SET OF PARTS FOR INSTALLING A FLOOR COVERING

Abstract

A set of parts for installing a floor covering includes a plurality of floor panels and a plurality of profiles. The floor panels are provided for being installed over an underlying surface. In an installed condition, the bottom major surface of each of the floor panels is elevated from the underlying surface by means of the corresponding profile. The floor panels at least at their top major surface include a decor formed by a print, a wood veneer or a stone veneer.

Description

The subject matter disclosed herein relates generally to a set of parts for installing a floor covering and to floor coverings installed using such set. The invention relates in particular to exterior flooring that can be installed over existing exterior underlying surfaces, such as surfaces of an outdoor deck.

Easy to assemble, or “do it yourself” (DIY) floor panels have increased in popularity for use as replacements for interior parquet floors, linoleum sheet floors, and wall-to-wall carpets. Such floor panels offer consumers durable and aesthetically pleasing products at affordable price points. In conventional systems, opposing first and second edges of a floor panel are provided with a groove and a tongue, respectively, such that adjacent floor panels can directly engage and lock together. For example, a tongue of a first floor panel can engage and lock directly with a groove of a second floor panel. All four edges of a conventional floor panel can lock directly with one or more adjacent panels forming joints directly therebetween.

Conventional floor panels, systems, and methods have several disadvantages rendering them unsuitable for outdoor use and are therefore, unsuitable for use in exterior floor covering applications. For example, one disadvantage of conventional floor panels, systems, and methods is that there is no effective manner in which the panels can be secured for outdoor use. A first type of conventional floor panels for interior use, is known e.g. from WO96/27721. These floor panels can be pulled together tight on all four sides forming substantially gap-free joints therebetween without the need of glue. A second type of conventional floor panels is installed using the conventional method of gluing panels together. A floor covering installing using such method may not be resistant to adverse weather, may be insufficient to secure the panels to exterior surfaces on windy days or during cleaning, and/or may be ineffective when exposed to the elements during outdoor use. When used in an outdoor environment, water will pool on the surface of conventional floor panels which can create an undesirable and potentially dangerously slippery surface. Large quantities of moisture and/or liquids resulting from weather or outdoor environmental conditions could also accumulate on surfaces of floor panels and cause adverse effects such as swelling and/or buckling of the floor panels. Accordingly, a need remains for floor coverings adapted for exterior or outdoor use.

The present invention in the first place aims at an alternative floor covering that is adapted for exterior use. According to preferred embodiments solutions are offered to the problems with the floor coverings of the prior art. In particular certain embodiments provide a less slippery surface, and/or a less tendency to pool water on the surface.

The first aspect of the invention is a set of parts for installing a floor covering, preferably for installing an exterior flooring. The set of parts comprises a plurality of floor panels and a plurality of profiles. Preferably the profiles are thin-walled profiles. The floor panels are provided for being installed over an underlying surface. In installed condition the bottom major surface of each of the floor panels is elevated from the underlying surface by means of the corresponding profile. The floor panels at least at their top major surface comprise a decor formed by a print, a wood veneer or a stone veneer.

It is a benefit of the set of parts according to the invention that a decorative floor covering can be installed, even outside.

A preferred set of parts is characterized in that the profiles are extruded profiles or are profiles obtained through roll forming a metal sheet. Such profiles are well suited for exterior use.

A preferred set of parts is characterized in that in installed condition the profile touches the bottom major surface of its corresponding floor panel over less than 90%, less than 80% or less than 70% of the bottom major surface area, or even more preferred over less than 60% of the bottom major surface area. It is a benefit of such embodiments that minimum material can be used in the production of the profiles and that room can be available for the evacuation of water, e.g. of rain water.

A preferred set of parts is characterized in that the profiles are configured such that in installed condition the profiles allow for air to freely circulate along at least 10%, more preferably at least 20%, more preferably at least 30%, or even more preferably at least 40% of the area of the bottom major surface of the corresponding floor panel. Such embodiments have the benefit the floor panels can be aerated from their bottom, which can increase the speed of drying of the floor covering.

A preferred set of parts is characterized in that the profiles are configured such that in installed condition the profiles extend in the vertical direction over a distance that is equal to the thickness of the floor panels or larger, e.g. over a distance that is at least 1.5 times or at least twice the thickness of the floor panels. Such embodiments are preferred, as extra room is provided for air to freely circulate below the floor panels.

A preferred set of parts is characterized in that the floor panels are rectangular with a first and a second longitudinal edge opposite to one another, and that the profiles are configured such that in installed condition the profiles extend at least beyond a first longitudinal edge of their corresponding floor panel in the width direction of the floor panel. It is a benefit that installation of a floor covering is facilitated, also installation of a floor covering outside.

Preferably, the profiles are configured such that in installed condition the profiles do not extend beyond the second longitudinal edge, or extend beyond the second longitudinal edge of its corresponding floor panel to a lesser extent than it does beyond the first longitudinal edge. Installation of the floor covering is facilitated in such embodiments.

The profiles can preferably be configured such that in installed condition the profiles can be connected to the underlying surface at least at a first portion thereof that extends beyond the first longitudinal edge of the corresponding floor panel. Installation of the floor covering is facilitated, as consecutive installation of floor panel and profile are possible.

The profiles can preferably comprise a second portion configured for being engaged during installation with a first longitudinal edge of a first floor panel and/or with a second longitudinal edge of a second floor panel. Installation of the floor covering if facilitated this way.

More preferably, the second portion is positioned on the part of the profile that in installed condition extends beyond the first longitudinal edge of the corresponding floor panel. This way, installation is even more facilitated.

Preferably, engaging the second portion during installation with a first longitudinal edge of a first floor panel and/or with a second longitudinal edge of a second floor panel comprises the positioning of the second portion at least in part in a groove provided in the respective longitudinal edge of the corresponding floor panel. This way, installation of the floor covering is even more facilitated.

A preferred set of parts is characterized in that the floor panels at the top major surface comprise a polyurethane or acrylic coating applied on top of the decor. Such coatings provide weather resistance to the floor panels; making the floor covering suited for outside use.

Preferably, the coating is thermally cured, UV cured, excimer cured and/or Electron Beam cured. Such curing delivers excellent quality of curing and therefore excellent resistance of the coating.

A preferred set of parts is characterized in that the floor panels at the top major surface have a slip resistance of at least R10, or more preferably at least R11, as measured and defined by DIN 51130: 2004. Such embodiments are preferred, as the set of parts is better suited for outdoors floor coverings, and even for floor coverings around pools, whether inside or outdoor pools.

A preferred set of parts is characterized in that the floor panels at the top major surface have a texture. A surface texture provides slip resistance. The texture also provides a more realistic imitation of natural materials, e.g. of wood panel or of marble.

The texture can have a pattern, preferably in register with the decor. It is a benefit that a more realistic imitation of natural materials, e.g. of wood panels or of marble can be provided.

In a preferred embodiment, the texture has a uniform appearance over substantially the entire top major surface. Such embodiments are preferred, as the uniform texture provides uniform anti-slip protection over the full surface of the floor covering.

The texture can at least be formed by means of embossments provided in the top major surface. This is an efficient way of creating the texture.

In a preferred embodiment, the texture is at least formed by means of an additive available in a coating applied on top of the decor. Such embodiments provide improved anti-slip properties to the floor covering, which is especially important for outside use, as the floor covering can be wet.

The print preferably is a digital print. Digital printing offers a broader range of possibilities and is more flexible.

The print can comprises organic or inorganic pigments.

Preferably, the top major surface of the floor panels is domed. Such set is better suited for outdoor use, as dewatering of the installed floor covering is facilitated.

A preferred set of parts is characterized in that the floor panels are rectangular and that the top major surface in the width direction is domed more than 0.2%, more preferably more than 0.5%, as measured in accordance with EN 13329 Annex A.4.7. Such set is better suited for outdoor use, as dewatering of the installed floor covering is facilitated.

A preferred set of parts is characterized in that the floor panels are rectangular and that the top major surface in the length direction is domed more than 1%, preferably more than 2%, as measured in accordance with EN 13329 Annex A.4.8. Such set is better suited for outdoor use, as dewatering of the installed floor covering is facilitated.

Preferred floor panels for use in the invention are rectangular and have a thickness that is 3% of the width or more. Such embodiments provide sufficient rigidity to the floor panels for ease of installation.

Preferred floor panels for use in the invention are rectangular and have a width, or a dimension in the width direction, of at least 100 mm, and more preferably less than 350 mm.

A preferred set of parts is characterized in that the floor panels include a plurality of layers of thermosetting resin impregnated paper sheets bonded together. Preferably, the thermosetting resin is a phenol formaldehyde resin. Thanks to the presence of the thermosetting resin, good water resistance of the floor panels is obtained.

The floor panels preferably at their top major surface comprise a decor paper layer, i.e. a paper layer provided with the print, wherein the decor paper layer is provided with thermosetting resin.

More preferably, the floor panels at their top major surface also comprise a transparent paper layer impregnated with thermosetting resin. The durability of the floor coverings of such embodiments is improved.

The thermosetting resin is preferably, for each layer independently, selected from the list consisting of phenol formaldehyde, urea formaldehyde, melamine formaldehyde, polyurethane−more preferably applied as a polyurethane dispersion—or acrylate. Such embodiments provide good bonding of the layers, resulting in improved durability of the floor covering installed with the set of parts.

The floor panels preferably comprise a core formed from at least a plurality of resin impregnated paper sheets, more preferably impregnated with phenol formaldehyde or melamine formaldehyde, and a top major surface comprising a decor paper layer and a transparent paper layer applied on top of the decor paper layer. The transparent paper layer and the decor paper layer are both impregnated with melamine formaldehyde or with a polyurethane—more preferably applied as a polyurethane dispersion—or with acrylate or with mixtures thereof.

Such floor panels are very well suited for outdoor use, thanks to the good resistance to humidity and water.

A preferred set of parts is characterized in that the floor panels at the top major surface comprise a film onto which the décor is printed. More preferably, the film is a thermoplastic film, e.g. out of polypropylene, polyethylene, polyvinyl chloride or polyester.

Such embodiments result in installed floor coverings that are well suited for outdoor use, as such floor panels have a top major surface that is very well resistant to outdoor conditions.

More preferably, the floor panels at the top major surface further comprise a transparent film. Such embodiments provide improved durability of the floor covering installed with such set of panels. The transparent film is more preferably a thermoplastic film, e.g. out of polypropylene, polyethylene, polyvinyl chloride or polyester.

Preferably, the floor panels at the top major surface further comprise one or a plurality of lacquer layers. It is a benefit of such embodiments that the durability of the floor covering is improved.

The one or the plurality of lacquer layers are preferably selected from acrylate or polyurethane; more preferably the one or the plurality of lacquer layers is a UV-resistant acrylate lacquer. It is a benefit of such embodiments that the durability of the floor covering is improved.

A preferred set of parts is characterized in that the floor panels comprise a core formed from at least a plurality of resin impregnated paper sheets, preferably impregnated with phenol formaldehyde or melamine formaldehyde, and a top major surface comprising a decor paper layer and a transparent paper layer applied on top of the decor paper layer, wherein the transparent paper layer and the decor paper layer are both impregnated with melamine formaldehyde or with a polyurethane—preferably applied as a polyurethane dispersion—or with acrylate or with mixtures thereof. Such embodiments provide floor coverings that are very durable, even in very wet environments such as in outdoor use.

A preferred set of parts is characterized in that the floor panels comprise a compact laminate material. It is a benefit of such embodiments that a floor covering is made that is very durable in outside use.

A preferred set of parts is characterized in that the floor panels comprise a core and an applied thereon top layer comprising the decor. The core can be made in large volumes. Mass customization can be done by selecting the decors applied onto the core, in order to obtain floor coverings e.g. simulating a natural material such as wood or marble which are very durable in outdoor use.

The core is preferably a mineral-based core, such as a core comprising magnesiumoxysulphate and/or magnesiumoxychloride and/or Portland cement, or a core comprising glued together wood fibers and/or mineral wool fibers (such as e.g. rockwool fibers), or a core comprising a thermoplastic polymer, such as polyvinylchloride, polyethylene terephthalate, polypropylene or polyethylene, or a core comprising a thermosetting polymer, such as unsaturated polyester crosslinked with styrene.

The top layer can be glued onto the core.

Alternatively, the top layer can be adhered to the core in the absence of separate glue layers.

Floor panels for use in the invention preferably have a thickness of 4 to 8 mm. Such floor panels have sufficient rigidity and are still light, both features facilitate installation of the floor covering.

A preferred set of parts is characterized in that the floor panels at one or more edges are provided with lowered edge areas. Such embodiments provide floor coverings with easier evacuation of water, e.g. of rain water in outside floor coverings or of pool water for floor coverings around indoor or outdoor pools.

The decor more preferably continuously extends from the global major surface into the lowered edge area, more preferably at least up to the associated edge. Such embodiments provide a more realistic imitation of a natural material such as wood or marble, while water is easily evacuated from the floor covering.

The decor can even extend beyond the associated edge.

A preferred set of parts is characterized in that a nonwoven fiber mesh or an elastic pad contacts the bottom major surface of the floor panel. A nonwoven fiber mesh or an elastic pad has a certain elasticity. It means that they can be compressed during installation of the floor coverings. It facilitates installation and allows to compensate for production tolerances. It is a further benefit that the nonwoven fiber mesh or elastic pad avoids movement of the floor panels when walked upon.

A preferred set of parts is characterized in that a nonwoven fiber mesh or an elastic pad provides the bottom major surface of the floor panel. A nonwoven fiber mesh or an elastic pad has a certain elasticity. It means that they can be compressed during installation of the floor coverings. It facilitates installation and allows to compensate for production tolerances. It is a further benefit that the nonwoven fiber mesh or elastic pad avoids movement of the floor panels when walked upon.

The nonwoven fiber mesh or the elastic pad can preferably be bonded thermally or bonded by means of an adhesive into the floor panel.

A preferred set of parts comprises one or plurality of nonwoven fiber meshes or elastic pads, for being installed contacting the bottom of the floor panels in the floor covering. A nonwoven fiber mesh or an elastic pad has a certain elasticity. The nonwoven fiber mesh or elastic pad can be put at the bottom of the floor panels during installation. The nonwoven fiber mesh of the elastic pad can be compressed during installation of the floor coverings. It facilitates installation and allows to compensate for production tolerances.

The second aspect of the invention is a floor covering, characterized in that the floor covering is realized using a set of parts as in any embodiment of the set of parts of the first aspect of the invention.

The third aspect of the invention is a floor covering, optionally a floor covering as in the second aspect of the invention. The floor covering of the third aspect of the invention comprises a plurality of floor panels arranged over an underlying surface, wherein the bottom major surface of the floor panels is elevated from the underlying surface, wherein the floor panels at least at their top major surface comprise a decor formed by a print, a wood veneer or a stone veneer.

Such floor covering can be easily installed, even for outdoor use.

The floor covering of the third aspect of the invention can comprise floor panels and/or profiles as described in any embodiment of the first aspect of the invention. Such embodiments do not only provide a floor covering with excellent durability, e.g. for outdoor use; but can be installed easily.

A preferred floor covering is characterized in that the underlying surface comprises one or more inclined portions, e.g. to allow for dewatering.

A preferred floor covering is characterized in that the bottom major surface of the floor panels is elevated from the underlying surface by means of a profile. Such floor coverings can be installed easily; and is well suited for outdoor use.

The profile can be configured as the profile in any embodiment of the set of parts of the first aspect of the invention.

In a preferred floor covering, the profile extends in the vertical direction over a distance that is equal to the thickness of the floor panels or larger, e.g. at least 1.5 times or at least twice the thickness of the floor panels. Such embodiments are preferred, as extra room is provided for air to freely circulate below the floor panels.

A preferred floor covering is characterized in that the profile contacts the bottom major surface over less than 90%, less than 80% or less than 70% of the bottom major surface area, or even more preferred over less than 60% of the bottom major surface area. It is a benefit of such embodiments that minimum material can be used in the production of the profiles and that room can be available for the evacuation of water, e.g. of rain water.

A preferred floor covering is characterized in that the profile allows for air to freely circulate along at least 10%, at least 20%, at least 30%, or even more preferred at least 40% of the area of the bottom major surface. Such embodiments are favorable as the floor panels can be aerated from their bottom, which can increase the speed of drying of the floor covering.

A preferred floor covering is characterized in that the floor panels are rectangular with a first and a second longitudinal edge opposite to one another, and that the profile extends at least beyond a first longitudinal edge of the floor panel in the width direction of the floor panel. It is a benefit that installation of the floor covering is facilitated, also installation of the floor covering outside.

More preferably, the profile does not extend beyond the second longitudinal edge, or extends beyond the second longitudinal edge to a lesser extent than it does beyond the first longitudinal edge. Installation of the floor covering is facilitated in such embodiments.

The profile can be connected to the underlying surface at least at a first portion thereof that extends beyond the first longitudinal edge. Such embodiments facilitate the installation of the floor covering. A gradual installation of floor panels and profiles is made possible.

The profile preferably comprises a second portion engaging with a first longitudinal edge of a first floor panel and/or with a second longitudinal edge of a second floor panel. Such embodiments facilitate the installation of the floor covering even more.

The second portion is preferably positioned on the part of the profile that extends beyond the first longitudinal edge. Such profiles contribute to the ease of installation of the floor covering.

Preferably engaging the second portion with the first longitudinal edge comprises the positioning of said second portion at least in part in a groove provided in the respective longitudinal edge. This way, installation of the floor covering is even more facilitated.

A preferred floor covering is characterized in that a nonwoven fiber mesh or an elastic pad contacts the bottom major surface of the floor panel. A nonwoven fiber mesh or an elastic pad has a certain elasticity. It means that they can be compressed during installation of the floor coverings. It facilitates installation and allows to compensate for production tolerances. It is a further benefit that the nonwoven fiber mesh or elastic pad avoids movement of the floor panels when walked upon.

The nonwoven fiber mesh or the elastic pad can be firmly attached to the floor panel. The nonwoven fiber mesh or the elastic pad can be bonded thermally or bonded by means of an adhesive into the floor panel.

Alternatively, the nonwoven fiber mesh or the elastic pad is not attached to the floor panel.

A preferred floor covering is characterized in that a nonwoven fiber mesh or an elastic pad provides the bottom major surface of the floor panel. A nonwoven fiber mesh or an elastic pad has a certain elasticity. It means that they can be compressed during installation of the floor coverings. It facilitates installation and allows to compensate for production tolerances. It is an additional benefit that the nonwoven fiber mesh or elastic pad avoids movement of the floor panels when walked upon.

A preferred floor covering according to the second or third aspect of the invention is an outdoor decking.

With the intention of better showing the characteristics according to the invention, in the following, as an example without limitative character, several embodiments are described, with reference to the accompanying drawings, wherein

FIG. 1 shows a schematic perspective view of a floor covering according to the invention installed as an outdoor decking;

FIG. 2 at a larger scale shows a cross-section in accordance with line II-II indicated on FIG. 1;

FIG. 3 at a larger scale shows a view on the area indicated with F3 in FIG. 2;

FIG. 4 in a similar view illustrates a variant; and

FIG. 5 shows in a similar view as FIG. 2 an alternative embodiment of the invention.

FIG. 1 shows a schematic perspective view of a floor covering according to the invention installed as an outdoor decking. FIG. 2 at a larger scale shows a cross-section in accordance with line II-II indicated on FIG. 1. FIG. 3 at a larger scale shows a view on the area indicated with F3 in FIG. 2. The floor covering is installed using a set of parts according to the invention.

The floor covering of FIGS. 1, 2 and 3 comprises a plurality of rectangular floor panels 1 arranged over an underlying surface 2. The floor panels 1 have thickness T (e.g. between 4 and 8 mm) and width W. The floor panels 1 comprise at least at their top major surface 4 a decor 5. In the example shown, the décor 5 is formed by a print. However, alternative ways to form a décor are possible, such as e.g. a wood veneer or a stone veneer.

The top major surface 4 can be provided with a texture. The texture can have a pattern, e.g. in register with the décor 5. The texture can be formed by embossments provided in the top major surface of the panels 1.

The bottom major surface 3 of the floor panels 1 is elevated from the underlying surface 2 by means of a profile 6. The profile 6 can be a thin-walled profile. The profile can be an extruded profile or a profile obtained through roll forming of a metal sheet. Each floor panel 1 has a corresponding profile 6.

The profile 6 extends in the vertical direction V over a distance d that is equal to the thickness T of the floor panels 1 or larger, e.g. at least 1.5 times or at least twice the thickness T of the floor panels 1.

In the example shown, the profile 6 contacts the bottom major surface 3 over less than 60% of the bottom major surface area of the floor panel 1.

In the example shown, the profile 6 is configured such that it allows for air to freely circulate along at least 40% of the area of the bottom major surface 3 of the floor panel 1.

The floor panels 1 are rectangular with a first and a second longitudinal edge 7, 8 opposite to one another. The profile 6 extends at least beyond a first longitudinal edge 7 of the floor panel 1 in the width direction W of the floor panel.

In the example shown, the profile 6 does not extend beyond the second longitudinal edge 8 of the corresponding floor panel. It is also possible in alternative embodiments (not shown in the figures) that the profile extends beyond the second longitudinal edge to a lesser extent than it does beyond the first longitudinal edge.

The profile 6 is connected to the underlying surface 2 at least at a first portion 9 of the profile which extends beyond the first longitudinal edge 7 of the corresponding floor panel 1.

The profile 6 comprises a second portion 10 engaging with a first longitudinal edge 7 of a first floor panel 1 and with a second longitudinal edge 8 of a second floor panel. The engaging comprises the positioning of the second portion 10 at least in part in a groove 12 provided in the respective longitudinal edge 7. In the example shown, the second portion 10 is positioned on the part 11 of the profile 6 which extends beyond the first longitudinal edge 7 of the corresponding panel.

The floor panels 1 of FIG. 2 comprise a compact laminate material 17. The floor panels 1 comprise a core 16 and a top layer 18 applied on the core 16. The top layer 18 comprises the decor 5. Other compositions of the floor panels are possible.

The composition of the floor panels 1 of the example of FIG. 2 is further illustrated in FIG. 3. The reference numerals in FIG. 3 have the same meaning as in FIGS. 1 and 2. The floor panel 1 comprises a compact laminate material 17. The floor panels 1 comprise a core 16 and a top layer 18 applied on the core 16. The top layer 18 comprises the decor 5. The core 16 is provided by a plurality of layers of thermosetting resin impregnated paper sheets 13 bonded together. The thermosetting resin can e.g. be a phenol formaldehyde resin.

The floor panels 1 comprise at the top major surface 4 a decor paper layer 14, i.e. a paper layer provided with the print. The decor paper layer 14 is provided with thermosetting resin, e.g. with a melamine formaldehyde resin. The floor panels 1 also comprise at the top major surface 4 a transparent paper layer 15 impregnated with thermosetting resin, e.g. with phenol formaldehyde, urea formaldehyde, melamine formaldehyde, polyurethane or acrylate.

In the example of FIG. 3, the thermosetting resin of the different layers of the floor panels can provide for the bonding between the layers, without the need for an additional adhesive.

The floor panels of the example are at the first longitudinal edge 7 as well as at the second longitudinal edge 8 provided with lowered edge areas 19. The decor 5 continuously extends from the global major surface into the lowered edge area 19. The décor 5 can extend at least up to the associated edge 20; or the décor 5 can even extend beyond the associated edge 20.

FIG. 4 in a similar view as FIG. 3 illustrates a variant. The reference numerals in FIG. 4 have the same meaning as in FIGS. 1-3.

The floor panels 1 comprise a core 16 and a top layer 18 applied on the core 16. The top layer 18 comprises the decor 5.

The core 16 can be a mineral-based core, such as a core comprising magnesiumoxysulphate and/or magnesiumoxychloride and/or Portland cement, or a core comprising glued together wood fibers and/or mineral wool fibers (such as e.g. rockwool fibers), or a core comprising a thermoplastic polymer, such as polyvinylchloride, polyethylene terephthalate, polypropylene or polyethylene, or a core comprising a thermosetting polymer, such as unsaturated polyester crosslinked with styrene.

The floor panels 1 of the example of FIG. 4 comprise at the top major surface 4 a decor paper layer 14, i.e. a paper layer provided with the print. The decor paper layer 14 is provided with thermosetting resin, e.g. with a melamine formaldehyde resin. The floor panels 1 also comprise at the top major surface 4 a transparent paper layer 15 impregnated with thermosetting resin, e.g. with phenol formaldehyde, urea formaldehyde, melamine formaldehyde, polyurethane or acrylate.

Alternatively, the floor panels 1 at the top major surface 4 can be provided with a film onto which the décor is printed. The film can be a thermoplastic film, e.g. out of polypropylene, polyethylene, polyvinyl chloride or polyester. The floor panels 1 can also comprise at the top major surface 4 a transparent film; preferably a thermoplastic film, e.g. out of polypropylene, polyethylene, polyvinyl chloride or polyester.

The floor panels can be provided at their top major surface with one or a plurality of lacquer layers. The one or the plurality of lacquer layers can be selected from acrylate or polyurethane; e.g. the one or the plurality of lacquer layers can be UV-resistant acrylate lacquers.

FIG. 5 shows in a similar view as FIG. 2 an alternative embodiment of the invention. The reference numerals have the same meaning as in FIG. 2. In the embodiment shown in FIG. 5, a nonwoven fiber mesh 25 contacts the bottom major surface 3 of the floor panel 1. It means that the nonwoven fiber mesh 25 is installed between the profile 6 and the floor panel 1.

Instead of a nonwoven fiber mesh, an elastic pad can be provided between the profiles and the panels.

The nonwoven fiber mesh 25 (or elastic pad) can also provide the bottom major surface of the floor panel 1. To this end, the nonwoven fiber mesh 25 or the elastic pad can be thermally bonded or bonded by means of an adhesive into the floor panel 1, thereby forming the bottom major surface of the floor panel 1.

The present invention is in no way limited to the above described embodiments, but such floor coverings may be realized according to several variants without leaving the scope of the invention.

The invention also relates to the following list of numbered items:

Item 1. —Set of parts for installing a floor covering, preferably for installing an exterior flooring, wherein the set of parts comprises a plurality of floor panels (1) and a plurality of profiles (6), preferably thin-walled profiles;

• • wherein the floor panels are provided for being installed over an underlying surface (2),
  • wherein in installed condition the bottom major surface (3) of each of the floor panels (1) is elevated from the underlying surface (2) by means of the corresponding profile (6);
  • wherein said floor panels (1) at least at their top major surface (4) comprise a decor (5) formed by a print, a wood veneer or a stone veneer.

Item 2. —Set as in item 1, characterized in that said profiles are extruded profiles or are profiles (6) obtained through roll forming a metal sheet.

Item 3. —Set according to any of the preceding items, characterized in that in installed condition said profile (6) touches the bottom major surface (3) of its corresponding floor panel (1) over less than 90%, less than 80% or less than 70% of the bottom major surface area (3), or even more preferred over less than 60% of the bottom major surface area.

Item 4. —Set according to any of the preceding items, characterized in that the profiles (6) are configured such that in installed condition said profiles (6) allow for air to freely circulate along at least 10%, preferably at least 20%, more preferably at least 30%, or even more preferably at least 40% of the area of the bottom major surface (3) of the corresponding floor panel (1).

Item 5. —Set according to any of the preceding items, characterized in that the profiles (6) are configured such that in installed condition said profiles (6) extend in the vertical direction (V) over a distance (d) that is equal to the thickness (T) of said floor panels (1) or larger, e.g. over a distance (d) at least 1.5 times or at least twice the thickness (T) of said floor panels (1).

Item 6. —Set according to any of the preceding items, characterized in that said floor panels (1) are rectangular with a first and a second longitudinal edge (7, 8) opposite to one another, and that the profiles (6) are configured such that in installed condition the profiles (6) extend at least beyond a first longitudinal edge (7) of their corresponding floor panel (1) in the width direction (W) of the floor panel (1).

Item 7. —Set according to item 6, characterized in that the profiles (6) are configured such that in installed condition said profiles (6) do not extend beyond said second longitudinal edge (8), or extend beyond said second longitudinal edge (8) of its corresponding floor panel (1) to a lesser extent than it does beyond said first longitudinal edge (7).

Item 8. —Set according to item 6 or 7, characterized in that the profiles are configured such that in installed condition said profiles (6) can be connected to said underlying surface (2) at least at a first portion (9) thereof that extends beyond said first longitudinal edge (7) of the corresponding floor panel (1).

Item 9. —Set according to any of items 6 to 8, characterized in that said profiles (6) comprise a second portion (10) configured for being engaged during installation with a first longitudinal edge (7) of a first floor panel (1) and/or with a second longitudinal edge (8) of a second floor panel.

Item 10. —Set according to item 9, characterized in that said second portion (10) is positioned on the part (11) of the profile (6) that in installed condition extends beyond said first longitudinal edge (7) of the corresponding floor panel (1).

Item 11. —Set according to item 9 or 10, characterized in that said engaging the second portion (10) during installation with a first longitudinal edge (7) of a first floor panel (1) and/or with a second longitudinal edge (8) of a second floor panel comprises the positioning of said second portion (10) at least in part in a groove (12) provided in the respective longitudinal edge (7) of the corresponding floor panel (1).

Item 12. —Set according to any of the preceding claims, characterized in that said floor panels (1) at said top major surface (4) comprise a polyurethane or acrylic coating applied above said decor.

Item 13. —Set according to item 12, characterized in that said coating is thermally cured, UV cured, excimer cured and/or Electron Beam cured.

Item 14. —Set according to any of the preceding items, characterized in that said floor panels (1) at said top major surface (4) have a slip resistance of at least R10, or preferably at least R11, as measured and defined by DIN 51130: 2004.

Item 15. —Set according to any of the preceding items, characterized in that said floor panels (1) at said top major surface (4) have a texture.

Item 16. —Set according to item 15, characterized in that said texture has a pattern, preferably in register with said decor (5).

Item 17. —Set according to item 15, characterized in that said texture has a uniform appearance over substantially the entire top major surface (4).

Item 18. —Set according to any of items 15 to 17, characterized in that said texture is at least formed by means of embossments provided in said top major surface (4).

Item 19. —Set according to any of items 15 to 18, characterized in that said texture is at least formed by means of an additive available in a coating applied above said decor (5).

Item 20. —Set according to any of the preceding items, characterized in that said print is a digital print.

Item 21. —Floor covering according to any of the preceding items, characterized in that said print comprises organic or inorganic pigments.

Item 22. —Set according to any of the preceding items, characterized in that said top major surface (4) is domed.

Item 23. —Set according to any of the preceding items, characterized in that said floor panels (1) are rectangular and that said top major surface (4) in the width direction (W) is domed more than 0.2%, preferably more than 0.5%, as measured in accordance with EN 13329 Annex A.4.7.

Item 24. —Set according to any of the preceding items, characterized in that said floor panels (1) are rectangular and that said top major surface (4) in the length direction (L) is domed more than 1%, preferably more than 2%, as measured in accordance with EN 13329 Annex A.4.8.

Item 25. —Set according to any of the preceding items, characterized in that said floor panels (1) are rectangular and have a thickness (T) that is 3% of the width or more.

Item 26. —Set according to any of the preceding items, characterized in that said floor panels (1) are rectangular and have a width, or a dimension in said width direction (W), of at least 100 mm, and preferably less than 350 mm.

Item 27. —Set according to any of the preceding items, characterized in that said floor panels (1) include a plurality of layers of thermosetting resin impregnated paper sheets (13) bonded together; preferably the thermosetting resin is a phenol formaldehyde resin.

Item 28. —Set according to any of the preceding items, characterized in that said floor panels (1) at said top major surface (4) comprise a decor paper layer (14), i.e. a paper layer provided with said print, wherein said decor paper layer (14) is provided with thermosetting resin.

Item 29. —Set according to item 28, characterized in that said floor panels (1) at said top major surface (4) also comprise a transparent paper layer (15) impregnated with thermosetting resin.

Item 30. —Set according to any of items 27 to 29, characterized in that said thermosetting resin is, for each layer independently, selected from the list consisting of phenol formaldehyde, urea formaldehyde, melamine formaldehyde, polyurethane—preferably applied as a polyurethane dispersion—or acrylate.

Item 31. —Set according to any of items 27 to 30, characterized in that said floor panels comprise a core (16) formed from at least a plurality of resin impregnated paper sheets (13), preferably impregnated with phenol formaldehyde or melamine formaldehyde, and a top major surface (4) comprising a decor paper layer (14) and a transparent paper layer (15) applied on top of said decor paper layer (14), wherein said transparent paper layer (15) and said decor paper layer (14) are both impregnated with melamine formaldehyde or with a polyurethane—preferably applied as a polyurethane dispersion—or with acrylate or with mixtures thereof.

Item 32. —Set according to any of the items 1-26, characterized in that the floor panels (1) at said top major surface (4) comprise a film onto which the décor is printed; preferably wherein the film is a thermoplastic film, e.g. out of polypropylene, polyethylene, polyvinyl chloride or polyester.

Item 33. —Set according to item 32, characterized in that said floor panels (1) at said top major surface (4) further comprise a transparent film; preferably wherein the transparent film is a thermoplastic film, e.g. out of polypropylene, polyethylene, polyvinyl chloride or polyester.

Item 34. —Set according to any of the items 32-33, characterized in that said floor panels (1) at said top major surface (4) further comprise one or a plurality of lacquer layers, preferably wherein the one or the plurality of lacquer layers are selected from acrylate or polyurethane; more preferably the one or the plurality of lacquer layers is a UV-resistant acrylate lacquer.

Item 35. —Set according to any of the preceding items, characterized in that said floor panels comprise a core (16) formed from at least a plurality of resin impregnated paper sheets (13), preferably impregnated with phenol formaldehyde or melamine formaldehyde, and a top major surface (4) comprising a decor paper layer (14) and a transparent paper layer (15) applied on top of said decor paper layer (14), wherein said transparent paper layer (15) and said decor paper layer (14) are both impregnated with melamine formaldehyde or with a polyurethane—preferably applied as a polyurethane dispersion—or with acrylate or with mixtures thereof.

Item 36. —Set according to any of the preceding items, characterized in that said floor panels (1) comprise a compact laminate material (17).

Item 37. —Set according to any of the preceding items 1-34, characterized in that said floor panels comprise a core (16) and an applied thereon top layer (18) comprising said decor (5).

Item 38. —Set according to item 37, characterized in that said core (16) is a mineral-based core, such as a core comprising magnesiumoxysulphate and/or magnesiumoxychloride and/or Portland cement, or a core comprising glued together wood fibers and/or mineral wool fibers (such as e.g. rockwool fibers), or a core comprising a thermoplastic polymer, such as polyvinylchloride, polyethylene terephthalate, polypropylene or polyethylene, or a core comprising a thermosetting polymer, such as unsaturated polyester crosslinked with styrene.

Item 39. —Set according to item 37, characterized in that said top layer (18) is glued onto said core (16); or is adhered to the core (16) in the absence of separate glue layers.

Item 40. —Set according to any of the preceding items, characterized in that said floor panels (1) have a thickness (T) of 4 to 8 mm.

Item 41. —Set according to any of the preceding items, characterized in that said floor panels (1) at one or more edges (7, 8) are provided with lowered edge areas (19).

Item 42. —Set according to item 41, characterized in that said decor (5) continuously extends from the global major surface into said lowered edge area (19), preferably at least up to the associated edge (20).

Item 43. —Set according to item 42, characterized in that said decor (5) extends beyond said associated edge (20).

Item 44. —Set according to any of the preceding items, characterized in that the set of parts comprises one or plurality of nonwoven fiber meshes (25) or elastic pads, for being installed contacting the bottom of the floor panels in the floor covering.

Item 45. —Set according to any of the preceding items, characterized in that a nonwoven fiber mesh (25) or an elastic pad contacts the bottom major surface of the floor panel (1).

Item 46. —Set according to any of the preceding items, characterized in that a nonwoven fiber mesh (25) or an elastic pad provides the bottom major surface of the floor panel; preferably wherein the nonwoven fiber mesh or the elastic pad is thermally bonded or bonded by means of an adhesive into the floor panel.

Item 47. —Floor covering comprising a plurality of floor panels (1) arranged over an underlying surface (2), wherein the bottom major surface (3) of the floor panels (1) is elevated from the underlying surface (2), wherein said floor panels (1) at least at their top major surface (4) comprise a decor (5) formed by a print, a wood veneer or a stone veneer.

Item 48. —Floor covering according to item 47, characterized in that said floor panels at said top major surface (4) further comprise a polyurethane or acrylic coating applied above said decor.

Item 49. —Floor covering according to item 48, characterized in that said coating is thermally cured, UV cured, Excimer cured and/or Electron Beam cured.

Item 50. —Floor covering according to any of the preceding items 47-49, characterized in that said floor panels (1) at said top major surface (4) have a slip resistance of at least R10, or preferably at least R11, as measured and defined by DIN 51130: 2004.

Item 51. —Floor covering according to any of the preceding items 47-50, characterized in that said floor panels (1) at said top major surface (4) have a texture.

Item 52. —Floor covering according to item 51, characterized in that said texture has a pattern, preferably in register with said decor (5).

Item 53. —Floor covering according to item 51, characterized in that said texture has a uniform appearance over substantially the entirety of said top major surface (4).

Item 54. —Floor covering according to any of items 51 to 53, characterized in that said texture is at least formed by means of embossments provided in said top major surface (4).

Item 55. —Floor covering according to any of items 51 to 54, characterized in that said texture is at least formed by means of an additive available in a coating applied above said decor (5).

Item 56. —Floor covering according to any of the preceding items 46-55, characterized in that said print is a digital print.

Item 57. —Floor covering according to any of the preceding items 46-56, characterized in that said print comprises organic or inorganic pigments.

Item 58. —Floor covering according to any of the preceding items 46-57, characterized in that said top major surface (4) is domed.

Item 59. —Floor covering according to any of the preceding items 46-58, characterized in that said floor panels (1) are rectangular and that said top major surface (4) in the width direction (W) is domed more than 0.2%, preferably more than 0.5%, as measured in accordance with EN 13329 Annex A.4.7.

Item 60. —Floor covering according to any of the preceding items 46-59, characterized in that said floor panels (1) are rectangular and that said top major surface (4) in the length direction (L) is domed more than 1%, preferably more than 2%, as measured in accordance with EN 13329 Annex A.4.8.

Item 61. —Floor covering according to any of the preceding items 46-60, characterized in that said floor panels (1) are rectangular and have a thickness (T) that is 3% of the width or more.

Item 62. —Floor covering according to any of the preceding items 46-61, characterized in that said floor panels (1) are rectangular and have a width, or a dimension in said width direction (W), of at least 100 mm, and preferably less than 350 mm.

Item 63. —Floor covering according to any of the preceding items 46-62, characterized in that said underlying surface (2) comprises one or more inclined portions, e.g. to allow for dewatering.

Item 64. —Floor covering according to any of the preceding items 46-63, characterized in that the bottom major surface (3) of said floor panels (1) is elevated from the underlying surface (2) by means of a, preferably thin-walled, profile (6).

Item 65. —Floor covering according to item 64, characterized in that said profile is an extruded profile (6) or a profile (6) obtained through roll forming of a metal sheet.

Item 66. —Floor covering according to any of items 64 to 65, characterized in that said profile (6) extends in the vertical direction (V) over a distance (d) that is equal to the thickness (T) of said floor panels (1) or larger, e.g. at least 1.5 times or at least twice the thickness (T) of said floor panels (1).

Item 67. —Floor covering according to any of items 64 to 66, characterized in that said profile (6) contacts said bottom major surface (3) over less than 90%, less than 80% or less than 70% of the bottom major surface area (3), or even more preferred over less than 60% of the bottom major surface area.

Item 68. —Floor covering according to any of items 64 to 67, characterized in that said profile (6) allows for air to freely circulate along at least 10%, at least 20%, at least 30%, or even more preferred at least 40% of the area of said bottom major surface (3).

Item 69. —Floor covering according to any of items 64 to 68, characterized in that said floor panels (1) are rectangular with a first and a second longitudinal edge (7, 8) opposite to one another, and that said profile (6) extends at least beyond a first longitudinal edge (7) of said floor panel (1) in the width direction (W) of the floor panel (1).

Item 70. —Floor covering according to item 69, characterized in that said profile (6) does not extend beyond said second longitudinal edge (8), or extends beyond said second longitudinal edge (8) to a lesser extent than it does beyond said first longitudinal edge (7).

Item 71. —Floor covering according to item 69 or 70, characterized in that said profile (6) is connected to said underlying surface (2) at least at a first portion (9) thereof that extends beyond said first longitudinal edge (7).

Item 72. —Floor covering according to any of items 69 to 71, characterized in that said profile (6) comprises a second portion (10) engaging with a first longitudinal edge (7) of a first floor panel (1) and/or with a second longitudinal edge (8) of a second floor panel.

Item 73. —Floor covering according to item 72, characterized in that said second portion (10) is positioned on the part (11) of the profile (6) that extends beyond said first longitudinal edge (7).

Item 74. —Floor covering according to item 72 or 73, characterized in that said engaging of the second portion (10) with the first longitudinal edge (7) comprises the positioning of said second portion (10) at least in part in a groove (12) provided in the respective longitudinal edge (7).

Item 75. —Floor covering according to any of the preceding items 47-74, characterized in that said floor panels (1) include a plurality of layers of thermosetting resin impregnated paper sheets (13) bonded together.

Item 76. —Floor covering according to any of the preceding items 47-75, characterized in that said floor panel (1) at said top major surface (4) comprises a decor paper layer (14), i.e. a paper layer provided with said print, wherein said decor paper layer (14) is provided with thermosetting resin.

Item 77. —Floor covering according to item 76, characterized in that said floor panel (1) at said top major surface (4) further comprises a transparent paper layer (15) impregnated with thermosetting resin.

Item 78. —Floor covering according to any of items 75 to 77, characterized in that said thermosetting resin is, for each layer independently, selected from the list consisting of phenol formaldehyde, urea formaldehyde, melamine formaldehyde, polyurethane—preferably applied as a polyurethane dispersion—or acrylate.

Item 79. —Floor covering according to any of items 75 to 78, characterized in that said floor panels comprise a core (16) formed from at least a plurality of resin impregnated paper sheets (13), preferably impregnated with phenol formaldehyde or melamine formaldehyde, and a top major surface (4) comprising a decor paper layer (14) and a transparent paper layer (15) applied on top of said decor paper layer (14), wherein said transparent paper layer (15) and said decor paper layer (14) are both impregnated with melamine formaldehyde or with a polyurethane—preferably applied as a polyurethane dispersion—or with acrylate or with mixtures thereof.

Item 80. —Floor covering according to any of the items 47-75, characterized in that the floor panel (1) at said top major surface (4) comprises a film onto which the décor is printed; preferably wherein the film is a thermoplastic film, e.g. out of polypropylene, polyethylene, polyvinyl chloride or polyester.

Item 81. —Floor covering according to item 80, characterized in that said floor panel (1) at said top major surface (4) further comprises a transparent film; preferably wherein the transparent film is a thermoplastic film, e.g. out of polypropylene, polyethylene, polyvinyl chloride or polyester.

Item 82. —Floor covering according to any of the items 80-81, characterized in that said floor panel (1) at said top major surface (4) further comprises one or a plurality of lacquer layers, preferably wherein the one or the plurality of lacquer layers are selected from acrylate or polyurethane; more preferably the one or the plurality of lacquer layers is a UV-resistant acrylate lacquer.

Item 83. —Floor covering according to any of the preceding items 47-82, characterized in that said floor panels comprise a core (16) formed from at least a plurality of resin impregnated paper sheets (13), preferably impregnated with phenol formaldehyde or melamine formaldehyde, and a top major surface (4) comprising a decor paper layer (14) and a transparent paper layer (15) applied on top of said decor paper layer (14), wherein said transparent paper layer (15) and said decor paper layer (14) are both impregnated with melamine formaldehyde or with a polyurethane—preferably applied as a polyurethane dispersion—or with acrylate or with mixtures thereof.

Item 84. —Floor covering according to any of the preceding items 47-83, characterized in that said floor panels (1) comprise a compact laminate material (17).

Item 85. —Floor covering according to any of items 47 to 84, characterized in that said floor panels comprise a core (16) and an applied thereon top layer (18) comprising said decor (5).

Item 86. —Floor covering according to item 85, characterized in that said core (16) is a mineral-based core, such as a core comprising magnesiumoxysulphate and/or magnesiumoxychloride and/or Portland cement, or a core comprising glued together wood fibers and/or mineral wool fibers (such as e.g. rockwool fibers), or a core comprising a thermoplastic polymer, such as polyvinylchloride, polyethylene terephthalate, polypropylene or polyethylene, or a core comprising a thermosetting polymer, such as unsaturated polyester crosslinked with styrene.

Item 87. —Floor covering according to item 86, characterized in that said top layer (18) is glued onto said core (16) or is adhered to the core (16) in the absence of separate glue layers.

Item 88. —Floor covering according to any of the preceding items 47-87, characterized in that said floor panels (1) have a thickness (T) of 4 to 8 mm.

Item 89. —Floor covering according to any of the preceding items 47-88, characterized in that said floor panels (1) at one or more edges (7, 8) are provided with lowered edge areas (19).

Item 90. —Floor covering according to item 89, characterized in that said decor (5) continuously extends from the global major surface into said lowered edge area (19), preferably at least up to the associated edge (20).

Item 91. —Floor covering according to item 90, characterized in that said decor (5) extends beyond said associated edge (20).

Item 92. —Floor covering according to any of the preceding items 47-91, characterized in that a nonwoven fiber mesh (25) or an elastic pad contacts the bottom major surface of the floor panel

Item 93. —Floor covering according to any of the preceding items 47-91, characterized in that a nonwoven fiber mesh (25) or an elastic pad provides the bottom major surface of the floor panel; preferably wherein the nonwoven fiber mesh or the elastic pad is thermally bonded or bonded by means of an adhesive into the floor panel.

Item 94. —Floor covering according to any of the preceding items 47-93, characterized in that the floor panels and/or the profiles are configured as described in any of the preceding items 1-46.

Item 95. —Floor covering, characterized in that the floor covering is realized using a set of parts as in any of the preceding items 1-46.

Item 96. —Floor covering according to any of the preceding items 47-95, characterized in that said floor covering is an outdoor decking.

Claims

1.-53. (canceled)

54. A set of parts for installing a floor covering, for installing an exterior flooring, wherein the set of parts comprises a plurality of floor panels and a plurality of profiles; wherein the floor panels are provided for being installed over an underlying surface,wherein in installed condition the bottom major surface of each of the floor panels is elevated from the underlying surface by means of the corresponding profile;wherein said floor panels at least at their top major surface comprise a decor formed by a print, a wood veneer or a stone veneer.

55. The set according to claim 54, wherein in installed condition said profile touches the bottom major surface of its corresponding floor panel over less than 90 of the bottom major surface area.

56. The set according to claim 54, wherein the profiles are configured such that in installed condition said profiles allow for air to freely circulate along at least 10% of the area of the bottom major surface of the corresponding floor panel.

57. The set according to claim 54, wherein the profiles are configured such that in installed condition said profiles extend in the vertical direction over a distance that is equal to the thickness of said floor panels or larger.

58. The set according to claim 54, wherein said floor panels are rectangular with a first and a second longitudinal edge opposite to one another, and that the profiles are configured such that in installed condition the profiles extend at least beyond a first longitudinal edge of their corresponding floor panel in the width direction of the floor panel.

59. The set according to claim 58, wherein the profiles are configured such that in installed condition said profiles do not extend beyond said second longitudinal edge, or extend beyond said second longitudinal edge of its corresponding floor panel to a lesser extent than it does beyond said first longitudinal edge.

60. The set according to claim 58, wherein the profiles are configured such that in installed condition said profiles can be connected to said underlying surface at least at a first portion thereof that extends beyond said first longitudinal edge of the corresponding floor panel.

61. The set according to claim 58, wherein said profiles comprise a second portion configured for being engaged during installation with a first longitudinal edge of a first floor panel and/or with a second longitudinal edge of a second floor panel.

62. The set according to claim 61, wherein said second portion is positioned on the part of the profile that in installed condition extends beyond said first longitudinal edge of the corresponding floor panel.

63. The set according to claim 61, wherein said engaging the second portion during installation with a first longitudinal edge of a first floor panel and/or with a second longitudinal edge of a second floor panel comprises the positioning of said second portion at least in part in a groove provided in the respective longitudinal edge of the corresponding floor panel.

64. The set according to claim 54, wherein said floor panels at said top major surface comprise a polyurethane or acrylic coating applied above said decor.

65. The set according to claim 64, wherein said coating is thermally cured, UV cured, excimer cured and/or Electron Beam cured.

66. The set according to claim 54, wherein said floor panels at said top major surface have a slip resistance of at least R10, as measured and defined by DIN 51130: 2004.

67. The set according to claim 54, wherein said floor panels at said top major surface have a texture.

68. The set according to claim 67, wherein said texture has a pattern.

69. The set according to claim 67, wherein said texture has a uniform appearance over substantially the entire top major surface.

70. The set according to claim 67, wherein said texture is at least formed by means of embossments provided in said top major surface.

71. The set according to claim 67, wherein said texture is at least formed by means of an additive available in a coating applied above said decor.

72. The set according to claim 54, wherein said top major surface is domed.

73. The set according to claim 54, wherein said floor panels are rectangular and that said top major surface in the width direction is domed more than 0.2% as measured in accordance with EN 13329 Annex A.4.7.