Patent Grant
10100532
1. Field of the Invention
This invention relates to floor elements, as well as to floor coverings which are composed of such floor elements, and to a method for composing such floor elements to a floor covering. The invention also relates to locking systems which can be applied in the aforementioned floor elements.
2. Related Art
More particularly, the invention relates to floor elements, which are intended for forming a floating floor covering and which, during installation, can be coupled at their edges by means of mechanical coupling parts, the latter either being made in one piece with the floor element or not. Such coupling parts can be made such that they provide for a mutual locking of the floor elements in horizontal as well as in vertical direction, for example, as described in the international patent applications WO 94/26999, WO 97/47834, WO 01/98603 and WO 01/96688.
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.
However, the fact that smaller floor elements or floor elements with smaller, in particular less wide, decorative parts, in particular when wood parquets or parquet imitations are concerned, are much desired from an esthetically point of view, is contradictory to the aforementioned striving. It is also noted that, although smaller wooden floor elements in respect to material costs per unit of surface area are cheaper than large wooden floor elements, the higher installation costs for smaller floor elements result in that, when the total cost price of the floor covering is brought into account, they will be more expensive than a floor covering composed of large wooden floor elements. Moreover, long, narrow floor elements show the tendency to warp around an axis perpendicular to their decorative side, which leads to problems when installing such floor elements. These problems are very pronounced when the floor elements are installed without glue, i.e., for example, by means of mechanical coupling means, as the aforementioned warping results in difficulties when engaging the coupling means. When installing with glue, when the floor elements are warped, the already installed floor elements have to be strongly tensioned by means of tensioning tools designed especially to this end, which tools as such are known, for example, from WO 99/01629.
In order to offer a solution for the above-mentioned contradictions and problems, rectangular floor elements exist in the state of the art, which as such comprise several decorative portions. Known examples thereof are floor elements which comprise or represent at least two adjacent wooden decorative portions or rows of wooden decorative portions. Depending on the number of such rows, they are called two-planks, three-planks or four-planks. For examples of this solution from the state of the art, reference is made to GB 2 085 357 and WO 93/01378.
The herein above-described rectangular floor elements originating from the state of the art have the disadvantage that it is impossible to compose, starting therefrom, a floor covering with a random bond of decorative parts, as the decorative parts of each time two or more adjacent rows, depending whether a two-plank or a multi-plank, respectively, are concerned, in longitudinal direction of the rows concerned necessarily simultaneously merge into decorative parts of another floor element in the floor covering. The lack of a random bond in such floor covering is seen as disturbing.
The state of the art comprises several suggestions for the improvement of two- or multi-plank elements.
For example, the abovementioned WO 93/01378 suggests matching the decorative parts at the opposing short sides of the rectangular floor elements to each other, such that the motifs of decorative portions, which portions are adjacent to each other, merge into each other where the short sides of two floor elements adjoin each other. It is evident that this technique can only be applied to floor elements with artificially obtained decorative portions, such as decorative portions comprising a printed decor. Moreover, the adaptation of the printed decor in order to obtain such matching is time-consuming and represents a huge restriction of the freedom of design. Also, the lack of a random bond still will be noticeable when, for example, minimal height differences between the different floor elements are present.
In JP 07-076923, EP 1 103 672 and U.S. Pat. No. 4,953,335 is suggested to make the different rows of decorative parts equally long, however, to include them in the floor element at a fixed location in longitudinal direction displaced in relation to each other. The floor elements obtained in this manner are no longer rectangular, but show a pair of stepped opposite sides. However, this suggestion for improving two- or multi-plank elements still has a number of disadvantages. First, the bond which can be obtained by means of such floor elements, still can not relate to a real random bond, as in each case the same step shape would be recognizable in the floor covering, and second, the suggested floor elements, due to their stepped shape, are difficult to package.
In the first instance, the present invention envisages an alternative and/or improved floor element with which an optionally floating or not floating floor covering can be formed, wherein this floor element simultaneously may result in an increased laying or installation comfort and/or new laying or installation possibilities. Second, the invention, according to several of its preferred embodiments, relates to a floor element which can remedy at least one of the above-mentioned problems, disadvantages or contradictions of the state of the art. To this aim, the invention according to its first aspect relates to a floor element of the type having, at least at two opposite edges, coupling means or coupling parts allowing that two of such floor elements can cooperate with each other at the respective edges, with the characteristic that the floor element comprises at least two components, as well as at least comprises entity-forming means, which, starting from said components, can effect an entity in which said components can adopt at least two mutual positions, whether or not by the disruption of the entity provided by said means. It is clear that a plurality of such floor elements can be applied for forming a floor covering.
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 the entities or floor elements, which according to the present invention are formed starting from the components, preferably have dimensions which can be handled by a single person in a simple manner. Hereby, this preferably relates to entities with a length that is smaller than two meters, and still better is comprised within the range of 75 centimeters to 150 centimeters, and with a width that is smaller than one meter and still better is within the range of 15 centimeters to 50 centimeters. The floor element preferably has a thickness which is usual for floor panels for parquet or imitation parquet; that is, a thickness between 5 and 25 millimeters.
The particularity of the first aspect of the present invention is situated in the fact that at least two components of a floor element form an entity and still can adopt positions differing in respect to each other. In this way, it is possible to design a floor element, said entity thereof allowing the user to adapt the shape of the floor element, for example, when installing the floor element. Further, it is possible that said components of the floor elements adopt a certain mutual position in the package, for example, a mutual position in which the floor elements can easily be packaged, whereas the user still can readjust or adjust this position before or during the installation of the floor covering. Preferably, said components may adopt a mutual position in which the floor element has a globally rectangular shape. A rectangular or square shape is very beneficial for packaging the floor elements.
It is clear that, the larger the number of different mutual positions of the components, the more installation possibilities with the floor element concerned are offered and the simpler a random bond of decorative parts can be achieved. Therefore, it is also preferred that these mutual positions can be chosen freely and preferably unrestrictedly by the user. This is contrary to an embodiment allowing only a limited number of mutual positions among said components. However, it is noted this last-mentioned embodiment also can have advantages. By limiting the number of possible mutual positions, for example, installation faults can be avoided, or it is possible that one or more installation patterns, such as a herringbone pattern, may already be integrated in the floor elements.
In a preferred embodiment, said components can be shifted in respect to each other. In the case that the components are made as boards, in particular panels or planks, it is preferred that they can be shifted in mutual respect in their length and/or in width direction. Such shifting can be performed in two important manners. On the first hand, such shifting can be performed while the components are situated in the same plane, on the other hand, such shifting can also be performed while the components are angled with their upper sides over a certain angle towards each other. It is also not excluded that the components can be shifted in mutual respect, while they are angled over a certain angle with the undersides towards each other.
Whether boards or planks are concerned, it is preferred that each of said components has a substantially flat side forming a decorative side, and that this decorative side still better is situated at least partially at the upper side of said entity and/or of the floor element. In such case it is clear that the user will be able to change the mutual position of at least the respective decorative sides of said components. This is of particular importance when creating random bonds. Preferably, said components globally have a similar pattern. So, they may have or represent a plank pattern consisting of a certain kind of wood. According to a preferred embodiment, each component has a decorative side, which, viewed in the width of such component, has the appearance of one plank and, viewed in the length, has the appearance of one or more planks. In such case, preferably on one and the same floor element components are combined having a different number of wooden decorative parts, more particularly components which, viewed in the length, have the appearance of a differing number of planks.
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.
For the sake of the simplicity of the construction and/or of the composing of the floor elements to a floor covering it is recommended to use components having each a decorative side with uniform and equally-sized dimensions. Nevertheless, particular effects may also be achieved when the decorative sides of the components of one and the same floor element, for example, have a different length and/or width.
According to an important embodiment of the present invention, said components have a decorative side with a rectangular oblong shape, wherein said cooperation preferably is such that the decorative sides of said components, at least in said two mutual positions, are positioned with their longitudinal directions next to each other and preferably have a same mutual distance. This means that the resulting displacement from the one mutual position to the other mutual position may be, for example, a mere displacement or shifting of one of the components in its longitudinal direction.
The aforementioned important embodiment may allow, amongst others, to realize an improved floor element of the type two-plank or multi-plank element. Preferably, said decorative sides of said components in such floor element have wooden decorative parts, or respectively one or more rows of wooden decorative parts, which decorative parts or rows then, according to this important embodiment, can adopt a plurality of mutual positions. A user can, at least during the installation of the floor elements, decide on the mutual position which the components of the respective floor element are to adopt in the floor covering, and in this manner can create a composition of the decorative parts thereof himself. It is noted that, when the decorative side of each component shows only a single decorative part or only a single row of decorative parts, a floor element is obtained with which a random bond can be achieved. In other words, in such case this relates to components with a decorative side which, viewed in the width of such component, has the appearance of one plank and, viewed in the length, has the appearance of one or more planks.
In respect to the effected entity, it is noted that it can vary. In the following, a difference is made between two important possible kinds of entity. However, the invention is not restricted to these possibilities or the combinations thereof.
A first possible kind of entity relates to an entity consisting at least of said two mutual positions of the components, or, in other words, said entity-forming means are active at least in said two mutual positions. Preferably, this entity also is maintained during changing from the one mutual position to the other mutual position of the components.
A second possible kind of entity relates to an entity, which is disrupted when changing the one mutual position of the components to the other mutual position. Possibly, herein the entity can be such that a possible disruption thereof is remedied or can be remedied when reaching said second position and/or when returning to said first position. However, it is not excluded that the entity is such that a possible disruption thereof is irrevocable. It is noted that, when a disruption of the entity is mentioned, such disruption preferably can take place without machine-operated tools. However, the use of manual tools, such as a knife, a tapping block, a hammer or the like is not excluded, but it is preferred that such disruption of the entity can take place with bare hands.
The entity-forming means can be made in a plurality of manners, depending whether they must be able to effect an entity of the first and/or of the second kind and/or of another kind. Different possible embodiments are explained 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.
In a second possible embodiment, said entity-forming means consist at least of a portion of the floor element, which is situated at the underside of the floor element and which in its turn forms at least one projecting portion, which extends or can extend from a first component of this floor element beneath a second component, wherein preferably the projecting portion covers at least a surface which is approximately equal to the surface of the second component or is larger. Herein, said portion then preferably forms a basic structure. According to a first possibility, this basic structure is made in one piece with the first component or, in other words, forms a part of this component, such that the first component in fact extends or can extend with said projecting portion up to beyond one or more other components. According to a second possibility, this basic structure is made as a separate basic board or basic layer, upon which then the first component is fixedly attached, for example, glued, and this basic board or basic layer projects with said projecting part beyond this first component.
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.
The basic structure, which is applied according to said second possible embodiment, may also fulfill other functions within the entity of the floor element than solely effect the aforementioned entity. Thus, it can provide, for example, for the dampening of reflection and/or transmitted sound. From this point of view, it is preferred to apply so-called softboard, which comprises pressed wood fibers, and/or cross-linked polyethylene in said basic structure. It is noted that by means of a portion of the floor element, which can be situated or extend at least partially beneath said components, as described by means of this second possibility, an entity of the first as well as of the second kind can be effected. It is noted that such basic structure, in case of narrow components, for example, when at least one of said components has a length-to-width ratio larger than 10, can contribute to a considerable extent to the rigidity of the floor element as a whole and at the same time can offer resistance against the warping of such components, as a result of which it is possible to compose a floor covering by means of such floor elements without any problems.
In a third possible embodiment, said entity-forming means consist at least of a separate attachment means, which can connect at least said components. So, the entity-forming means may consist, for example, at least of an adhesive or glue connection, whether releasable or not, or of a separate mechanical coupling part. By means of the entity-forming means according to this third embodiment, an entity of the third as well as of the second kind can be effected.
It is noted that according to the invention it is not excluded that the entity-forming means are made in another manner than according to the herein-described possibilities and/or that they consist of a combination of the herein-above described possibilities. Such entity-forming means can be provided at any location at the floor element. Thus, they may be provided as well beneath, on or between said components. As an example for an entity-forming means, which is situated on the respective components, reference is made to the possibility to connect the components by providing a, whether or not transparent or translucent, adhering film on their upper side or decorative side, which adhesive connection them of course must allow for that said components can adopt at least the two aforementioned mutual positions. For this application, micro-spherical glues of the type as described in U.S. Pat. No. 3,691,140 can be usefully applied.
For other and/or practical examples of entity-forming means, reference is made to the detailed description.
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.
It is clear that the floor elements of the present invention can be constructed in various manners.
For example, this may relate to floor panels, which can be applied for forming solid parquet or an imitation of such parquet. In the first case, this relates to floor elements, of which at least one of said components, and preferably all components, consist of solid real wood, with the exception of a possible wear-resistant top layer, for example, of varnish or lacquer. In the second case, this relates to floor elements of which at least one, and preferably each of said components, has a core and a top layer provided upon the latter. This top layer, or anyhow at least a portion of this top layer, can form a decorative side, which is situated at least partially at the top side of the floor element. The top layer may be a top layer on the basis of synthetic material, which preferably comprises a printed decor with, for example, a wood pattern, as this may be the case with a laminate top layer manufactured by means of a DPL (Direct Pressure Laminate) or HPL (High Pressure Laminate) method. It is known as such to form a DPL top layer by bringing one or more carriers, provided with resin, for example, paper sheets, together with a core material into a press and forming said laminate top layer by means of heat and pressure directly on the core material. For a HPL top layer, one starts from an already earlier formed laminate top layer consisting as such of carriers provided with resin, such as paper sheets, which laminate top layer then is attached to a core material, more particularly glued thereon. Instead of a top layer on the basis of synthetic material, also a top layer on the basis of wood can be applied, wherein preferably the wood structure determines the appearance of said decorative side. Herein, this may relate to a veneer layer or a layer of wood, which is thicker than veneer, for example, thicker than 2 millimeters. For said core on which the top layer is situated, a wood-based material can be chosen, such as, for example, a material on the basis of finely-ground wood, for example MDF or HDF (medium-density fiberboard or high-density fiberboard), or such as an either composed or not composed wood material, for example, solid pinewood or a so-called lamellar core, wherein a core is composed of various laths. For a general example of a floor panel with lamellar core, reference is made to DE 203 10 959 U1.
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”.
It is clear that the invention is not restricted to floor elements which can be applied for forming solid parquet or an imitation thereof. Said printed decor, which is used with laminate top layers, thus can also represent other patterns than a wood pattern. For example, it may represent a stone pattern or a fantasy pattern. Moreover, for said top layer use can also be made of top layers on the basis of a material chosen from the group of textile, carpet, cork, vinyl, ceramics, natural stone, artificial stone and brick-like stone. It is also possible that at least one of said components is constructed of another solid material than wood, as, for example, stone, compact laminate, synthetic material or the like.
For composing the floor elements of the first aspect, use can be made of various possible methods. In the following, a first and a second possibility are described, which each separately relate to independent aspects of the invention. This means that they possibly can also be applied to other floor elements than those of the first aspect.
According to a first possibility, and thus according to a second independent aspect of the invention, this relates to a method for composing floor elements to a floor covering, with the characteristic that one starts from floor elements comprising at least a first and a second component, wherein starting from at least one such first component and one such second component an entity can be effected by means of entity-forming means, and that the method at least comprises the step of effecting such entity and/or of changing such entity, as well as at least the step of bringing said components into their final position in the floor covering. The entity and the entity-forming means can be realized in the same manner as discussed above by means of the first aspect. This first possible method allows, when composing the floor elements, to make optimum use of the presence of the entity-forming means and the entity they may form.
Preferably, the changing, as aforementioned, of an entity at least consists in that this entity is at least temporarily disrupted.
Such method according to this first possibility can be applied, for example, for composing floor elements, the components of which are situated in a mutual starting position, wherein the step of changing an entity then consists at least in that said components are brought out of said mutual starting position. For example, said components can be brought as an entity into the floor covering, after which possibly, before reaching their respective mutual positions, said entity is changed. When the floor elements in said mutual starting position of the components have a rectangular, possibly oblong, entity, a very practical installation method is obtained. The floor elements can also be packaged in this mutual starting position, however, not necessarily.
The method can also be applied for composing a floor covering, wherein said entity-forming means are active in the final positions of said components, in other words, in these final positions effect an entity between a first and a second component. The fact that the entity consists at least in the final position of the components, may result, depending on the applied entity-forming means, in various different advantages in connection with the strength of the obtained floor covering, reduction of reflection or transmitted sound and the like.
Each of said components can be provided with a decorative side, which, in the final position of the respective component in the floor covering, is intended for forming a portion of the floor surface. Preferably, the method in this case comprises at least the step of changing the mutual positions of the respective decorative sides, after the components already have been brought into the plane of the floor covering.
According to a second possibility and, therefore, a third independent aspect of the invention, this relates to a method for composing floor elements to a floor covering, wherein these floor elements do not necessarily comprise entity-forming means in the meaning of the first aspect. To this aim, in this second possible method one starts from a first component and a second component, which are situated in a mutual starting position, wherein each of these components is provided with a decorative side, which, in the final position of the respective component in the floor covering, is intended for forming a part of the floor surface, with the characteristic that the method successively comprises at least the steps of bringing, in said mutual starting position, the first as well as the second component together into the plane of the floor covering, bringing the first and the second component out of the mutual starting position and providing at least said first component as well as at least said second component in their respective final position in the floor covering. Due to the fact that two movable components are brought together into the plane of the floor covering, the installation time required with such method can be restricted. When it is provided for that the floor elements in said mutual starting position of the components have a rectangular, and still better also oblong, shape, the installation time can be even more restricted, as such floor elements usually are very practical in their application.
The aforementioned step of bringing the first and the second component out of their mutual starting position preferably comprises that the second component is provided in the floor covering in a position which is shifted in respect to said first component. Preferably, said first component is brought into its final position in the floor covering before the second component is provided in its final position in this floor covering.
The aforementioned first and second possible methods preferably are applied for forming a floor covering representing rows of decorative parts, wherein this floor covering comprises at least a first row of decorative parts, which is formed by first components, and also comprises at least a second row of decorative parts, which is formed by second components, wherein said first row and said second row are lying laterally, i.e., in width direction of the rows, directly next to each other. It is also possible that each row of decorative parts respectively is composed of only one of said components. In the case of a floor element of the type two-plank element, preferably in each case a row of first components alternates with a row of second components. It is clear that, according to the number of components of the floor element, each time preferably adjacent rows of first, second, third and further components are formed in the floor covering.
It is noted that the aforementioned two or more components may have respective decorative sides with substantially equal dimensions as well as decorative sides with dimensions that differ from each other. For example, one may work with decorative sides of different width and/or different length. In the most preferred embodiment of the invention, however, all components of one and the same floor element have the same length and preferably the same width, too.
It is clear that the first and/or the second possible method can be applied for installing the floor elements with the characteristics of the first aspect and the preferred embodiments thereof. Preferably, the methods are applied for composing floor elements having, at least at two opposite edges, coupling means allowing that two of such floor elements can cooperate with each other at the respective edges. In such case, the method preferably also comprises at least the step of coupling the floor elements at the respective edges.
The first and/or in particular the second possible method also offer significant advantages when the width of the components has a width of less than 10 centimeters. According to the methods, in fact one works with packages of these components that are better to handle and to install. Namely, either use is made of an entity of at least two of these components, or a step is performed consisting in bringing at least two components together into the floor covering.
According to a different variant of said second possibility, the step for bringing the first as well as the second component, in said mutual starting position, together into the plane of the floor covering, can also be replaced by a step in which at least said first component, while as such being connected, in said mutual starting position, to said second component, is connected to a third component already arranged in the floor covering. Such connection of the first and the second component and/or of the first and the third component can be realized in the respective step, whether or not completely. Possibly, a partial connection may be used, for example, when the upper sides of the respective connected components are not yet situated in a common plane, but adopt an inclined position in respect to each other. It is clear that such partial connection in said mutual starting position may also be present between the first and the second component. In the further step of bringing the first and the second component out of the mutual starting position, the connection between the first and the third component then may or may not be completely realized. It is clear that the step of providing the first and the second component in their respective final position in the floor covering then at least means that at least the first and the second component as well as at least the first and the third component are completely connected to each other, for example, at least by angling the first and/or the second component into the plane of the floor covering. Said step of bringing the first and the second component into the final position may also comprise at least a relative shifting movement of the second in respect to the first component, wherein this shifting movement then either is performed in said partially joined condition of these two components or not, more particularly in said inclined position of these two components.
The first and/or the second possible method and/or said differing variant thereof show their advantages in particular when starting from floor elements with two or more components, which are situated in equal positions next to each other and thus define in their starting position a globally rectangular, either oblong or square, whole, after which, by means of the method, a final position is created by bringing one or more of said components in a shifted position in respect to the other components. In particular, it is preferred that one starts from components with decorative sides representing oblong laths or planks, wherein these, in the starting position, extend with their long sides parallel next to each other.
Further, it is clear that the invention also relates to a floor covering, which is composed by means of the floor elements of the first aspect and/or by means of said first or second possible method or differing variant thereof. The invention also relates to a set of two or more components and entity-forming means, which are intended for forming, starting from said components, an entity, and wherein this sets allows to compose a floor element according to the first aspect of the invention or anyhow at least a portion thereof. Further, the invention relates to a component for a floor element, which is intended for forming an entity, together with a second, whether or not similar, component, by the intermediary of entity-forming means. It is clear that such sets and components can lead to the composition of floor elements showing the characteristics of the first aspect, and therefore also can effect the advantages coupled to this aspect.
Further, the invention relates to a locking system, which can be applied in a useful manner with floor elements with the characteristics of the first aspect, however, which is not restricted to such floor elements. To this aim, the invention, according to a fourth independent aspect, relates to a locking system for the lateral mutual coupling of floor elements or components of floor elements, wherein the locking system is of the type, which, when coupling a side of a first floor element to a side of a second floor element, effects a locking of the floor elements in a vertical direction perpendicular to the plane of the floor elements, as well as in a horizontal direction perpendicular to the respective coupled sides, wherein the locking system consists at least of coupling means, which substantially are made as a tongue at said side of the first floor element and as a groove, said groove being bordered by means of a lower lip and an upper lip, at said side of the second floor element, and which also are provided with locking means, wherein said locking means comprise a projecting locking element at one of said lips which border the groove, and a cooperating-therewith locking element at the tongue, with the characteristic that the locking system allows that coupled floor elements at the respective coupled side may adopt at least two mutual orientations, namely, on the one hand, a first mutual orientation, wherein the upper surfaces of the floor elements substantially are situated in the same plane and wherein surfaces of said locking elements have portions coming into mutual contact, which portions extend between a lower and an upper horizontal plane, and, on the other hand, a second mutual orientation, wherein the upper surfaces of these floor elements enclose an angle of less than 180 degrees and said surfaces of the locking elements are free from mutual contact, wherein the portion, which comes into contact in the first mutual orientation, of a first of these surfaces, in the second mutual orientation, extends above said upper horizontal plane, and wherein the floor elements at the respective side in the second mutual orientation still are locked in vertical as well as in horizontal direction. By the fact that the portion, which comes into contact in the first mutual orientation, extends in the second mutual orientation above said upper horizontal plane, it is meant that the surfaces, which formed a contact in said first mutual orientation, are completely turned away from each other or, in other words, are no longer turned towards each other.
The fact that the locking system allows that the floor elements or their components can adopt a mutual orientation, in which the contact at the height of the locking elements is completely eliminated, can provide for that the floor elements in this orientation, while they are still coupled in vertical and horizontal directions, can shift along each other with a minimum resistance. This feature can be usefully applied in many installation methods and surely with said first and/or second possible methods for composing floor elements with the characteristics of the first aspect.
Preferably, the floor elements in said first mutual orientation are coupled free from play. This preferred embodiment results in the particularly useful combination of free-from-play coupling with a connection that simply can be shifted in longitudinal direction.
In the second mutual orientation, however, preferably a clearance is present between the sides of the floor elements coupled by means of the locking system, wherein this clearance allows that the floor elements can move over a limited distance in horizontal direction, and that preferably in said second mutual orientation, said locking in vertical and horizontal direction remains maintained over at least half of, and still better the entire range of the possible movement associated with the clearance. By this preferred embodiment, it is obtained that the simplicity of shifting can be maximized, whereas the risk of uncoupling the connection of the floor elements or their components is minimized.
It is possible that in said first mutual orientation said lip forming the projecting locking element is elastically deformed. Preferably, in this case it is less or not at all deformed in said second mutual orientation; for example, in said second mutual orientation there remains only a plastic deformation of this lip, or, still better, it has entirely or almost entirely returned into the position it had before the coupling of the floor elements to the respective side. When a remaining portion of the bending-out is found in the second mutual orientation, it is best smaller than half of the bending in the first mutual orientation, such that the major part of the bending is elastic.
In the most preferred embodiment, said lip containing the projecting locking element relates to said lower lip. Such locking system may be made, for example, by means of a milling process in a simple manner, wherein the respective sides then are provided with profiled areas, which preferably are made in one piece with the floor panel. Such milling process can be applied even simpler when the lower lip extends up to beyond the upper lip. Of course, the invention is not limited to locking systems with a longer lower lip. The lower lip may be made, for example, also equally long or shorter than the upper lip. In respect to milling processes, reference is also made to WO 97/47834, which, amongst others, relates to the milling of coupling means situated on the edge of floor panels.
The mutual orientations allowed for by the locking system can be adopted by the floor panels in any manner. Preferably, the floor elements can be brought from the first to the second mutual position by means of a relative angling movement around the coupled side.
It is noted that the fact that the locking system allows for two mutual orientations between the floor elements or components, does not mean that the respective floor elements, as soon as the respective orientation is reached, will stay in this orientation by themselves, although this is not excluded. Rather, it is meant that the locking system allows that the user, preferably manually, can bring the coupled floor elements into these two mutual orientations and/or hold them there.
Preferably, the locking system of the second aspect also allows that coupled floor elements, at the respective coupled side, may adopt at least a third mutual orientation, in which the top surfaces of these floor elements enclose an angle that is smaller than the angle which they include in the second mutual orientation, and wherein said locking elements also show contacting surfaces. Still better, the floor elements are coupled in this third mutual orientation free from play. Also in this third mutual orientation it is possible that said lip comprising the projecting locking element is elastically deformed. This preferred embodiment provides for an extra barrier against the uncoupling of the floor elements. Of course it remains possible to uncouple the floor elements, however, it is possible that first a certain resistance has to be overcome to do so.
With the same objective as in the fourth aspect, the invention according to its fifth aspect relates to a locking system for laterally coupling together floor elements or components of floor elements, wherein the locking system is of the type that, when coupling a side of a first floor element to a side of a second floor element, effects a locking of the floor elements in a vertical direction perpendicular to the plane of the floor elements, as well as in a horizontal direction perpendicular to the respective coupled sides, wherein the locking system consists at least of coupling means, which substantially are formed as a tongue on said side of the first floor element and a groove, bordered by means of a lower lip and an upper lip, at said side of the second floor element, and which also are provided with locking means, wherein said locking means comprise a projecting locking element at one of said lips bordering the groove, and a cooperating-therewith locking element at the tongue, and said lip comprising the projecting locking element, in a coupled condition of two floor elements, is elastically deformed, wherein the locking systems allows that two floor elements coupled by means thereof can be uncoupled from each other by means of a relative angling movement around the coupled side, with the characteristic that the locking system is made such that said elastic deformation of the lip comprising the projecting locking element, when uncoupling the floor elements by means of said angling movement, undergoes at least three successive changes, namely, a first change, in which the elastic deformation decreases, a second change, in which the elastic deformation increases, and a third change, in which the elastic deformation again decreases. Preferably, said angling movement relates to a movement wherein the included angle between the upper sides of both floor elements decreases.
The fact that in the first change the elastic deformation decreases in order to afterwards, during a second change, increase again, means that the floor elements at the end of the first change come into a mutual orientation, in which this elastic deformation has a local minimum and they thus are less solidly joined, however, this also means that the risk of uncoupling by further angling out is minimized in that said increase of the elastic deformation during the second change forms a barrier to this. A mutual orientation, in which a local minimum of the elastic deformation exists, opens various new possibilities. So, for example, is it possible to provide for that the floor elements in the mutual orientation in which the local minimum of the elastic deformation is reached, can shift with a minimum resistance along each other, while they still are coupled in vertical and horizontal directions. This feature can be usefully applied in many installation methods and surely in the case of said first or second possible method for composing floor elements.
Said elastic deformation may comprise or relate to, for example, a bending of the respective lip. In such case, it is preferred that during said first change a bending of the respective lip decreases, preferably at least about 50 percent; that during the second change the bending of the respective lip increases and that during the third change the bending of the respective lip decreases again. Said lip comprising the projecting locking element preferably relates to the lower lip.
In a preferred embodiment of the fifth aspect, said elastic deformation and/or the bending of the respective lip decreases during the first and/or the second change, until it is approximately completely or completely relaxed. When at the end of the first change a complete relaxation is obtained, the comfort of shifting both floor elements or components along the coupled sides is maximized.
It is clear that the invention also relates to a floor element of the type having, at least at two opposite sides, coupling means, with as a characteristic that said coupling means allow to form, with the coupling means of a similar floor element, a locking system having the characteristics of the fourth and/or the fifth aspect of the invention.
Further, it is clear that the entity-forming means of the floor elements of the first aspect may at least consist of a locking system with the characteristics of the fourth and/or fifth aspect, by which then preferably said components are coupled. Also, it is possible that said coupling means, which the floor elements of the first aspect have at least at two opposite edges, allow forming a locking system according to the fourth and/or the fifth aspect with the coupling means of a similar floor element. Further, it is possible that said components are coupled to each other by means of a locking system according to the fourth and/or the fifth aspect, whether entity-forming means are concerned or not.
Further, the invention also relates to a locking system which is extremely useful for being applied at least at one pair of opposite sides of the aforementioned components and which still allows a simple installation of the floor elements of the invention at difficult to reach locations, such as under overhanging cabinets or beneath door posts. In the case of oblong, rectangular components, the respective locking system preferably is applied at the short opposite sides of these components, whereas at the long sides of these components preferably a locking system is applied which allows at least a coupling by means of an angling movement. The respective locking system is not only useful in the floor elements of the present invention, but can also be applied more broadly in any floor elements. To this end, the invention, according to a sixth independent aspect thereof, relates to a locking system for laterally coupling together floor elements, components of floor elements, respectively, wherein this locking system substantially consists of a male coupling part and a female coupling part situated at the edges of the floor elements or components to be coupled, wherein said coupling parts are provided with locking means, which, in a coupled condition of a side of a first floor element or component and a side of a second floor element or component, effect a locking of the floor elements or components in a horizontal direction perpendicular to the coupled sides in the plane of the floor elements or components, however, wherein these coupling parts are free of locking means which, during coupling to the respective side, effect a locking in a vertical direction perpendicular to the plane of the floor elements or components, with the characteristic that said coupled condition can be obtained by means of said locking system at choice, either by providing said male coupling part of the first floor element or component with a substantially downward movement in the female coupling part of the second floor element or component, or by moving the first and the second floor element or component with the edges, which are provided with said coupling parts, with a substantially horizontal shifting movement towards each other.
Thus, the sixth aspect of the invention relates to a locking system allowing both a locking by means of a downward movement as well as a locking by means of a substantially horizontal shifting movement of the components, but with which, however, solely a horizontal locking is obtained and no vertical locking of the respective components or floor elements is obtained.
With the intention of better showing the characteristics of the invention, hereafter, as an example without any limitative character, several preferred embodiments are described, with reference to the accompanying drawings, wherein:
Each of said components 2-3 has a substantially flat side forming a decorative side 11. These decorative sides 11 are situated at the upper side of the composed floor element 1, where in this case they form or represent two adjacent rows 12 of decorative parts 13. Thus, the floor element relates to an example of an improved multi-plank element, in particular a two-plank element.
The improvement obtained according to the invention in this kind of floor elements 1, is obtained by the fact that, although said components 2-3 form an entity 4, they still can adopt, as
The particularity of the floor element 1 from the
Although by means of said layer 15 an entity 4 has been effected between the two components 2-3, the cooperation of this layer 15 with said coupling means 9A-10A still allows that the components 2-3 can adopt different mutual positions P1-P2. Adopting another position may take place by either unlocking or not unlocking the coupled sides 5A-6A of the components 2-3. When changing the position, for example, from the mutual position P1 of
The components represented in
As already became evident from
It is clear that according to a not-represented variant, the coupling means 9 and 10, at the long sides 5-6 of the floor element, as well as the coupling means 9A-10A, can be made differently than the coupling means 30 and 31 at the short sides of the floor element. In a practical embodiment thereof, the coupling means 9-10 and/or 9A-10A, for example, will be made such that the components, at their long sides, laterally can be joined into each other exclusively by means of an angling movement and not by means of a shifting and engaging movement, whereas the coupling means 30-31 in their turn allow a joining by means of a shifting and engaging movement.
In
From
From
Of course, it is possible that the floor elements 1 can adopt still other mutual orientations than orientations with the characteristics of said first or second mutual orientation O1-O2, such as the third mutual orientation mentioned in this respect in the introduction, wherein preferably again a locking free from play is obtained and/or said lower lip is elastically deformed again.
The lower lip 39 undergoes a first change when the floor element 1 is brought from the orientation shown in
The second change takes place when the floor element is angled still further until it reaches the orientation represented in
The third change manifests itself when the floor element 1, from the orientation represented in
The
By comparing the contour 48 of the lower lip 39, said contour being represented in dashed line, for coupling the floor elements 1, it is evident from
To those skilled in the art, it is evident how the embodiments of floor elements 1 according to the first aspect of
In general, such embodiments have the characteristics that, starting from three or more components 2-3, by means of one or more entity-forming means 14, for example, by means of a basic structure 28, an entity 4 is effected, wherein at least one of these components 3, and preferably at least two, and still better all components can adopt different positions P1-P2 in respect to all remaining components 2 of this floor element 1. Further, it is preferred that each of these components 2-3 has a decorative side 11, which is situated at the upper side of the floor element 1. As an example, in the
The difference between both floor elements 1 depicted in
It is noted that, in the case when at least one of the components 2 is fixedly connected to the basic structure 28, whether by means of a glue or adhesive connection, or by the fact that the respective component 2 is formed at least partially in one piece with the basic structure 28, or by means of mechanical coupling means, or by a combination of the above possibilities, a good connection can be obtained in the floor covering 54 already by means of the coupling means 9-10 of the basic structure 28, as in such case zones 55 of adjacent components may exist, which are mutually connected by means of the coupling means 9-10 of the basic structure 28. These zones 55 are shown in
It is noted that in the example of
Further, it is noted that in the example of
It is clear that the
It is clear that each of said components 2-3 of the floor elements 1, with which the floor covering 54 according to
Of course it is possible by means of said first and second possible method to obtain also other floor coverings 54, as, for example, the floor coverings illustrated by means of
In general and with reference to
As
When the decorative sides 11 of the components 2-3, as it is the case, amongst others, in
Generally, it is noted that chamfers 59 or imitation chamfers 59A, due to the fact that an entity 4 is formed starting from components 2-3 with floor elements 1, can be provided in floor elements 1 according to the invention in many respects simpler than in floor elements of the state of the art.
For providing the imitation chamfers 59A and/or the pertaining separate decorative layer 61, automatic techniques may be considered for detecting the transition 62 between the respective decorative parts 13 by means of sensors, such as cameras. By means of this information, the machining or other treatment for forming the imitation chamfer can be controlled such that the imitation chamfer, and possibly the pertaining separate decorative layer 61, can be provided in such manner that it corresponds as well as possible to said transition 62. The forming of the imitation chamfers 59A may be performed possibly simultaneously to, or at least in the same machine as, the forming of the coupling means at the short sides of the respective component. To this aim, an additional entity can be introduced in a typical edge treatment machine, which entity, viewed transversely to the passage direction of the components, is situated between the milling tools shaping the coupling means. Such arrangement may mean an economy of space in a production line for manufacturing the floor elements of the invention.
As already mentioned earlier, in floor elements 1, such as the one depicted in
It is noted that in the case that the basic structure consists of a board, for example, as in
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.
In respect to the basic structures 28 or basic boards represented in the figures, for example, in
A particular, not represented variant of a floor element according to the first aspect of the invention relates to a floor element, wherein at least one of the aforementioned components as such is composed of a plurality of elements. In the example of
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
It is noted that the coupling means which are represented in
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
It is noted that a possible partial disruption of the connection 67, wherein the respective components 3-52 during angling-up adopt a mutually inclined position, is not excluded. Such situation is illustrated in
In the positions shown in
It is possible that, contrary to what is represented in
It is clear that, when further components, such as a fourth component 53, are situated on the basic structure 28, those can be connected in a similar manner. Also, it is clear that for performing the method represented in the
Further, it is clear that the method illustrated by means of
It is clear that in the case that the short sides 7-8 of the components 2-3-52 are provided with coupling means allowing a coupling by a downward movement as well as a coupling by a substantially horizontal shifting movement, in each case the shifting of the components can be chosen during the installation of the floor elements 1 and possibly may be alternated between the inclined or not inclined position.
According to not represented variants of the invention, marks may be provided on the components, more particularly on the coupling means, and/or on the entity-forming means, for example, on a possible basic board or basic layer. For example, this may relate to marks giving the user some directions for the extent in which the components can be displaced. Possibly, also trade names or usage instructions can be provided on a possible basic board or basic layer. It is also possible that the package or a portion thereof may be applied as a template for indicating the extent to which the components can be shifted.
It is also noted that when manufacturing the floor elements of the invention, more particularly when manufacturing the floor elements having the characteristics of the portrait definition, automatic devices possibly can be applied for connecting the components of one and the same floor element by means of the coupling means. In the case of oblong components, this preferably relates to coupling together the long sides of these components by means of the mechanical coupling means present thereon. By means of such device, packages of in each case two or more components can be coupled, wherein the basic layer, basic board or basic structure then can be attached to the underside of one of more components of this package, for example, can be glued thereto. In this manner, entities with the characteristics of the invention can be obtained. It is also possible to automatically couple the components together, while already one or more components are fixedly attached to the basic structure. In case that the coupling means at the long sides of the components allow a connection by means of an angling movement, a rotary system may be applied for automatic coupling. For example, a rotary drum with a polygonal cross-section may be applied, wherein components are applied against the outer sides of these drum, for example, by suctioning them against the respective side, and wherein the components, after a certain rotation of the drum, are removed therefrom, more particularly rolled off therefrom, while gradually performing a connection with a panel that already has been rolled off. In case the coupling means at the long sides of the components allow a connection by means of a horizontal shifting movement or a so-called snap coupling, it is also possible to work with to-and-fro translation movements for connecting the respective coupling means.
The present invention is in no way limited to the embodiments described by way of example and represented in the figures, on the contrary may such floor elements be realized according to various variants and such methods can also be performed according to various variants without leaving the scope of the invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2006/0641 | Dec 2006 | BE | national |
| 20 2007 013 059 U | Sep 2007 | DE | national |
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| Entry |
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| International Search Report from corresponding PCT Application No. PCT/IB2007/004153, dated Jul. 17, 2008. |
| Number | Date | Country | |
|---|---|---|---|
| 20170089078 A1 | Mar 2017 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14329157 | Jul 2014 | US |
| Child | 15372735 | US | |
| Parent | 12519456 | US | |
| Child | 14329157 | US |
