Patent Application
20240287818
The invention relates to a multi-purpose tile system, in particular a floor tile system, comprising a plurality of multi-purpose tiles, in particular floor tiles, wall tiles, or ceiling tiles. The invention also relates to a tile covering, in particular floor covering, ceiling covering, or wall covering, consisting of mutually coupled tiles according to the invention. The invention further relates to a tile for use in multi-purpose tile system according to the invention. The invention moreover relates to an installation method for installing the system according to the invention to create a tile covering.
The last decade has seen enormous advance in the market for laminate for hard floor covering. It is known to install floor panels on an underlying floor in various ways. It is, for example, known that the floor panels are attached at the underlying floor, either by gluing or by nailing them on. This technique has a disadvantage that is rather complicated and that subsequent changes can only be made by breaking out the floor panels. According to an alternative installation method, the floor panels are installed loosely onto the subflooring, whereby the floor panels mutually match into each other by means of a tongue and groove coupling, whereby mostly they are glued together in the tongue and groove, too. The floor obtained in this manner, also called a floating parquet flooring, has as an advantage that it is easy to install and that the complete floor surface can move which often is convenient in order to receive possible expansion and shrinkage phenomena. A disadvantage with a floor covering of the above-mentioned type, above all, if the floor panels are installed loosely onto the subflooring, consists in that during the expansion of the floor and its subsequent shrinkage, the floor panels themselves can drift apart, as a result of which undesired gaps can be formed, for example, if the glue connection breaks. In order to remedy this disadvantage, techniques have already been thought of whereby connection elements made of metal are provided between the single floor panels in order to keep them together. Such connection elements, however, are rather expensive to make and, furthermore, their provision or the installation thereof is a time-consuming occupation. Floor panels having complementarily shaped coupling parts at opposing panel edges are also known. These known panels are typically rectangular and have complementarily shaped angling-down coupling parts at opposing long panel edges and complementarily shaped fold-down coupling parts at opposing short panel edges. Installation of these known floor panels is based upon the so-called fold-down technique, wherein the long edge of a first panel to be installed is firstly coupled to or inserted into the long edge of an already installed second panel in a first row, after which the short edge of the first panel is coupled to the short edge of an already installed third panel in a second row during lowering (folding down) of the first panel, which installation fulfils the targeted requirement of a simple installation. In this manner a floor covering consisting of a plurality of parallel oriented rows of mutually coupled floor panels can be realized.
It is a first object of the invention to provide a multi-purpose tile system, wherein tiles can be mutually coupled in an improved manner.
It is a second object of the invention to provide a multi-purpose tile system, wherein tiles can be mutually coupled and uncoupled in an improved manner.
It is a third object of the invention to provide a multi-purpose tile system, wherein an increased degree of freedom during installation of the tiles can be achieved.
It is a fourth object of the invention to provide a multi-purpose tile system, wherein special installation patterns, such as herringbone patterns, can be realized, in an improved manner.
It is a fifth object of the invention to provide a multi-purpose tile system, wherein the tiles can be produced in a relatively cost efficient manner.
At least one of these objects can be achieved by providing a multi-purpose system according to the preamble, wherein the tiles, and preferably each tile, comprise: at least one first edge having a first coupling profile comprising: a sideward tongue extending in a direction substantially parallel to the upper side of the tile, at least one first downward flank lying at a distance from the sideward tongue, and a first downward recess formed between the sideward tongue and the first downward flank, at least one second edge having a second coupling profile comprising:
A benefit of the combination of the (optional) presence of a second locking element, preferably provided at the second downward flank and a third locking element, preferably provided at a distal side of the lower lip facing away from the third recess and/or a distal side of the upward locking element facing away from the third recess, on one hand, and at least a part of the proximal side of the upward locking element of the third coupling profile, facing the third recess, being upwardly inclined in a direction away from the upper lip, on the other hand, is that coupling of adjacent panels is rather simple while sufficient mutual (vertical) locking between said panels can be ensured. The absence of locking element at said positions in combination with the so-called open groove structure may result in an unstable locking situation between the male and the female coupling parts of adjacent panels, in particular for coupling between the second coupling profile and the third coupling profile. The presence of described second and third locking elements may additionally prevent that the male coupling part of the second coupling profile might (slightly) displace, and in particular (slightly) tilt, for example towards the open space of the third recess, during use. Hence, friction between adjacent panels in a coupling condition can be prevented.
Typically, each tile of the tile system according to the invention comprises at least one first coupling profile, at least one second coupling profile, and at least one third coupling profile, and preferably a plurality, e.g. two, third coupling profiles. However, it is imaginable that at least a first tile (a first tile type) comprises at least one first coupling profile and at least one third coupling profile, without having a second coupling profile, while a second tile (a second tile type) comprises at least one second coupling profile and at least one third coupling profile, without having a first coupling profile. Alternatively, it is e.g. imaginable that at least a first tile (a first tile type) comprises at least one first coupling profile and at least one second coupling profile, without having a third coupling profile, while a second tile (a second tile type) comprises at least one third coupling profile without having a first coupling profile and/or a second coupling profile. Hence, each tile of the tile system according to the invention may have at least one first coupling profile and/or at least one second coupling profile and/or at least one third coupling profile. In case a tile of the system according to the invention is not provided with a coupling profile chosen from the group consisting of: the first coupling profile, the second coupling profile, and the third coupling profile; then this lacking coupling profile of said tile will be included in another tile of the system according to the invention.
Hence, according to another aspect to the invention, it relates to a multi-purpose tile system, in particular a floor tile system, comprising a plurality of multi-purpose tiles, in particular floor tiles, wherein at least one first tile (type) comprises at least one first edge having a first coupling profile comprising: a sideward tongue extending in a direction substantially parallel to the upper side of the tile, at least one first downward flank lying at a distance from the sideward tongue, and a first downward recess formed between the sideward tongue and the first downward flank, wherein at least one second tile (type) comprises at least one second edge having a second coupling profile comprising: a downward tongue extending in a direction substantially perpendicular to the upper side of the tile, at least one second downward flank lying at a distance from the downward tongue, a second downward recess formed between the downward tongue and the downward flank, and preferably, at least one second locking element, preferably provided at the second downward flank of the second coupling profile, and wherein at least one third tile (type) comprises at least one third edge having a third coupling profile comprising: a third recess configured for accommodating at least a part of the sideward tongue of the first coupling profile of a further tile, said third recess being defined by an upper lip and a lower lip, wherein said lower lip is provided with an upward locking element, and preferably, at least one third locking element, preferably provided at a distal side of the lower lip facing away from the third recess and/or a distal side of the upward locking element facing away from the third recess, wherein the proximal side of the upward locking element of the third coupling profile, facing the third recess, is at least partially, preferably entirely, upwardly inclined in a direction away from the upper lip, wherein the proximal side of the upward locking element comprises a third lower contact portion extending in a first direction and a third upper contact portion extending in a second direction, optionally deviating from the first direction, and wherein the first coupling profile and the third coupling profile are configured such that two of such tiles can be coupled to each other at the first and third edges, preferably by means of a turning movement, wherein, in coupled condition: at least a part of the sideward tongue of the first coupling profile of a first tile is inserted into the third recess of the third coupling profile of an third tile, and at least a part of the upward locking element of the third coupling profile is inserted into the first downward recess of the first coupling profile, a proximal side of the sideward tongue, facing the first downward flank, co-acts with the third upper contact portion and/or third lower contact portion of the upward locking element of the third coupling profile, and wherein the second coupling profile and the third coupling profile are configured such that the two of such tiles can be coupled to each other at the second and third edges, preferably by means of a fold-down movement and/or a vertical movement and/or horizontal movement, wherein, in coupled condition: at least a part of the downward tongue of the second coupling profile of a second tile is inserted in the third recess of the third coupling profile of a third tile, and at least a part of the upward locking element of the third coupling profile is inserted in the second downward recess of the second coupling profile, if applied, at least one second locking element is facing, and preferably co-acting with, at least one third locking element to realise a vertical effect. The first tile and/or the second tile and/or the third tile may be formed by the same tile. The first tile may comprise at least one second coupling profile and/or at least one third coupling profile. The second tile may comprise at least one first coupling profile and/or at least one third coupling profile. The third tile may comprise at least one first coupling profile and/or at least one second coupling profile.
The tile system according to the invention has a plurality of significant advantages. A first main advantage is that the third coupling profile (female profile) is configured to co-act with both the first coupling profile (first male profile) and the second coupling profile (second male profile). This provides an enormous increase in how all tiles are mutually oriented in a tile covering to be realized. The classical row by row installation of tiles is still possible, but the compatibility of the third coupling profile with both the first coupling profile and the second coupling profile also allows the installation of various alternative installation patterns, such as for example, but not limited to, a herringbone pattern, while needing and using only a single tile type. In case of oblong (rectangular) tiles, the short edge of a tile can for example be coupled to either a short edge or to a long edge of an adjacent tile. Furthermore, each tile of the tile system can be manufactured in a relatively cost-efficient manner, since only three different coupling profiles, instead of the usual four different coupling profiles, will have to be realized during the production process, which will lead to at least a cost-saving in the machinery, and in particular the milling tools, which are used during the production process.
A further major benefit of the tile system according to the invention is that the different male coupling profiles (i.e. the first coupling profile and the second coupling profile) are configured to co-act with different third contact portions of the third coupling profile. This facilitates optimization of the coupling profiles either to realize a facilitated coupling between a male coupling profile and a female coupling profile, wherein the coupling profiles can be coupled in a relatively smooth manner while preserving sufficient locking (in horizontal and/or vertical direction) in coupled condition of two tiles, and/or to allow a relatively smooth uncoupling of two coupled tiles, preferably by means of an upward turning movement (angling out movement). The third lower contact portion and the third upper contact portion may be at least partially overlapping portion. However, preferably the third lower contact portion and the third upper contact portion are non-overlapping contact portion which may connect to each other or which may be positioned at a distance from each other. Preferably the first coupling profile is configured to co-act, preferably solely, with the third upper contact portion, which facilitates angling in and angling out of the first coupling profile with respect to the third coupling profile. Preferably the second coupling profile is configured to co-act, preferably solely, with the third lower contact portion, which is in favour of realizing a stable connection between the second coupling profile and the third coupling profile.
Preferably, third lower contact portion connects to the third upper contact portion, wherein the third lower contact portion extends in a first direction, and the third upper contact portion extends in a second direction, deviating from the first direction, wherein, more preferably, both the third upper contact portion and the third lower contact portion are upwardly inclined in a direction away from the upper lip. This results in the situation that that the third upper contact portion and the third lower contact portion have different inclinations (with respect to a plane defined by the tiles). It is imaginable that the third lower contact portion connects via at least one intermediate curved zone, preferably a convex zone, to the third upper contact portion, wherein the third lower contact portion extends in a first direction, and the third upper contact portion extends in a second direction, deviating from the first direction. An optional curved zone prevents damaging of the coupling profiles during (un)coupling. An optional convex curved zone facilitates the third lower contact portion to be more steep than the third upper contact portion. In other words, a first angle enclosed by the first direction in which the third lower contact portion extends and a plane defined by the tile is preferably larger than a second angle enclosed by the second direction in which the third upper contact portion extends and a plane defined by the tile. A less steep third upper contact portion facilitates e.g. coupling and uncoupling of the first coupling profile and the third coupling profile. A more steep third lower contact portion facilitates e.g. a stable connection between the second coupling profile and third coupling profile with a horizontal locking effect. Preferably, the first direction in which the third lower contact portion extends encloses an angle with a plane define by the tile which is 50° to 85°, preferably between 60° and 75°, more preferably between 63° and 67°, in particular approximately 65°. Preferably, the second direction in which the third upper contact portion extends encloses an angle with a plane define by the tile which is 30° to 65°, preferably between 40° and 55°, more preferably between 47° and 53°, in particular approximately 50°.
Preferably, and as already briefly addressed above, in coupled condition of the first coupling profile and the third coupling profile of adjacent tiles, the proximal side of the sideward tongue, facing the first downward flank, co-acts only with the third upper contact portion of the upward locking element of the third coupling profile. At least a part of the proximal side of the sideward tongue configured to co-act with the third upper contact portion preferably runs substantially parallel to the third upper contact portion. This substantially parallel orientation leads to a line contact in coupled condition of two tiles, as seen from a cross-sectional view of the tiles, which is more stable than a line contact.
Preferably, and as already briefly addressed above, in coupled condition of the second coupling profile and the third coupling profile of adjacent tiles, the proximal side of the downward tongue, facing the second downward flank, co-acts only with the third lower contact portion of the upward locking element of the third coupling profile. At least a part of the proximal side of the downward tongue configured to co-act with the third lower contact portion preferably runs substantially parallel to the third lower contact portion. This substantially parallel orientation leads to a line contact in coupled condition of two tiles, as seen from a cross-sectional view of the tiles, which is more stable than a line contact.
Preferably, a heel of the downward tongue, defined by a bottom side of the downward tongue and the proximal side of the downward tongue, is provided with a cut-out portion to facilitate uncoupling of second coupling and the third coupling profile. The cut-out portion provides more space to uncouple the second coupling profile with respect to the third coupling profile by means of an angling out movement (turning movement). Preferably, the maximum height of the cut-out portion is at least 0.2 mm. Preferably, the maximum height of the cut-out portion is less than 0.4 mm to secure sufficient contact between the downward tongue and upward locking element in coupled condition.
Preferably, the first edge and the third edge, in coupled condition, define a first closing surface defined as a first vertical plane through the upper edges of the coupled tiles or at least the location where the tiles come together at the upper side of the tiles. Preferably, the first coupling profile and the third coupling profile are configured such that in coupled condition, each of the sideward tongue and the third recess extends through said first vertical plane (joint plane). This facilitates to realize a vertical locking effect. By “extending through” is meant that a part of the sideward tongue is located at one side of the first vertical plane and another part of the sideward tongue is located at an opposite side of the first vertical plane. The same applies to the third recess. The lower lip which limits the lower side of the third recess typically extends beyond the upper lip. Preferably the upper lip defines said vertical plane (joint plane) of two tiles in coupled condition. Preferably, the upward locking element is positioned at a distance from said vertical plane. Here, the upward locking element and the upper lip are typically positioned at opposing sides of the joint plane. Here, the possible difference between the upper lip and lower lip which border the third recess, measured in the plane of the tile is preferably smaller than one time the total thickness of the tile. This will save material loss during manufacturing of the tile. However, in another preferred embodiment, the difference between the upper lip and the lower lip, measured in the plane of the tile is larger than 1.0 times, and is preferably at least 1.25 times, the thickness of the tile. In this embodiment, the lower lip is relatively long having as advantage that the third recess and the matching sideward tongue and downward tongue can be dimensioned relatively large (compared to the situation in which a relatively short lower lip is applied), which is beneficial for the robustness, stability and durability of the couplings achieved by means of the coupling profiles of adjacent tiles. The second vertical plane normally coincides with the aforementioned first vertical plane. The second coupling profile and the third coupling profile are preferably configured such that in coupled condition, the downward tongue is positioned at one side of the second vertical plane, and the third recess extends through said second vertical plane. In a preferred embodiment, the distal side of the downward tongue, facing away from the second downward flank, is provided with a fourth locking element, and the upper lip of the third coupling profile is provided with a fifth locking element configured to face, and preferably co-act with, said fourth locking element to achieve a vertical locking effect, in coupled condition of the second coupling profile and the third coupling profile of adjacent tiles, wherein, in coupled condition of the second coupling profile and the third coupling profile of adjacent tiles, the fourth locking element and the remaining part of the downward tongue are preferably situated at opposite sides of the second vertical plane, and wherein, in coupled condition of the second coupling profile and the third coupling profile of adjacent tiles, the fifth locking element and the remaining part of the upper lip are preferably situated at opposite sides of the second vertical plane. Preferably, the fourth element comprises a bulge having an upper side which extends in a third direction, wherein said upper side is downwardly inclined in a direction away from the second downward flank, wherein, preferably, a third angle enclosed by said third direction and a plane defined by the tile is between 25° and 35°, preferably between 28° and 32°, in particular approximately 30°. Preferably, the (protruding) fourth locking element has a maximum width with respect to the second vertical plane of 0.06 to 0.16 mm, preferably 0.08 to 0.12 mm. A width below 0.08 mm, in particular below 0.06 mm, typically leads to a poor or even absent vertical locking effect, while a width over 0.12 mm, in particular over 0.16 mm, typically renders uncoupling of the second coupling profile with respect to the third coupling profile, by means of an angling out movement (upward turning movement), rather difficult, and could even make such uncoupling impossible.
Preferably, an upper side of the lower lip defines a support surface for both the downward tongue of the second coupling profile of an adjacent tile, and the sideward tongue of the first coupling profile of an adjacent tile. More preferably, the support surface of the lower lip comprises a second support portion for supporting the downward tongue of the second coupling profile of an adjacent tile, and a first support portion for supporting the sideward tongue of the first coupling profile of an adjacent tile, wherein the second support portion and the first support portion are partially overlapping portion, or, typically more preferably, non-overlapping portions, wherein the second support portion and the first support portion connect to each other or, and this is even more preferred, are positioned at a distance from each other. Preferably, the second support portion is located closer to the upward locking element than the first support portion. At least a part of the first support portion and the second support portion are preferably located at different side of the (first or second) vertical plane, as defined above. Preferably, the support surface of the lower lip is substantially flat, which makes this support surface suitable to act as sliding surface (guiding surface) for the sideward tongue during insertion of the sideward tongue to the third recess. Preferably, the support surface of the lower lip is downwardly inclined in a direction towards the upward locking element. This inclination creates more space for insertion of the sideward tongue, which facilitates the coupling process between the first coupling profile and third coupling profile, and moreover, creates more space for accommodating the downward tongue which can be design in a more voluminous manner, which increases the strength of the downward tongue, and hence the strength of the coupling connection between the second coupling profile and third coupling profile. Preferably, the inclined support surface and a plane defined by the tile mutually enclose an angle of between 1° and 4°, in particular 2° to 3°.
In a cross-sectional view of the third coupling profile (and the first and second coupling profiles), the width of the first support portion is preferably smaller than the width of the second support portion. Preferably, in a cross-sectional view of the third coupling profile, the first support portion defines a point contact (or first line contact) and the second support portion defines a (second) line contact (which is larger than the first line contact).
Preferably, the sideward tongue comprises a tip, facing away from the first downward flank, and a heel, facing towards the first downward flank, wherein a bottom side of the sideward tongue situated in between said tip and said heel is upwardly inclined in a direction towards the first downward flank. This typically creates a substantially triangular space between the first coupling profile and third coupling profile in coupled condition. Said inclination of the bottom side of the sideward tongue is favourable as this creates somewhat more space to angle in and angle out the first coupling profile with respect to the third coupling profile. Preferably, the direction in which the bottom side of the sideward tongue extends and the plane defined by the tile mutually enclose an angle of between 2° and 10°, preferably between 4° and 6°, in particular approximately 5°.
The lowest portion of the bottom side of the sideward tongue normally defines a contact surface configured to co-act with the first support portion of the lower lip of the third coupling profile. In coupled condition of the first coupling profile and the third coupling profile, the tip of the sideward tongue is preferably clamped in between the lower lip and upper lip, more in particular in between the first support portion and the lower side of the upper lip.
Although it is imaginable that the first downward flank is provided with a first locking element configured to co-act with the third locking element of the third coupling profile, it is commonly preferred that the first downward flank is free of any locking element. This creates more space in between the first coupling profile and the third coupling profile, which facilitates both coupling and uncoupling.
Preferably, each tile comprises a first pair of opposing edges consisting of the first edge and the third edge. Each tile preferably comprises a second pair of opposing edges consisting of the second edge and the third edge. By arranging the coupling profiles, which are configured to mutually cooperate, at opposing edges, the installation of the tiles of the tile system can be facilitated. The tiles of the tile system typically have a square, rectangular, triangular, hexagon, octagon, or other polygonal shape. However, other shapes, like a parallelogrammical shape, are also imaginable as will be elucidated further below. Preferably, in case of a tile with an even number of edges, the number of third coupling profiles of said tile corresponds to the sum of the number of first coupling profiles and the number second coupling profiles. Typically, the number of first coupling profiles of a tile corresponds to the number of second coupling profiles, although deviations are imaginable, wherein a tile may for example comprise more second coupling profiles than first coupling profiles, or vice versa.
At least a number of tiles of the tile system according to the invention may be rigid or may be flexible (resilient), or slightly flexible (semi-rigid). Each tile is typically made as one of the following kinds: as a laminate floor panel; as a so-called “resilient floor panel”; a “LVT” (luxury vinyl tile) panel or “VCT panel” (vinyl composite tile) or comparable panel on the basis of another synthetic material than vinyl; a floor panel with a first synthetic material-based, preferably foamed, substrate layer (core layer), with thereon a preferably thinner second substrate layer (second core layer) of or on the basis of vinyl or another synthetic material; as a floor panel with a hard synthetic material-based substrate.
It is preferred that the tile comprise one-piece coupling profiles, and in particular with one-piece vertically active coupling profiles, such by applying certain structural features and/or material characteristics and/or designs of the coupling profiles. The coupling profiles are preferably an integral part of each tile, and are typically made of one or more material layers which constitute the tile body. Preferably, the first coupling profile and the third coupling profile are configured for locking together tiles both vertically and horizontally. Preferably, the second coupling profile and the third coupling profile are configured for locking together tiles both vertically and horizontally. Since the first coupling profile is configured to be coupled to the third coupling profile by means of a turning movement, also referred to as a rotational movement or angling down movement, and since the second coupling profile is configured to be coupled to the third coupling profile by means of a fold-down movement and/or vertical movement, also referred to as a scissoring movement or zipping movement, the tiles of the tile system according to the invention can still be installed by using the user-friendly fold-down installation technology. The advantages achieved by the couplings thus in general lie in an improved tile with improved coupling profiles, wherein the advantage of a simple manufacture, by making use of easy to manufacture coupling profiles, namely, because they do not necessarily have to make use of separate connection pieces, the advantage that the tiles preferably can be installed according to the user-friendly fold-down principle, and the advantage of offering a relatively reliable and durable coupling, are combined.
In a preferred embodiment, at least one second locking element of the second coupling profile is provided at the second downward flank of the second coupling profile, and wherein at least one third locking element of the third coupling profile is provided at a distal side of the lower lip facing away from the third recess and/or a distal side of the upward locking element facing away from the third recess. It is commonly favourable to positioning at least one second locking elements and at least one third locking element at the predefined locations, since at these locations there is relatively much space, which allows the design of the locking elements to be more robust, which will be in favour of the vertical locking effect.
In a preferred embodiment, at least one second locking element of the second coupling profile is provided at a distal side of the downward tongue facing away from the second downward recess, and wherein at least one the third locking element of the third coupling profile is provided at a side of the upper lip, in coupled condition facing said distal side of the downward tongue of the second coupling profile of an adjacent tile. This alternative positioning of the locking elements has the advantage that the locking elements are positioned close to the upper seam formed between adjacent tiles, which contributes to the stabilization of said seam, and which counteracts that tiles will vertically shift with respect to each other close to the seam. It is indicated that this alternative positioning of the locking elements may be combined with the positioning of the locking elements described in the previous paragraph, in case a plurality of second locking elements and a plurality of third locking elements are applied. More preferably, the co-action between the second locking element and the third locking element for creating a vertical locking effect in coupled condition of two tiles, defines a tangent T1 which encloses an angle A1 with a plane defined by the tile, which angle A1 is smaller than an angle A2 enclosed by said plane defined by the tile and a tangent T2 defined by a co-action between an inclined part of a proximal side of the upward locking element facing toward the third recess and an inclined part of a proximal side of the downward tongue facing toward the second downward flank. Here, preferably, the greatest difference between angle A1 and angle A2 is situated between 5 and 20 degrees. It is preferable that said second locking element and said third locking element are positioned closer to the upper side of the tile compared to an upper side of the upward locking element. This will reduce the maximum deformation of one or more coupling profiles, whereas the connection process and deformation process can be executed in successive steps. Less deformation leads to less material stress which is in favour of the life span of the coupling profiles and hence of the tile(s).
The first coupling profile preferably comprises at least one first locking element configured to face, and preferably co-act with, the third locking element of the third coupling profile of an adjacent tile in coupled condition. The presence of this at least one first locking element and the co-action of this first locking element with the third locking element in coupled condition further improves the stability of the coupling between the first coupling profile and the third coupling profile. Preferably, at least one first locking element of the first coupling profile is provided at the first downward flank of the first coupling profile, and wherein at least one third locking element of the third coupling profile is provided at a distal side of the lower lip facing away from the third recess and/or a distal side of the upward locking element facing away from the third recess. It is however also imaginable, optionally in addition to the aforementioned positioning of the first locking element, that at least one first locking element of the first coupling profile is provided at a distal side of the first coupling profile, being located above at least a part of the sideward tongue, and wherein at least one the third locking element of the third coupling profile is provided at a side of the upper lip, in coupled condition facing said distal side of the first coupling profile of an adjacent tile.
Preferably, the third locking element comprises a, preferably downwardly facing, third contact portion, and the second locking element comprises a, preferably upwardly facing, second contact portion, wherein, in coupled condition of adjacent tiles, the second contact portion is facing, and preferably co-acting with, the third contact portion. Preferably, the second contact portion and third contact portion define the only contact portions of the second locking element and third locking element. Preferably, an entire upper second section of the second locking element, located above said, preferably upwardly facing, second contact portion, and an entire upper third section of the third locking element, located above said, preferably downwardly facing, third contact portion, are positioned at a distance from each other to form a cavity (or space). This cavity may extend to a contact zone between the proximal side of the downward tongue and the third coupling profile, which means that the upper side of the upward locking element and the upper side of the first downward recess are entirely located at a distance from each other. In this manner, the contact zones between the second coupling profile and third coupling profile could reliably de defined which is in favour of establishing a secure locking between said coupling profiles.
In a preferred embodiment, at least a part of the proximal side of the upward locking element of the third coupling profile, facing the third recess, is upwardly inclined in a direction away from the upper lip, preferably in such a way that an angle is enclosed with the normal perpendicular to the plane defined by each tile wherein said angle is situated between 0 and 60 degrees, in particular between 0 and 45 degrees. This inclination results in an open third recess which facilitates insertion both of the sideward tongue and of the downward tongue.
Preferably, at least a part of the proximal side of the downward tongue of the second coupling profile, facing the second downward recess, is downwardly inclined in a direction away from the second downward flank, preferably in such a way that an angle is enclosed with the normal perpendicular to the plane defined by each tile wherein said angle is situated between 0 and 60 degrees, in particular between 0 and 45 degrees. Preferably, at least a part of the proximal side of the sideward tongue of the first coupling profile, facing the first downward recess, is downwardly inclined in a direction away from the first downward flank, preferably in such a way that an angle is enclosed with the normal perpendicular to the plane defined by each tile wherein said angle is situated between 0 and 60 degrees, in particular between 0 and 45 degrees. By applying a corresponding inclination, a more complementary shape is given to the first coupling profile and/or second coupling profile, which normally results in a more stable coupling between the first and third coupling profiles and between the second and third coupling profiles.
In an alternative embodiment, at least a part of the proximal side of the upward locking element of the third coupling profile, facing the third recess, is upwardly inclined in a direction towards the upper lip, preferably in such a way that an angle is enclosed with the normal perpendicular to the plane defined by each tile wherein said angle is situated between 0 and 60 degrees, in particular between 0 and 45 degrees. This inward inclination leads to a (slightly) closed third recess, wherein the upward locking element may be used to hook around or clamp around the sideward tongue and/or the downward tongue once inserted in said third recess. This is in particularly possible in case at least a part of the proximal side of the downward tongue of the second coupling profile, facing the second downward recess, is downwardly inclined in a direction towards the second downward flank, preferably in such a way that an angle is enclosed with the normal perpendicular to the plane defined by each tile wherein said angle is situated between 0 and 60 degrees, in particular between 0 and 45 degrees. And the aforementioned gripping around effect and/or clamping effect of the upward locking element can for example also be achieved in case at least a part of the proximal side of the sideward tongue of the first coupling profile, facing the first downward recess, is downwardly inclined in a direction towards the first downward flank, preferably in such a way that an angle is enclosed with the normal perpendicular to the plane defined by each tile wherein said angle is situated between 0 and 60 degrees, in particular between 0 and 45 degrees.
Preferably, a first transition zone between the proximal side of the sideward tongue of the first coupling profile and a lower side of the sideward tongue of the first coupling profile is curved. This curved first transition zone may be used to guide the sideward tongue into the third recess during coupling of adjacent tiles. It is also imaginable that a second transition zone between the proximal side of the downward tongue of the second coupling profile and a lower side of the downward tongue of the second coupling profile is curved. This curved second transition zone may be used to guide the downward tongue into the third recess during coupling of adjacent tiles. A third transition zone between the proximal side of the upward locking element of the third coupling profile and an upper side of the upward locking element of the third coupling profile is preferably (also) curved to facilitate insertion of the downward tongue and the sideward tongue into the third recess.
Preferably, at the lower side of the lower lip of the third coupling profile, a recess is present, which extends up to the distal end of the lower lip and which allows a bending of the lower lip in downward direction. Bending of the lower lip in downward direction allows the third recess to widen during coupling, which will facilitate insertion of the sideward tongue and the downward tongue into the third recess. Dependent on the specific design of the coupling profiles, the lower lip may remain in bended state in a coupled condition of adjacent tiles. To this end, the first coupling profile and the third coupling profile may be configured such that in coupled condition the first coupling profile is clamped by the third coupling profile. And to this end, the second coupling profile and the third coupling profile may (also) be configured such that in coupled condition the second coupling profile is clamped by the third coupling profile. The clamping effect will commonly be the result of a deformation, either an elastic bending or an elastic compression (squeezing), or a combination of both. The clamping effect will typically improve the mutually locking and coupling of cooperating coupling profiles.
The pretension is preferably realized by using overlapping contours of matching coupling profiles, in particular overlapping contours of the downward tongue and the third recess and/or overlapping contours of the upward locking element and the first and/or second downward recess. Overlapping contours doesn't mean that the complete contour should overlap, and merely requires that at least of part of the (outer) contour of the first and/or second coupling profile overlaps with at least a part of the (outer) contour of the third coupling part. The contours are typically compared by considering the contours of the first coupling part and the second coupling part from a side view (or cross-sectional view). By applying overlapping contours, the first and/or second coupling profiles and/or the third coupling profile will typically remain (elastically) deformed, in particular squeezed and/or bent, in a coupled state, provided the desired stability of the coupling. Normally, with overlapping contours the downward tongue will be (slightly) oversized with respect to the third recess, and/or the upward locking element will be (slightly) oversized with respect to the first and/or second downward recess. However, it should be understood that overlapping contours may also be realized in another manner, for example by applying overlapping (first, second, and/or third) locking elements.
In a preferred embodiment, the contour of the first coupling profile part which is configured to enclose the upward locking element of the third coupling profile is substantially identical to the (corresponding) contour of the second coupling profile part which is configured to enclose the upward locking element of the third coupling profile. The contour of a remaining part of the first coupling profile and the contour of a remaining part of the second coupling profile are typically mutually distinctive. The contact surface between the first coupling profile and the third coupling profile, in coupled condition, is preferably larger than the contact surface between the second coupling profile and the third coupling profile, in coupled condition. Preferably, the connection (coupling) between the first coupling profile and the third coupling profile leads to a firmer engagement per unit edge length in the longitudinal direction of the third recess and parallel to the plane of the tile(s) than the connection (coupling) between the second coupling profile and the third coupling profile.
During coupling of the tiles, the upward locking element may be (elastically) deformed, in particular squeezed and/or bent. Bending will take place from its initial position (slightly) in outward direction, away from the upper lip. A bent state of the upward locking element may remain in the coupled state of two tiles. The bending angle of the proximal side of the upward locking element, facing the upward flank, will commonly be restricted and situated in between 0 and 2 degrees.
It is imaginable, and even preferable, that the second coupling profile and the third coupling profile are configured such that in coupled condition a so-called pretension is existing, while the first coupling profile and the third coupling profile are configured such a coupled condition is substantially free of pretension. This (hybrid) embodiment may facilitate coupling of the tiles.
In an alternative embodiment, the first coupling profile and the third coupling profile are configured such that a coupled condition is substantially free of pretension between the first coupling profile and the third coupling profile. The same may apply between the second coupling profile and the third coupling profile, wherein the second coupling profile and the third coupling profile may be configured such that a coupled condition is substantially free of pretension between the second coupling profile and the third coupling profile. This can typically be achieved in case the contour of the first coupling profile and/or the second coupling profile fits into or with the contour of the third coupling profile, preferably without play to counteract the risk of the occurrence of creaking noises.
In a preferred embodiment, the first coupling profile and the third coupling profile are configured such that in coupled condition a plurality of, preferably at least three, distant contact zones are present, wherein in between each pair of adjacent contact zones a space remains. Preferably, the second coupling profile and the third coupling profile are configured such that in coupled condition a plurality of, preferably at least three, distant contact zones are present, wherein in between each pair of adjacent contact zones a space remains. By applying one or more intentional (air) gaps between the coupling profiles in coupled condition. These, the created clearance(s) or gap(s) is/are advantageous for the purpose of absorbing expansion of the tile, for instance resulting from environmental temperature changes, and/or for accumulation of dust, in particular environmental dust or dust created during production of the tile(s).
Typically, (also) the second edge and the third edge, in coupled condition, define a second closing surface defining a second vertical plane through the upper edges of the coupled tiles or at least the location where the tiles come together at the upper side of the tiles. Preferably, the second coupling profile and the third coupling profile are configured such that in coupled condition, the downward tongue is positioned at one side of the second vertical plane, and the third recess extends through said second vertical plane. This means that the one outer end of the third recess, typically also referred to as the tip of the third recess, remains empty when the second coupling profile and the third coupling profile are mutually coupled.
A distal side of the downward tongue, facing away from the second downward recess, preferably comprises at least a vertical upper wall part adjacent to the upper side of the tile, and, adjacent to and located below said vertical wall part, an angled wall part that angles inward toward a chamfered and/or curved lower wall part of said distal side of the downward tongue. The lower wall part of said distal side is preferably connected to a lower side of the downward tongue. Preferably, in between said angled wall part and said lower wall part an intermediate vertical wall part is situated. This intermediate vertical wall part allows the downward tongue to be design in a more robust manner. This specific shape is commonly the most preferred shape during production, and provides said distal side of the downward tongue both a guiding function (defined by the lower wall part) for guiding the downward tongue into the third recess, and a closing function for creating a closed seam between the upper edges of adjacent panels (defined by the upper wall part). One of the aforementioned wall parts, and preferably the upper wall part of the distal side of the downward tongue may be provided with a second locking element to realize and/or improve a vertical locking between coupled tiles.
In a preferred embodiment, a lower side of the sideward tongue of the first coupling profile, in coupled condition of two tiles, is supported by a lower surface of the upward third recess of the third coupling profile. The lower surface of the third recess is defined by an upper side of the lower lip. This supporting contact preferably causes a fixation in the mutual position of the first coupling profile and the third coupling profile. The second coupling profile and third coupling profile preferably cooperate under tension at this supporting contact zone or supporting contact point. The same is preferably applied with respect to the second coupling profile and the third coupling profile. To this end, a lower side of the downward tongue of the second coupling profile, in coupled condition of two tiles, is supported by a lower surface of the (upward) third recess of the third coupling profile. This supporting contact preferably causes a fixation in the mutual position of the second coupling profile and the third coupling profile. The coupling second profile and coupling third profile preferable cooperate under tension at this supporting contact zone or supporting contact point. A stable support of the sideward tongue and the downward tongue by the lower lip, in coupled condition, may further stabilize the coupling between the coupling profiles, and may also counteract the risk of the occurrence of creaking noises (squeaking).
In a preferred embodiment, in a coupled condition of tiles, the first downward flank of the first coupling profile and a distal side of the upward locking element and/or lower lip of the third coupling profile, facing the first downward flank, are positioned at a distance from each other. Preferably, in a coupled condition of tiles, the second downward flank of the second coupling profile and a distal side of the upward locking element and/or lower lip of the third coupling profile, facing the second downward flank, are positioned at a distance from each other. This intermediate (vertical) space between adjacent tiles creates some space for the lower lip and the upward locking element to (slightly) deform during coupling, and optionally to remain in a (slightly) deformed state in coupled condition of the tiles. This technical effect typically facilitates coupling and may also improve the stability of the coupling.
At least a part of, and preferably the complete, upper side of the upward locking element is inclined downwardly in a direction facing way from the upper lip of the third coupling profile. Preferably, at least a part of, and preferably the complete, upper side of the first downward recess is inclined downwardly towards the first downward flank. Preferably, both inclinations mutually enclose an angle between (and including) 0 and 5 degrees. The inclination of the upper side of the upward locking element is preferably situated between 15 and 45 degrees, more preferably between 25 and 35 degrees, and is most preferably about 30 degrees, with respect to a horizontal plane (being a plane defined by the tile). The inclination of the upper side of the upward locking element is preferably constant, which means the upper side has a substantially flat orientation. Preferably, an upper side of the first downward recess and/or the second downward recess has a, preferably likewise (compared to the inclination of the upper side of the upward locking element) inclining orientation, which is more preferably upward in the direction of the sideward tongue and/or in the direction of the downward tongue. A first lower surface of a first bridge connecting the downward tongue to the core (main body) of the tile is defined by the upper side of the first downward recess (or vice). A second lower surface of a second bridge connecting the downward tongue to the core (main body) of the tile is defined by the upper side of the second downward recess (or vice). Applying an inclined upper side of the first downward recess will result in a varying thickness of the first and/or second bridge, as seen from the core in the direction of the downward tongue. This position-dependent bridge thickness, wherein the bridge thickness is preferably relatively large close to the core and relatively small close to the downward tongue, bridge thickness has multiple advantages. The thicker part of the first and/or second bridge, close to the core, provides the bridge more and sufficient strength and robustness, while the thinner part of the bridge, close to the sideward tongue and/or downward tongue, forms the weakest point of the bridge and will therefore be decisive for the location of first deformation (pivoting point) during coupling. Since this point of deformation is located close to the sideward tongue and/or downward tongue the amount of material to be deformed to be able to insert the sideward tongue and/or downward tongue into the third recess can be kept to a minimum. Less deformation leads to less material stress which is in favour of the life span of the coupling profile(s) and hence of the tile(s). In the coupled state of adjacent tiles, the upper side of the first downward recess or second downward recess could be at least partially, and preferably substantially completely, supported by the upper side of the upward locking element, which provides additionally strength to the coupling as such. To this end, it is advantageous that the inclination of the upper side of the first downward recess and/or second downward recess substantially corresponds to the inclination of the upper side of the upward locking element. This means that the inclination of the upper side of the first downward recess and/or second downward recess is preferably situated between 15 and 45 degrees, more preferably between 25 and 35 degrees, and is most preferably about 30 degrees, with respect to a horizontal plane. This inclination may be either flat or rounded, or eventually hooked.
In coupled condition of two tiles, the (inclined or horizontal) upper side of the upward locking element of the third coupling profile is preferably positioned at a distance from the (inclined or horizontal) upper side of the first downward recess of the first coupling profile due to facilitate coupling and to allow dust to accumulate within the space created directly above the upward locking element.
In a preferred embodiment, an upper side of the upward locking element is positioned at a lower level than the upper lip of the third coupling profile. This allows sufficient space to dimension the first coupling profile and the second coupling profile in a relatively robust manner, which is in favour of the strength of the first coupling profile and the second coupling profile. Moreover, this configuration facilitates insertion of the sideward tongue and the downward tongue into the third recess.
The third locking element preferably comprises at least one outward bulge, and that the second locking element and—if applied—the first locking element comprise(s) at least one first locking groove or second locking groove, respectively, which outward bulge is adapted to be at least partially received in the first locking groove and second locking groove of an adjacent coupled tile for the purpose of realizing a locked coupling, preferably a vertically locked coupling. The third locking element and the second locking element preferably have a substantially complementary shape. Alternatively, the third locking element comprises at least one third locking groove, and the second locking element and—if applied—the first locking element comprises at least one outward bulge (ridge), which outward bulge is adapted to be at least partially received in said locking groove of an adjacent coupled tile for the purpose of realizing a locked coupling. It is also conceivable that the first locking element (if applied), the second locking element and the third locking element are not formed by a bulge-groove combination, but by another combination of co-acting profiled surfaces and/or high-friction contact surfaces. In this latter embodiment, the at least one locking element of the first, second, or third locking element may be formed by a (flat of otherwise shaped) contact surface composed of a, optionally separate, plastic material configured to generate friction with the other locking element of another tile in engaged (coupled) condition. Examples of plastics suitable to generate friction include:
Typically, though not necessarily, the third locking element is positioned at a distal side of the lower lip and/or the upward locking element, and at a distance both from a lower side of the lower lip and an upper side of the upward locking element. This allows the third locking element to co-act with a relatively large surface area, and therefore intensively, with a complementary first locking element and/or second locking element.
Typically, the upward locking element protrudes in vertical direction (i.e. a direction perpendicular to the plane defined by the panel) with respect to the lower lip. Preferably, the effective height of the upward locking element (in said vertical direction) is defined as the maximum (vertical) distance between a highest location of the upward locking element and a lowest location of the lower lip. Preferably, the effective height of the upward locking element is at least 20%, more preferably at least 25%, and even more preferably at least 30% of the panel thickness. Preferably, the combined thickness of the lower lip and the upward locking element is at least 50% of the panel thickness. These preferred features all aim to improve the horizontal locking effect between two panels in coupled condition.
Each coupling profile is preferably free from hook and loop fasteners and/or adhesive connections. Each tile preferably does not comprise any other coupling profile than at least one first coupling profile, at least one second coupling profile, and at least one, preferably at least two, third coupling profile(s). Preferably, each coupling profile is provided with chamfers, such as bevels, at or near the upper side of the tiles. The presence of the chamfers, such as bevels, typically make seam gaps less visible. The presence of chamfers lead to the situation that when two tiles are brought together for attachment, a valley or V-shaped recess is formed. Preferably, the tapered or bevelled edges are at an angle of from about 15° to about 55°, and more preferably at about a 17° angle. Also, the width of the bevelled or tapered edge is about 1.0 mm to about 7.0 mm.
When realizing a chevron pattern, it is advantageous in case the system comprises two different types of tiles (A and B respectively), and wherein the coupling profiles of one type of tile along are arranged in a mirror-inverted manner relative to the corresponding coupling profiles of the other type of tile. To this end, it is preferred in case the system comprises a plurality of tiles having a parallelogrammical shape, wherein said tiles are configured to being joined in a chevron pattern, wherein two pairs of adjacent edges enclose an acute angle, and wherein two pairs of other adjacent edges enclose an obtuse angle. The acute angle is typically situated between 30 and 60 degrees, and is preferably substantially 45 degrees. The obtuse angle is typically situated between 120 and 150 degrees, and is preferably substantially 135 degrees. Preferably, at least one parallelogrammical tile (A) has a configuration, wherein the edges are arranged, as seen from a top view in a clockwise direction, in the order: a first edge, a third edge, another third edge, and a second edge, and wherein at least one parallelogrammical tile (B) has a configuration, wherein the edges are arranged, as seen from a top view in a clockwise direction, in the order: a first edge, a second edge, a third edge, and another third edge. Distinctive visual markings, for example coloured labels, symbolic labels, (pre-attached) differently coloured backing layers, and/or text labels, may be applied to different tile types to allow a user to easily recognize the different tiles types during installation. Preferably the visual markings are not visible in a coupled condition of the tiles (from a top view). A visual marking may, for example, be applied onto the upper side of the upward locking element and/or inside the third recess and/or inside the first or second downward recess. It is imaginable that the system according to the invention comprises more than two different types of tiles.
At least one tile, and preferably each tile, preferably comprises a core layer and at least one upper substrate affixed—either directly or indirectly—to an upper side the core layer, wherein said upper substrate preferably comprises a decorative layer. The upper substrate is preferably at least partially made of at least one material selected from the group consisting of: metals, alloys, macromolecular materials such as vinyl monomer copolymers and/or homopolymers; condensation polymers such as polyesters, polyamides, polyimides, epoxy resins, phenol-formaldehyde resins, urea formaldehyde resins; natural macromolecular materials or modified derivatives thereof such as plant fibres, animal fibres, mineral fibres, ceramic fibres and carbon fibres. Here, the vinyl monomer copolymers and/or homo-polymers are preferably selected from the group consisting of polyethylene, polyvinyl chloride (PVC), polystyrene, polymethacrylates, polyacrylates, polyacrylamides, ABS (acrylonitrile-butadiene-styrene) copolymers, polypropylene, ethylene-propylene copolymers, polyvinylidene chloride, polytetrafluoroethylene, polyvinylidene fluoride, hexafluoropropylene, and styrene-maleic anhydride copolymers, and derivates thereof. The upper substrate most preferably comprises polyethylene, polyurethane (PU), or polyvinyl chloride (PVC). The polyethylene can be low density polyethylene, medium density polyethylene, high density polyethylene or ultra-high density polyethylene. The upper substrate layer can also include filler materials and other additives that improve the physical properties and/or chemical properties and/or the processability of the product. These additives include known toughening agents, plasticizing agents, reinforcing agents, anti-mildew (antiseptic) agents, flame-retardant agents, and the like. The upper substrate typically comprises a decorative layer and an at least partially transparent or translucent wear layer covering said decorative layer, wherein a top surface of said wear layer is the top surface of said tile, such that decorative layer is visible through the transparent wear layer.
Preferably, at least one tile, and preferably each tile, comprises an upper substrate affixed—either directly or indirectly—to an upper side of at least one core layer, wherein said upper substrate preferably comprises a veneer layer. Said veneer layer preferably has a Mohs hardness of greater than 3. Said veneer layer preferably has a thickness of between 2 and 8 mm. Said veneer layer being dimensioned so as not to overlie the supporting core layer and/or the at least one or more coupling profiles applied. The veneer layer is preferably composed of a material selected from the group consisting of natural stone, marble, granite, slate, glass, and ceramics. More preferably, the veneer layer is a ceramic of a type selected from the group consisting of Monocuttura ceramic, Monoporosa ceramic, porcelain ceramic, or multi-casted ceramic. Preferably, the veneer layer has a breaking modulus greater than 10 N/mm2, more preferably greater than 30 N/mm2.
The thickness of the upper substrate typically varies from about 0.1 to 3.5 mm, preferably from about 0.5 to 3.2 mm, more preferably from about 1 to 3 mm, and most preferably from about 2 to 2.5 mm. The thickness ratio of the core layer to the upper substrate commonly varies from about 1 to 15:0.1 to 3.5, preferably from about 1.5 to 10:0.5 to 3.2, more preferably from about 1.5 to 8:1 to 3, and most preferably from about 2 to 8:2 to 2.5, respectively.
Each tile may comprise an adhesive layer to affix the upper substrate, directly or indirectly, onto the core layer. The adhesive layer can be any well-known bonding agent or binder capable of bonding together the upper substrate and the core layer, for example polyurethanes, epoxy resins, polyacrylates, ethylene-vinyl acetate copolymers, ethylene-acrylic acid copolymers, and the like. Preferably, the adhesive layer is a hot-melt bonding agent.
The decorative layer or design layer, which may be part of the upper substrate as mentioned above, can comprise any suitable known plastic material such as a known formulation of PVC resin, stabilizer, plasticizer and other additives that are well known in the art. The design layer can be formed with or printed with printed patterns, such as wood grains, metal or stone design and fibrous patterns or three-dimensional figures. Thus the design layer can provide the tile with a three dimensional appearance that resembles heavier products such as granite, stone or metal. The thickness of the design layer typically varies from about 0.01 to 0.1 mm, preferably from about 0.015 to 0.08 mm, more preferably from about 0.2 to 0.7 mm, and most preferably from about 0.02 to 0.5 mm. The wear layer that typically forms the upper surface of the tile can comprise any suitable known abrasion-resistant material, such as an abrasion-resistant macromolecular material coated onto the layer beneath it, or a known ceramic bead coating. If the wear layer is furnished in layer form, it can be bonded to the layer beneath it. The wear layer can also comprise an organic polymer layer and/or inorganic material layer, such as an ultraviolet coating or a combination of another organic polymer layer and an ultraviolet coating. For example, an ultraviolet paint capable of improving the surface scratch resistance, glossiness, antimicrobial resistance and other properties of the product. Other organic polymers including polyvinyl chloride resins or other polymers such as vinyl resins, and a suitable amount of plasticizing agent and other processing additives can be included, as needed.
In a preferred embodiment, at least one tile comprises a plurality of strip shaped upper substrates directly or indirectly affixed to an upper side the core layer, wherein said upper substrates are arranged side by side in the same plane, preferably in a parallel configuration. Here, the plurality of upper substrates preferably substantially completely cover the upper surface of the core layer, and more preferably extend from the first edge to the second edge of the tile. Each of the plurality of upper substrates comprises a decorative layer, wherein the decorative layers of at least two adjacently arranged upper substrates preferably have different appearances. The application of a plurality of strip shaped upper substrates, are arranged side by side in the same plane and directly or indirectly affixed to the core layer will create the attractive aesthetical effect that the tile is defined by the strip shaped upper substrates as such, while having the advantages that during installation merely the tiles as such will have to be coupled rather than the strip shaped upper substrates, which would be time-consuming and expensive.
Preferably, the core layer comprises at least one foaming agent. The at least one foaming agent takes care of foaming of the core layer, which will reduce the density of the core layer. This will lead to light weight tiles, which are lighter weight in comparison with tiles which are dimensionally similar and which have a non-foamed core layer. The preferred foaming agent depends on the (thermo)plastic material used in the core layer, as well as on the desired foam ratio, foam structure, and preferably also the desired (or required) foam temperature to realise the desired foam ratio and/or foam structure. To this end, it may be advantageous to apply a plurality of foaming agents configured to foam the core layer at different temperatures, respectively. This will allow the foamed core layer to be realized in a more gradual, and more controller manner. Examples of two different foaming agents which may be present (simultaneously) in the core layer are azodicarbonamide and sodium bicarbonate. In this respect, it is often also advantageous to apply at least one modifying agent, such as methyl methacrylate (MMA), in order to keep the foam structure relatively consistent throughout the core layer.
Polymer materials suitable for forming the core layer may include polyurethane (PUR), polyamide copolymers, polystyrene (PS), polyvinyl chloride (PVC), polypropylene (PP), polyethylene terephthalate (PET), Polyisocyanurate (PIR), and polyethylene (PE) plastics, all of which have good moulding processability. The at least one polymer included in the core layer may either may be solid or may be foamed (expanded). Preferably, chlorinated PVC (CPVC) and/or chlorinated polyethylene (CPE) and/or another chlorinated thermoplastic material is/are used to further improve the hardness and rigidity of the core layers, and of the tiles as such, reducing the vulnerability of the pointed vertexes of each tile, which makes the tile even more suitable to be used as parallelogrammatic/rhombic tile for realizing chevron patterns. Polyvinyl chloride (PVC) and polyurethane (PU) materials are especially suitable for forming the core layer because they are chemically stable, corrosion resistant, and have excellent flame-retardant properties. The plastic material used as plastic material in the core layer is preferably free of any plasticizer in order to increase the desired rigidity of the core layer, which is, moreover, also favourable from an environmental point of view.
The core layer may also at least partially be composed of a, preferably PVC-free, thermoplastic comprising composition. This thermoplastic composition may comprise a polymer matrix comprising (a) at least one ionomer and/or at least one acid copolymer; and (b) at least one styrenic thermoplastic polymer, and, optionally, at least one filler. An ionomer is understood as being a copolymer that comprises repeat units of electrically neutral and ionized units. Ionized units of ionomers may be in particular carboxylic acid groups that are partially neutralized with metal cations. Ionic groups, usually present in low amounts (typically less than 15 mol % of constitutional units), cause micro-phase separation of ionic domains from the continuous polymer phase and act as physical crosslinks. The result is an ionically strengthened thermoplastic with enhanced physical properties compared to conventional plastics.
The polymer(s) used in the upper substrate and/or the core layer may be virgin polymers, although it is often preferred that a mixture of virgin polymeric material and (the same) recycled polymeric material is used. Here, it is e.g. imaginable that at least a part of the core layer is composed of a mixture of virgin and recycled PU. Instead of PU, also other polymers may be used in this respect, such as PVC, PP, and/or PET.
The core layer may be made of a composite of at least one polymer and at least one non-polymeric material. The composite of the core layer preferably comprises one or more fillers, wherein at least one filler is selected from the group consisting of: talc, chalk, wood, calcium carbonate, titanium dioxide, calcined clay, porcelain, a(nother) mineral filler, rice, rice hulls, rice powder, and a(nother) natural filler. The filler may be formed by fibres and/or may be formed by dust-like particles. Here, the expression “dust” is understood as small dust-like particles (powder), like wood dust, cork dust, or non-wood dust, like mineral dust, stone powder, in particular cement. The average particle size of the dust is preferably between 14 and 20 micron, more preferably between 16 and 18 micron. The primary role of this kind of filler is to provide the core layer, and the parallelogrammatic/rhombic tile(s) as such, sufficient hardness. This will allow the tiles, including their—commonly relatively vulnerable—pointed vertexes, to realize chevron patterns in a reliable and durable manner. Moreover, this kind of filler will typically also improve the impact strength of the core layer and of the tile(s) as such. The weight content of this kind of filler in the composite is preferably between 35 and 75%, more preferably between 40 and 48% in case the composite is a foamed composite, and more preferably between 65 and 70% in case the composite is a non-foamed (solid) composite.
It is imaginable that the core layer (and/or another layer) comprises a composite of at least one polymer and rice. Preferably, the rice is formed by rice hulls, more preferably a mixture of separated rice hulls, ground rice hulls and rice hull powder. Preferably, the different rice hull types have different average particle sizes. The polymer(s) act(s) as polymeric binder, wherein preferably an at least partially recycled plastic polymer, such as TPU, PP, PE, PET, and/or PVC, is used. The unground rice hull can for example be present in an amount of 1-98% by weight relative to the weight rice hull mixture. Likewise, the ground rice hull and powdered rice hull can also be present in an amount of 1-98% by weight relative to the weight of the rice hull mixture. Preferably, in one embodiment the rice hull mixture comprises 20-50% by weight of each of the unground rice hull, the ground rice hull and the rice hull powder. In a particularly preferred embodiment, the rice hull mixture comprises about 33% by weight of each of the unground rice hull, the ground rice hull and the rice hull powder. The amount of the polymeric binder present in the rice hull mixture can vary and may e.g. be 1-30%, preferably 10-25%, more preferably 12-20% by weight of the rice hull mixture. The rice hull powder preferably has an average particle size of 0.175-1.20 millimetre.
In an alternative configuration of the tile system according to the invention, each tile comprises a substantially rigid core layer at least partially made of a non-foamed (solid) composite comprising at least one plastic material and at least one filler. A solid core layer may lead to an improved tile strength, and hence a reduced vulnerability of the pointed vertexes, and may further improve the suitability to use the tiles to realize a chevron pattern. A drawback of applying a solid composite in the core layer instead of a foamed composite in the core layer is that the tile weight will increase (in case core layers of identical thicknesses would be applied), which may lead to higher handling costs, and higher material costs.
Preferably, the composite of the core layer comprises at least one filler of the core layer is selected from the group consisting of: a salt, a stearate salt, calcium stearate, and zinc stearate. Stearates have the function of a stabilizer, and lead to a more beneficial processing temperature, and counteract decomposition of components of the composite during processing and after processing, which therefore provide long-term stability. Instead of or in addition to a stearate, for example calcium zinc may also be used as stabilizer. The weight content of the stabilizer(s) in the composite will preferably be between 1 and 5%, and more preferably between 1.5 and 4%.
The composite of the core layer preferably comprises at least one impact modifier comprising at least one alkyl methacrylate, wherein said alkyl methacrylate is preferably chosen from the group consisting of: methyl methacrylate, ethyl methacrylate, propyl methacrylate, isopropyl methacrylate, t-butyl methacrylate and isobutyl methacrylate. The impact modifier typically improves the product performance, in particular the impact resistance. Moreover, the impact modifier typically toughens the core layer and can therefore also be seen as toughening agent, which further reduces the risk of breakage. Often, the modifier also facilitates the production process, for example, as already addressed above, in order to control the formation of the foam with a relatively consistent (constant) foam structure. The weight content of the impact modifier in the composite will preferably be between 1 and 9%, and more preferably between 3 and 6%. Preferably, the substantially complete core layer is formed by either a foamed composite or a non-foamed (solid) composite. At least one plastic material used in the core layer is preferably free of any plasticizer in order to increase the desired rigidity of the core layer, which is, moreover, also favourable from an environmental point of view.
The core layer and/or another layer of the tile may comprise wood-based material, for example, MDF, HDF, wood dust, prefabricated wood, more particularly so-called engineered wood. This wood-based material may be part of a composite material of the core layer.
The density of the core layer typically varies from about 0.1 to 1.5 grams/cm3, preferably from about 0.2 to 1.4 grams/cm3, more preferably from about 0.3 to 1.3 grams/cm3, even more preferably from about 0.4 to 1.2 grams/cm3, even more preferably from about 0.5 to 1.2 grams/cm3, and most preferably from about 0.6 to 1.2 grams/cm3.
The polymer used in the core layer and/or the core layer as such preferably has an elastic modulus of more than 700 MPa (at a temperature of 23 degrees Celsius and a relative humidity of 50%). This will commonly provide sufficient rigidity to the core layer, and hence to the parallelogrammatic/rhombic tile as such.
The core layer preferably layer has a thickness of at least 3 mm, preferably at least 4 mm, and still more preferably at least 5 mm. It is imaginable that each tile comprises a plurality of core layers. Different core layers may have either identical compositions or different compositions.
The density of the core layer preferably varies along the height of the core layer. This may positively influence the acoustic (sound-dampening) properties of the tiles as such. Preferably, at a top section and/or a bottom section of a foamed core layer a crust layer may be formed. This at least one crust layer may form integral part of the core layer. More preferably, both the top section and the bottom section of the core layer form a crust layer enclosing the foam structure. The crust layer is a relatively closed (reduced porosity, preferably free of bubbles (cells)) layer, and hence forms a relatively rigid (sub)layer, compared to the more porous foam structure. Commonly, though not necessary, the crust layer is formed by sealing (searing) the bottom and top surface of the core layer. Preferably the thickness of each crust layer is between 0.01 and 1 mm, preferably between 0.1 and 0.8 mm. A too thick crust will lead to a higher average density of the core layer which increases both the costs and the rigidity of the core layer. The thickness of the core layer (core layer) as such is preferably between 2 and 10 mm, more preferably between 3 and 8 mm, and is typically approximately 4 or 5 mm. Preferably, a top section and/or a bottom section of the (composite) core layer forms a crust layer having a porosity which is less than the porosity of the closed cell foam plastic material of the core layer, wherein the thickness of each crust layer is preferably between 0.01 and 1 mm, preferably between 0.1 and 0.8 mm.
Preferably, each tile comprises at least one backing layer affixed to a bottom side of the core layer, wherein said at least one backing layer at least partially made of a flexible material, preferably an elastomer. The thickness of the backing layer typically varies from about 0.1 to 2.5 mm. Non-limiting examples of materials whereof the backing layer can be made of are polyethylene, cork, polyurethane and ethylene-vinyl acetate. The thickness of a polyethylene backing layer is for example typically 2 mm or smaller. The backing layer commonly provides additional robustness and impact resistances to each tile as such, which increases the durability of the tiles. Moreover, the (flexible) backing layer may increase the acoustic (sound-dampening) properties of the tiles. In a particular embodiment, the core layer is composed of a plurality of separate core layer segments affixed to said at least one backing layer, preferably such that said core layer segments are mutually hingeable. The lightweight features of the tiles are advantageous for obtaining a secure bond when installing the tile on vertical wall surfaces. It is also especially easy to install the tile at vertical corners, such as at inside corners of intersecting walls, pieces of furniture, and at outside corners, such as at entry ways. An inside or outside corner installation is accomplished by forming a groove in the core layer of the tile to facilitate bending or folding of the tile.
Each tile may comprises at least one reinforcing layer. At least one reinforcing layer may be situated in between the core layer and the upper substrate. At least one reinforcing layer may be situated in between two core layers. The application of a reinforcing layer may lead to further improvement of the rigidity of the tiles as such. This may also lead to improvement of the acoustic (sound-dampening) properties of the tiles. The reinforcement layer may comprise a woven or non-woven fibre material, for example a glass fibre material. They may have a thickness of 0.2-0.4 mm. It is also conceivable that each tile comprises a plurality of the (commonly thinner) core layer stacked on top of each other, wherein at least one reinforcing layer is situated in between two adjacent core layers. Preferably, the density of the reinforcing layer is preferably situated between 1,000 and 2,000 kg/m3, preferably between 1,400 and 1,900 kg/m3, and more preferably between 1,400 and 1,700 kg/m3.
Preferably, at least a part of the first coupling profile and/or at least a part of second coupling profile and/or at least a part of the third coupling profile of each tile is integrally connected to the core layer. In this case one-piece tiles are formed, which are relatively easy and cost-efficient to produce.
The first coupling profile and/or the second coupling profile and/or the third coupling profile preferably allows deformation during coupling and uncoupling of tiles. At least a number of tiles is identical. It is also imaginable that at least a number of tiles have different sizes and/or different shapes. Apart from the already discussed parallelogrammical shaped tiles for realizing chevron patterns, it is also imaginable that the tile system comprises different types of tiles (A and B respectively), wherein the size of a first type of tile (A) differs from the size of second type of tile (B). These A and B panels may e.g. have a rectangular and/or square shape. Distinctive visual markings may be applied to different tile types, preferably for installation purposes. To this end, distinctive visual markings are preferably applied to an upper side of third recess and/or an upper side of the upward locking element of the third coupling profile of each tile type.
The invention also relates to a tile covering, in particular floor covering, wall covering, ceiling covering and/or furniture covering, consisting of mutually coupled tiles according to the invention. The invention also relates to a tile for use in multi-purpose tile system according to the invention.
The terms Fig., Figs., Figure, and Figures are used interchangeably to refer to the corresponding figures in the drawings.
The invention will be elucidated on the basis of non-limitative exemplary embodiments shown in the following figures, wherein:
The third coupling profile (106) comprises a third recess (430) configured for accommodating at least a part of the sideward tongue (400) of the first coupling profile (104) of a further tile (100, 201, 202, 301), said third recess (430) being defined by an upper lip (431) and a lower lip (432), wherein said lower lip (432) is provided with an upward locking element (433). The upper lip (431) further comprises a third closing surface (420) and an upper lip contact portion (424), wherein said third closing surface (420) and upper lip contact portion (424) are situated at opposite sides of a fifth locking element (407), which in this instance is formed by a cut-out portion (408). The proximal side (434) of the upward locking element (433) of the third coupling profile (106), facing the third recess (430), is upwardly inclined in a direction away from the upper lip (431). The proximal side (434) of the upward locking element (433), comprises a third upper and third lower contact portion (434a, 434b), wherein said third upper and third lower contact portions (434a, 434b) are extending in a first direction and a second direction, said second direction deviating from said first direction. The third lower and third upper contact portions (434a, 434b) are connected via at least one intermediate curved zone, which in this instance is a convex zone. Preferably, said third upper contact portion (434a) extending in the first direction is inclined at a second angle (γ) with respect to the lower side (437) of the lower lip (432). The third lower contact portion (434b) extending in the second direction is inclined at a first angle (ϕ) with respect to the lower side (437) of the lower lip (432). Said second angle (γ) may be substantially similar compared to the angle (β) of the first proximal side contact portion (403′) of the sideward tongue (400) of a second tile (100, 201, 202, 301), such that these contact portions (434a, 403′) mutually co-act in a locked configuration. It is preferred that the second angle (γ) is smaller with respect to the first angle (ϕ). A third transition zone (435) can be defined between the proximal side (434), in particular the third upper contact portion (434a) thereof, of the upward locking element (433) and an upper side (436) of the upward locking element (433), which third transition zone (435) is in this instance partially deviates from the curved first transition zone (404). The upper side (436) of the upward locking element (433) is in the depicted tile (100, 201, 202, 301) inclined downwardly in a direction facing away from the upper lip (431) of the third coupling profile (106). At the lower side (437) of the lower lip (432) of the third coupling profile (106), a recess (438) is present. This recess (438) allows bending of the lower lip (432) in a downward direction, in particular during coupling. The third coupling profile (106) may further comprise a third locking element (440) that may co-act with a second locking element (422) of the second coupling profile (105) of an adjacent tile (100, 201, 202, 301) to establish a vertical lock between the coupled tiles (100, 201, 202, 301). The third locking element (440) may hereto be provided at a distal side (441) of the lower lip (432) facing away from the third recess (430) and/or at a distal side (442) of the upward locking element (433) facing away from the third recess (430). The third locking element (440) may, as depicted here, specifically be positioned at a distance both from a lower side (437) of the lower lip (432) and an upper side (436) of the upward locking element (433). In the presently depicted tile, the third locking element (440) comprises at least one outward bulge (443) which outward bulge (443) may be provided with an third locking element contact portion (440′), wherein said third locking element contact portion (440′) is configured to co-act with at least one second locking element (422) of the second coupling profile (105), in particular with a second locking element contact portion (422′) thereof, of an adjacent coupled tile (100, 201, 202, 301) for the purpose of realizing a (vertically) locked coupling.
The coupling profiles (105, 106) of the multi-purpose tiles (100, 201, 202, 301) shown in
In the
At least a portion, in particular a distal portion of the sideward tongue (400) extends beyond the left side of the first vertical plane (502), where it clamps between a portion of the support surface (500), in particular the first support portion (500a) and a part of the upper lip contact portion (424). This clamping may be realized in different ways. It may be conceivable that the thickness of the sideward tongue (400), in particular defined by a vertical line and/or portion extending from the bottom side contact portion (405′) substantially vertically towards the sideward tongue contact portion (409), is larger compared to a vertical line and/or portion extending from the third support portion (500a) and a part of the upper lip contact portion (424), in particular the part of the upper lip contact portion (424) located vertically above the third support portion (500a). The different thickness may be a result of a marginal difference in the angle (i.e. a difference in angle of around 1 degree) between a first and second angle, the first angle may be defined by the upper side (107) and the sideward tongue contact portion (409), and the second angle may be defined by the upper side (107) and the upper lip contact portion (424). The difference in thickness allows the sideward tongue (400) to be clamped and vertically locking the mutual tiles (100, 201, 202, 301). It is also conceivable that the shape of the sideward tongue (400) follows the contours of the inward portion of the third recess (430), such that in locked position the sideward tongue (400) exactly fits in said inward portion of the third recess (430) and mutually vertically locking the two tiles (100, 201, 202, 301). In locked configuration, there is a first cavity (506) on the left of the tip (444) of the sideward tongue (400). This cavity (506) allows for a more easy coupling and decoupling of the two tiles (100, 201, 202, 301), especially since the coupling and decoupling of the first and third coupling profile (104, 106) occur under an angling movement, wherein the sideward tongue (400) is angled into or out of the third recess (430). During this angling movement, the cavity (506) allows the tip (444) of the sideward tongue (506) to move, preventing that the sideward tongue (400) remains stuck as a result of friction between the tip (444) of the sideward tongue (400) and the third recess (430). Moreover, during this angling movement while coupling or decoupling the first and third coupling profiles (104, 106), the bottom side contact portion (405′) functions as a gliding line contact, due to which line contact said bottom side contact portion (405′) may easily slide over the support surface (500) of the third coupling profile (106). In the coupled position, the bottom side contact portion (405′) will be supported by the third support portion (500a). Towards the heel (404) of the sideward tongue (400) there may be, in a coupled configuration of the first and third coupling profiles (104, 106), a (triangular) second cavity (507). Due to said second cavity (507) there may be more space available during the angling movement for the sideward tongue (400), hence as a result of which allows for an easier coupling of the first and third coupling profiles (104, 106). In the coupled configuration, the first proximal side contact portion (403′) abuts the upper contact portion (434a) of the upward locking element (433), which results in a horizontal locking of the two tiles (100, 201, 202, 301). This horizontal locking may be realized by friction between the first proximal side contact portion (403′) and the upper contact portion (434a) of the upward locking element (433). On the right of the distal side (442) of the upward locking element (433) facing away from the third recess (430) there may be, in a coupled configuration of the first and third coupling profiles (104, 106), a third cavity (508) which defines an open space (508) between the first downward flank (401) and the lower lip (431), in particular the upward locking element (433). Due to this open space (508) the downward movement of the panel may be easier since there is substantially less, preferably no, friction between the first downward flank (401) and the distal side (442) of the upward locking element (433) facing away from the third recess (430).
The ordinal numbers used in this document, like “first”, “second”, “third”, etcetera, are used only for identification purposes. Hence, the use of the expressions “third locking element” and “second locking element” does therefore not necessarily require the co-presence of a “first locking element”.
The tiles of the tile system according to the invention may also be referred to as panels. The core layer may also be referred to as base layer, and may be composed of a plurality of sub-layers, which may e.g. include a reinforcement layer, such as a glass-fiber layer. The coupling profiles may also be referred to as coupling parts or as connecting profiles. By “complementary” coupling profiles is meant that these coupling profiles can cooperate with each other. However, to this end, the complementary coupling profiles do not necessarily have to have complementary forms. By locking in “vertical direction” is meant locking in a direction perpendicular to the plane of the tile. By locking in “horizontal direction” is meant locking in a direction perpendicular to the respective coupled edges of two tiles and parallel to or falling together with the plane defined by the tiles. In case in this document reference is made to a “floor tile” or “floor panel”, these expressions may be replaced by expressions like “tile”, “wall tile”, “ceiling tile”, “covering tile”, “panel”, “wall panel”, “ceiling panel”, “covering panel”. In the context of this document, the expressions “foamed composite” and “foamed plastic material” (or “foam plastic material”) are interchangeable, wherein in fact the foamed composite comprises a foamed mixture comprising at least one (thermo)plastic material and at least one filler (non-polymeric material).
The above-described inventive concepts are illustrated by several illustrative embodiments. It is conceivable that individual inventive concepts of an embodiment may be applied without, in doing so, also applying other details of said embodiment. It is not necessary to elaborate on examples of all conceivable combinations of the above-described inventive concepts, as a person skilled in the art will understand numerous inventive concepts can be (re)combined in order to arrive at a specific application. It is explicitly emphasized here that all mathematical combinations are possible among the features mentioned above and referred to in the claims as filed, as far as the respectively obtained combination does not include any contradictory characteristics. In this manner, this application thus also forms a reservoir of possibilities of claimed subject-matter.
It will be apparent that the invention is not limited to the working examples shown and described herein, but that numerous variants are possible within the scope of the attached claims that will be obvious to a person skilled in the art.
The verb “comprise” and conjugations thereof used in this patent publication are understood to mean not only “comprise”, but are also understood to mean the phrases “contain”, “substantially consist of”, “formed by” and conjugations thereof.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2028776 | Jul 2021 | NL | national |
This application is the United States national phase of International Application No. PCT/EP2022/070234 filed Jul. 19, 2022, and claims priority to The Netherlands Patent Application No. 2028776 filed Jul. 19, 2021, the disclosures of which are hereby incorporated by reference in their entireties.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/070234 | 7/19/2022 | WO |
