Patent Application
20250012085
The invention relates to decorative panels for forming a covering.
More specifically, the invention relates to decorative panels for forming a covering, preferably for forming a floor covering, wherein the panel comprises a first pair of opposite edges and a second pair of opposite edges; wherein the first pair of opposite edges optionally comprises coupling parts that allow two such panels to be coupled together and wherein these coupling parts have the following characteristic features:
An aim of the invention is to make decorative panels available that can be installed reliably and with greater certainty to form a covering.
The first aspect of the invention relates to a decorative panel for forming a covering, preferably for forming a floor covering, wherein this panel comprises a first pair of opposite edges and a second pair of opposite edges; wherein the first pair of opposite edges optionally comprises coupling parts that allow two such panels to be coupled together and wherein these coupling parts have the following characteristic features:
The decorative panel of the invention is, according to a first definition, further characterized in that in the coupled state of the first such panel to the second such panel on their second pair of opposite edges there is no contact between the underside of the downward directed locking element of the first such panel and the upper side of the lip of the lower hook-shaped portion of the second such panel, wherein the distance between the underside of the downward directed locking element of the first such panel and the upper side of the lip of the lower hook-shaped portion of the second such panel is everywhere at least 0.05 mm. Herein, “everywhere” means “over almost the entire or over the entire underside of the aforementioned downward directed locking element”, i.e. from the distal end of this underside to the aforementioned first contact zone, or at the very least over 85% of the contour of the underside of the downward directed locking element. Thus, it is for example possible that the first contact zone is preceded by a local rounding, at the location of which the aforementioned distance is not maintained. According to an alternative, second, definition, the decorative panel of the invention is further characterized in that in the aforementioned coupled state it is free from vertically acting supporting surfaces between the underside of the aforementioned downward directed locking element and the upper side of the lip of the lower hook-shaped portion, wherein “vertically acting supporting surfaces” means contact surfaces that are horizontal or are at an angle to the horizontal of less than 25°.
It is clear that “underside” means those surfaces of a respective part that are directed freely downwards, i.e. surfaces directed freely downwards whose normal comprises a component directed vertically downwards. “Freely” means that the respective surface does not coincide in a vertical projection with another lower-situated surface.
The panels according to the invention, whether according to the first or the second definition thereof, have the advantage that they can always be installed reliably to form a visually attractive and durable covering even if somewhat larger production deviations occur during milling of the coupling parts on the second pair of opposite edges.
A preferred embodiment of the invention is characterized in that the coupling parts of the second pair of opposite edges are produced mainly from the material of the panel itself.
A preferred embodiment of the invention is characterized in that the vertically acting locking system on the second pair of opposite edges comprises a first locking part and a second locking part, wherein the first locking part is located at the distal end of the downward directed locking element and wherein the second locking part is located at the proximal end of the edge that comprises the female part, wherein the first locking part comprises a third contact surface, wherein the second locking part comprises a fourth contact surface; wherein in the coupled state of a first such panel to a second such panel on their second pair of opposite edges, the third contact surface of the first panel makes contact in a second contact zone with the fourth contact surface of the second such panel, wherein locking is formed in the direction perpendicular to the thus coupled panels. This configuration increases the reliability of installation of the panels to form a visually attractive covering, since height differences between panels are avoided.
More preferably, in the coupled state of a first such panel to a second such panel on their second pair of opposite edges wherein the male part of the first such panel is brought into the female part of the second such panel, the vertical projection of the first locking part of the first such panel in the plane of the panels overlaps, over less than 0.10 mm, and preferably over at most 0.07 mm, with the vertical projection in the plane of the panels of the second locking part of the second such panel and/or in the coupled state of a first such panel to a second such panel on their second pair of opposite edges wherein the male part of the first such panel is brought into the female part of the second such panel, the vertical projection of the aforementioned second contact zone in the plane of the panels extends over less than 0.10 mm, and preferably over at most 0.07 mm, measured perpendicular to the respective edges. This improves the reliability of installation of panels even if there are somewhat larger deviations during milling of the respective coupling parts.
A preferred embodiment of the invention is characterized in that in the coupled state of a first such panel to a second such panel on their second pair of opposite edges wherein the male part of the first such panel is brought into the female part of the second such panel, the tangent in the second contact zone makes an angle with the plane of the panel of at least 15°, preferably at least 20°, more preferably at least 25°; and preferably of less than 75°, more preferably less than 60°, more preferably less than 50° and more preferably less than 40°, and wherein the aforementioned tangent preferably increases in the distal direction considered on the female part. This contributes to the case of reliable coupling of the panels. The stated values for the angle are also advantageous for panels that can be dismantled again by outward rotation, since this facilitates outward rotation.
A preferred embodiment of the invention is characterized in that the third contact surface is located on the upper side of a projecting component of the downward directed locking element, preferably wherein this projecting part is located under a recess in the downward directed locking element; and wherein the fourth contact surface is formed by at least a part of the upper side of an undercut in the edge that comprises the female part.
A preferred embodiment of the invention is characterized in that the third contact surface is located on the underside of a recess in the downward directed locking element and in that the fourth contact surface is formed at least partly on the underside of a component that projects on the edge that comprises the female part.
A preferred embodiment of the invention is characterized in that the third contact surface is located on the upper side of a projecting component of the downward directed locking element, preferably wherein this projecting part is located under a recess in the downward directed locking element; and wherein the fourth contact surface is formed by at least a part of the upper side of an undercut in the edge that comprises the female part; and in that the edge that comprises the male part comprises a third sealing face substantially perpendicular to the plane of the panel and wherein the edge that comprises the female part comprises a fourth sealing face substantially perpendicular to the plane of the panel, wherein in the coupled state of a first such panel to a second such panel on their second pair of opposite edges wherein the male part of the first such panel has been brought into the female part of the second such panel, the third sealing face of the first such panel and the fourth sealing face of the second such panel come into contact or come close together, wherein the edge that comprises the female part above the plane parallel to the surface of the panel and in that it comprises the most proximally located point of the undercut in the edge that comprises the female part, does not comprise any components that project outside the fourth sealing face. These embodiments allow panels to be made even better, which can still be installed easily and reliably if deviations occur during milling of the coupling parts. This is because no components have to be milled on the upper side of the panel on the edge that comprises the female part, which project outside the fourth scaling face.
A preferred embodiment of the invention is characterized in that the fourth contact surface is formed by the upper side of an undercut, wherein this undercut is delimited on the upper side by a part that projects from the edge and whose underside, for at least a part thereof, forms part of the fourth contact surface.
A preferred embodiment of the invention is characterized in that the edge that comprises the male part comprises a third sealing face substantially perpendicular to the plane of the panel and wherein the edge that comprises the female part comprises a fourth sealing face substantially perpendicular to the plane of the panel, wherein in the coupled state of a first such panel to a second such panel on their second pair of opposite edges wherein the male part of the first such panel has been brought into the female part of the second such panel, the third sealing face of the first such panel and the fourth sealing face of the second such panel come into contact or come close together, wherein the fourth contact surface is formed by the upper side of an undercut in the edge that comprises the female part; preferably wherein this undercut, at least in the direction perpendicular to the edge of the panel and in the plane of the panel from the fourth sealing face, has a depth of at least 1 mm, and more preferably of at least 1.4 mm. These embodiments provide a certain elasticity in the coupling parts, so that even with deviations of the dimensions of the coupling parts during milling, reliable coupling still becomes possible.
A preferred embodiment of the invention is characterized in that the panel is configured so that in the coupled state of a first such panel to a second such panel on their second pair of opposite edges wherein the male part of the first such panel has been brought into the female part of the second such panel, locking is obtained in the direction perpendicular to the coupled panels at the distal end of the downward directed locking element of the first such panel, wherein this locking is produced at least by an inserted piece at the distal end of the downward directed locking element of the first such panel, interacting with a recess in the edge of the second such panel; or by a recess at the distal end of the downward directed locking element of the first such panel, interacting with an inserted piece in the edge of the second such panel; wherein during coupling, the inserted piece or at least a part thereof moves, slides or bends from its original position, and then at least partly goes back towards its original position, so that locking is obtained in the direction perpendicular to the plane of the coupled panels. These embodiments offer the synergistic advantage that wider tolerances are allowable in the production of the coupling parts. The inserted piece is a separate component, which can be made by specific production techniques. Because the inserted piece- or at least a part thereof-moves, slides or bends during coupling, it has the flexibility to compensate for production tolerances in the coupling parts.
A preferred embodiment of the invention is characterized in that the distal end of the downward directed locking element is free from vertically acting locking parts, so that in the coupled state of a first such panel to a second such panel on their second pair of opposite edges, wherein the male part of the first such panel has been brought into the female part of the second such panel, no locking is achieved in the direction perpendicular to the coupled panels at the distal end of the downward directed locking element of the first such panel. Since no locking parts have to be milled at the distal end of the downward directed locking element, the milling of this edge is easier. The reliability of installation of these panels is increased thereby.
A preferred embodiment of the invention is characterized in that the coupling parts on the second pair of opposite edges are configured so that in the coupled state of a first such panel to a second such panel on their second pair of opposite edges wherein the male part of the first such panel has been brought into the female part of the second such panel, the angle between the plane of the coupled panels and the tangent in the first contact zone is 90° or less than 90°, wherein this angle is the angle in the proximal direction of the first such panel.
A preferred embodiment of the invention is characterized in that the coupling parts on the second pair of opposite edges are configured so that in the coupled state of a first such panel to a second such panel on their second pair of opposite edges wherein the male part of the first such panel has been brought into the female part of the second such panel, the angle between the plane of the coupled panels and the tangent in the first contact zone is less than 75°, and preferably is more than 50°, wherein this angle is the angle in the proximal direction of the first such panel. These embodiments make the panels easier to install, and so also increase the reliability of installation. It may happen during installation of a panel that a panel must be removed again and reinstalled. In this embodiment the panel can be removed on the second pair of opposite edges by rotating the panel outwards. This is a simple method, which also avoids damaging panels that have to be removed and refitted.
A preferred embodiment of the invention is characterized in that the coupling parts on the second pair of opposite edges are configured so that in the coupled state of a first such panel to a second such panel on their second pair of opposite edges wherein the male part of the first such panel has been brought into the female part of the second such panel, considering the tangent in the first contact zone in the direction toward the upper side of the coupled panels and toward the first such panel, the angle between the plane of the coupled panels and the tangent in the first contact zone is more than 90°, and preferably is more than 90°, and preferably is less than 105°, wherein this angle is the angle in the proximal direction of the first such panel. In this embodiment the first contact zone provides locking of the coupled panels in the direction perpendicular to the plane of the panels. This embodiment is advantageous for being able to install panels reliably even with deviations during milling of the respective coupling parts. This first contact zone is located at a certain distance from the upper side of the panel. Deviations during milling can be compensated by bending or deforming the lip of the upward directed lower hook-shaped portion. This does not lead to a visually different appearance of the installed panels.
A preferred embodiment of the invention is characterized in that the downward directed locking element and the upward directed locking element are configured so that on coupling a first such panel to a second such panel on their second pair of opposite edges, a pretension is formed in the first contact zone, preferably through application of overlapping contours of the downward directed locking element and upward directed locking element, more preferably wherein these overlapping contours have a difference in angle with the plane of the panels of at most 5°, more preferably of at most 4°, more preferably of at most 3°. This pretension is advantageous for pushing the edges of the coupled panels against each other and avoiding a height difference between coupled panels. This ensures better installation. The choice of the difference of the angles of the overlapping contours is also such that if there are milling tolerances, reliable installation is still possible.
The pretension may be the result of a deformation, either an elastic deflection, or an elastic compression, or a combination thereof.
A preferred embodiment of the invention is characterized in that the distal end of the upward directed locking element or the distal end of the lip of the lower hook-shaped portion comprises a fifth locking part for producing, in the coupled state of a first such panel to a second such panel on their second pair of opposite edges wherein the male part of the first such panel has been brought into the female part of the second such panel, locking in the direction perpendicular to the plane of the coupled panels, wherein the fifth locking part of the second such panel interacts with a sixth locking part on the opposite edge of the first such panel. This configuration increases the reliability of installation if there are production tolerances in the respective coupling and locking parts. These are located relatively low down in the panel. Production tolerances can be compensated without this becoming visible in the installed panels. The lip of the upward directed lower hook-shaped portion can for example bend somewhat to compensate for tolerances.
Preferably, in the coupled state of the first such panel to the second such panel on their second pair of opposite edges, the fifth locking part of the second such panel comes into contact with the sixth locking part on the opposite edge of the first such panel. This ensures good locking of the installed panels and thus a visually attractive covering.
A preferred embodiment of the invention is characterized in that, according to a first possibility, the fifth locking part is at least formed by a projection at the distal end of the upward directed locking element or at the distal end of the lip of the lower hook-shaped portion and the sixth locking part is at least formed by an undercut or a recess on the edge that comprises the male part; or in that, according to a second possibility, the fifth locking part is at least formed by an undercut at the distal end of the upward directed locking element or at the distal end of the lip of the lower hook-shaped portion and the sixth locking part is at least formed by a projecting part on the edge that comprises the male part; preferably wherein this undercut makes an angle of between 20° and 30° with the plane of the panel.
A preferred embodiment of the invention is characterized in that in the coupled state of the first such panel to the second such panel on their second pair of opposite edges, the fifth locking part of the second panel does not come into contact with the sixth locking part on the opposite edge of the first panel. Since there is no contact between the fifth locking part and the sixth locking part on coupled edges of the second pair of opposite edges, production tolerances at least of these locking parts, but also other production tolerances, can be compensated without this having a negative effect on the case of installation of the panels or the visual result of the covering formed by these panels.
A preferred embodiment of the invention is characterized in that in the coupled state of the first such panel to the second such panel on their second pair of opposite edges wherein the male part of the first such panel has been brought into the female part of the second such panel, the perpendicular projections in the plane of the coupled panels of the fifth locking part of the second such panel and the sixth locking part of the first such panel have an overlap of less than 0.15 mm, and preferably of less than 0.12 mm and more preferably of at most 0.10 mm. These embodiments provide compensation of production tolerances as well as good vertical locking of the coupling of panels on their second pair of opposite edges. This also contributes to reliable installation of the panels to form a visually attractive covering, even with somewhat wider production tolerances in the coupling parts on the second pair of opposite edges.
A preferred embodiment of the invention is characterized in that in the coupled state of the first such panel to the second such panel on their second pair of opposite edges wherein the male part of the first such panel has been brought into the female part of the second such panel, perpendicular to the fifth locking part of the second such panel, there is everywhere a distance from the sixth locking part of the first such panel of at least 0.15 mm, preferably of at least 0.17 mm. These embodiments provide compensation of production tolerances as well as good vertical locking of the coupling of panels on their second pair of opposite edges. This also contributes to reliable installation of the panels to form a visually attractive covering, even with somewhat wider production tolerances in the coupling parts on the second pair of opposite edges.
A preferred embodiment of the invention is characterized in that the fifth locking part is at least formed by an undercut at the distal end of the upward directed locking element or at the distal end of the lip of the lower hook-shaped portion; and in that the sixth locking part is at least formed by a projecting part on the edge that comprises the male part.
A preferred embodiment of the invention is characterized in that the absolute value of the difference between the angle that the surface of the fifth locking part makes with the plane of the panels and the angle that the surface of the sixth locking part makes with the plane of the panels is less than 5°, is preferably less than 3°, more preferably is less than 2°.
A preferred embodiment of the invention is characterized in that neither the distal end of the upward directed locking element nor the distal end of the lip of the lower hook-shaped portion comprises a locking part for providing locking in the direction perpendicular to the coupled panels on coupling a first such panel to a second such panel on their second pair of opposite edges wherein the male part of the first such panel is brought into the female part of the second such panel.
A preferred embodiment of the invention is characterized in that in the coupled state of a first such panel to a second such panel on their second pair of opposite edges wherein the male part of the first such panel is brought into the female part of the second such panel, the distance measured in the direction perpendicular to the plane of the panels between the underside of the downward directed locking element of the first such panel and the upper side of the lip of the lower hook-shaped portion of the second such panel in the distal half of the vertical projection in the plane of the panels of the downward directed locking element of the first panel is everywhere at least 0.07 mm, and preferably is everywhere at least 0.10 mm. Such panels have the advantage that they can still be installed in a more reliable manner to form a visually attractive and durable covering even if somewhat larger production deviations occur during milling of the coupling parts on the second pair of opposite edges.
A preferred embodiment of the invention is characterized in that in the coupled state of a first such panel to a second such panel on their second pair of opposite edges wherein the male part of the first such panel is brought into the female part of the second such panel, the smallest value of the distance measured in the direction perpendicular to the plane of the panels between the underside of the downward directed locking element of the first panel and the upper side of the lip of the lower hook-shaped portion of the second such panel in the distal half of the vertical projection in the plane of the panels of the downward directed locking element of the first panel is greater than the smallest value of the distance measured in the direction perpendicular to the plane of the panels between the underside of the downward directed locking element of the first panel and the upper side of the lip of the lower hook-shaped portion of the second panel in the proximal half of the vertical projection in the plane of the panels of the downward directed locking element of the first panel. Such panels have the advantage that they can still be installed in a more reliable manner to form a visually attractive and durable covering even if somewhat larger production deviations occur during milling of the coupling parts on the second pair of opposite edges.
A preferred embodiment of the invention is characterized in that on the underside of the lip of the lower hook-shaped portion there is a recess extending to the distal end of the lip, preferably wherein this recess extends in the proximal direction to beyond the upward directed locking element. This embodiment allows downward bending of the lip of the upward directed lower hook-shaped portion, so that deviations during milling can be compensated during installation of the panels.
More preferably, in the coupled state of a first such panel to a second such panel on their second pair of opposite edges wherein the first such panel has been brought with its male part into the female part of the second such panel, the recess on the underside of the lip of the lower hook-shaped portion of the second such panel does not extend in the proximal direction of the second such panel to the vertical projection of the first contact zone on the underside of the thus coupled panels.
A preferred embodiment of the invention is characterized in that the downward directed locking element extends deeper in the proximal half thereof than in the distal half thereof, wherein this difference preferably is at least 0.20 mm, and more preferably is at least 0.25 mm. This embodiment makes it possible, in the coupled state, to make the vertical distance between the underside of the downward directed locking element and the lip of the upward directed lower hook-shaped portion in the distal part of the downward directed locking element greater than in the proximal part of the downward directed locking element. As a result, deviations in the production of coupling parts can be compensated better, so that reliable installation of a visually attractive covering can be obtained.
A preferred embodiment of the invention is characterized in that the decorative panel comprises a top layer and a substrate; wherein the substrate consists of or comprises one or more of
A preferred embodiment of the invention is characterized in that the decorative panel comprises a top layer and a substrate, wherein the top layer comprises a decorative layer in the form of printing, preferably wherein the decorative layer is obtained in one of the following ways: printing on the substrate, a printed layer of paper impregnated with resin (preferably impregnated with melamine resin or with an acrylate resin), or a printed polymer film (preferably a printed polyvinyl chloride film).
A preferred embodiment of the invention is characterized in that the decorative panel comprises a top layer and a substrate, wherein the top layer comprises a transparent or translucent wear layer, wherein the wear layer comprises one or more of a polymer film (preferably a polyvinyl chloride film), a layer of paper impregnated with resin (preferably melamine resin or an acrylate resin) or a varnish coat (preferably an acrylate layer).
More preferably the wear layer comprises particles that increase the abrasion resistance of the wear layer. Corundum particles are an example of such particles.
A preferred embodiment of the invention is characterized in that the coupling parts on the first pair of opposite edges are made mainly from the material of the panel itself; and in that the coupling parts on the first pair of opposite edges are configured so that two such panels can be coupled together on these edges by means of a rolling motion and/or by means of a horizontal sliding motion with a snap effect.
A preferred embodiment of the invention is characterized in that the coupling parts on the first pair of opposite edges are formed by a tongue and a groove; wherein the groove is delimited by an upper lip and a lower lip, wherein preferably the lower lip projects farther than the upper lip, wherein the edge that comprises the tongue and the edge that comprises the groove each comprise a locking part for locking in the direction in the plane of the panels and perpendicular to the coupled edges when coupling two such panels on their first pair of opposite edges.
More preferably, the locking part on the edge that comprises the tongue is formed by a recess on the underside of the tongue; and the locking part on the edge that comprises the groove is formed by a vertical locking part on the lower lip, preferably at the distal end of the lower lip. This embodiment leads to a configuration that is especially robust for production deviations. Thus, for example a bulging of the lower lip can be obtained in the coupled state. The provision of coupling parts with a view to said bulging makes it possible, in a variety of circumstances, to obtain a high-quality coupled state, wherein the seams can be closed, and wherein also vertical support of the underside of the tongue on the lower groove lip can be guaranteed.
As mentioned above, the interaction between tongue and groove, according to the most preferred embodiment of the present invention, provides vertical supporting surfaces formed by one or more contacts between the underside of the tongue and the upper side of the lower groove lip. Preferably at least one contact is located on the portion of the lower lip that extends beyond the upper groove lip. Said contact may be located in the immediate surroundings of the vertical locking part, here almost abutting or abutting and/or more proximal at a distance from the aforementioned locking part, for example with a portion of the contact vertically beneath the distal end of the upper groove lip or with a portion of the contact at a distance from the distal end of the upper groove lip that is less than the depth of the groove measured horizontally. It is also possible that both contacts are present, for example one contact contiguous with the vertical locking part and one contact at a distance from the distal end of the upper groove lip, wherein these contacts are separated by a space or air chamber. Preferably, in the aforementioned coupled state the lower groove lip is bent, for example over a vertical distance of at least 0.03 mm. This preferably relates to an elastic deflection that is at least partially relieved on decoupling. This elastic deflection may provide active tightening of any seams.
A preferred embodiment of the invention is characterized in that the edges of the decorative panel are configured so that the edge of the second pair of opposite edges that comprises the male part can be coupled to the edge of the first pair of opposite edges that comprises the groove, wherein both locking of these coupled edges in the plane of these coupled panels and perpendicular to the respective edges is obtained, and locking in the direction perpendicular to the plane of the coupled panels.
A preferred embodiment of the invention is characterized in that the edges of the decorative panel are configured so that the edge of the first pair of opposite edges that comprises the tongue can be coupled to the edge of the second pair of opposite edges that comprises the female part, wherein both locking of these coupled edges in the plane of these coupled panels and perpendicular to the respective edges is obtained, and locking in the direction perpendicular to the plane of the coupled panels.
These embodiments make it possible to use the same configuration of panels both in standard installation patterns and in special installation patterns, for example such as herringbone pattern. For a herringbone pattern, two types of panels are required, wherein one type of panel is reflected with respect to coupling parts on the first pair of opposite edges relative to the second type of panels.
A preferred embodiment of the invention is characterized in that the tongue and the undercut that comprises the fourth contact surface on the upper side are configured so that the edge of the first pair of opposite edges that comprises the tongue can be coupled to the edge of the second pair of opposite edges that comprises the female part, wherein the tongue is brought at least partly into the undercut that comprises the fourth contact surface on the upper side, wherein this tongue and this undercut provide locking in the direction perpendicular to the thus coupled panels.
A preferred embodiment of the invention is characterized in that the panel is at most 5 mm thick, and preferably is at most 4.5 mm thick, and more preferably is at most 4 mm thick.
It is noted in general that the lack of vertically acting supporting surfaces as defined on the basis of the second alternative definition of the first aspect, is preferably compensated based on one or a combination of two or more of the following characteristic features:
The second aspect of the invention relates to a set of decorative panels. The set comprises a first type of panels and the set comprises a second type of panels. Both with the first type of panels and with the second type of panels, the edges of the panels are configured so that the edge of the second pair of opposite edges that comprises the male part can be coupled to the edge of the first pair of opposite edges that comprises the groove, wherein both locking of these coupled edges in the plane of these coupled panels and perpendicular to the respective edges is obtained, and locking in the direction perpendicular to the plane of the coupled panels. Both with the first type of panels and with the second type of panels, the edges of the panels are configured so that the edge of the first pair of opposite edges that comprises the tongue can be coupled to the edge of the second pair of opposite edges that comprises the female part, wherein both locking of these coupled edges in the plane of these coupled panels and perpendicular to the respective edges is obtained, and locking in the direction perpendicular to the plane of the coupled panels. In addition, the edges of the decorative panel of the first type and the edges of the decorative panel of the second type are configured so that the edge of the second pair of opposite edges that comprises the male part of a panel of the first type can be coupled to the edge of the first pair of opposite edges that comprises the groove of a panel of the second type, wherein both locking of these coupled edges in the plane of these coupled panels and perpendicular to the respective edges is obtained, and locking in the direction perpendicular to the plane of the coupled panels. In addition, the edges of the decorative panel of the first type and the edges of the decorative panel of the second type are configured so that the edge of the first pair of opposite edges that comprises the tongue of a panel of the second type can be coupled to the edge of the second pair of opposite edges that comprises the female part of a panel of the second type, wherein both locking of these coupled edges in the plane of these coupled panels and perpendicular to the respective edges is obtained, and locking in the direction perpendicular to the plane of the coupled panels.
With this set of panels, a covering can be produced in herringbone, which can be installed reliably to form a visually attractive herringbone covering, even if relatively large deviations occurred during production of the coupling parts of one or of both types of panels.
A preferred embodiment of the second aspect of the invention is characterized in that the coupling parts on the first pair of opposite edges of the first type of panels are reflected with respect to the coupling parts on the first pair of opposite edges of the second type of panels.
With a view to better illustration of the features of the invention, some preferred embodiments are described hereunder, as examples without any limiting character, referring to the appended drawings, in which:
The decorative panels 1 of this example are configured on their edges in such a way that they are mutually couplable according to the so-called fold-down principle. This is a principle that is known per se, and that consists therein that said floor panels 1 may be coupled together on the first pair of edges 2-3 by a rolling motion R, and may be coupled together on the second pair of edges 4-5 by a downward motion M, wherein the downward motion M is a consequence of the rolling motion R and so takes place substantially at the same time. The floor panels 1 are herein also configured on their edges 2-3 and 4-5 so that finally locking takes place in the vertical direction V as well as in the horizontal direction H, the latter perpendicular to the respective edges.
The second pair of opposite edges 4-5 comprises coupling parts 8-9 that allow two such panels 1 to be coupled together. These coupling parts 8-9 are mainly made from the material of the panel 1 itself. The coupling parts 8-9 comprise a horizontally acting locking system, which in a coupled state of two such panels 1 achieves locking in the plane of the panels 1 and perpendicular to the respective edges 4-5. The horizontally acting locking system of the second pair of edges 4-5 is formed from an upward directed lower hook-shaped portion 10 that is located on one of these two edges 4, and from a downward directed upper hook-shaped portion 11 that is located on the opposite edge 5. The lower hook-shaped portion 10 consists of a lip 12 with an upward directed locking element 13 that defines, proximally thereto, a female part 14 in the form of a recess, while the upper hook-shaped portion 11 consists of a lip 15 with a downward directed locking element 16 that forms a male part 17.
Two such panels 1 can be coupled to each other on their respective edges 4-5 by means of a downward motion M of a first such panel 1 relative to a second such panel 1, wherein the male part 17 of the first such panel 1 is brought into the female part 14 of the second such panel 1.
The proximal end of the downward directed locking element 16 comprises a first contact surface 18. The proximal end of the upward directed locking element 13 comprises a second contact surface 20.
In the coupled state, as shown in
In the coupled state of the first such panel 1 to the second such panel 1 on their second pair of opposite edges 4-5 there is no contact between the underside 70 of the downward directed locking element 16 of the first such panel and the upper side 71 of the lip 12 of the lower hook-shaped portion 10 of the second such panel. The distance D1 between the underside 70 of the downward directed locking element 16 of the first such panel 1 and the upper side 71 of the lip 12 of the lower hook-shaped portion 10 of the second such panel 1 is everywhere at least 0.05 mm. In this example, 0.05 mm is the smallest distance D6 between the underside of the downward directed locking element 16 of the first such panel 1 and the upper side of the lip 12 of the lower hook-shaped portion 10 of the second such panel 1.
It is to be noted that panel 1 from the example also has the characteristic features of the second alternative definition of the first aspect of the invention, namely that panel 1 in the coupled state is free from vertically acting supporting surfaces between the underside 70 of the downward directed locking element 16 and the upper side 71 of the lip 12 of the lower hook-shaped portion 10.
The decorative panel 1 comprises a vertically acting locking system on the second pair of opposite edges 4, 5. In the panel of the example, this vertically acting locking system comprises a first locking part 19 and a second locking part 21. The first locking part 19 is located at the distal end of the downward directed locking element 16. The second locking part 21 is located at the proximal end of the edge 4 that comprises the female part 14. The first locking part 19 comprises a third contact surface 23. The second locking part 21 comprises a fourth contact surface 24. In the coupled state of a first such panel 1 to a second such panel 1 on their second pair of opposite edges 4, 5, the third contact surface 25 of the first panel 1 comes into contact in a second contact zone C2 with the fourth contact surface 24 of the second such panel 1, wherein locking is formed in the direction perpendicular to the thus coupled panels 1.
In the example shown, the third contact surface 23 is located on the upper side of a projecting component of the downward directed locking element 16. This projecting part is located under a recess 72 in the downward directed locking element 16. The fourth contact surface 24 is formed by at least a part of the upper side of an undercut 73 in the edge 4 that comprises the female part 14.
The edge 5 that comprises the male part 17 comprises a third sealing face 74 substantially perpendicular to the plane of the panel. The edge 4 that comprises the female part 14 comprises a fourth sealing face 75 substantially perpendicular to the plane of the panel. In the example shown, this undercut 73 has, in the direction perpendicular to the edge of the panel 1 and in the plane of the panel 1 from the fourth sealing face 75, a depth D2 of 1.5 mm.
In the coupled state of a first such panel 1 to a second such panel 1 on their second pair of opposite edges 4, 5 wherein the male part 17 of the first such panel 1 has been brought into the female part 14 of the second such panel 1, the third sealing face 74 of the first such panel 1 and the fourth sealing face 75 of the second such panel 1 come into contact with each other or come close together.
In the example shown, the edge 4 with the female part 14, above the plane H1 parallel to the surface of the panel 1 and that comprises the most proximally located point 81 of the undercut 73 in the edge 4 that comprises the female part 14, does not comprise any components that project outside the fourth sealing face 75.
Alternatively, it is also possible that the fourth contact surface 24 is formed by the upper side of an undercut, wherein this undercut is delimited on the upper side by a part that projects from the edge 4 and whose underside, for at least a part thereof, forms part of the fourth contact surface 24.
In the example shown, the tangent T2 in the second contact zone C2 makes an angle A2 with the plane of the panel of 30°, wherein the respective tangent T2 increases in the distal direction considered relative to the edge 4 with the female part 14.
In the example shown, in the coupled state the vertical projection of the first locking part 19 of the first such panel 1 overlaps in the plane of the panels over a distance D8 equal to 0.07 mm with the vertical projection in the plane of the panels 1 of the second locking part 21 of the second such panel 1. It is to be noted that, in the example, in the coupled state of a first such panel 1 to a second such panel 1 on their second pair of opposite edges 4-5 wherein the male part 17 of the first such panel 1 is brought into the female part 14 of the second such panel 1, the vertical projection of the aforementioned second contact zone C2 extends in the plane of the panels 1 over a distance D8 of less than 0.10 mm, and preferably over at most 0.07 mm, measured perpendicular to the respective edges 4-5.
In the example shown, the angle A1 between the plane of the coupled panels and the tangent T1 in the first contact zone C1 is 67°. This angle A1 is the angle in the proximal direction of the first such panel, angle A1 as indicated in
In the example shown, the downward directed locking element 16 and the upward directed locking element 13 are configured so that on coupling, a pretension is formed in the first contact zone C1 through application of overlapping contours of the downward directed locking element 16 and the upward directed locking element 13. In the example shown, these overlapping contours have a difference in angle A1 with the plane of the panels of 3°. The pretension is the consequence of elastic deflection of the upward directed locking element 13.
In the example shown, the distal end of the upward directed locking element 13 or the distal end of the lip 12 of the lower hook-shaped portion 10 comprises a fifth locking part 76 for producing, by interacting with a sixth locking part 77 on the opposite edge 5 of the first such panel 1, locking in the vertical direction; this is in the direction perpendicular to the coupled panels 1.
The fifth locking part 76 is formed in this embodiment by an undercut 82 at the distal end of the upward directed locking element 13 or at the distal end of the lip 12 of the lower hook-shaped portion 10. This undercut makes an angle A3 of 25° with the plane of the panel 1.
The sixth locking part 77 is formed in this embodiment by a projecting part 83 on the edge 4 that comprises the male part 17.
In the coupled state on the second pair of opposite edges 4-5, the fifth locking part 76 does not come into contact with the sixth locking part 77 on the coupled edge 4 of the other panel 1. The perpendicular projections in the plane of the coupled panels 1 of the fifth locking part 76 and the sixth locking part 77 of the coupled edges 4-5 have, in the example, an overlap D3 equal to or approximately equal to 0.10 mm.
In the coupled state there is, perpendicular to the fifth locking part 76, everywhere a distance D4 from the sixth locking part 77 of at least 0.10 mm.
In the example, the absolute value of the difference between the angle that the surface of the fifth locking part 76 makes with the plane of the panels 1 and the angle that the surface of the sixth locking part 77 makes with the plane of the panels 1 is less than 2°. Preferably there is no difference between these angles.
In the coupled state, the distance D5 measured in the direction perpendicular to the plane of the panels 1 between the underside 70 of the downward directed locking element 16 and the upper side 71 of the lip 12 of the lower hook-shaped portion 10 of the panel coupled thereto in the distal half of the vertical projection in the plane of the panels 1 of the downward directed locking element 16 of the first panel 1 is everywhere at least 0.10 mm.
In the coupled state, the smallest value of the distance D5 measured in the direction perpendicular to the plane of the panels 1 between the underside of the downward directed locking element 16 and the upper side of the lip 12 of the lower hook-shaped portion 10 of the panel 1 coupled thereto in the distal half of the vertical projection in the plane of the panels 1 of the downward directed locking element 16 of the first panel is greater than the smallest value of the distance D6 measured in the direction perpendicular to the plane of the panels between the underside of the downward directed locking element 16 and the upper side of the lip 12 of the lower hook-shaped portion 10 of the panel 1 coupled thereto in the proximal half of the vertical projection in the plane of the panels 1 of the downward directed locking element 16 of the first panel.
In the example shown, the underside 84 of the lip 12 of the lower hook-shaped portion 10 comprises a recess 45 extending to the distal end of the lip. This recess 45 does not extend, in the example shown, in the proximal direction of the edge 4 that comprises this recess 45, to the vertical projection of the first contact zone C1 on the underside of the thus coupled panels 1. In other words the recess 45 only extends from the distal end of the lip 12 up to a distance of the vertical projection from the first contact zone C1. Thus, the actual contact zone C1 remains supported vertically.
In the example shown, the downward directed locking element 16 extends in the proximal half thereof deeper than in the distal half thereof, in the example this difference is 0.25 mm.
The coupling part on a first edge 2 is formed by a tongue 58 and the coupling part on the second edge 3 is formed by a groove 59. The groove 59 is delimited by an upper lip 61 and a lower lip 60. The lower lip 60 projects farther than the upper lip 61. Each of these edges 2, 3 comprises a locking part 62-63 for locking in the direction in the plane of the panels 1 and perpendicular to the coupled edges 2-3 on coupling two such panels 1 on their first pair of opposite edges 2, 3. The locking part on the edge 2 that comprises the tongue 58 is formed by a recess 62 on the underside of the tongue; and the locking part on the edge 3 that comprises the groove 59 is formed by a vertical locking part 63 at the distal end of the lower lip 60.
The example of the invention illustrated in
As is illustrated in
As is illustrated in
In this example, neither the distal end of the upward directed locking element 13 nor the distal end of the lip 12 of the lower hook-shaped portion 10 comprises a locking part for providing locking in the direction perpendicular to the coupled panels 1. Thus, on coupling such panels 1 on their second pair of opposite edges 4-5, no coupling is obtained in the vertical direction (this is the direction perpendicular to the plane of the panels) at the location of the distal end of the edges 4 of the panels 1 that comprise the upward directed locking element 13.
In this embodiment, neither the distal end of the upward directed locking element 13 nor the distal end of the lip 12 of the lower hook-shaped portion 10 comprises a locking part for providing locking in the direction perpendicular to the coupled panels 1. Thus, on coupling such panels 1 on their second pair of opposite edges 4-5, no coupling in the vertical direction (this is the direction perpendicular to the plane of the panels) is obtained at the location of the distal end of the edges 4 of the panels 1 that comprise the upward directed locking element 13.
In this embodiment, neither the distal end of the upward directed locking element 13 nor the distal end of the lip 12 of the lower hook-shaped portion 10 comprises a locking part for providing locking in the direction perpendicular to the coupled panels 1. Thus, on coupling such panels 1 on their second pair of opposite edges 4-5, no coupling in the vertical direction (this is the direction perpendicular to the plane of the panels 1) is obtained at the location of the distal end of the edges 4 of the panels 1 that comprise the upward directed locking element 13.
In the embodiment in
In this embodiment, the coupling parts 8, 9 on the second pair of opposite edges 4-5 are configured so that, in the coupled state of a first such panel I to a second such panel 1 on their second pair of opposite edges 4-5 wherein the male part 17 of the first such panel 1 has been brought into the female part 14 of the second such panel 1, the angle A1 between the tangent T1 in the first contact zone C1 and the plane of the coupled panels is more than 90°. This angle A1 is the angle in the proximal direction of the first such panel; angle A1 as indicated in
In the example shown, the distal end of the upward directed locking element 13 comprises a fifth locking part 76 for providing, by interacting with a sixth locking part 77 on the opposite edge 5 of the first such panel 1, locking in the vertical direction; this is in the direction perpendicular to the coupled panels 1. The fifth locking part 76 is formed by a projection at the distal end of the upward directed locking element 13 and the sixth locking part 77 is formed by a recess on the edge 5 that comprises the male part 17. In the coupled state on the second pair of opposite edges 4-5, the fifth locking part 76 comes into contact with the sixth locking part 77 on the coupled edge 4 of the other panel 1.
It is to be noted that the panels from the examples preferably have one or more of the following characteristic features, such as are for example shown in
It should also be noted that the decorative panels 1 shown in the figures comprise a top layer 57 and a substrate 80.
The present invention is by no means limited to the embodiments described above, but decorative panels of this kind can be produced according to several variants while remaining within the scope of the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2021/5932 | Dec 2021 | BE | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2022/061265 | 11/22/2022 | WO |
