NZ605679B - Floor panel - Google Patents

Abstract

605679 A reinforced rectangular floor panel (1) is disclosed. The panel has complementary profiles for interconnecting adjacent floor panels on at least two opposite edges (3, 4). The profiles have a frontal face (5) and a counter face (9). The corresponding profile also has a frontal face (10) and counter face (14) that cooperate to lock the panels together. The frontal faces and the counter faces are provided with locking tabs (15-18) cooperating in the interconnected position of adjacent floor panels. The floor panel further also has two reinforcement layers (19, 20) extending substantially in parallel to the upper and lower sides of the floor panel. The locking tabs are substantially positioned at the level of the reinforcement layers. counter face (14) that cooperate to lock the panels together. The frontal faces and the counter faces are provided with locking tabs (15-18) cooperating in the interconnected position of adjacent floor panels. The floor panel further also has two reinforcement layers (19, 20) extending substantially in parallel to the upper and lower sides of the floor panel. The locking tabs are substantially positioned at the level of the reinforcement layers.

Description

PATENTS FORM NO. 5 Our ref: CHW 234798NZPR NEW ZEALAND PATENTS ACT 1953 COMPLETE SPECIFICATION Floor panel We, IVC N.V. a Belgian company of heidslaan 29, B-8580 Avelgem, Belgium hereby declare the ion, for which we pray that a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the following statement: (followed by page 1a) Floor panel The invention relates to a rectangular floor panel with mutually parallel, ntially planar upper and lower sides and with two pairs of respective mutually opposite side edges connecting the upper and lower sides, wherein the opposite side edges of a pair are provided with complemen— tary profiles for interconnecting adjacent floor panels, wherein of at least one pair of opposite side edges the pro- file of a first side edge is defined by a frontal face ex— tending substantially vertically from the upper side and over part of the thickness of the floor panel, a first sup— port face extending inwardly substantially in a horizontal direction from the lower end of said frontal face, a locking face extending upwardly from the inner end of said first support face to a position at some distance from the upper side of the floor panel, a second support face extending in— wardly again from the upper end of said locking face and fi— nally a counter face ing downwardly from the inner end of said second support face all the way to the lower side of the floor panel, and wherein the profile of the correspond— ing second side edge of the respective pair of te side edges is d by a frontal face extending ntially vertically from the lower side and over part of the thick— ness of the floor panel, a first support face extending in— wardly substantially in a horizontal direction from the up— per end of said frontal face, a locking face extending down— wardly from the inner end of said first support face to a on at some distance from the lower side of the floor panel, a second support face extending inwardly again from the lower end of said locking face and finally a counter face extending ly from the inner end of said second support face all the way to the upper side of the floor pan— el, wherein for maintaining two adjacent floor panels in an (followed by page 2) interconnected on a frontal face of a e cooperates with a counter face of the other profile, the first support face of a profile cooperates with the second support face of the other profile and the locking faces of both profiles cooperate with each other, and wherein the frontal faces and the counter faces are provided with locking tabs ating in the interconnected position of adjacent floor panels.

Such a type of floor panel is known from the US patent application 2009/133358. The described profiles with locking tabs in the onnected state of adjacent floor panels create a locking between adjacent panels in the horizontal and vertical direction. In particular, primarily the ation between the frontal faces and the counter faces and between the locking faces causes a horizontal locking, whereas the vertical locking (and positioning in a common plane) primarily is caused by the cooperation between the first and second support faces and between the locking tabs. However, it is noted that the term cooperating should not be construed in such a d sense that the respective faces at all times would engage each other.

It is an object of the t invention to provide an improved floor panel of the type referred to above.

Alternatively it is an object to at least provide the public with a useful choice.

Thus, in accordance with the present ion the floor panel further is provided with two reinforcement layers extending substantially in parallel to the upper and lower sides of the floor panel, wherein the locking tabs substantially are positioned at the level of said reinforcement .

By virtue of the use of the reinforcing layers it becomes possible to optimally adapt several parts of the floor panel to demands imposed thereupon using an appropriate choice of material, without detrimentally influencing the effect of the operation of the locking tabs. By means of the reinforcement layers the locking tabs at one hand may be designed iently le, while at the other hand be— ing sufficiently . Further it becomes possible to make the reinforcement layers stiffer than the remainder of the floor panel (which possible may be constructed from compo— nents having a different modulus of elasticity).

A floor panel to which the present invention re— lates may, in a manner known per se, be constructed from different layers and may have different dimensions and thicknesses. Within the scope of the present invention it is not necessary to further elucidate these aspects. Further it is possible that the floor panel (or components thereof) comprise a considerable amount (for e more than 30%) of recycled ic) material.

Using the invention a floor panel is ed which together with corresponding floor panels may be inter— connected in an easy manner for creating a floor ng which during a prolonged life defines a stable assembly. The floor panel may be machined in many, very divers manners.

In a red embodiment of the floor panel ac— cording to the present invention, the reinforcement layers extend into the locking tabs. As a result these locking tabs in an optimal manner take advantage of the effect of these reinforcement layers.

However, the above does not preclude the possibil- ity that the reinforcement layers end near to the g tabs without extending therein. Also in such a case a strengthening effect on the locking tabs already may be ob- tained.

Preferably the locking tabs and the reinforcement layers are positioned in the immediate vicinity of the lower side and upper side of the floor panel.

The (locking) forces acting between floor panels in the interconnected position of such adjacent floor panels extend inclined between pairs of cooperating locking tabs at the upper side and at the lower side of the floor panels.

The closer such pairs of ating locking tabs are to the upper side and lower side, respectively, of the floor pan— els, the larger will be the part of the thickness of said floor panels contributing to the force transmittal (and the more strong the connection n the adjacent floor panels will be).

In one embodiment of the floor panel the lower and upper reinforcement layers are positioned at a level of be— tween 8 and 14% and a level of between 93 and 96%, respec— tively, of the total ess of the floor panel. For exam- ple, when the floor panel has a thickness of about 4,5 mm, the lower and upper reinforcement layers then are positioned at a level of between 0,4 and 0,6 mm and a level of between 4,2 and 4,3 mm, respectively, above the lower side of the floor panel.

The above does not preclude that the floor panel also may have a different thickness, for example between 4 and 8 mm.

In another embodiment of the floor panel according to the present ion the upper reinforcement layer is positioned above the second support face of the profile of the first side edge and wherein the lower reinforcement lay— er is positioned below the second support face of the pro— file of the second side edge.

Basically this means that both reinforcement lay— ers extend uninterrupted along the entire length (and/or width) of the floor panel t being interrupted by the profiles defined at the respective side edges, such that their reinforcing effect may be used in an optimal manner. 3O The reinforcement layers may comprise a woven or ven fibre material, for example a glass fibre materi— al. They may have a thickness of 0,2 — 0,4 mm.

In another embodiment of the floor panel according to the present invention the locking face of the profile of the first side edge is inclined upwardly and inwardly with a first angle of 14—21° with respect to the al, whereas the locking face of the profile of the second side edge is ed downwardly and inwardly with a second angle of 15— 22° with respect to the vertical and wherein the second an— gle is at most 1° larger than the first angle.

As a result of such a shape, interconnecting two adjacent floor panels may be carried out with ease, while the said locking faces slide along each other and the lock— ing gradually get engaged. The l angles depend from the shape and material properties of the locking tabs.

Interconnecting adjacent floor panels at said first and second side edges primarily occurs through a mutu— al al (translating) connecting movement. When both pairs of opposite side edges are provided with said comple— mentary profiles with frontal faces, first and second sup— port faces, locking faces and counter faces, such a vertical motion occurs here.

However, it is conceivable too that laying floor panels is a combination of (primarily) a rotation around one of the side edges, whereas at the two side edges perpendicu— lar to said side edge primarily a vertical motion occurs. In such a case the respective shape will differ among pairs of opposite side edges, as is known per se.

The floor panel substantially may comprise a num- ber of stacked plastic—based layers, such as for example a top layer comprising a first reinforcing layer, and a core layer positioned there below comprising a second reinforcing layer. Further it is possible that the top layer successive— ly comprises a arent finishing layer, a decorative 3O layer and a thermoplastic support layer. The core layer may comprise a thermoplastic al.

In another embodiment the floor panel comprises bevels at the connection of the frontal face of the profile of the first side edge and the connection of the counter face of the profile of the second edge, respectively, with the upper side of the floor panel. Such bevels may be manufactured in different ways, for example by locally heating and next displacing material and/or by milling off material.

Unless the context clearly requires otherwise, throughout the ption and claims the terms “comprise”, “comprising” and the like are to be construed in an inclusive sense, as opposed to an ive or tive sense. That is, in the sense of “including, but not limited to”.

Hereinafter the invention is elucidated by means of the drawing, in which: Figure 1 illustrates a cross section of two adjacent, not yet interconnected, floor panels according to the invention; Figure 2 illustrates a cross section of two adjacent floor panels according to the invention during interconnecting, Figure 3 illustrates a cross section of two nt, onnected, floor panels according to the invention.

It is noted that indications of directions and positions always relate to floor panels which assume a horizontal, planar position. In the respective figures a cross section is illustrated of (in a top plan view) substantially rectangular floor panels. Each floor panel ses a planar upper side 1 and a substantially planar lower side 2 in parallel therewith. r, each panel comprises two pairs of respective mutually opposite side edges 3,4 connecting the upper and lower sides. In the figures always only the side edges belonging to one pair are shown.

The opposite side edges of a pair are provided with complementary es for interconnecting nt floor panels. In the illustrated embodiment the profile of a first side edge 3 of the illustrated pair of opposite side edges is defined by a frontal face 5 extending substantially vertically from the upper side 1 and over part of the thickness of the floor panel, a first support face 6 extending inwardly substantially in a horizontal direction from the lower end of said frontal face 5, a locking face 7 extending upwardly from the inner end of said first support face 6 to a position at some distance from the upper side 1 of the floor panel, a second support face 8 extending inwardly again from the upper end of said locking face 7 and finally a counter face 9 extending downwardly from the inner end of said second support face 8 all the way to the lower side 2 of the floor panel.

In a ponding manner the e of the cor— responding second side edge 4 of the respective pair of op— posite side edges is defined by a frontal face 10 extending substantially vertically from the lower side 2 and over part of the ess of the floor panel, a first support face 11 extending inwardly substantially in a horizontal direction from the upper end of said frontal face 10, a locking face 12 extending downwardly from the inner end of said first support face 11 to a position at some distance from the low— er side 2 of the floor panel, a second t face 13 ex— tending inwardly again from the lower end of said locking face 12 and finally a counter face 14 extending upwardly from the inner end of said second support face 13 all the way to the upper side 1 of the floor panel.

For in an onnected position maintaining the relative position of two adjacent floor panels (see figure 3) a frontal face 5 and 10, respectively, of a profile coop— erates with a counter face 14 and 9, respectively, of the other profile. Further, the first support face 6 and 11, re- spectively, of a e ates with the second support face 13 and 8, respectively, of the other profile. Finally the locking faces 7 and 12 of both profiles cooperate with each other.

The frontal faces 5,10 and the counter faces 9,14 3O are provided with locking tabs 15—18 ating in the in— terconnected position of adjacent floor panels. In the in— terconnected position (figure 3) the tabs 15 and 17 engage behind the tabs 18 and 16, such that basically a good mutual vertical locking between adjacent floor panels is obtained.

The floor panel further is provided with two re— inforcement layers 19,20 extending substantially in parallel to the upper and lower sides of the floor panel, wherein the locking tabs 15—18 substantially are positioned at the level of said reinforcement . The reinforcement layers 19,20 may extend into the locking tabs 15—18 (for example all the way to the most protruding part thereof) but may also end close thereto.

The locking tabs 15-18 and the reinforcement lay— ers 19,20 are positioned in the immediate vicinity of the lower side 2 and upper side 1 of the floor panel. As a re— sult, when one tries to move the floor panels apart (force 21) in the interconnected position of adjacent floor panels (figure 3), a connecting force (arrow 22) is created which extends inclined over a large part of the total ess of the floor panels, thus in an l manner using the strength of the floor panels.

For example it is possible that the lower and up- per reinforcement layers 20 and 19, respectively, are posi— tioned at a level of between 8 and 14% and a level of be— tween 93 and 96%, tively, of the total thickness of the floor panel (counted from the lower side 2 of the floor panel).

The upper reinforcement layer 19 is positioned above the second support face 8 of the profile of the first side edge 3, whereas the lower reinforcement layer 20 is po- sitioned below the second support face 13 of the profile of the second side edge 4. As a result these reinforcing layers are not interrupted by these profiles. 3O AS illustrated in figure 2, the locking face 7 of the profile of the first side edge 3 is inclined upwardly and ly with a first angle A of 14—21° with respect to the vertical, whereas the locking face 12 of the profile of the second side edge 4 is inclined rdly and ly with a second angle B of 15—22° with respect to the verti— cal. The second angle B is at most 1° larger than the first angle A. As a result of such an inclined orientation of the locking faces 7,12 the locking movement, during which the locking faces slide along each other, may occur in an opti— mal manner while bringing the cooperating locking tabs 15,18 and 17,16, respectively, into engagement with each other.

Such a movement occurs by (according to arrow 23) pressing down a floor panel while the adjacent floor panel rests on a floor 26 with its lower side.

Finally the floor panel ing to the present invention may comprise bevels 24,25 at the connection of the frontal face 5 of the profile of the first side edge 3 and the connection of the counter face 14 of the profile of the second edge 4, respectively, with the upper side 1 of the floor panel. This may contribute to ing a decorative appearance in the assembled position.

The ion is not d to the embodiments described before which may be varied widely within the scope of the invention as defined by the appending claims.

Claims (15)

1. gular floor panel with ly parallel, substantially planar upper and lower sides and with two pairs of respective mutually opposite side edges connecting the upper and lower sides, wherein the te side edges of a pair are provided with complementary profiles for interconnecting adjacent floor panels, wherein of at least one pair of opposite side edges the profile of a first side edge is defined by a frontal face extending substantially vertically from the upper side and over part of the thickness of the floor panel, a first support face extending inwardly substantially in a horizontal direction from the lower end of said frontal face, a locking face extending upwardly from the inner end of said first support face to a position at some distance from the upper side of the floor panel, a second support face extending inwardly again from the upper end of said locking face and finally a counter face extending downwardly from the inner end of said second support face all the way to the lower side of the floor panel, and wherein the profile of the ponding second side edge of the respective pair of opposite side edges is defined by a frontal face extending substantially vertically from the lower side and over part of the thickness of the floor panel, a first support face extending inwardly substantially in a horizontal direction from the upper end of said frontal face, a locking face extending downwardly from the inner end of said first support face to a position at some distance from the lower side of the floor panel, a second support face extending inwardly again from the lower end of said locking face and finally a counter face extending upwardly from the inner end of said second support face all the way to the upper side of the floor panel, wherein for maintaining two adjacent floor panels in an interconnected position a l face of a profile cooperates with a counter face of the other profile, the first support face of a e cooperates with the second t face of the other profile and the g faces of both es cooperate with each other, and n the frontal faces and the counter faces are provided with locking tabs cooperating in the interconnected position of adjacent floor panels, wherein the floor panel further is provided with two reinforcement layers extending substantially in parallel to the upper and lower sides of the floor panel, wherein the locking tabs substantially are positioned at the level of said reinforcement layers.

2. Floor panel according to claim 1, wherein the reinforcement layers extend into the locking tabs.

3. Floor panel according to claim 1 or 2, wherein the locking tabs and the reinforcement layers are oned in the immediate vicinity of the lower side and upper side of the floor panel, that is, wherein at least part of the lower and upper reinforcement layers are positioned at a level of between 8 and 14% and a level of between 93 and 96%, respectively, of the total thickness of the floor panel.

4. Floor panel according to claim 3 having a thickness of about 4,5 mm, wherein the lower and upper reinforcement layers are positioned at a level of between 0,4 and 0,6 mm and a level of between 4,2 and 4,3 mm, respectively, above the lower side of the floor panel.

5. Floor panel according to any one of the previous claims, n the upper reinforcement layer is positioned above the second support face of the profile of the first side edge and wherein the lower reinforcement layer is positioned below the second support face of the profile of the second side edge.

6. Floor panel according to any one of the previous claims, n the reinforcement layers comprise a woven or non-woven fibre material.

7. Floor panel according to claim 6, wherein the reinforcement layers comprise a glass fibre material.

8. Floor panel according to any one of the previous claims, n the reinforcement layers have a thickness of 0,2 - 0,4 mm.

9. Floor panel according to any one of the previous claims, n the locking face of the profile of the first side edge is inclined upwardly and inwardly with a first angle of 14-21° with respect to the vertical, s the locking face of the e of the second side edge is inclined downwardly and inwardly with a second angle of 15-22° with respect to the vertical and wherein the second angle is at most 1° larger than the first angle.

10. Floor panel according to any one of the previous claims, wherein both pairs of opposite side edges are ed with said complementary es with l faces, first and second support faces, g faces and counter faces.

11. Floor panel according to any one of the previous , and substantially comprising a number of stacked plastic-based layers, such as for example a top layer comprising a first reinforcing layer, and a core layer positioned there below comprising a second reinforcing layer.

12. Floor panel according to claim 11, wherein the top layer successively comprises a transparent finishing layer, a decorative layer and a thermoplastic support layer.

13. Floor panel according to claim 11 or 12, wherein the core layer comprises a thermoplastic material.

14. Floor panel according to any one of the previous claims and comprising bevels at the connection of the frontal face of the profile of the first side edge and the connection of the r face of the profile of the second edge, respectively, with the upper side of the floor panel.

15. A rectangular panel substantially as described herein with reference to the accompanying drawings. 21:15 20 9876 2 01112132? Fi 11125 119 220169876