Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/02—Flooring or floor layers composed of a number of similar elements
  • E04F15/02005—Construction of joints, e.g. dividing strips
  • E04F15/02016—Construction of joints, e.g. dividing strips with sealing elements between flooring elements
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/02—Flooring or floor layers composed of a number of similar elements
  • E04F15/08—Flooring or floor layers composed of a number of similar elements only of stone or stone-like material, e.g. ceramics, concrete; of glass or with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass
  • E04F15/082—Flooring or floor layers composed of a number of similar elements only of stone or stone-like material, e.g. ceramics, concrete; of glass or with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass in combination with a lower layer of other material
  • E04F15/087—The lower layer being of organic plastic with or without reinforcements or filling materials
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F2201/00—Joining sheets or plates or panels
  • E04F2201/05—Separate connectors or inserts, e.g. pegs, pins, keys or strips
  • E04F2201/0505—Pegs or pins
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F2201/00—Joining sheets or plates or panels
  • E04F2201/05—Separate connectors or inserts, e.g. pegs, pins, keys or strips
  • E04F2201/0511—Strips or bars, e.g. nailing strips
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F2201/00—Joining sheets or plates or panels
  • E04F2201/05—Separate connectors or inserts, e.g. pegs, pins, keys or strips
  • E04F2201/0523—Separate tongues; Interlocking keys, e.g. joining mouldings of circular, square or rectangular shape
  • E04F2201/0529—Separate tongues; Interlocking keys, e.g. joining mouldings of circular, square or rectangular shape the interlocking key acting as a dovetail-type key

Definitions

• the present invention relates to a floor system, a coupling insert and a floor covering comprising such a floor system.
• the invention is related to a floor system for forming a floor covering, wherein the floor system comprises a floor element, wherein this floor element comprises a decorative layer made of a brittle material such as natural stone, glass or sintered ceramic materials like porcelain, earthenware or the like.
• the decorative layer can, for example, be a ceramic tile.
• ceramic tiles are installed by laying them side by side on a surface such as a floor or wall.
• an adhesive compound is used to attach the tiles to the surface. Seams between the tiles are grouted.
• the tiles are bonded to a rigid surface, for example a concrete subfloor, thereby improving their impact strength.
• the bound with the subfloor, and thus also with the structure of the dwelling, also leads to a high attenuation of walking sounds, both in the room where the floor is installed, and in quarters below the respective room.
• the tiled surface is water impervious and hygienic, since it can be cleaned in a very wet manner.
• the step of installing the tiles with an adhesive is, however, labor intensive and represents a significant portion of the labor involved in a typical floor covering installation. Moreover, this installing technique requires a high professional competence in order to obtain a well levelled floor covering. Thus, due to the time and labor involved in the installation, it is typically quite costly to have tiles professionally installed. Further, expansion gaps need to be provided in the tiled surface in accordance with the expected expansion of the subfloor. Installing on a wooden subfloor may lead to failure due to the different expansion mechanism of the subfloor and the ceramic tile.
• the floor elements disclosed in those documents can be laid on a surface and mechanically coupled together to form a floor covering without the use of an adhesive, thereby reducing the labor and time of the installing phase.
• Such kind of floor covering is known as a floating floor covering.
• a ceramic tile or natural stone slab is fixed to a support layer that comprises coupling elements, in the form of tongue and groove, configured to realize a coupling with coupling elements of an adjacent floor element, thereby forming a floor covering. Due to its floating nature, the floor covering can be laid over expansion gaps foreseen in the subfloor.
• floor elements with mechanical coupling elements and a hard decorative layer can be heavy and complicated to handle during installation to achieve the mechanical coupling.
• this kind of coupling elements can allow lay down of the floor elements in a limited number of configurations.
• WO 2015/005860 discloses ceramic tiles that are connected at adjacent edges by means of separate coupling inserts.
• the edges of the ceramic tiles have been provided with profiled edges. Intricate machining of edges of ceramic tiles is difficult, and the required grooves and/or undercuts may render the edges vulnerable to damage on impact load, or even with localized static loading.
• the present invention aims in the first place to provide an alternative floor system, which, in accordance with several of its preferred embodiments, is directed to solving one or more of the problems arising in the state of the art.
• the present invention relates to a floor system comprising a floor element, wherein said floor element comprises a top layer, preferably comprising a ceramic tile, and a support layer, wherein said support layer comprises edges provided with coupling elements, wherein the system comprises at least one coupling insert adapted to interact with one coupling element of the floor element.
• a floor system comprising a floor element, wherein said floor element comprises a top layer, preferably comprising a ceramic tile, and a support layer, wherein said support layer comprises edges provided with coupling elements, wherein the system comprises at least one coupling insert adapted to interact with one coupling element of the floor element.
• the support layer is provided with edges having coupling elements, intricate profiling of the top layer edges can be omitted.
• the support layer may further provide stabilizing, levelling and/or sound attenuating effects to the floor covering.
• the floor system is preferably suitable for floating installation. The floating installation leads to an easy removal or even a temporary, possibly repeated, use of the same floor elements or parts thereof. Exist
• Additional cushioning and/or sound attenuation may be attained by an underlayment available between the subfloor and the floor element, more particularly the support layer of the floor element.
• the floor elements in particular the support layers of the floor elements, may be loosely installed over such underlayment or may be glued onto such underlayment.
• the glue may be factory applied on the underlayment and/or on the bottom of said support layer and, for example, shielded by means of a removable foil. Glueing the floor elements to an underlayment may create additional stability to the floor covering, while maintaining the floating nature of the floor covering, inclusive the underlayment.
• said top layer e.g. ceramic tile
• said top layer is reinforced by means of reinforcing means.
• Said reinforcing means can comprise one or more of a resin material, a glue, a glass fiber sheet and a steel sheet available in between said support layer and said ceramic tile.
• said top layer preferably a ceramic tile, is at its bottom or downward oriented side impregnated by means of a resin material having one or a combination of two or more of the following properties:
• the application of such resin material may bring about a floor element having an impact resistance greater than 5 J, also when said top layer is a brittle material, such as a ceramic tile.
• the resin material at the same time functions as a glue adhering said top layer to said support layer.
• WO 2021/225808 and WO 2021/055260 disclose suitable resin materials for reinforcing top layers of brittle material and are incorporated herein by reference in their entirety.
• the material of said top layer is porous at the lower or downward oriented surface thereof.
• Such porosity allows for glue and/or resin material to impregnate the bottom of said top layer. In that way a reinforcing effect can be obtained.
• said top layer is a ceramic tile having a porosity as measured by means of the boiling method described in ISO 10545-3:2018 of 0.01% to 10%, or 0.1% to 10% or 0.01% to 6%, or 0.1% to 6%.
• the top layer is a ceramic tile having a porosity as measured by means of the boiling method described in ISO 10545-3:2018 is from 0.01% to 0.5%. In the latter case, the ceramic tile is of porcelain quality.
• a minimum amount of porosity is desired to obtain some penetration of glue and/or resin material into the lower or downward oriented surface of the ceramic tile. Too high a porosity is preferably avoided in order to economize on the resin material, as well as to maintain an acceptable impact resistance of the floor element.
• a preferable amount of glue for obtaining the desired reinforcing effect can be above 150 gm/sqm.
• said support layer comprises edges provided with coupling elements.
• Said coupling elements can be the same on opposite edges of the support layer, and preferably on all the edges of the support layer.
• manufacturing the support layer, and consequently the floor element can be simplified.
• installation can be simplified as one coupling insert, and possibly the same coupling movement, can be used on all the edges of the support layer.
• the coupling elements can be configured such that in a coupled condition with the coupling insert, relative movement between the coupling insert and the floor element in one or more vertical and/or horizontal direction is limited or prevented.
• said coupling elements can comprise one or more first contact surfaces adapted to contact respective first contact surfaces of the insert to thereby prevent or limit said movement in one or more vertical directions.
• Said first contact surfaces preferably extend horizontally or substantially horizontal, i.e. parallel or substantially parallel to the plane of the support layer, or extend at an angle of less than 45° with the horizontal plane or the plane of the support layer.
• said coupling elements can comprise one or more second contact surfaces adapted to contact respective second contact surfaces of the insert to thereby prevent or limit said movement in one or more horizontal directions.
• Said second contact surfaces preferably extend vertically or substantially vertical, i.e. perpendicular or substantially perpendicular to the plane of the support layer, or extend at an angle of less than 45° with the vertical plane or the plane of the support layer.
• said coupling elements and insert prevent or limit the mutual movement in one or more vertical directions only, or in one or more horizontal directions only.
• said coupling elements and insert prevent or limit the mutual movement in one or more horizontal directions by means of a friction connection.
• said friction connection in itself prevents or limits the mutual movement in one or more vertical directions.
• said coupling insert may clamp a portion of said coupling elements. The clamping may be brought about by means of a tightened mechanical connection, such as by means of a screw connection or a snapping connection, preferably comprising one or more hooks and undercuts.
• the coupling elements are disposed partially, preferably entirely, at a horizontal level below said top layer, more particularly below the bottom or downward oriented side of said top layer.
• said coupling element can project inwardly with respect to a respective edge of the top layer for a major portion or in its entirety.
• said first contact surfaces, when available, and/or said second contact surfaces, when available extend at least partially, and preferably wholly, vertically below said downward oriented surface of said top layer.
• said coupling elements can partially or entirely extend beyond a respective edge of the top layer.
• said coupling elements are partially or entirely formed in or by respective portions of the support layer that extend beyond respective edges of the top layer.
• the coupling elements are configured to allow coupling with the coupling insert in an angling, horizontal and/or downward, e.g. vertical, movement. Downward or vertical movement is preferred above the other as it is more similar to the movement required in traditional installation of ceramic tiles. A horizontal movement can also be executed quite naturally and intuitively, and is therefore also an advantageous embodiment.
• the coupling of the coupling insert with the coupling element is purely mechanical, i.e. obtained by the geometry of the insert and element.
• the coupling may comprise an adhesive that may or may not be pre-applied to said coupling insert or said floor element, in particular to said coupling element.
• the coupling elements can be present substantially continuously along the entire length of the respective edge. In this way, multiple installation configurations can be achieved. Furthermore, continuous profiling of such edge to form said coupling elements may be executed fluently in an industrial manner, for example by using so-called end-tenoners, wherein the support layer, whether or not already connected to the top layer, is transported with the respective edge in a continuous manner past rotating milling cutters.
• said coupling elements are at least in part, preferably integrally, formed in said support layer.
• the coupling elements can be milled in the support layer, for example as stated above using an end-tenoner.
• the coupling element can be partially formed by the top layer, for example the coupling elements can be in the form of a recess, or can comprise a recess, between a downward oriented surface of the top layer and an upward oriented surface of the support layer.
• obtaining a sturdy coupling remains possible even in thin support layers, for example in support layers having a thickness of 2 to 3.5 mm.
• the support layer is in the form of a panel, or a board, attached, for example laminated, to a lower surface of the top layer.
• the lamination can be obtained by means of a resin material or a glue that for example impregnates the downward oriented surface of the top layer.
• said support layer can be made of thermoplastic material, for example PE (poly ethylene), PP (poly propylene), PVC (poly vinyl chloride), PET (poly ethylene terephthalate).
• PE poly ethylene
• PP poly propylene
• PVC poly vinyl chloride
• PET poly ethylene terephthalate
• the material forming the support layer is rigid as it may contribute in improving the impact resistance of the top layer.
• the material forming the support layer can comprise a high content of mineral filler, for example above 50 %, more preferably equal or above 60 %, based on the weight of the support layer itself.
• Said mineral filler can comprise chalk or calcium carbonate.
• the material forming the support layer can comprise low or no content of plasticizer, for example a content of plasticizer lower than 15 phr, or lower than 5 phr.
• the PVC for example PVC with a plasticizer content of 5 phr or lower, comprises a thermal expansion coefficient below 85 ⁇ m/m per °C, preferably below 60 ⁇ m/m per °C for example 50 ⁇ m/m per °C.
• thermal expansion coefficient of the support layer can be comprised between 20 ⁇ m/m per °C and 85 ⁇ m/m per °C, preferably between 40 ⁇ m/m per °C 60 ⁇ m/m per °C.
• the differential expansion between the support layer and a typical brittle top layer, such as a ceramic tile can be limited and warping effects, as well as the risk for subsequent failure of the flooring elements can be minimized.
• said support layer may comprise wood-based material, such as an MDF or HDF board, or, comprise mineral-based material, such as a cement fiber board, a gypsum board, or a magnesium oxide board, or, comprise thermosetting plastic material, for example unsaturated polyester or a copolymer of unsaturated polyester.
• wood-based material such as an MDF or HDF board
• mineral-based material such as a cement fiber board, a gypsum board, or a magnesium oxide board
• thermosetting plastic material for example unsaturated polyester or a copolymer of unsaturated polyester.
• the top layer can preferably be made of a ceramic tile, more preferably of the kind having a ceramic body and one or more glaze coatings covering the upper surface of the tile.
• a decorative pattern can be present in said glaze coatings.
• the ceramic body is made of porcelain stoneware, but alternatively can be made of other ceramic materials like, for example, red body ceramic.
• the top layer comprises a lower, i.e. bottom or downward directed, surface which is substantially flat, i.e. free from any relief structure or comprising a relief structure showing a depth below 1 mm.
• said top layer has a flat, or nearly flat bottom surface over at least 85%, or at least 95%, of the area of said bottom surface.
• the maximum deviation of said bottom surface from a least squares plane defined by said bottom surface, or defined by at least 85% or at least 95% of said bottom surface is less than 500 ⁇ m, or less than 250 ⁇ m.
• said top layer is a ceramic tile that has been produced using a continuously operated powder scattering line with subsequent continuously or semi-continuously operated pressing. An example of a continuously operated pressing is disclosed in EP 1 356 909 which is incorporated herein in its entirety by reference.
• said top layer has a thickness larger than the thickness of said support layer, for example a thickness that is at least 150% or at least 200% of the thickness of said support layer.
• the top layer can for example be a ceramic tile with a thickness of at least 7 millimeter, while the support layer can have at thickness of 4.5 millimeter or less, for example 3.5 mm.
• Such support layer may be an extruded board material, for example mainly comprising a thermoplastic material, such as PVC, and filler material, preferably inorganic filler material, such as CaCO3, sand and/or talcum.
• said support layer has a thickness of at least 2 mm, or at least 3 mm.
• Such thickness of support layer allows forming coupling elements at the edges of the support layer, while offering a sufficient levelling ability.
• the floor elements can comprise an intermediate layer between the top layer and the support layer.
• the intermediate layer can preferably comprise a resin material bonding together the tile and the support layer. Preferably this concerns a resin material as described above, that may impregnate the downward oriented surface of said top layer.
• the intermediate layer comprises a sheet of metal and/or a textile layer, such a glass fiber layer, either woven or non-woven, or a complex of a woven and non-woven textile or glass fiber layer.
• the coupling insert can be adapted to interact with two or more floor elements, for example three floor elements or four floor elements.
• said insert can comprise a central portion and two or more lateral portions extending laterally from said central portion wherein at least said lateral portions are adapted to interact with respective coupling elements of the floor elements.
• the central portion can be configured to maintain a desired width, as measured in the plane of the floor covering and perpendicular to the respective edges, between the top layers and/or the support layers of the floor elements concerned.
• the coupling insert more particularly the central portion, can comprise abutting surfaces for contacting adjacent edges of said top layers and/or support layers. The abutting surfaces may be vertically or substantially vertically oriented.
• the floor elements may be configured for cooperation with a plurality of differently dimensioned and/or shaped coupling inserts.
• the floor elements may be configured for cooperation with at least a first and a second coupling inserts, wherein said first coupling insert maintains a first width as measured in the plane of the floor covering and perpendicular to the respective edges, between the top layers and/or the support layers of the floor elements, and wherein said second coupling insert maintains a second width as measured in the plane of the floor covering and perpendicular to the respective edges, between the top layers and/or the support layers of the floor elements, and wherein said first width is larger than said second width, for example at least 1 mm larger.
• the coupling insert can be adapted for being coupled to three or four floor elements.
• said coupling inserts are adapted to interact with a corner area of the floor elements.
• the coupling insert can be adapted to interact with one coupling element in an area at an extreme of the respective edge, which is at a corner of the floor element.
• one coupling insert is adapted to couple with two coupling elements on two different, preferably consecutive, edges of one floor element.
• said two different edges extend perpendicular to one another, and said one coupling insert cooperates with coupling elements on said two edges where the respective edges meaat in a corner area of the floor element.
• the coupling insert can provide for a good alignment between the floor elements in the floor covering.
• said coupling insert can, in a top view, be T-shaped or Y-shaped, for coupling together three floor elements, wherein three lateral portions extend laterally from said central portion.
• a Y-shaped coupling insert can allow coupling of floor elements having a non-rectangular shape, like hexagonal or chevron shape.
• said coupling insert can, in a top view, be cross-shaped, for coupling together four floor elements, wherein four lateral portions may extend laterally from said central portion.
• the system can comprise multiple coupling inserts of different types.
• the system can comprise one or more T-shaped (or Y-shaped) coupling inserts and one or more cross-shaped coupled inserts and/or one or more coupling inserts adapted to cooperate with only two floor elements.
• the system can comprise cross-shaped coupling inserts, for coupling floor elements at the corner areas thereof and, and coupling inserts adapted to cooperate with only two floor elements, for coupling together two floor elements substantially at the mezzanine off the respective edges.
• floor elements are often not perfectly flat and can show a convex/concave shape. This defect is often irrelevant when the dimensions of the floor element are limited but can become more visible and noticeable in floor elements of large dimensions.
• said central portion can be formed by a body that extends substantially perpendicularly from the lateral portions.
• Said central portion is adapted, in an installed floor, to stay in between two or more floor elements so that its width can determine, or at least contribute to determine, a distance between the top layers of said floor elements.
• such central portion comprises abutting surfaces for contacting the edges of adjacent support layers and/or top layers.
• At least said lateral portions comprise first and/or second contact surfaces adapted to contact respective first and/or second contact surfaces of the coupling elements.
• one lateral portion can be formed by an upper and/or a lower lip having one or more humps or protrusions adapted to define said second contact surface and to interact with respective recesses in the coupling elements (or vice versa, said lip of the coupling insert can have one or more recesses adapted to define said second contact surface and to interact with respective humps or protrusions in the coupling elements).
• the central portion of the coupling insert can comprise one or more of said first and/or second contact surfaces adapted to contact respective first and/or second contact surfaces of the coupling elements.
• said body of the central portion can comprise one or more humps or protrusions adapted to define said first contact surface and to interact with respective recesses in the coupling elements (or vice versa, said body of the central portion of the coupling insert can have one or more recesses adapted to define said first contact surface and to interact with respective humps or protrusions in the coupling elements).
• said first contact surfaces formed in the body of the central portion are directed to limit or prevent vertical movements between the coupling inserts and the floor element. Said first contact surfaces may be formed by said lateral portions, in particular by said upper lip and/or lower lip.
• the coupling insert can be made of a material that is different from the material forming the support layer and/or the top layer. In some embodiments, the coupling insert can be made of a material being more elastic than the material forming the support layer and/or the top layer. For example, the material forming the coupling insert can be compressible. Alternatively, said coupling insert can be adapted to deform while coupling with the coupling element of the floor element. For example, said coupling insert may comprise one or more deformable, for example flexible, portions. In this way, the coupling insert can be at least partially inserted into a recess of the support layer and exert an elastic reaction, by means of the material itself or by means of a deformable portion, which holds the coupling insert and the floor element together.
• thermoplastic material for example PE (poly ethylene), PP (poly propylene), PVC (poly vinyl chloride), PET (poly ethylene terephthalate).
• PE poly ethylene
• PP poly propylene
• PVC poly vinyl chloride
• PET poly ethylene terephthalate
• the insert can be formed of a relatively economic material and can, for example, be manufactured by means of injection molding which can lead to low manufacturing cost and on the other hand can allow forming of complex geometries.
• this is made of metal, for example steel or aluminum, for example by means of stamping.
• the coupling insert may also be composed of two or more portions of a same or similar material, or of different materials, for example one portion made of metal and one portion made of plastic material, either thermoplastic or thermosetting.
• said coupling insert comprises a lower portion and a separate upper portion, wherein the lower portion and the upper portion are preferably connected over a tightened or tightenable mechanical joining system.
• Said mechanical joining system may comprise a screw connection and/or a snapping connection, preferably comprising one or more hooks and undercuts, for example a ratchet.
• said first portion can be engaged with the support layer, for example by placing it with a part thereof below said support layer, or by introducing said part in a groove or undercut of said coupling elements.
• An adjacent floor element may then be placed, preferably also engaging its support layer with an opposite part of said first portion, preferably in a same or similar manner, i.e.
• said adjacent floor element can be installed and made to engage with said opposite part by means of a movement substantially in the plane of the installed floor elements.
• said second portion can be tightened by using said tightenable mechanical joining system.
• said second portion in a tightened condition, contacts the support layer of at least one of, and preferably both of, said adjacent floor elements. Said contact may be a contact under pressure.
• said coupling insert and said coupling elements preferably limits at least the motion of said floor elements in a vertical direction perpendicular to the plane of installed floor elements.
• said first portion and said second portion may clamp adjacent edges of support layers in between them. Due to said clamping first contact surfaces may be formed as described above. According to a preferred embodiment, in said tightened condition, said first and/or said second portion may form second contact surfaces to thereby prevent or limit the movement of adjacent edges of support layers in a horizontal direction in the plane of installed floor elements and perpendicular to said adjacent edges.
• said floor elements and/or said coupling inserts can comprise cavities and/or hollow portions adapted for being partially filled with an adhesive material, for example a grout, filling a space between the top layers of two floor elements in a floor covering so that the adhesive material can contribute to limiting vertical and/or horizontal movements between the floor elements.
• an adhesive material for example a grout
• a floor element and a coupling insert as described in relation to the first independent aspect can both form an invention per se, as well as the pertaining methods for installing a floor covering using such floor elements and coupling inserts.
• the invention is a floor element comprising a top layer, preferably made of a ceramic material, and a support layer, wherein said support layer comprises edges provided with coupling elements adapted for being coupled with a coupling insert. It is particularly preferable that the floor element has the characteristic that said coupling elements are the same on opposite edges of the support layer, more preferably on all the edges of the support layer. It is to be noted that the floor element of the second independent aspect can comprise one or more of the features described above in relation to the first aspect.
• the invention also relates to a coupling insert for installing floor elements in a floor covering, comprising contact surfaces adapted to cooperate with contact surfaces of a floor element. It is particularly preferred that the coupling inserts comprises one or more of the following characteristics:
• the coupling insert of the third independent aspect can comprise one or more of the features described above in relation to the first aspect.
• the invention is a coupling insert for installing floor elements in a floor covering, wherein said coupling insert comprises at least a first portion and a second portion, characterized in that said first and said second portion are connected over a tightened or tightenable mechanical joining system.
• said mechanical joining system comprises a screw connection and/or a snapping connection, preferably comprising one or more hooks and undercuts, for example a ratchet.
• said coupling insert comprises a means for tightening said mechanical joining system, wherein said means preferably extends above the horizontal plane defined by the floor covering.
• said means is connected to said first and/or second portion over a weakened material portion.
• such weakened material portion is available below the horizontal plane defined by the floor covering.
• the means for tightening can be easily removed by causing a rupture at said weakened material portion for example by hammering sideways on said means or by giving said means a kick by the foot.
• Said means may be formed as a knob, or a nut, such as a butterfly nut.
• the mechanical connection is preferably tightened by turning said means, for example in case the mechanical connection is a screw connection.
• said means may be tightened by downward pressure and/or by levering action.
• the means may be formed as a knob as well.
• the invention also relates to a floor covering comprising a plurality of floor elements and a plurality of coupling inserts, for example as described in relation to any of the preceding aspects.
• the floor covering comprises a plurality of floor elements, wherein the floor element comprises a top layer, preferably made of a ceramic material, and a support layer, wherein said support layer comprises edges provided with coupling elements; and a plurality of coupling inserts, wherein each of said coupling inserts is mechanically coupled with at least a coupling element of at least two of said floor elements.
• the floor elements and the coupling insert of the fifth independent aspect can comprise any of the features described in the preceding aspects of the invention.
• the floor covering can comprise an adhesive material, preferably a grout, at least partially filling a space between the top layers of the floor elements.
• Said adhesive material can be polymer-based and/or, less preferably, cement-based.
• the grout is polymer-based it can be polyurethan-based, epoxy-based or silicone-based.
• the floor covering can comprise an underlayer between said floor elements and a floor basement to be covered, said underlayer can be a sound insulating mat, a moisture insulating mat or a heat insulator. It is to be noted that in alternative embodiments, the underlayer can be integrally formed in, or solidly fixed to, the floor elements, in particular in or to the support layer thereof.
• the present invention is a floor covering comprising a plurality of floor elements, wherein the floor elements comprise a top layer, preferably made of a ceramic material, and a support layer, wherein said floor covering further comprises an adhesive material, preferably a grout, at least partially filling a space between adjacent edges of top layers of said floor elements, with as a characteristic that at said space a clearance is available between adjacent edges of support layers of said floor elements.
• the available clearance can be used to set the desired width of the eventual space, for example groutline, between adjacent top layers in the floor covering.
• the clearance need not necessary be empty, but can be filled with said adhesive material and/or with an insert. Such insert may be used to set said desired width of the eventual space between the adjacent top layers or the groutline.
• the clearance may further allow for some expansion of the support layer.
• said clearance is parallel, or substantially parallel to said adjacent edges of top layers. It is clear that with a clearance between adjacent edges of the support layers, it is meant that there are no directly abutting surfaces of said adjacent edges of support layers that would hinder a moving together of the respective support layers.
• said floor elements are square or rectangular and oblong, wherein the floor elements comprise two pairs of opposite edges.
• such clearance is available at at least two opposite edges of the support layer of said floor elements, or at at least two perpendicularly extending edges of the support layer of said floor elements, or at at least two pairs of opposite edges of the support layer of said floor elements.
• said clearance is continuous over the entire thickness of said adjacent edges of support layers.
• said clearance may be available along a same plane, preferably a vertical plane, over the entire thickness of said adjacent edges.
• said adjacent edges may be overlapping vertically with either said clearance being continuous over the entire thickness of said adjacent edges of support layers or not. In this alternative case, said clearance would not be available along a same vertical plane over the entire thickness of said adjacent edges.
• said adhesive material fills said clearance at least partially, preferably wholly.
• the adhesive material at least partially or wholly fills a clearance in between adjacent edges of support layers brings additional stability to the floor covering, including to the groutline formed by means of the adhesive material filling at least partially the space between adjacent edges of top layers.
• said gap and at least a part of said clearance form a single void between said floor elements, in the absence of extraneous matter such as adhesive or an insert.
• said gap and at least a part of said clearance are available along a same vertical plane. In such case the clearance is at least partly available vertically below said space between adjacent edges of top layers.
• the smallest width of said clearance as measured in a horizontal plane and perpendicular to said adjacent edges is smaller than the smallest width of said space between adjacent edges of top layers of the respective floor elements.
• the smallest width of said clearance defines the potential for movement of the support layers towards each other in the absence of extraneous matter, such as said adhesive or an insert. Since the smallest width of said clearance is smaller than said space, an insert can be introduced through said gap into said clearance under the condition that the clearance is at least partly available vertically below said space between adjacent edges of top layers. Such insert can be used for setting the width of said clearance, and subsequently of said space between top layers of adjacent floor elements.
• vertical and/or horizontal movement of said adjacent edges of support layers and/or top layers is limited at least by means of a coupling insert cooperating with said adjacent edges of support layers and/or top layers.
• At least one of said adjacent edges of said support layers and/or top layers is profiled.
• the profiles may comprise coupling elements as described in previous aspects of the present invention.
• At least one of said adjacent edges of said support layers and/or top layers defines a groove or an undercut.
• Such groove or undercut may form part of coupling elements configured to cooperate with a coupling insert.
• the present invention is a floor covering comprising a plurality of floor elements, wherein the floor elements comprise a top layer, preferably made of a ceramic material, and a support layer, with as a characteristic that vertical and/or horizontal movement of adjacent edges of support layers of said floor elements is limited at least by means of a coupling insert cooperating with at least one, preferably with both, of said adjacent edges of said support layers and/or said top layers.
• said floor covering further comprises an adhesive material, preferably a grout, at least partially filling a space between adjacent edges of top layers of said floor elements.
• the floor covering of the seventh independent aspect can comprise floor elements and/or coupling inserts that can comprise any of the features described in the preceding aspects of the invention.
• At least one of said adjacent edges of said support layers and/or top layers is profiled.
• the profiles may comprise coupling elements as described in previous aspects of the present invention.
• At least one of said adjacent edges of said support layers and/or top layers defines at least a groove and/or at least an undercut, and in that said coupling insert cooperates at least with said groove and/or said undercut.
• said groove is bordered by an upper lip and a lower lip, wherein an upper surface of said lower lip is formed in said support layer.
• a bottom surface of said lower lip may be formed by means of the bottom or downward oriented surface of said top layer, or, alternatively, is formed in said support layer.
• Said undercut may be formed at the bottom of said support layer.
• said coupling insert is configured to be brought into engagement with at least one of said adjacent edges by means of a substantially horizontal movement or a downward movement of said coupling insert towards the respective edge.
• Such coupling insert in particular a coupling insert that can be brought into engagement at least with a substantially horizontal movement enables a more fluent installation.
• said coupling insert comprises one or more openings, cavities or hollow portions filled with said adhesive material.
• the ability for the adhesive material to pass through an opening in the coupling insert, to fill a cavity or hollow portion of the coupling insert, allows for a more stable floor covering also at places where the coupling insert is available. In this way, the adhesive material may mechanically lock the coupling insert in place.
• the adhesive material may enter any grooves or undercuts forming part of the coupling elements at the respective edges.
• the finally obtained floor covering may be attributed with an enhanced stability.
• at least 30% or at least 50%, or even at least 75% of the length of an edge of a support layer is free from coupling insert.
• this is the case at all edges of a respective support layer.
• said coupling insert comprises abutting surfaces in contact with said adjacent edges.
• Such coupling insert allows setting the desired width, as measured in a horizontal plane perpendicular to the adjacent edges, of the space between adjacent top layers, for example the width of a groutline between ceramic top layers.
• said floor elements are installed in a checkerboard pattern, i.e. in parallel rows without offset between adjacent tiles, and in that said coupling insert is at least available at the position where corners of four floor elements are adjacent to each other, meet or face each other.
• the coupling insert of the above mentioned particular independent aspect is applied and/or said coupling insert comprises a lower portion and a separate upper portion, wherein the lower portion and the upper portion are preferably connected over a tightened or tightenable mechanical joining system.
• said mechanical joining system may comprise a screw connection and/or a snapping connection, preferably comprising one or more hooks and undercuts.
• at least a clamping of a portion of the adjacent support layers is obtained.
• at least a limitation of the mutual vertical motion of adjacent support layers is obtained.
• the clamping may additionally result in a limitation of the mutual horizontal motion of adjacent support layers.
• Figure 1 shows a top view of a floor covering 1 comprising a plurality of floor elements 2 separated by a gap 3 filled with a grout 4.
• the floor elements 2 are squared and are disposed in a checkerboard configuration.
• the floor elements 2 comprise a top layer 5 attached on top of a support layer 6.
• the top layer 5 is a ceramic tile and the support layer 6 is made of PVC, more particularly rigid PVC or PVC having 5 phr of plasticizer or less.
• the support layer further comprises calcium carbonate and form a so-called SPC.
• Figure 2 further shows that the gap 3, filled with the grout 4, is defined between adjacent edges 7-8 of top layers 5 of the floor elements 2.
• a clearance 9 is available between adjacent edges 10-11 of support layers 6 of said floor elements 2.
• said clearance 9 is continuous over the entire thickness T2 of support layers 6.
• the clearance 9 is partially filled with said grout 4.
• the adjacent edges 10-11 of said support layers 6 are overlapping vertically, while said clearance 9 is available along a same plane, in this case inclined plane P1, over the entire thickness T2 of said adjacent edges 10-11 of said support layers 6.
• Said gap 3 between the adjacent edges 7-8 of said top layers 5 and at least a part of said clearance 9 form a single void between said floor elements 2, in the absence of extraneous matter such as adhesive or an insert.
• the clearance 9 is at least partly available vertically below said gap 3 between adjacent edges 7-8 of top layers 5.
• the smallest width W9 of said clearance 9 as measured in a horizontal plane and perpendicular to said adjacent edges 10-11 is smaller than the smallest width W3 of said gap between adjacent edges 7-8 of top layers 5 of the respective floor elements 2.
• the smallest width W9 of said clearance 9 defines the potential for movement of the support layers 6 towards each other in the absence of extraneous matter, such as said grout 4 or an insert.
• Figure 3 illustrates an embodiment where the adjacent edges 10-11 of the support layers 6 are overlapping vertically and the clearance 9 is available along the entire thickness T2 of the support layer 6, albeit not continuously.
• the clearance 9 is formed by a top portion 12 and a bottom portion 13.
• only the top portion 12 of said clearance forms a common void with said gap 3.
• the top portion 12 of said clearance 9 can be filled with said grout 4 or with another adhesive material.
• the clearance 9 allows to set the desired width W3 of the gap 3 between the edges 7-8 of the top layers 5. Adjacent edges 10-11 of the support layers 6 contact each other at contact surfaces 14-15 that, in this example, do not hinder a horizontal moving together of the support layers 6.
• Figure 4 illustrates an embodiment where the clearance 9 is continuous along the entire thickness T2 of the support layer 6.
• the clearance 9 is available along a same vertical plane, for example the plane P2 along the entire thickness T2 of the support layers 6.
• the clearance 9 has been filled with an insert 16 that sets the desired width W3 of the gap 3 between adjacent edges 7-8 of the top layers 5.
• the insert 16 can be introduced through said gap 3 into said clearance 9 under the condition that the clearance 9 is at least partly available vertically below said gape between adjacent edges 7-8 of top layers 5, before said grout 4 is provided in the gap 3.
• Figure 5 illustrates an embodiment with the characteristics of, amongst others, the first, fifth, sixth and seventh independent aspect of the present invention.
• vertical movement of adjacent edges 10-11 of support layers 6 is limited by means of a coupling insert 17 cooperating with adjacent edges 10-11 of support layers 6.
• said adjacent edges 10-11 of said support layers 6 have been provided with profiles comprising coupling elements 18.
• the coupling elements 18 comprise a groove 19, bordered by an upper lip 20 and a lower lip 21, wherein an upper surface of said lower lip 21 and a lower surface of said upper lip 20 are both formed in said support layer 6.
• first contact surfaces 22 responsible for limiting said vertical movement between said coupling insert 17 and said support layer 6 are formed on said upper surface of said lower lip 21 and on said lower surface of said upper lip 20.
• the coupling insert 17, illustrated here, further comprises abutting surfaces 23 extending substantially vertically, or in this case vertically, contacting adjacent edges 10-11 of said support layers 6.
• the abutting surfaces 23 may assist in setting the desired width W3 of said gap 3 between adjacent edges 7-8 of top layers 5.
• FIG. 6 clearly shows that the coupling insert 17 of figure 5 may cooperate with facing corner areas of four floor elements 2.
• the grout 4 is not shown in this figure.
• all edges 10-11 of support layers 6 have been provided with a similar or same profiles comprising coupling elements 18.
• the coupling insert 17 has a cross shape with a cross shaped central portion 24 and lateral portions 25 engaging with said grooves 19.
• the lateral portions 25 have a slightly smaller vertical thickness than said central portion 24.
• FIG 6 further shows that the coupling insert 17 is provided with an opening 26, in this case, located in the central portion 24.
• the opening 26 may allow the grout 4 or another adhesive to enter through the coupling insert 17.
• the edges 10-11 of the support layer 6 extend beyond the associated edge 7-8 of the top layer 5 at all sides of the floor element 2.
• Figure 7 shows another example wherein the support layer 6 extends beyond an edge of the top layer 5 and wherein between the top layer 5 and the extending edge of the support layer 2 is formed an upper groove 19A below the top layer 5 adapted to receive a lateral portion 25 of the coupling insert 17.
• the upper groove 19A is bordered by an upper lip 20 and a lower lip 21.
• the lower surface of the upper lip 20 is formed by the downward oriented surface 27 of said top layer 5.
• the upper surface of the lower lip 21 is formed by the upper surface of the extending edge of the support layer 6.
• an upward oriented recess 28 adapted to receive a downward oriented hump 29 of a lateral portion 25 of the coupling insert 17 so that second contact surfaces 30 are formed limiting movement of the coupling insert 17 in the horizontal direction H.
• the central portion 24, that extends vertically from the lateral portion 25 thereof, comprises a protrusion 31 extending horizontally and coupled into the groove 19 formed in the support layer 6 so that two sets of first contact surfaces 22 are formed limiting the movement of the coupling insert 17 in the vertical direction V.
• Figure 8 shows a slightly different system or floor covering from that in figure 7 .
• the difference is mainly in that first contact surfaces 22 are formed in an undercut 19B at the bottom of the support layer 6.
• the protrusion 31 of the central portion 24 of the coupling insert 17 forms only one set of first contact surfaces 22 limiting the movement in one vertical direction V; the second set of contact surfaces 22 limiting the movement in the opposite vertical direction is formed by the lower surface of the lateral portion 25 and the upper surface of the lower lip 21 of the upper groove 19A, which is formed in the support layer 6.
• Figure 9 shows a system that differs from that of figure 8 in that the coupling insert 17 can be coupled upside down compared to the other system and there is no upper groove 19A between the downward oriented side 27 of the top layer 5 and the support layer 6.
• the coupling elements 18 of the support layer 6 are therefore formed mainly in a recessed area 19C at the bottom of the support layer 6 itself. This configuration may help limit the thickness T2 of the support layer 6.
• Figure 10 shows a system that differs from that of figure 9 in that the support layer 6 does not extend beyond the edges 7-8 of the top layer 5. In this way the width W3 of the distance between the edges 7-8 of the top layer 5 is completely defined by the width W24 of the central portion 24 of the coupling insert 17.
• Figure 11 shows a variant of the system of figure 8 , wherein the coupling elements 18 are entirely formed in the portion of the support layer 6 that extends horizontally beyond the edge 7-8 of the top layer 5.
• Figure 12 shows a variant of the system of figure 5 wherein the coupling insert 17 is substantially flat.
• the coupling insert does not form the set of second contact surfaces 30 limiting the movement in the horizontal direction H, but only the second set of first contact surfaces 22 limiting the movement in vertical directions V.
• the grout 4 filling the gap 3 between the edges 7-8 of the top layers 5 can limit the horizontal movement by sticking together the top layers 1, and in figure 12 it is shown that the grout 4 can fill the upward facing recess 28 on the upper surface of the support layer 6 thereby improving its anchoring and the effectiveness in limiting the horizontal movement.
• Figure 13 shows a simpler variant of the example of figure 12 wherein the extending portion of the support layer 6 is minimized and there are no other coupling elements 18 with the exception of the groove 19 hosting the coupling insert 17.
• the coupling insert 17 can be made of an elastic material, for example a compressible material that is press-fitted in the groove 19 so that the elastic reaction exerts a force limiting the horizontal movement.
• Figure 14 shows an example wherein the coupling insert 17 has, in its lateral portions 25, downward facing humps 29 adapted to cooperate with upward oriented recesses 28 in the support layer 6 to form second contact surfaces 30 limiting the movement in the horizontal direction H.
• the movement in the vertical directions V is not limited by the coupling insert 17.
• the coupling insert 17 can comprise hollow portions or openings 26 adapted to receive the grout 4.
• Figure 15 shows perspective views of the coupling insert 17 which a top view can be cross-shaped or T-shaped. It is noted that the coupling insert in any of the example can be cross-shaped or T-shaped.
• Figure 16 illustrates an embodiment, in accordance with the fourth independent aspect, practicing a coupling insert 17 formed by two separate bodies.
• the coupling insert 17 comprises at least a lower first portion 36 and a separate upper second portion 37, wherein said first portion 36 and said second portion 37 are connected over a tightened or tightenable mechanical joining system 38.
• Figure 16 illustrates the coupling insert 17 during installation.
• the mechanical joining system 38 is, in this case, a snapping connection having a plurality of hooks 39 and undercuts 40.
• Said second portion 37 can be tightened onto the edges 10-11 of the support layer 6, and in this case be brought with the humps 29 thereof in a tightened engagement with the upwardly facing recesses 28 in said support layer 6 so that second contact surfaces 30 are formed limiting the movement in horizontal directions.
• the coupling insert 17 further comprises means 41,42 for tightening said mechanical joining system 38, more particularly said second portion 37.
• said means 41,42 comprise a knob 41 for turning a screw 42 that presses on the second portion 37.
• the knob 41 extends above the horizontal plane defined by the floor covering 1, i.e. above the upper surface of the top layers 5.
• the second portion 37 can be pressed down and its hooks 39 can engage with undercuts 40 located further down until the support layer 6 hinders further downward movement of said second portion 37.
• the first portion 36 is placed below the edges 10-11 of said support layer 6, in this configuration the extending portions 10-11 of the support layer 6 are clamped between said first and second portion 36, 37 so that two couple of first contact surfaces 22 limiting the movement in opposite vertical directions.
• the screw 42 rotates over a threaded portion 43 of an upward directed stem 44 connected to the first portion 36 passing through an opening 26 in the second portion 37.
• said means 41,42 are connected to said first portion 36 over a weakened material portion 45, for example in said upward directed stem 44.
• the weakened material portion 45 is available at a location below the horizontal plane defined by the floor covering, i.e. below the upper surface of the top layers 5.
• the weakened material portion 45 allows for easily removing the means 41, 42 for example with the blow of a hammer.
• the gap 3 between the edges 7-8 of the top layers 5 can be filled with grout 4.
• Figure 17 shows another example of a coupling insert 17 having a first portion 36 and a separate second portion 37 that are connected over a mechanical connection 38.
• the mechanical connection 38 is a screw connection made by a threaded opening 26 in the second portion 37 engaged to the threaded portion 43 of the upward directed stem 44.
• the means 41 for tightening are in the example also shaped as a knob, but are here connected to said second portion 37 over a weakened material portion 45, in the example placed above the second portion 37 itself. Turning the knob 41 will rotate the second portion 37 down the threaded upward directed stem 44 and tighten it up against an upper surface of the support layer 6.
• the second portion 37 and the first portion 36 are configured to clamp the edges 10-11 of said support layers 6 and form substantially horizontal first contact surfaces 22 that limit movement in the vertical direction V. The tightened contact may limit the movement in the horizontal direction H as well.
• Figure 18A and 18B shows a similar coupling insert 17 as figure 16 and 17 , wherein the edges 10-11 of the support layer 6 do not extend beyond the edges 7-8 of the top layers 5.
• the upper groove 19A is formed in between the edge 10-11 of the support layer 6 and the top layer 5.
• the undercut 19B is formed, that in this case has a downward faced recess to host an hump 29 in the first portion 36 for forming the second set of contact surfaces 30 that limit movement in the horizontal direction H.
• the mechanical joining system 38 is formed by a plurality of hooks 39 and undercuts 40 to form a linear ratchet.
• the means 41,42 comprise a knob 41 connected to the second portion 37.
• the second portion 37 is pressed against the edge 10, 11 of the support layers 6 in the upper groove 19A so that the first and second portions 36, 37 clamps the edge 10, 11 of the support layers 6 and two sets of first contact surfaces 22 to limit movement in vertical directions V.
• the mechanical joining system 38 is configured to prevent the second portion 37 from raising up and loosening the clamping action on the support layer 6.
• the upper groove 19A provides room underneath the top layer 5 for the contact surfaces 22,30 while limiting the width W3 of the gap 3 between the top layers 5.
• Figure 18A and 18B show two different configuration of the same floor system described above.
• the support layer 6 is not yet clamped between the first and second portions 36, 37 of the coupling insert 17.
• figure 18B it is shown a configuration wherein the support layer 6 is clamped between the first and second portions 36, 37 of the coupling insert 17.
• the means 41, 42A are removed and the gap 3 is filled with the grout 4.
• an underlayment 50 is installed between the support layer 6 and the subfloor 51.
• the present invention relates to one or more of the items as listed below.

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• Floor Finish (AREA)

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• 2025
  • 2025-04-16 EP EP25171005.9A patent/EP4636194A2/de active Pending

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