges, has an edge configuration which provides for that the actual panels in installed condition extend along these edges in a non-overlapping manner alongside each other, more particularly can adjoin each other exclusively by butt joint.

According to a preferred embodiment, the floor panel further is characterized in that the edge configuration of the second pair of edges is completely free from locking systems, thus, also from connection systems other than mechanical locking systems, such as adhesive means or the like. According to a possibility, then at least one of the edges of the second pair is provided with a seat, such as a recess or the like, for applying an adhesive, such as glue, during installation of the floor panels.

According to another possibility, the floor panel is characterized in that the edge configuration of the second pair of edges is provided with adhesive means, which allow a connection between the edges. Various possibilities are described in the detailed description and in the claims.

According to an embodiment, the invention further provides for a floor panel for forming a floor covering, wherein this floor panel substantially is realized on the basis of synthetic material and preferably as a layer-shaped, either single-layer or multi-layer, substrate; wherein this floor panel is rectangular, either oblong or square, and thus comprises a first pair of opposite edges and a second pair of opposite edges, wherein in the case of an oblong panel, the second pair of edges forms the short sides; wherein the second pair of opposite edges comprises coupling parts, which allow that a plurality of such floor panels mutually can be coupled to each other; wherein these coupling parts form a first mechanical locking system, which, in a coupled condition of two of such floor panels, effects a locking in the plane of the floor panels and perpendicular to the respective edges, as well as form a second mechanical locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the panels; wherein these coupling parts allow coupling by means of a turning movement; characterized in that on the first pair of sides coupling parts are present, selected from coupling parts of the drop-in type, push-lock type, or of the type with overlapping portions with adhesive, in such a manner that such floor panel first can be coupled on one edge of the second pair to a preceding floor panel in the same row and subsequently, via a downward movement, can be coupled with an edge of the first pair to one or more floor panels of a preceding row, this latter preferably by means of a rolling movement.

According to an embodiment, the invention further relates to a floor panel for forming a floor covering, wherein this floor panel substantially is realized on the basis of synthetic material and preferably as a layer-shaped, either single-layer or multi-layer, substrate; wherein this floor panel is rectangular, either oblong or square, and thus comprises a first pair of opposite edges and a second pair of opposite edges; wherein the first pair of opposite edges as well as the second pair of opposite edges comprises coupling parts, which allow that a plurality of such floor panels mutually can be coupled to each other; wherein these coupling parts form a first mechanical locking system, which, in a coupled condition of two of such floor panels, effects a locking in the plane of the floor panels and perpendicular to the respective edges, as well as form a second mechanical locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the panels; characterized in that the floor panel, on at least one pair of edges, comprises "velcro"-type fastening parts as a vertically active locking system, whether or not combined with further mechanical locking systems.

In this embodiment, the floor panel can show one or more of the following characteristics:.

More specific characteristics are defined in the detailed description following below and/or in the appended claims.

It is noted that by "mechanically horizontally or vertically active locking systems", systems are understood wherein a locking is achieved solely via mechanically locking surfaces. An adhesive connection does not fall in this category, even if the adhesive, in solidified condition or otherwise, should form a locking surface.

Pure friction also is not considered a mechanically active locking system.

A horizontally active locking system is a system in which two floor panels, if they are moved out of each other in the same plane, are counteracted and/or restricted therefrom.

A vertically active locking system is a system, which prevents that two coupled floor panels can be moved out of each other vertically, or at least counteracts this movement.

With the intention of better showing the characteristics of the invention, herein below, as an example without any limitative character, some embodiments according to the invention are described and also embodiments not according to the invention to illustrate the invention, with reference to the accompanying drawings, wherein:.

The figures are schematic representations which are self-evident. The general references P1 and P2 in the figures refer to the first pair of edges and second pair of edges, respectively. Reference A schematically represents an adhesive means or the like, whereas reference Z refers to locating edges.

The various cross-sectional views substantially have the purpose of visualizing the principles of the locking in certain directions or not locking in certain directions.

So, for example, <FIG> represent three principal possibilities of interconnecting edges of the first pair P1, whereas <FIG> represent a number of principal possibilities for the second pair P2. <FIG> thus forms a cross-section according to line II-II in <FIG>, whereas the <FIG> represent variants thereof. <FIG> is a cross-section according to line V-V in <FIG>, whereas <FIG> are variants of this cross-section.

The invention is explained herein below by means of <FIG>, which schematically represent some examples according to the invention or not according to the invention.

The invention relates to a floor panel <NUM> for forming a floor covering <NUM>, wherein this floor panel <NUM> is realized substantially on the basis of synthetic material and preferably as a layer-shaped, either single-layer or multi-layer, substrate <NUM>; wherein this floor panel <NUM> is rectangular, either oblong or square, and thus, as indicated in <FIG>, comprises a first pair of opposite edges P1 and a second pair of opposite edges P2. The first pair P1 is formed by the edges <NUM> and <NUM>, whereas the second pair P2 is formed by the edges <NUM> and <NUM>.

The first pair of opposite edges <NUM>-<NUM>, as in the examples of <FIG>, comprises coupling parts <NUM>-<NUM>, which allow that a plurality of such floor panels <NUM> mutually can be coupled to each other; wherein these coupling <NUM>-<NUM> parts form a first mechanical locking system and a second mechanical locking system. The first mechanical locking system is of such kind that, in a coupled condition of two of such floor panels, it effects a locking in the plane of the floor panels and perpendicular to the respective edges, in other words, provides for a horizontal locking, wherein the shifting apart of the floor panels according to a direction transverse to their edges is counteracted. The second mechanical locking system is of such kind that, in a coupled condition of two of such floor panels, it effects a locking transverse to the plane of the panels, in other words, provides for a vertical locking. Herein, the coupling parts, on the first pair of opposite edges, preferably are realized substantially in the material of the floor panel itself, and more particularly in said substrate <NUM>.

It is noted that such coupling parts <NUM>-<NUM>, which in coupled condition provide for a mechanical locking in horizontal as well as vertical direction, can be realized in different manners and are not limited to the embodiments of the <FIG>. The embodiments of <FIG>, however, will be explained below in a short version.

According to <FIG>, coupling parts <NUM>-<NUM> of the first pair of opposite edges are configured such that two of such panels <NUM> on these edges can be coupled to each other by means of a turning movement R. In the example, the coupling parts <NUM>-<NUM> on the first pair of opposite edges to this aim consist of a tongue <NUM> and a groove <NUM>, as well as of locking parts <NUM>-<NUM>, which, in the coupled condition, prevent the shifting apart of the tongue and groove. Herein, the groove <NUM> preferably is bordered by an upper lip <NUM> and a lower lip <NUM>, which latter in distal direction reaches farther than the upper lip, in other words, protrudes to beyond the upper lip. The locking part <NUM> is situated on the lower side of the tongue, whereas the locking part <NUM> is formed on the protruding part of the lower lip <NUM>.

It is noted that, in the case that, as aforementioned, the first pair of opposite edges is configured such that two of such panels <NUM> can be coupled to each other at these edges by means of a turning movement R, it is preferred that the second pair of edges is configured such that successively floor panels simply can be installed via a fold-down principle, such as further will become clear from the description of the second pair of edges. In the present application, by the "fold-down principle" must be understood that, when a newly to install floor panel is coupled to a preceding row of floor panels via said turning movement R, this movement also automatically has the final effect that the newly installed floor panel will arrive with its third or fourth edge in the intended end position in respect to the fourth or third edge of the preceding floor panel of the same row.

<FIG> shows another possibility for the edges <NUM> and <NUM>. Hereby, these edges are provided with coupling parts <NUM>-<NUM>, which in this case, too, form a first mechanical locking system, which, in the coupled condition of two of such floor panels, effects a locking in the plane of the floor panels and perpendicular to the respective edges, as well as form a second mechanical locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the panels; wherein these coupling parts, on the first pair of opposite edges, as represented, preferably are realized substantially in the material of the floor panel itself, and more particularly in said substrate. The specific characteristic of the coupling parts of <FIG> consists in that the respective edges <NUM> and <NUM> can be joined together by means of a downward movement M of one panel in respect to the other, this whereas therein a locking in horizontal as well as in vertical direction is achieved. Said first locking system, which provides for the horizontal locking, is formed in that the coupling parts <NUM>-<NUM> are realized as hook-shaped elements with locking parts <NUM>-<NUM>, which engage behind each other as a result of the downward movement M. The second locking system, which provides for the vertical locking, is formed by locking parts <NUM>-<NUM>, which hook behind one another, which engage behind each other by means of a snap action. It is noted that the locking parts <NUM>-<NUM>, viewed in cross-section, can also be present on other locations on the coupling parts.

In <FIG>, an embodiment for the coupling parts of the edges <NUM>-<NUM> not according to the invention is represented, to which will be returned further in de description,.

The floor panel is characterized in that the floor panel, on the second pair of edges, is provided with an edge configuration which allows that two of such floor panels <NUM> can be positioned with their respective edges <NUM>-<NUM> alongside each other, wherein the configuration of the edges is free from mechanical horizontally active locking systems.

According to the invention, the second pair of edges is also free from mechanical vertically active locking systems.

In <FIG>, an embodiment not according to the invention is represented wherein the floor panel, on the second pair of edges <NUM>-<NUM>, has an edge configuration which provides for that the actual panels in installed condition extend along these edges in a non-overlapping manner alongside each other, more particularly can adjoin each other exclusively by butt joint.

In <FIG>, embodiments not according to the invention are represented wherein the floor panel, on the second pair of edges, has an edge configuration which provides for that the actual panels extend along these edges <NUM>-<NUM> alongside each other in an overlapping manner, thus for embodiments which also are characterized in that the edge configuration of the second pair of edges is entirely free from locking systems, thus, also is also free from other locking systems than mechanical locking systems, such as adhesive means or the like.

As represented in <FIG>, the overlapping preferably is realized by means of an upper flange <NUM>, which, partially or completely, overlaps a lower flange <NUM>, wherein the upper flange <NUM> preferably rests on the lower flange <NUM>.

<FIG> represents an example with flanges <NUM>-<NUM>, which come into mutual contact via inclined surfaces.

Preferably, however, use shall be made of flat flanges. <FIG> are three examples thereof.

It is noted that the flanges <NUM>-<NUM> preferably have a thickness which is larger than <NUM>/<NUM> of the overall thickness of the floor panel.

<FIG> illustrate that the flanges can be realized in one piece. According to an alternative, which is represented in <FIG>, the lower flange forms part of a separate part <NUM>, for example, in the form of a strip, which is attached to the floor panel, in this case in a recess <NUM>.

The embodiments of <FIG> also illustrate that, seen in cross-section, the overlapping extends over a distance D which is larger than the overall thickness of the floor panel.

As represented in <FIG>, a space <NUM> can be present at the bottom side, distally from the lower flange <NUM>. Alternatively, no space is present, such as in the embodiment of <FIG>.

In general, the overlapping indeed shall be realized such that the floor panels in installed condition adjoin against each other in the proximity of their upper edges.

In <FIG>, the edges <NUM>-<NUM> also are free from mechanical vertically active locking parts, however, wherein indeed use is made of an adhesive means A, which realizes a connection between the edges. Herein, this relates to an adhesive means which is already present on the floor panels beforehand. In the represented examples, the adhesive means A beforehand is present on one edge; however, it is clear that instead thereof, it might also be present on the other edge or may even be present on both edges. In the latter case, it is preferred that in the installed condition, the adhesive means come into contact with each other.

In <FIG> not according to the invention, the edges <NUM>-<NUM> have a non-overlapping form, and an adhesive means A is present on the side of one edge. <FIG> represents an embodiment according to the invention, wherein the adhesive means A is provided in a seat <NUM> at the bottom and protrudes beyond the edge of the floor panel and in this manner a subsequent floor panel, during the installation thereof, can come into contact with this adhesive means A.

<FIG> represent embodiments not according to the invention which also make use of an overlapping configuration, combined with the presence of adhesive. In the embodiments of <FIG>, the adhesive means A is present on the lower flange <NUM>. In <FIG>, a separate part <NUM> is applied, analogous to <FIG>.

In <FIG>, an embodiment is represented wherein the overlapping is realized in that on one of the edges of the second pair of edges a protruding flap <NUM> is provided, which is attached to the lower side of the floor panel <NUM>. The adhesive means A is present on the lower flange. The protruding flap is formed as a strip of a foil-like or film-like material and is attached to the lower side of the floor panel, for example, also by means of an adhesive, for which purpose possibly the same adhesive means A can be applied.

According to a not represented alternative, such lower flange also may be formed by a foil which is present on the lower side of the floor panel in an uninterrupted manner, for example, a backing layer which extends farther than the substrate itself.

As explained in the introduction, various types of adhesive can be applied for the herein above-mentioned adhesive means A; however, preferably use is made of a pressure-sensitive adhesive or glue.

<FIG> represent various embodiments not according to the invention, wherein the second pair of edges <NUM>-<NUM> now indeed is provided with a vertically active locking system, which is formed by mutually cooperating locking parts <NUM>-<NUM>.

Preferably, however, not necessarily, this relates to locking parts which can be forced into their coupled condition simply by deformation, such that an installation by fold-down remains possible.

<FIG> show embodiments without adhesive means, whereas <FIG> provide for embodiments which indeed make use of adhesive means A.

In a particular embodiment not according to the invention, this is characterized in that on the first pair of edges the aforementioned second locking system is absent and preferably the coupling parts are realized exclusively from a so-called drop-in system, whether or not combined with an adhesive means. <FIG> represents an example hereof. It is clear that all herein above and herein below described coupling parts for the second pair of edges can also be applied in the same floor panel in combination with such drop-in system on the first pair of edges.

As is evident in <FIG>, it is preferred that the floor panel is rectangular and oblong and that the aforementioned pair of edges is formed by the edges which form the long sides, and the second pair of edges is formed by the edges which form the short sides.

<FIG> illustrate two embodiments not according to the invention of the second pair of edges <NUM>-<NUM> of floor panels. De mechanical locking in horizontal direction herein is obtained by locking parts <NUM>-<NUM>, which engage behind each other.

In <FIG>, a drop-in system is applied, whereas in <FIG> a so-called push-lock system is applied. In a drop-in system, there is no vertical locking. In a push-lock system, there is a vertical locking indeed.

<FIG> shows an example of the second pair of edges of a floor panel which is realized not according to the invention, wherein the intended locating edges are realized as Z.

<FIG> illustrate embodiments not according to the invention for oblong floor panels <NUM>. On the second pair of edges P2, now, as represented in <FIG>, coupling parts are applied which allow a coupling by means of a turning movement. On the first pair of edges, coupling parts are applied selected from coupling parts of the drop-in type, push-lock type or of the type with overlapping portions with adhesive means, in such a manner that such floor panel first can be coupled on an edge of the second pair to a preceding floor panel in the same row and subsequently, via a downward movement, can be coupled with an edge of the first pair to one or more floor panels of a preceding row, this latter preferably by means of a rolling movement RM. Examples of the aforementioned three types of coupling parts are represented in <FIG>, respectively.

Finally, <FIG> show three embodiments of edges not according to the invention which are equipped with "velcro"-type fastening parts.

In the embodiment of <FIG>, use is made of "velcro"-type fastening parts <NUM>, die make use of a plurality of small separate "velcro"-type fastening elements.

In <FIG>, use is made of at least one "velcro"-type fastening part with a plurality of profile-shaped "velcro"-type elements.

In the embodiment of <FIG>, the "velcro"-type fastening parts are formed in one piece in the material of the floor panel.

As becomes evident from the examples, it is generally preferred that the "velcro"-type fastening parts are active between overlapping flanges. Preferably, no other mechanical vertically active locking systems are applied therewith. Moreover, it is also preferred that no other horizontally active locking systems are applied therewith. For the first pair of edges, preferably coupling parts are applied of the type such as in <FIG>, thus, coupling parts which can be joined into each other by a turning movement R or a downward movement M.

It is clear that according to the invention primarily decorative floor panels are concerned, thus, with a decorative upper side, for forming a floor covering on an existing supporting floor, and more particularly for forming a floating floor covering.

The invention is in particular intended for floor panels which substantially consist of synthetic material, or which comprise at least one or more basic layers on the basis of synthetic material, and more particularly with floor panels of the supple type.

Still more particularly, the invention shows its advantages best with vinyl panels, in particular so-called vinyl tiles, and in particular with panels of the so-called LVT type ("Luxury Vinyl Tile") or VCT type ("Vinyl Composite Tile", also called "Vinyl Composition Tile"). Of course, also comparable panels of other synthetic materials, such as PU, are applicable.

Such synthetic material floor panel, and in particular supple synthetic material floor panel, and more particularly such vinyl tile, preferably shows one of the following characteristics:.

It is noted that "soft PVC" is a term expressing that this relates to supple PVC, in other words, PVC which is relatively smoothly bendable. The term soft PVC is widely known in the technique. Such soft PVC consists of PVC which has been softened, preferably by means of a plasticizer added during the production process. Depending on the added amount of plasticizer, of course different degrees of suppleness can be achieved.

By a plasticizer, any material must be understood which by being added results in a more supple PVC. Typical examples are phthalate plasticizers and isosorbide plasticizers.

By PVC which is softened, of course also PVC can be understood or a composition on the basis of PVC, which as such has the feature of being supple, for example, in that it is modified.

The same is valid for other "soft synthetic materials", and the above is not limited to PVC.

As already stated herein above, the present invention shows its advantages best when it is applied with floor panels which substantially are manufactured of supple or soft synthetic material, or in other words with supple panels.

By supple floor panels, floor panels are intended, which panels, when they, in the case of a rectangular panel, for example, with a width of less than <NUM> centimeters, are clamped on one of the two short sides of the panel and herein protrude over a length of <NUM> centimeters and are not supported, will bend under the influence of their own weight, wherein this bending at the height of the free extremity in respect to the clamped extremity is minimum <NUM> centimeters. For this bending, a bending time of <NUM> seconds is taken into account, and wherein the panel starts from a flat horizontal position.

The present invention is in no way limited to the embodiments described by way of example and represented in the figures; on the contrary, the floor panels can be realized according to various variants, without leaving the scope of the invention according to the appended claims.

So, the invention can also be applied, for example, with synthetic material-based floor panels which have a composed substrate, which panels also can be called hybrid floor panels. More particularly, this herein relates to a floor panel which consists at least of two substrate layers, each of a well-defined thickness, namely a first synthetic material-based substrate layer and a second substrate layer, situated there above, preferably directly there above, which second substrate layer has a thickness of at least <NUM>, preferably at least <NUM>; wherein this composed substrate, the floor panel concerned, respectively, also shows one of the following characteristics or any combination of these characteristics:.

Claim 1:
Floor covering system, wherein this floor covering system comprises floor panels (<NUM>); wherein the floor panels (<NUM>) substantially are realized on the basis of synthetic material and preferably as a layer-shaped, either single-layer or multi-layer, substrate; wherein the floor panels (<NUM>) are rectangular, either oblong or square, and thus comprises a first pair of opposite edges (P1) and a second pair of opposite edges (P2); wherein the first pair of opposite edges comprises coupling parts (<NUM>-<NUM>), which allow that a plurality of such floor panels (<NUM>) mutually can be coupled to each other; wherein these coupling parts (<NUM>-<NUM>) form a first mechanical locking system, which, in a coupled condition of two of such floor panels, effects a locking in the plane of the floor panels and perpendicular to the respective edges, as well as form a second mechanical locking system, which, in a coupled condition of two of such floor panels, effects a locking transverse to the plane of the panels; wherein these coupling parts, on the first pair of opposite edges (<NUM>-<NUM>), preferably are realized substantially in the material of the floor panels itself, and more particularly in said substrate (<NUM>); wherein the floor panels, on the second pair of edges (<NUM>-<NUM>), are provided with an edge configuration which allows that two of such floor panels can be positioned with their respective edges alongside each other, wherein the configuration of the edges (<NUM>-<NUM>) is free from mechanical horizontally active locking systems and also free from mechanical vertically active locking systems, wherein the connection between the edges of the second pair of edges (P2) is provided with adhesive means (A) which provides for a horizontal connection and which is provided in a seat, and wherein the floor panels, on the second pair of edges (<NUM>-<NUM>),
have an edge configuration which provides for that the actual panels in installed condition extend along these edges in a non-overlapping manner alongside each other, and can adjoin each other exclusively by butt joint, characterized in that the adhesive means also provides for a vertical connection and the coupling parts on the first pair of edges are configured such that in the mounted condition of two of such floor panels these are forced towards each other with a tensioning force, such that a so-called pre-tension is achieved.