The present invention relates to panels, e.g. floor panels wall panels or ceiling panels, having one or more features making them particularly suitably to be installed, upon choice of the installer, with either major surface facing the room.
Reversible floor panels are known from WO2016/010414. The coupling means at the edges of the panels disclosed in WO2016/010414 either allow for a connection by means of a horizontal shifting movement of the respective edges towards each other, or by means of a downward movement of one of the edges towards the other. The panels disclosed in WO2016/010414 suffer from several disadvantages. The panels are hard to produce, since an absolute matching of thickness among the panels and a closing of the joint at both major surfaces is necessary or desired. Height differences may be unavoidable at at least the bottom or top major surface, due to thickness variations among adjacent floor covering panels. The panels of WO2016/010414 are furthermore hard to disassemble.
The present invention in the first place seeks to provide alternatives to the panels of the state of the art, and, in accordance with several preferred embodiments, offers a solution to one or more of the problems with the panels from the state of the art.
The first aspect of the invention is a panel. Preferably, the panel is a floor panel for forming a floor covering, or a panel for forming a wall covering, or a panel for covering a ceiling. The panel comprises a first pair of opposite edges. The first pair of opposite edges comprises a first edge and an opposite second edge. The first edge comprises first coupling parts. The second edge comprises second coupling parts. The first coupling parts comprise an upper lip. The lower side of the upper lip comprises a first insert. The first insert comprises a first male section and/or a first female section. The second coupling parts comprise a lower lip. The upper side of the lower lip comprises a second insert. The second insert comprises a second female section and/or a second male section. The first coupling parts are configured for coupling the panel at the first edge to the second coupling parts at the second edge of a second such panel—preferably by means of a downward movement of the first edge of the panel relative to the second edge of the second such panel—thereby establishing a locking in in the direction in the plane of the panel and perpendicular to the coupled edges as well as in the direction perpendicular to the plane of the panel. During such coupling the first male section of the panel engages in the second female section of the second such panel; and/or the second male section of the second such panel engages in the first female section of the panel.
The coupling parts of the panel according to the first aspect of the invention—more specifically the use of the insert—provides a versatile way to equip panels with locking parts to lock the coupled panels.
It has to be understood that the configuration of the upper lip of the first coupling parts and the lower lip of the second coupling parts is such that when two such panels are coupled to each other with the first coupling parts of a first such panel coupled to the second coupling parts of the second such panel with the upper lip of the first coupling parts of the first such panel to the room, the lower lip of the second coupling parts of the second panel is positioned below the upper lip of the first coupling parts of the first such panel.
Preferably the first insert is attached in the upper lip by means of an adhesive or by means of geometrical or frictional constraint.
Preferably the second insert is attached in the lower lip by means of an adhesive or by means of geometrical or frictional constraint.
Preferably, the upper surface of the upper lip forms part of the upper surface of the panel. Preferably, the lower surface of the lower lip forms part of the lower surface of the panel.
In a preferred embodiment, the first insert and/or the second insert is a strip. Providing the first and/or the second insert as a strip has the advantage that the insert can be easily produced, e.g. by means of extrusion of a plastic or elastomeric material; and that the insert can be easily introduced in the panel.
Preferably, the first insert and/or the second insert have along their longitudinal direction a constant cross section. Such embodiments have the advantage that such inserts can be easily manufactured—e.g. via extrusion of e.g. thermoplastic or elastomeric material. Furthermore, as the cross section is constant, it is possible after coupling panels along their respective first pair of opposite edges, to shift the so-coupled edge in the direction parallel with the first pair of opposite edges. This is especially interesting when the panel is provided with a second pair of opposite edges; and the second pair of opposite edges is provided with coupling parts that comprise locking parts. E.g. the panel can be provided at its second pair of opposing edges with coupling parts that allow coupling such panels at their respective second pair of opposite edges by means of a horizontal movement of the panels, preferably including a snap movement, such that panels coupled at their respective second pair of opposite edges are locked in the plane parallel with the panels and perpendicular to the second pair of opposite edges, as well as in the plane perpendicular to the panels. The second pair of opposite edges can also be provided with coupling parts that allow coupling by means of a downward movement of the third edge relative to the fourth edge of another such panel, preferably resulting in a fold-down coupling arrangement of such panels.
In a preferred panel, the cross section perpendicular to the first edge of the first male part and/or the cross section perpendicular to the second edge of the second male part comprises a mushroom shape. More preferably, the mushroom shape comprises a stem and a mushroom head.
In a preferred embodiment, the bottom of the mushroom head comprises a concave section. More preferably, the female part provided for coupling with the mushroom head is configured to contact or engage with in coupled condition of two such panels at their first pair of opposite edges at least part of the concave section of the mushroom head, thereby locking the two panels to each other. Such embodiments provide a very effective locking of the so-coupled panels, as increased force is required to overcome the locking provided by the female and the male insert.
It is also possible that the bottom of the mushroom head comprises a flat section; and/or that the bottom of the mushroom head comprises a convex section. Such embodiments are preferred if it must be more easily possible to unlock and re-install already coupled panels.
Preferably, the cross section perpendicular to the first edge of the first female part and/or the cross section perpendicular to the second edge of the second female part comprises two legs between which a male part of a corresponding edge of a second such panel can be locked. Such embodiments provide particularly effective locking between so-coupled panels. More preferably, at least one of the two legs—and preferably both legs—comprise an inclined extension configured to act as locking parts for locking the female part comprising the legs to a male part of another such panel.
More preferably, at least part of the surface of the inclined extension is configured such that it can contact or engage with at least part of a concave section of a coupled such panel, wherein the contact or engagement creates a locking of the female part to the male part of the coupled such panel. Such embodiments are particularly preferred, as a very efficient locking of so-coupled panels is realized.
Preferably, the first insert and/or the second insert is extruded.
Preferably, the first insert and/or the second insert is/are out of a thermoplastic material or out of an elastomeric material. PVC can e.g. be used.
In preferred embodiments of the invention the first female part undergoes an elastic deformation during the coupling in order to engage the second male part; and/or the second female part undergoes an elastic deformation during the coupling in order to engage the first male part.
In preferred embodiments of the invention the first male part undergoes an elastic deformation during the coupling in order to engage the second female part; and/or the second male part undergoes an elastic deformation during the coupling in order to engage the first female part.
The upper lip of a preferred panel comprises a first recess. More preferably the first recess comprises or consists of a groove. Even more preferably, the groove is parallel with the first edge of the panel into which the first insert is provided. Preferably, the first insert is attached in the first recess by means of an adhesive or by means of geometrical or frictional constraint.
The lower lip of a preferred panel comprises a second recess. More preferably the second recess comprises or consists of a groove. Even more preferably the groove is parallel with the second edge of the panel into which the second insert is provided. Preferably, the second insert is attached in the second recess by means of an adhesive or by means of geometrical or frictional constraint.
In a preferred embodiment, the first edge comprises a first upper lip section more proximal to the panel than the first insert. The second edge comprises a second lower lip section more distal to the panel than the second insert. In coupled condition of two such panels, the first upper lip section of the first coupled panel engages with—and preferably contacts—the second lower lip section of the second coupled panel. Such embodiments provide excellent locking in the direction perpendicular to the surface of the so-coupled panels. Preferably, the first upper lip section and the second lower lip section are made in one piece.
Preferably, the lower side of the first upper lip section and the upper side of the second lower lip section are at least over a part of their surface substantially parallel with the panel.
In a preferred embodiment, the first edge comprises a second upper lip section more distal to the panel than first insert. The second edge comprises a first lower lip section more proximal to the panel than the second insert. In coupled condition of two such panels, the second upper lip section of the first coupled panel engages with—and preferably contacts—the first lower lip section of the second coupled panel. Such embodiments provide excellent locking in the direction perpendicular to the surface of the so-coupled panels. Preferably, the second upper lip section and the first lower lip section are made in one piece.
Preferably, the lower side of the second upper lip section and the upper side of the first lower lip section are at least over a part of their surface substantially parallel with the panel.
In a first specific embodiment of the first aspect of the invention, the first insert comprises a first male section and a first female section. The second insert comprises a second male section and a second female section. During coupling, the first male section of the panel engages in the second female section of the second such panel; and the second male section of the second such panel engages in the first female section panel. Such embodiments of the first aspect of the invention provide panels that have an even stronger locking when coupled at their first pair of opposing edges.
Preferably, the first insert is identical to the second insert. It is understood that the orientation of the second insert is turned over 180° around its centerline compared to orientation of the first insert. Such embodiments have the benefit that only one type of insert is required, which is provided at the first edge and at the second edge of the first pair of opposite edges. This way, complexity is reduced in manufacturing of the inserts and of the panel.
In embodiments according to the first specific embodiment of the first aspect of the invention, the first male section and the first female section are provided as separate profiles in the first insert.
In embodiments according to the first specific embodiment of the first aspect of the invention, the second male section and the second female section are provided as separate profiles in the second insert.
Preferably, the first insert comprises no other male sections than the first male section and no other female section than the first female section.
Preferably, the second insert comprises no other male sections than the second male section and no other female section than the second female section.
In preferred embodiments of the first aspect of the invention, the distal end of the upper lip comprises a surface perpendicular to the surface of the panel.
In preferred embodiments of the first aspect of the invention, the distal end of the lower lip comprises a surface perpendicular to the surface of the panel.
In preferred embodiments of the first aspect of the invention, the first coupling parts are configured such that the first edge of the panel can be coupled, with the first insert of the panel directed downwards, by a downward movement of the panel into the first coupling parts of the first edge of a third such panel when this third panel is turned such that the first insert of the third such panel is directed upwards. In the downward movement the first insert of the panel is locked into the first insert of the third such panel. It is a benefit of such embodiments that a third such panel can be coupled with its first edge and with its second edge to the first edge of a first such panel. In these two mentioned coupling configurations, different surfaces of the third such panel face the room, while the same surface of the first panel faces the room. Such panels are preferably provided with decorative and/or functional surfaces on both surfaces of the panels. Depending on whether the both surfaces have a same decorative and/or functional surface; or different decorative and/or functional surface patterns, more complex patterns can be made using only one type of panel. As an example, Hungarian point patterns are possible with panels according to this embodiment, e.g. when both the upper side and the lower side of the panels are provided with the same decorative surface, e.g. a wood pattern. With the upper surface and the lower surface comprise the same decorative surface, it has to be understood that the décor of the upper surface and of the lower surface have the same color and visual and tactual aspect, however allowing structured or random differences such as are present in wood or stone simulating decorative surfaces. Other laying patterns with the panels are possible when both sides of the panel are provided with different decorative and/or functional surfaces.
In a preferred embodiment of the first aspect of the invention, the second coupling parts are configured such that the second edge of the panel can be coupled by a downward movement of the panel with the second insert of the panel directed downwards into the second coupling parts of the second edge of a fourth such panel with its second insert directed upwards. In the downward movement the second insert of the panel is locked into the second insert of the fourth such panel. It is a benefit of such embodiments that a fourth such panel can be coupled with its first edge and with its second edge to the second edge of a first such panel. In the two mentioned coupling configurations, different surfaces of the fourth such panel face the room, while the same surface of the first panel faces the room. Such panels are preferably provided with decorative and/or functional surfaces on both surfaces of the panels. Depending on whether the both surfaces have a same decorative and/or functional surface; or different decorative and/or functional surface patterns, more complex patterns can be made using only one type of panel. E.g. Hungarian point patterns are possible with panels according to this embodiment, e.g. when both the upper side and the lower side of the panels are provided with the same decorative surface, e.g. a wood pattern. Other laying patterns with the panels are possible when both sides of the panel are provided with different decorative and/or functional surfaces.
In preferred panels according to the first aspect of the invention, the first coupling parts and the second coupling parts of the second edge are configured such that in coupled condition of the panel at its first edge with a second such panel at its second edge, a point of symmetry is provided at the coupled edges of the panel with the second such panel, at the middle of the height of the panel, such that the first coupling parts of the panel are symmetrical relative to the point of symmetry with the second coupling parts of the second coupled panel. A first such panel can be coupled—with its same side facing towards the room—at its first or at its second edge, to both edges of the first pair of opposite edges of a second such panel. When a first edge is coupled to a second edge, both panels face with the same surface towards the room; when a first edge is coupled to a first edge, or when a second edge is coupled to a second edge, one of the so-coupled panels is turned upside down and different surfaces face the room. Such arrangements create a new range of laying patterns, wherein only one type/one configuration of panels needs to be used.
In preferred embodiments of the first aspect of the invention, the panel comprises a decorative surface and/or functional surface at the upper surface; and a decorative surface and/or functional surface at the lower surface of the panel. More preferably the upper surface and the lower surface each comprise a wear layer on top of their respective decorative surface. Functional surfaces that can be provided are e.g. surfaces that provide anti-slip properties to the surface. The decorative surface and/or functional surface at the upper surface can be different or can be the same as at the lower surface of the panel. With the upper surface and the lower surface comprise the same decorative surface has to be understood that the décor of the upper surface and of the lower surface have the same color and visual and tactual aspect, however allowing structured or random differences such as are present in wood or stone simulating decorative surfaces.
A particularly preferred panel according to the first aspect of the invention is rectangular and oblong. The first pair of opposite edges is provided at the long edges of the panel. However, it is not excluded that the first pair of opposite edges is provided at the short edges of a rectangular and oblong panel.
A preferred panel according to the first aspect of the invention has a second pair of opposite edges. The second pair of opposite edges comprises a third edge and a fourth edge. The second pair of opposite edges are perpendicular to the first pair of opposite edges, or the second pair of opposite edges make an angle different from 90° with the first pair or opposite edges. The third edge comprises third coupling parts. The third coupling parts comprise a male coupling part. The fourth edge comprises fourth coupling parts. The fourth coupling parts comprise a female coupling part. The third coupling parts and the fourth coupling parts are provided with locking elements for creating a locking, in the direction parallel with the plane of the coupled panels and perpendicular to the second pair of opposite edges, of the panel coupled at its third edge with the fourth edge of a second such panel. The male coupling part of the third edge and the female coupling part of the fourth edge are provided for creating a locking in the direction perpendicular to the surface of the panel coupled at its third edge with the fourth edge of the second such panel. The third coupling parts and the fourth coupling parts are provided for coupling the panel at its third edge to the fourth edge of the second such panel by means of a horizontal shifting of the male coupling part of the third coupling parts into the female coupling part of the fourth coupling parts involving a snapping of the locking elements.
A preferred panel according to the first aspect of the invention comprises a second pair of opposite edges. The second pair of opposite edges are configured according to the configuration of the first pair of opposite edges as described in any embodiment of the first aspect of the invention. It is a benefit of such embodiments that manufacturing is less complex, as the same inserts can be used in the first pair of opposite edges and in the second pair of opposite edges. Particular laying patterns—that otherwise require two different types/configurations of panels—can be made with such panels using only one type/one configuration of panels. Preferably, such panel is rectangular, square or oblong.
The second aspect of the invention is a panel. The panel preferably is a floor panel for forming a floor covering, or a panel for forming a wall covering, or a panel for covering a ceiling. The panel comprises a decorative surface and/or a functional surface at the upper surface and at the lower surface. Preferably, the upper surface and the lower surface each comprise a wear layer provided on top of their respective decorative surface. The panel comprises a first pair of opposite edges. The first pair of opposite edges comprises a first edge and an opposite second edge. The first edge comprises first coupling parts. The second edge comprises second coupling parts.
The first coupling parts are configured such that the panel can be coupled at its first edge to the first edge of another such panel, wherein the another such panel is turned upside down compared to when it is coupled with its second edge to the first edge of the panel, wherein a locking of the so-coupled panels is obtained in the direction parallel with the surface of the so-coupled panels and perpendicular to the so-coupled edges, as well as a locking of the so-coupled panels perpendicular to the surface of the so-coupled panels.
The second coupling parts are configured such that the panel can be coupled at its second edge to the second edge of another such panel turned upside down compared to the panel, wherein a locking of the so-coupled panels is obtained in the direction parallel with the surface of the so-coupled panels and perpendicular to the so-coupled edges, as well as a locking of the so-coupled panels perpendicular to the surface of the so-coupled panels.
The panel comprises a second pair of opposite edges. The second pair of opposite edges comprises a third edge and an opposite fourth edge. The third edge comprises third coupling parts. The third coupling parts are substantially third male coupling parts comprising one or more locking element. The fourth edge comprises fourth coupling parts. The fourth coupling parts are substantially fourth female coupling parts comprising one or more locking elements.
The third coupling parts and the fourth coupling parts are configured for coupling the third edge of the panel to the fourth edge of another such panel, wherein locking of the so-coupled panels is obtained in the direction parallel with the surface of the so-coupled panels and perpendicular to the so-coupled edges, as well as a locking of the so-coupled panels perpendicular to the surface of the so-coupled panels and wherein the same surface of both so-coupled panels faces the room, which is the first configuration.
The third coupling parts and the fourth coupling parts are configured for coupling the third edge of the panel to the fourth edge of another such panel wherein a locking of the so-coupled panels is obtained in the direction parallel with the surface of the so-coupled panels and perpendicular to the so-coupled edges, as well as a locking of the so-coupled panels perpendicular to the surface of the so-coupled panels; and wherein one of the so-coupled panels has been turned over compared to the first configuration such that its other decorative surface faces the room compared to the first configuration.
It is a benefit of the panels of the second aspect of the invention that installation patterns can be made using only one type/on configuration of panels; installation panels that otherwise require two different types/two different configurations of panels.
Optionally, each of the upper surface and the lower surface of each of the first edge, the second edge, the third edge and the fourth edge comprise closing surfaces—with closing surfaces is meant that contact is created between coupled edges or that the space between the closing surfaces of coupled edges is less than 0.2 mm; such that in each of the mentioned coupled configurations decorative surfaces are obtained, optionally with one or more of level transitions between coupled panels or structured transitions, e.g. bevels.
An example of a functional surface is e.g. a surface provided with anti-slippage properties.
In a preferred embodiment of the second aspect of the invention, the first coupling parts and the second coupling parts are configured such that in coupled condition of the panel at its first edge with a second such panel at its second edge, a point of symmetry at the middle of the height of the panel is provided at the coupled edges of the panel with the second such panel, such that the first coupling parts at the first edge of the panel are symmetrical relative to the point of symmetry with the second coupling parts at the second edge of the second coupled panel. Panels according to such embodiments allow reversible coupling.
In a preferred embodiment of the second aspect of the invention, the first coupling parts and the second coupling parts are configured such that the panel can be coupled at its first edge with the second edge of another such panel, preferably by a downward movement perpendicular to the surface of the panels of the panel with respect to the another such panel, wherein a locking of the so-coupled panels is obtained in the direction parallel with the surface of the so-coupled panels and perpendicular to the so-coupled edges, as well as a locking of the so-coupled panels perpendicular to the surface of the so-coupled panels.
A preferred panel of the second aspect of the invention is a panel according to any suitable embodiment of the first aspect of the invention.
In a preferred embodiment of the second aspect of the invention, the first coupling parts comprise a first tongue. Preferably, the first tongue is provided out of material of the panel. The second coupling parts comprise a second groove. Preferably, the second groove is provided out of material of the panel. The first tongue and the second groove are provided with locking surfaces for establishing a locking in the plane of the panels and perpendicularly to the plane of the panels. The first coupling parts comprise a first groove. Preferably, the first groove is provided out of material of the panel. The second coupling parts comprise a second tongue. Preferably, the second tongue is provided out of material of the panel. The first groove of the panel is provided for engagement with the second tongue of the another such panel. The second tongue and the first groove are provided with second locking surfaces for establishing a locking in the plane of the panels and perpendicularly to the plane of the panels. The first coupling parts and the second coupling parts are configured such that the panel can be coupled at its first edge with the second edge of another such panel by an angling movement of the panel relative to the another such panel; and/or by means of a horizontal movement of the panel relative to the another such panel.
In a preferred panel according to the second aspect of the invention, the third coupling parts and the fourth coupling parts are configured such that the third edge of such panel can be coupled to the fourth edge of such panel by a movement parallel with the surface of the panels and perpendicularly to the second pair of opposite edge, thereby creating a coupling by means of snapping of the third male coupling part into the fourth female coupling part. Such embodiment will be further referred to as “snap” embodiment of the second aspect of the invention.
In a preferred “snap” embodiment of the second aspect of the invention, the fourth female part comprises a groove between a first lip and a second lip; and the distances over which the first lip and the second lip extend from the panel are the same.
In a preferred “snap” embodiment of the second aspect of the invention, the third coupling parts or the fourth coupling parts comprise at least one male locking element for establishing a locking in the direction in the plane parallel with the panel and perpendicular to the second pair of opposite edges.
In a preferred “snap” embodiment of the second aspect of the invention, the fourth coupling parts or the third coupling parts comprise two female locking elements. The two female locking elements are symmetrically positioned relative to the plane in the middle of the thickness of the panel and parallel with the panel. Each of the two female locking elements are provided for engagement with the at least one male locking element in a coupling configuration of the panel at its third edge with the fourth edge of another such panel. It is meant that if the third coupling parts comprise at least one male locking element, then the fourth coupling parts comprise two female locking elements for interaction with the at least one male locking element of the third coupling parts of a coupled panel. It is meant that if the fourth coupling parts comprise at least one male locking element, then the third coupling parts comprise two female locking elements for interaction with the at least one male locking element of the fourth coupling parts of a coupled panel.
A third aspect of the invention is a panel. Preferably, the panel is a floor panel for forming a floor covering, or a panel for forming a wall covering, or a panel for covering a ceiling. The panel comprises a decorative surface and/or functional surface (e.g. providing anti-slip properties) at the upper surface and at the lower surface. Preferably, the upper surface and the lower surface each comprises a wear layer provided on top of their respective decorative surface. The panel comprises a first pair of opposite edges. The first pair of opposite edges comprises a first edge and an opposite second edge. The panel comprises a second pair of opposite edges. The second pair of opposite edges comprises a third edge and an opposite fourth edge. The first pair of opposing edges are not perpendicular to the second pair of opposing edges. Preferably, the first pair of opposing edges have a shorter length than the second pair of opposing edges. The first edge comprises first coupling parts. The second edge comprises second coupling parts.
The first coupling parts and the second coupling parts are configured such that the panel can be coupled at its first edge to the second edge of another such panel, wherein a locking of the so-coupled panels is obtained in the direction parallel with the surface of the so-coupled panels and perpendicular to the so-coupled edges, as well as a locking of the so-coupled panels perpendicular to the surface of the so-coupled panels.
The first coupling parts are configured such that the panel can be coupled at its first edge to the first edge of another such panel, wherein the another such panel is turned upside down compared to when it is coupled with its second edge to the first edge of the panel, wherein a locking of the so-coupled panels is obtained in the direction parallel with the surface of the so-coupled panels and perpendicular to the so-coupled edges, as well as a locking of the so-coupled panels perpendicular to the surface of the so-coupled panels. The second coupling parts are configured such that the panel can be coupled at its second edge to the second edge of another such panel turned upside down compared to the panel, wherein a locking of the so-coupled panels is obtained in the direction parallel with the surface of the so-coupled panels and perpendicular to the so-coupled edges, as well as a locking of the so-coupled panels perpendicular to the surface of the so-coupled panels.
The second pair of opposite edges comprises a third edge and an opposite fourth edge. The third edge comprises third coupling parts. The third coupling parts are substantially third male coupling parts comprising one or more locking elements. The fourth edge comprises fourth coupling parts. The fourth coupling parts are substantially fourth female coupling parts comprising one or more locking element. The third coupling parts and the fourth coupling parts are configured for coupling the third edge of the panel to the fourth edge of another such panel wherein a locking of the so-coupled panels is obtained in the direction parallel with the surface of the so-coupled panels and perpendicular to the so-coupled edges, as well as a locking of the so-coupled panels perpendicular to the surface of the so-coupled panels. Optionally, each of the upper surface and the lower surface of each of the first edge, the second edge, the third edge and the fourth edge comprise closing surfaces—with closing surfaces is meant that contact is created between coupled edges or that the space between the closing surfaces of coupled edges is less than 0.2 mm; such that in each of the mentioned coupled configurations decorative surfaces are obtained, optionally with one or more of level transitions between coupled panels or structured transitions, e.g. bevels.
Preferably, the upper surface and the lower surface comprise the same decorative surface, e.g. a simulation of a wood panel surface. With the upper surface and the lower surface comprise the same decorative surface has to be understood that the décor of the upper surface and of the lower surface have the same color and visual and tactual aspect, however allowing structured or random differences such as are present in wood or stone simulating decorative surfaces.
It is a benefit of the invention that a Hungarian point panel configuration can be laid only using one type of panels. It is not necessary to have two different types of panels.
In panels according to the fourth aspect of the invention, advantageously, the coupling parts of the first pair of opposite edges can be configured as described for the first pair of opposite edges of the second aspect of the invention.
A preferred panel according to the first aspect and/or according to the second aspect of the invention or according to the third aspect of the invention comprises a substrate, the substrate can be a medium density fiberboard (MDF) or a high density fiberboard (HDF) or wood.
A preferred panel according to the first aspect and/or of the second aspect of the invention and/or third aspect of the invention comprises a substrate. The substrate of the panel comprises a core. The core comprises a thermoplastic polymer—preferably polyvinylchloride—comprising filling material, e.g. one or more of stone particles, chalk, wood fibers or natural fibers.
A preferred panel according to the first aspect and/or of the second aspect of the invention and/or of the third aspect of the invention comprises a substrate. The substrate can comprise different materials, according to a number of possibilities.
According to a first possibility, the substrate of the floor panel can be mineral based, e.g. based on cement, on lime cement, on magnesium cement or on gypsum. In case of lime cement or portland cement, the substrate preferably is a panel out of fiber cement, e.g. of the type that is obtained in the so-called Hatschek process, e.g. as described in GB6455 of 1900. In case of magnesium cement, the substrate is substantially provided as a so-called magnesium oxide panel, e.g. as described in KR10-1152155B1, e.g. by curing of a slurry of magnesium oxide (50-70 percent by weight) and magnesium chloride (15-35 percent by weight), optionally with filling material (0-15 percent by weight) such as wood particles. Preferably, such magnesium oxide panel comprises at one or at both surfaces a glass fiber layer, preferably a woven glass fiber layer. In case of gypsum, the substrate substantially is a fiber gypsum panel, wherein the fibers can be cellulose fibers and/or glass fibers. Such fiber gypsum panel is preferably obtained by the hydraulic curing of gypsum slurry comprising fibers. Such fiber gypsum panel can be provided on one or on both of its surfaces with a reinforcement layer, such as paperboard and/or a glass fiber layer, preferably a non-woven glass fiber layer.
According to the second possibility, the substrate of the floor panels is substantially a synthetic composite material. The synthetic composite material comprises a polymer matrix—e.g. a thermoplastic matrix or a polyurethane matrix; and filling material. Preferably, the density of the filling material is higher than the density of the material of the polymer matrix. Filling materials having a higher density than the material of the polymer matrix positively affect the dimensional stability of the floor panel. Examples of filling materials that can be used are lime, limestone and talcum. Other mineral filling materials or organic filling materials, such as wood particles, straw or bamboo particles are not excluded
Preferably, the amount of filling material in the synthetic composite material is at least 40 percent by weight, preferably at least 50 percent by weight, more preferably 65 percent by weight, even more preferably more than 80 percent by weight. Particularly preferred is the use of mineral filling materials—such as lime, limestone or talc—between 65 and 87 percent by weight of the synthetic composite material.
In a particularly preferred embodiment of the second possibility, the polymer matrix comprises or consists of polyvinyl chloride. Preferably the polyvinyl chloride is free from plasticizers or comprises plasticizers in an amount less than 20 phr; more preferably in an amount between 5 and 15 phr; and even more preferably in an amount less than 5 phr. Such polymer matrix can, in the way as already mentioned, be filled with mineral filling material. Preferably, the amount of filling material in the synthetic composite material is at least 40 percent by weight, preferably at least 50 percent by weight, more preferably 65 percent by weight, even more preferably more than 80 percent by weight. Particularly preferred is the use of mineral filling materials—such as lime, limestone or talc—between 65 and 87 percent by weight of the synthetic composite material. More durable panels are obtained this way.
According to a second example of the second possibility, the polymer matrix comprises or consists of polypropylene, or polyethylene, or polyethylene terephthalate. Optionally, the polymer matrix material comprises an elastomer. As an example, the substrate material described in WO2017/122149 can be used. Such polymer matrix can, in the way as already mentioned, be filled with mineral filling material. Preferably, the amount of filling material in the synthetic composite material is at least 40 percent by weight, preferably at least 50 percent by weight, more preferably 65 percent by weight, even more preferably more than 80 percent by weight. Particularly preferred is the use of mineral filling materials—such as lime, limestone or talc—between 65 and 87 percent by weight of the synthetic composite material.
The material of the substrate can have a uniform composition over its thickness, without differences worth mentioning in composition or density over the thickness of the substrate. Preferably in such embodiments, the material of the substrate is free of inclusions of air, as is the case is unfoamed thermoplastic matrix material.
According to an alternative embodiment, the substrate can comprise layers having different composition. As an example, an internal layer can be foamed, e.g. comprising a closed-cell polyvinyl chloride foam, while one or both bordering layers are unfoamed, or less foamed. As well as in substrates having a uniform composition over its thickness as in substrates comprising two or more than two layers, one or more reinforcement layers can be integrated in or on the substrate. Such reinforcement layers can e.g. comprise or be glass fiber layers, e.g. woven glass fiber layers or non-woven glass fiber layers.
The fourth aspect of the invention is a Hungarian point pattern configuration of panels—e.g. a floor or a wall or a ceiling covering. Panels are used according to the fourth aspect of the invention. A first such panel is coupled along its third edge with the fourth edge of a second such panel. The first such panel and the second such panel are positioned with their same surface facing the room. The first such panel is coupled along its first edge with the first edge of a third such panel. The third such panel is positioned with the other surface facing the room than the first such panel. The first such panel is coupled along its second edge with the second edge of a fourth such panel. The fourth such panel is positioned with the other surface facing the room than the first such panel.
With the intention of better illustrating some features and aspects of the present invention, here below, as examples without any limitative character, some preferred embodiments are described with reference to the attached drawings, wherein:
The upper surface of the upper lip forms part of the upper surface of the panel. The lower surface of the lower lip forms part of the lower surface of the panel.
The first insert (11) and the second insert (15) are strips. In the example shown, the first insert is attached in the upper lip by means of an adhesive; and the second insert is attached in the lower lip by means of an adhesive.
The first insert (11) and the second insert (15) of the example have along their longitudinal direction a constant cross section. The first insert (11) and the second insert (15) are identical extruded strips of thermoplastic material, e.g. polyvinyl chloride. It is understood that the orientation of second insert is turned over 180° around its centerline compared to orientation of the first insert.
The cross section perpendicular to the first edge of the first male part and the cross section perpendicular to the second edge of the second male part comprises a mushroom shape (20). The mushroom shape comprises a stem (21) and a mushroom head (22). The bottom of the mushroom head comprises a concave section (23). The female part of the inserts provided for coupling with the mushroom head is configured to contact or engage with in coupled condition of two such panels at their first pair of opposite edges at least part of the concave section of the mushroom head, thereby locking the two panels to each other.
The cross section perpendicular to the first edge of the first female part (13) and the cross section perpendicular to the second edge of the second female part (17) comprises two legs (26) between which a male part of a corresponding edge of a second such panel can be locked. Both legs (26) comprise an inclined extension (27) configured to act as locking parts for locking the female part comprising the legs to a male part of the insert of another such panel. At least part (28) of the surface of the inclined extension (27) is configured such that it can contact with at least part of the concave section (23) of a coupled such panel. The contact creates a locking of the female part to the male part of the coupled such panel. During the coupling, both female parts and both male parts undergo an elastic deformation in order.
The first male section (12) and the first female section (13) are provided as separate profiles in the first insert (11). The second male section (16) and the second female section (17) are provided as separate profiles in the second insert (15).
The upper lip (6) comprises a first recess (30)—consisting of a groove parallel with the first edge of the panel—into which the first insert is provided. The lower lip (7) comprises a second recess (31)—consisting of a groove parallel with the second edge of the panel—into which the second insert is provided.
The first edge (2) comprises a first upper lip section (32) more proximal to the panel than the first insert. The second edge (3) comprises a second lower lip section (33) more distal to the panel than the second insert. The first upper lip section and the second lower lip section are made in one piece. The lower side of the first upper lip section and the upper side of the second lower lip section are over part of their surface substantially parallel with the panel. As is illustrated in
The first edge (2) comprises a second upper lip section (34) more distal to the panel than first insert. The second edge (3) comprises a first lower lip section (35) more proximal to the panel than the second insert. The lower side of the second upper lip section (34) and the upper side of the first lower lip section (35) are over part of their surface substantially parallel with the panel. The second upper lip section and the first lower lip section are made in one piece. As is illustrated in
The distal end of the upper lip (6) comprises a surface (38) perpendicular to the surface of the panel. The distal end of the lower lip (7) comprises a surface (39) perpendicular to the surface of the panel.
The coupling parts of the second edge (3) of the panel shown in
The first coupling parts (4) and the second coupling parts (5) of the panel (1) shown in
The panel (1) of
As an alternative insert for the insert shown in
Other inserts can be used in embodiments of the first aspect of the invention. Examples of such inserts are shown in
The second pair of opposite edges (42, 43) of the panel illustrated in
The combination of
The second coupling parts (5) are configured such that the panel can be coupled at its second edge (3) to the second edge (3) of another such panel turned upside down compared to the panel, wherein a locking of the so-coupled panels is obtained in the direction parallel with the surface of the so-coupled panels and perpendicular to the so-coupled edges, as well as a locking of the so-coupled panels perpendicular to the surface of the so-coupled panels.
The panel comprises a second pair of opposite edges (42, 43). The second pair of opposite edges comprises a third edge (42) and an opposite fourth edge (43). The third edge (42) comprises third coupling parts (44). The third coupling parts are substantially third male coupling parts (45) comprising two male locking elements (47). The fourth edge (43) comprises fourth coupling parts (46). The fourth coupling parts (46) are substantially fourth female coupling parts comprising two female locking elements (48). The third coupling parts (44) and the fourth coupling parts (45) are configured for coupling the third edge of the panel to the fourth edge of another such panel wherein a locking of the so-coupled panels is obtained in the direction parallel with the surface of the so-coupled panels and perpendicular to the so-coupled edges, as well as a locking of the so-coupled panels perpendicular to the surface of the so-coupled panels and wherein the same surface of both so-coupled panels faces the room, which is the first configuration.
The third coupling parts (44) and the fourth coupling parts (45) are configured for coupling the third edge (42) of the panel to the fourth edge (43) of another such panel wherein a locking of the so-coupled panels is obtained in the direction parallel with the surface of the so-coupled panels and perpendicular to the so-coupled edges, as well as a locking of the so-coupled panels perpendicular to the surface of the so-coupled panels; and wherein one of the so-coupled panels has been turned over compared to the first configuration such that its other decorative surface faces the room compared to the first configuration.
Each of the upper surface and the lower surface of each of the first edge, the second edge, the third edge and the fourth edge comprise closing surfaces (74, 75, 76, 77)—with closing surfaces is meant that contact is created between coupled edges or that the space between the closing surfaces of coupled edges is less than 0.2 mm; such that in each of the mentioned coupled configurations decorative surfaces are obtained.
As is illustrated in
The third coupling parts (44) comprise two male locking elements (47) for establishing a locking in the direction in the plane parallel with the panel and perpendicular to the second pair of opposite edges (42, 43). The two male locking elements (47) are symmetrically positioned relative to the plane (65) in the middle of the thickness of the panel and parallel with the panel. The fourth coupling parts (46) comprise two female locking elements (48). The two female locking elements (48) are symmetrically positioned relative to the plane (65) in the middle of the thickness of the panel and parallel with the panel. The two female locking elements (48) are provided for engagement with the two male locking element (47) in a coupling configuration of the panel at its third edge (42) with the fourth edge (43) of another such panel.
The panel (1) comprises a decorative surface at its upper surface (71) and at its lower surface (72). The panel comprises a first pair of opposite edges (2, 3). The first pair of opposite edges comprises a first edge (2) and an opposite second edge (3). The first edge comprises first coupling parts (4). The second edge comprises second coupling parts (5). The first coupling parts (4) and the second coupling parts (5) are configured such that the panel can be coupled at its first edge with the second edge of another such panel, wherein a locking of the so-coupled panels is obtained in the direction parallel with the surface of the so-coupled panels and perpendicular to the so-coupled edges, as well as a locking of the so-coupled panels perpendicular to the surface of the so-coupled panels. The first coupling parts (4) are configured such that the panel can be coupled at its first edge (2) to the first edge (2) of another such panel, wherein the another such panel is turned upside down compared to when it is coupled with its second edge to the first edge of the panel, wherein a locking of the so-coupled panels is obtained in the direction parallel with the surface of the so-coupled panels and perpendicular to the so-coupled edges, as well as a locking of the so-coupled panels perpendicular to the surface of the so-coupled panels. The second coupling parts (5) are configured such that the panel can be coupled at its second edge (3) to the second edge (3) of another such panel turned upside down compared to the panel, wherein a locking of the so-coupled panels is obtained in the direction parallel with the surface of the so-coupled panels and perpendicular to the so-coupled edges, as well as a locking of the so-coupled panels perpendicular to the surface of the so-coupled panels.
Each of the upper surface and the lower surface of each of the first edge, the second edge, the third edge and the fourth edge comprise closing surfaces (74, 75, 76, 77).
The coupling parts of the first edge (2) and the coupling parts of the second edge (3) are configured such that in coupled condition of the panel at its first edge with a second such panel at its second edge, a point of symmetry (40)—see
The first coupling parts (4) comprise a first tongue (50), provided out of material of the panel. The second coupling parts (5) comprise a second groove (51), out of material of the panel. The first tongue (50) and the second groove (51) are provided with locking surfaces (80) for establishing a locking in the plane of the panels and perpendicularly to the plane of the panels. The first coupling (4) parts comprise a first groove (52), provided out of material of the panel. The second coupling parts (5) comprise a second tongue (53), out of material of the panel. The first groove (52) of the panel is provided for engagement with the second tongue (53) of the another such panel. The second tongue (53) and the first groove (52) are provided with second locking surfaces (80) for establishing a locking in the plane of the panels and perpendicularly to the plane of the panels.
The first coupling parts and the second coupling parts are configured such that the panel can be coupled at its first edge with the second edge of another such panel by an angling movement (T) of the panel relative to the another such panel; and/or by means of a horizontal movement (S) of the one panel towards the another such panel.
The panels comprise a decorative at the upper surface (A) and at the lower surface (B). The panel comprises a first pair of opposite edges (2, 3). The first pair of opposite edges comprises a first edge (2) and an opposite second edge (3). The panels comprise a second pair of opposite edges, wherein the second pair of opposite edges comprises a third edge (91) and an opposite fourth edge (92). The first pair of opposing edges are not perpendicular to the second pair of opposing edges.
A first such panel (81) is coupled along its third edge (91) with the fourth edge (92) of a second such panel (82). The first such panel (81) and the second such panel (82) are positioned with their same surface (A) facing the room. The first such panel (81) is coupled along its first edge (2) with the first edge (2) of a third such panel (83). The third such panel (83) is positioned with the other surface (B) facing the room than the first such panel (81). The first such panel (81) is coupled along its second edge (3) with the second edge (3) of a fourth such panel (84). The fourth such panel (84) is positioned with the other surface (B) facing the room than the first such panel (81).
The first pair of opposite edges of the floor panels used in the Hungarian point floor covering configuration can be configured as the first pair of opposite edges as shown in
Filing Document | Filing Date | Country | Kind |
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PCT/IB2021/050126 | 1/8/2021 | WO |
Number | Date | Country | |
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62964356 | Jan 2020 | US |