US20230046217A1

US20230046217A1 - Reversible floor covering element

Info

Publication number: US20230046217A1
Application number: US17/793,122
Authority: US
Inventors: Benny Schacht; Jan De Rick
Original assignee: Flooring Industries Ltd SARL
Current assignee: Flooring Industries Ltd SARL
Priority date: 2020-01-16
Filing date: 2020-01-16
Publication date: 2023-02-16
Also published as: CA3164416A1; WO2021144613A1

Abstract

A floor covering element includes coupling means at two opposite edges. The floor covering element includes one or a combination of two or more of the following features: the top surface and/or the bottom surface is, at the respective edge, provided with a lowered surface, such as a bevel; the coupling means comprise a tongue with one or more elastically bendable portions; the coupling means are configured to allow for a closed connection at only one of the top and bottom surfaces; the coupling means allow for an assembly and/or disassembly by angling in, respectively out, upwardly and downwardly; the groove and/or the tongue are formed by a separate insert; the coupling means have a varying geometry along the respective edge; the floor covering element has a decorative surface at the top surface and at the bottom surface.

Description

The present invention relates to floor covering elements having one or more features making them particularly suitably to be installed, upon choice of the installer, with either major surface facing the room. The invention also relates to wall and ceiling elements having similar features.
Reversible floor covering elements are known from WO 2016/010414. The coupling means at the edges of the elements disclosed in WO '414 either allow for a connection by means of a horizontal shifting movement of the respective edges towards each other, or by means of a downward movement of one of the edges towards the other. The elements disclosed in WO '414 suffer from several disadvantages. The panels are hard to produce, since an absolute matching of thickness among the panels and a closing of the joint at both major surfaces is necessary or desired. Height differences may be unavoidable at at least the bottom or top major surface, due to thickness variations among adjacent floor covering elements. The panels of WO '414 are further hard to disassemble.
The present invention in the first place seeks to provide alternatives to the panels of the state of the art, and, in accordance with several preferred embodiments, offers a solution to one or more of the problems with the panels from the state of the art.
Therefore, the invention in accordance with its first independent aspect is a floor covering element having a major top surface and a major bottom surface and having at least two edges comprising coupling means, wherein these coupling means allow to create a mutual locking with a similar floor covering element at the respective edges, wherein the locking is active in a horizontal direction perpendicular to the respective edge and in the plane of the floor covering elements, and is active in a vertical direction perpendicular to the plane of the floor covering elements, characterized in that the floor covering element further shows one or a combination of two or more of the following features:
1/at least one of the top surface and the bottom surface is, at the respective edge, provided with a lowered surface, such as a bevel;
2/only one of the top surface and the bottom surface is, at the respective edge, provided with a lowered surface, such as a bevel, the other surface being free from lowered surface at the respective edge, such that the joint between two adjacent floor covering elements is flush at the other surface, or at least with height differences lower than 0.15 mm;
3/the coupling means are basically shaped as a tongue-in-groove joint, wherein the tongue comprises one or more elastically bendable parts that bend upon forming the joint, wherein the elastically bendable part preferably remains in a bent condition when connected;
4/the coupling means are configured to allow for a closed connection, i.e. without intermediate space or with a space smaller than 0.15 mm between the coupled edges, at only one of the top surface and the bottom surface, while at the other major surface a space is available larger than the possible space at the one surface;
5/the coupling means allow for a disassembly by angling out upwardly and downwardly;
6/the coupling means are basically shaped as a tongue-in-groove joint, wherein the groove and/or the tongue are partially or wholly formed by a separate plastic insert, e.g. made by extrusion or injection molding, wherein the insert is preferably made of a material harder or more flexible or less filled than the basic material of the floor covering element, wherein the insert is provided;
7/the coupling means have a varying geometry along the respective edge, and are preferably discontinuous along the edge; coupling means extending essentially along the entire edge with an invariable geometry are of course not excluded;
8/the floor covering element has a decorative surface at the top surface and at the bottom surface.
The first listed feature, wherein at least one of the top surface and the bottom surface is, at the respective edge, provided with a lowered surface, such as a bevel, enables the masking of possible height differences at the joint at the respective surface. Preferably, in general, the floor covering elements are such that one of both major surfaces is used as a reference surface for machining the coupling means. The coupling means are thus machined in a way that in a coupled condition the possible height differences between two adjacent panels at the respective edges and measured at the relevant surface fulfils the requirements of EN 13329 in this respect, or, in other words, the possible height difference is always smaller or equal to 0.15 mm, and is in average smaller or equal to 0.1 mm as prescribed in EN 13329. The lowered surface in accordance with the present first feature is then preferably at least present at the opposite major surface. It is at the side opposite the surface used as a reference that possible thickness variations among panels will be noticed.
The lowered surface can have any shape; but is preferably a bevel or a square shaped excavation. The lowered surface may be obtained in any way, such as by means of a material removal at the relevant edge or edges and/or by means of a deformation or embossment at the relevant edge or edges. Such lowered surface may be present at both or only one of a pair of opposite edges. In the case the lowered edge is performed as a bevel, preferably the lowered surface is preferably present at both opposite edges, such that in a coupled condition of two such floor panels at the relevant edge a V-groove is obtained at the joint. In the case the lowered edge is performed as a square bevel, preferably the lowered surface is present at only one edge of the pair of opposite edges.
In accordance with the second listed feature, only one of the top surface and the bottom surface is, at the respective edge, provided with a lowered surface, such as a bevel, the other surface being free from lowered surface at the respective edge, such that the joint between two adjacent floor covering elements is flush at the other surface, or at least with height differences lower than, or at maximum possibly equal to 0.15 mm.
In accordance with a third listed feature, the coupling means may be basically shaped as a tongue-in-groove joint, wherein the tongue comprises one or more elastically bendable parts that bend upon forming the joint, wherein the elastically bendable part preferably remains in a bent condition when connected. Preferably the elastically bendable part is provided with a horizontally active locking element. Such feature may bring about a pretension effect in the coupled condition. Such pretension effect may be beneficial in actively closing the joint at one or both major surfaces. Instead of a tongue any portion of the joint may be bent. Preferably such bending is not noticeable at any of the top and bottom major surface. Such portion is preferably a portion protruding beyond the edge of the top and the bottom surface, or a portion that is in vertical direction upwards and downwards bordered by removed material.
As has become clear in the above, preferably deformations of both major surfaces are avoided during and/or after joining, in order to prevent permanent damage to the decorative top and bottom surfaces.
In accordance with a fourth listed feature, the coupling means may be configured to allow for a closed connection, i.e. without intermediate space or with a space smaller than 0.15 mm between the coupled edges, at only one of the top surface and the bottom surface, while at the other major surface a space is available larger than the possible space at the one surface. Preferably the joint at one of the major surfaces is closed, while the joint at the opposite surface forms a space between the adjacent locked together edges which is smaller than 0.15 mm, e.g. 0.05 mm or less. As has been stated before, this fourth listed feature may be beneficially combined with the first or second listed feature, wherein preferably at least a lowered surface is provided at the joint having the largest space. Such lowered surface, e.g. a bevel, may hide the open seam, or may provide a more appealing look to such seam.
In accordance with a fifth listed feature, the coupling means allow for a disassembly by angling out upwardly and downwardly. The ability of disconnecting the coupling means by angling up independently of the orientation of the major surfaces largely simplifies the installation of a floor covering assembled from such panels with the top or bottom surface facing to the room upon choice of the installer. The joint may in itself be made such that it can be connected by means of a mainly horizontal shifting movement of the respective edges towards each other, and can be disassembled by angling up, irrespective of which major surface faces the room.
In accordance with a sixth listed feature, the coupling means may basically be shaped as a tongue-in-groove joint, wherein the groove and/or the tongue are partially or wholly formed by a separate plastic insert, e.g. made by extrusion or injection molding, wherein the insert is preferably made of a material harder or more flexible or less filled than the basic material of the floor covering element, wherein the insert is provided. Such inserts allow for a larger form freedom than milled profiles, and some of the features listed here may be more easily attainable using such plastic inserts, such depending on the properties of the core material.
In accordance with a seventh listed feature, the coupling means may have a varying geometry along the respective edge, and are, in such case, preferably discontinuous along the edge; coupling means extending essentially along the entire edge with an invariable geometry are of course not excluded. Discontinuous geometry may for example allow for disassembly by shifting along the edge. A shifting along the edges may for example be used to disengage any horizontally active locking elements. The shift is preferably over a distance considerably smaller than the length of the respective edge, for example over a distance smaller than 10% of the length. After the disengagement of such elements, the panels may be distanced from one another in a horizonal direction and become completely disassembled.
It is clear that, preferably, the floor covering element has a decorative surface at the top surface and at the bottom surface. Preferably the decorative surface comprises a wear layer provided over a decorative print.
The present invention may be applied with any type of floor covering element. Preferably such floor covering element is panel-shaped, such as a laminate floor panel, a panel of LVT (luxury vinyl tile), a panel having a core of, whether or not filled, thermoplastic material, a panel having a mineral core, such as a panel having a Portland cement based core or a magnesiumoxide (MgO) based core. As stated above these panels may be provided with one decorative surface layer, or with two decorative surface layers, namely one at each major surface.
In accordance with a variant the floor covering element is sheet-shaped, such as a cushion or compact vinyl sheet or polyolefin or polyurethane (PU) sheet.
Preferably the floor covering element has a thickness of 3 mm or more, preferably 4.2 mm or more. A thickness of 3 mm still allows for the machining of intricate profiled edges comprising coupling means as introduced above.
It is clear that the present invention is in the first place aiming at a floor covering element which is reversible in the sense that the user may, upon choice, install the floor covering element with any of the major surfaces facing to the room. The use of the words “top major surface” and “bottom major surface” are thus interchangeable, and only aiming at identifying one of the major surfaces. Further the words “upward” and “downward” are referring to directions, respectively towards the top major surface and the bottom major surface.
In preferred embodiments of the invention, the floor covering element is characterized in that the coupling means are configured such that the floor covering element is reversible in the sense that the user may, upon choice, install a plurality of such floor covering elements to form a floor covering, wherein in the floor covering at least one of the floor covering elements is installed with its major top surface facing to the room; coupled with its coupling means to the coupling means of at least one of the floor covering elements installed with its major bottom surface facing to the room. The use of the words “top major surface” and “bottom major surface” are thus interchangeable, and only aiming at identifying one of the major surfaces. Further the words “upward” and “downward” are referring to directions, respectively towards the top major surface and the bottom major surface. When the top surface and the bottom surface are provided with different decorative surfaces, a wealth of opportunities to design floor coverings with the floor covering elements is provided, as in rows or between rows of floor covering elements, the floor covering elements can be installed top-down and/or bottom-up.
Preferably, the floor covering elements are rectangular with a pair of opposing long edges and a pair of opposing short edges, wherein the coupling means are available at the pair of opposing long edges, and wherein the pair of opposing short edges is provided with coupling means as well.
The coupling means applied in the present invention may take various shapes.
In accordance with a first possibility, the coupling means allow for a connection by means of a mainly horizontal shifting movement of the respective edges towards each other. The use of a shifting movement is independent on the orientation of the major surfaces. Coupling means in accordance with the first possibility may be applied to long and/or short edges of rectangular floor covering elements.
According to a second possibility the coupling means allow for connection by means of a downward movement of one of the edges towards the other. The use of a downward movement may also be made independent on the orientation of the major surfaces. Coupling means in accordance with the second possibility may be applied to long and/or short edges of rectangular floor covering elements.
According to a third particularly preferred possibility the coupling means allow for connection by means of a rotational movement about the edges of the respective major upper surfaces, as well as by means of a rotational movement about the edges of the respective major bottom surfaces. This third possibility hence allows to connect the respective edges by means of a standard angling down operation irrespective of which major surface is oriented towards the room. This possibility allows providing the consumer with a reversible product which is in all cases intuitive to install. Preferably, the floor covering elements are rectangular with a pair of opposing long edges and a pair of opposing short edges, wherein the coupling means are available at the pair of opposing long edges, and wherein the pair of opposing short edges is provided with coupling means as well. Preferably, the coupling means at the pair of opposing short edges allow for a connection by means of a downward movement of either of the edges towards the other. The present preferred embodiment thus allows the floor covering elements to be connected by means of a so-called fold-down movement, irrespective of the orientation of the major surfaces. In a fold-down installation, floor covering elements are connected at one pair of edges by angling down, while being connected with a downward movement at the other pair of edges, usually in the same angling down motion.
The third possibility may be attained with a floor covering element, which is further characterized in that a first one of the pair of opposite long edges at least comprises a portion that horizontally extends beyond the edge of the major upper surface and an excavation formed in the side of the portion opposite the major upper surface, while a second one of the pair of opposite long edges at least comprises a portion that horizontally extends beyond the edge of the major bottom surface, and an excavation formed in the side of the portion opposite the major bottom surface, wherein in a coupled condition of two such floor panels, one or more of the following features are available:
horizontally locking surfaces are available on material portions bordering the excavations in a horizonal direction outwardly; the horizontally locking surfaces are preferably in contact and/or the horizontally locking surfaces extend at an angle with the major upper surface of 30 to 60°; the horizontally locking surfaces preferably extend at least about midway in the thickness of the floor covering elements;
vertically locking surfaces are available on one or more material portions bordering one or more of the excavations in a vertical direction; the vertically locking surfaces are preferably in contact and/or extend at an angle with the major upper surface of 20 to 45°;
the features of the previous two paragraphs combined, wherein the angle at which the horizontally locking surfaces extend is larger than the angle at which the vertically locking surfaces extend;
the angle enclosed between the vertical and the imaginary line connecting the edges of the major surfaces is at both opposite edges comprised between 10 and 30°;
the portions extending beyond the respective major surfaces both have a horizontal extension between 10 and 30% of the panel thickness; preferably the horizontal extension of both portions is about equal, i.e. have a ratio between 1:0.7 and 0.7:1;
in a connected condition all locking surfaces are arranged in an area which extends horizontally to a lesser extent than vertically; the horizontal extension is preferably less than 75% of the vertical extension. Preferably, such floor covering element is further characterized in that a first one of the pair of opposite short edges at least comprises a portion that horizontally extends beyond the edge of the major upper surface and an excavation formed in the side of the portion opposite the major upper surface, while a second one of the pair of opposite short edges at least comprises a portion that horizontally extends beyond the edge of the major bottom surface, and an excavation formed in the side of the portion opposite the major bottom surface, wherein in a coupled condition of two such floor panels, one or more of the following features are available:
horizontally locking surfaces are available on material portions bordering the excavations in a horizonal direction outwardly; the horizontally locking surfaces are preferably in contact and/or the horizontally locking surfaces extend at an angle with the major upper surface of 60° to 100°; the horizontally locking surfaces preferably extend at least about midway in the thickness of the floor covering elements;
vertically locking surfaces are available on one or more material portions bordering one or more of the excavations in a vertical direction; the vertically locking surfaces are preferably in contact and/or extend at an angle with the major upper surface of 20 to 45°;
the features of the previous two paragraphs combined, wherein the angle at which the horizontally locking surfaces extend is larger than the angle at which the vertically locking surfaces extend;
the angle enclosed between the vertical and the imaginary line connecting the edges of the major surfaces is at both opposite edges comprised between 35° and 60°;
the portions extending beyond the respective major surfaces both have a horizontal extension between 0.5% and 5% of the panel thickness; preferably the horizontal extension of both portions is about equal, i.e. have a ratio between 1:0.7 and 0.7:1;
in a connected condition all locking surfaces are arranged in an area which extends horizontally about equally as vertically; the horizontal extension is preferably within 80 to 120% of the vertical extension.
In a preferred embodiment, the coupling means of the floor covering element are provided such that in coupled condition in a floor covering of a first such floor covering element with a second such floor covering element both with their top surface facing to the room, at the coupled edges of the first such floor covering element with the second such floor covering element, a point of symmetry at the middle of the height of the floor covering element is provided. The point of symmetry is such that the coupling means of the first coupled floor covering element are symmetrical with respect to the point of symmetry with the coupling means of the second coupled floor covering element. Such embodiments allow that the floor covering element is reversible in the sense that the user may, upon choice, install a plurality of such floor covering elements to form a floor covering, wherein in the floor covering at least one of the floor covering elements is installed with its major top surface facing to the room; as well as wherein in the floor covering at least one of the floor covering elements is installed with its major bottom surface facing to the room; and wherein the two beforementioned floor covering elements are coupled by means of their coupling means. The use of the words “top major surface” and “bottom major surface” are thus interchangeable, and only aiming at identifying one of the major surfaces. Further the words “upward” and “downward” are referring to directions, respectively towards the top major surface and the bottom major surface. In such embodiments, when the top surface and the bottom surface are provided with different decorative surfaces, a wealth of opportunities to design floor coverings with the floor covering elements is provided, as in rows or between rows of floor covering elements, the floor covering elements can be installed top-down and/or bottom-up, meaning with their decorative top surface or with their decorative bottom surface facing to the room.
With the same goal as in the first independent aspect, the present invention in accordance with a second independent aspect relates to a floor covering element having a decorative surface at both the major top surface and the major bottom surface, wherein the floor covering element has straight edges and/or is provided with a tongue and groove joint only locking in the horizontal direction, or, only locking in the vertical direction. Such floor covering element can be conveniently used for glued installation to the subfloor or for installation using magnetic interaction with the subfloor, with the possibility of reversibility in the sense that the user may, upon choice, install the floor covering element with any of the major surfaces facing to the room.
In the above first and second aspects, the invention has been described with reference to floor covering elements. It is however clear to the skilled person that wall covering or ceiling covering elements may be obtained, mutatis mutandis, with similar advantages as described above.

With the intention of better illustrating some features and aspects of the present invention, here below, as examples without any limitative character, some preferred embodiments are described with reference to the attached drawings, wherein:

FIG. 1 schematically illustrates a floor covering element in accordance with the invention, in a cross-section of connected elements;

FIGS. 2 to 5 in a view similar to that of FIG. 1 illustrate variants;

FIG. 6 in perspective view illustrates a further example embodiment of the present invention;

FIG. 7 shows a planar view of a floor covering element with the characteristics of the present invention;

FIG. 8 on a larger scale shows a cross-section in accordance with the line VIII-VIII indicated on FIG. 7 ;

FIG. 9 in a similar view as FIG. 8 illustrates the reversed application of the floor panel of FIGS. 7 and 8 ;

FIG. 10 in a view similar to that of FIGS. 1 to 5 shows the connected condition of the coupling means illustrated in FIGS. 8 and 9 ;

FIG. 11 on a larger scale shows a cross-section in accordance with the line XI-XI indicated on FIG. 7 ;

FIG. 12 in a similar view illustrates the reversed application of the floor panel of FIGS. 7 to 11 ;

FIG. 13 shows the connected condition of the coupling means illustrated in FIGS. 11 and 12 ;

FIGS. 14 to 16 in a view similar to FIG. 13 illustrates variants;

FIG. 17 on a larger scale repeats the view of FIG. 10 ;

FIG. 18 , on a larger scale, shows a cross-section in accordance with the line VIII-VIII indicated on FIG. 7 of another embodiment of the invention;

FIG. 19 in a similar view as FIG. 18 illustrates the reversed application of the floor panel of FIG. 18 ; and

FIG. 20 in a view similar to that of FIGS. 1 to 5 shows the connected condition of the coupling means illustrated in FIGS. 18 and 19 .

FIG. 1 shows two floor covering elements 1 having a major top surface 2 and a major bottom surface 3 in a connected condition, as illustrated through the present cross-section. The floor covering elements 1 have at least two edges 4-5 comprising coupling means 6, wherein these coupling means allow to create a mutual locking at the respective edges 4-5. The locking, as illustrated here, is active in a horizontal direction H perpendicular to the respective edges 4-5 and in the plane of the floor covering elements 1, and is active in a vertical direction V perpendicular to the plan of the floor covering elements 1.
The floor covering elements 1 illustrated here have a core 7 and a top and bottom decoration layer 8 forming, respectively, the major top surface 2 and the major bottom surface 3. The floor covering elements 1 are reversible in the sense that the user may, upon choice, install the floor covering element 1 with any of the major surfaces 2-3 facing to the room.
As mentioned in the introduction, and as illustrated here, thickness variations among adjacent floor covering elements 1 may be present. The element 1 shown at the right hand side has a total thickness T1, while the element 1 at the left hand side has a thickness T2 which is larger than T1. The present example practices the first listed feature of the invention, namely in that at least one of the top and bottom surfaces 2-3 is provided with a lowered surface 9. In this case it concerns the major surface 3 depicted at the bottom in the present orientation of the floor covering element 1, and the lowered edge is shaped as a bevel at both opposite edges 4-5, such that in the shown connected condition a V-groove is formed.
The coupling means 6 have been machined taking the major surface 2, depicted here as top surface, as the reference surface, such that, in the coupled condition, the possible height difference between the adjacent elements 1 is within the requirements of EN 13329, or even at maximum smaller than 0.10 mm. The lowered surface 9 is present at the opposite major surface 3 to hide possible thickness differences ΔT, which are present in the case of the illustrated example elements 1.
It is further clear that in the represented example also the second listed feature has been practiced, namely in that only one of the major surfaces 3 has been provided with a lowered edge 9.
The example of FIG. 1 also illustrates the fourth listed feature, in that the coupling means 6 allow for a closed connection at only one of the top surface 2 and the bottom surface 3, while at the other major surface 3, in this case oriented as the bottom major surface 3, a space S is available. In this case, the space S is about 0.05 mm.
FIG. 2 shows another example of a floor covering element 1 in accordance with the invention, which is in many respects similar to the embodiment of FIG. 1 , except that the joint is closed at both major surfaces 2-3 and that the coupling means 6 contain an elastically bendable part 10, wherein the bending of the part 10 is not noticeable at any of the top and bottom major surfaces 2-3.
FIG. 2 forms an example of the application of the first till third listed feature. In this case the coupling means 6 are basically shaped as a tongue 11 in groove 12 joint, wherein the tongue 11 comprises the elastically bendable part 10. The bendable part 10 is provided with a horizontally active locking element 13, and may, as illustrated with the dashed line 14, remain in a bent condition when connected. The elastically bendable portion 10 protrudes beyond the edge 15 of the top and bottom surface 2-3; and is in vertical direction V upwards and downwards bordered by removed material 16.
The embodiment of FIG. 3 is largely identical to the embodiment of FIG. 2 , where also the fourth listed feature has been practiced. FIG. 3 further illustrates that the lowered surfaces 9 may be provided with a separate decoration 17. In dashed line 18 a further embodiment is illustrated in which the lowered surfaces 9 overlap in the vertical direction V, i.e., in a connected condition as illustrated here, the beveled edge at one edge 5 extends vertically beyond the beveled edge surface of the opposite edge 4, and vice-versa. In this manner the gap at the joint is more effectively hidden.
FIG. 4 shows an embodiment putting the first, second and fourth listed feature in to practice, but further fulfilling the requirements of the fifth listed feature, in that the coupling means 6 allow for a disassembly by angling out upwardly and downwardly, as shown with the arrow W, upon choice of the installer, such largely depending on the chosen orientation of the major surfaces 2-3. The illustrated joint can be connected by means of a mainly horizontal shifting movement S of the respective edges 4-5 towards each other.
The possibility to disassemble in two rotational senses is mainly attained through designing the groove 12 such that it is bordered by lips 19-20 of unequal length, and by orienting the vertically active contact surface 21 between the tongue 11 and the shortest lip 19 such that it is tangent or about tangent to a circle C1 having its centerpoint at the distal edge 15 of the major surface 2 covering the longest lip 20. Preferably, the contact surface 21 is planar and extends tangentially to or with a deviation D1 of not more than 30°, preferably not more than 10° or 5°, to the tangent of the circle C1.
The longer lip 20 may be more flexible than the short lip 19. The flexibility of the longer groove lip permits a deviation D1 as illustrated here, i.e. a deviation D1 such that the vertical locking surface 21 is closer oriented towards the horizontal than the tangent to the circle C1 is at this location, namely at least at the midpoint of the locking surface 21. The longer groove lip 20 preferably extends beyond the short groove lip 19 over a distance E that is within 0.5 to 1.5 times the elements thickness T.
Preferably, as illustrated, the joint is closed at the major surface 2 closest to the longest groove lip 20, while the joint shows a gap S at the major surface 3 closest to the shortest groove lip 19.
FIG. 5 shows an embodiment practicing the sixth listed feature, in that the coupling means 6 are basically shaped as a tongue 11 in groove 12 joint, wherein the groove 12 and the tongue 11 are wholly formed by a separate, preferably plastic, insert 22, in this case made by extrusion. The insert 22 is made of a material less filled than the core 7 of the floor covering element 1. The insert 22 forming the groove 12 clearly illustrates that the present embodiment also practices the third listed feature in that it comprises an elastically bendable portion 10, in this case carrying a locking element 13 that is horizontally active. The portion 10 is in vertical direction upwards and downwards bordered by clearances 16, which do not need to be necessarily formed by removing material.
FIG. 6 shows an embodiment which is largely the same as the embodiment of FIG. 5 , but where the seventh listed feature has been practiced as well. The coupling means 6 have a varying geometry along the edge 5, and are, in this case, discontinuous along the edge 5. A shifting in length direction L of the floor covering elements 1 along the edges 4-5 may in this case be used to disengage the horizontally active locking elements 13.
FIG. 7 illustrates a rectangular floor covering element 1 in accordance with the invention. Coupling means 6 are available at the pair of opposing long edges 4-5, and at the pair of opposing short edges 23-24. These coupling means 6 may show features as described by means of the previous figures.
FIGS. 8 and 9 illustrate that the long edges 4-5 may be provided with coupling means 6 that allow for connection by means of a rotational movement W about the edges 15 of the respective major upper surfaces 2, as well as by means of a rotational movement W about the edges 15 of the respective major bottom surfaces 3. The embodiment of FIGS. 8 and 9 hence allows to connect the respective edges 4-5 by means of a standard angling down operation W irrespective of which major surface 2-3 is oriented towards the room. FIGS. 8 and 9 illustrate the two possible orientations and the respective angling down operation W. FIG. 8 further illustrates that the present coupling means 6 may also be connected by means of a substantial horizontal shifting movement S of the edges 4-5 towards each other. It is clear that this is also possible in the orientation of FIG. 9 .
FIG. 10 illustrates the obtained connected condition in the orientation of FIG. 8 . It is clear that the connected condition in the orientation of FIG. 9 is the same, though upside down.
The embodiment of FIGS. 8 to 10 also fulfils the first, second, fourth and fifth listed features, and may be provided with an elastically bendable portion 10 in accordance with the third listed feature, as illustrated here. The lowered surfaces 9 practiced in this example are bevel shaped and the beveled surface of opposite long edges 4-5 extend vertically beyond each other in a coupled condition.
FIGS. 8 to 10 further illustrate that a first one of the pair of opposite long edges 4 at least comprises a portion 25 that horizontally extends beyond the edge 15 of the major upper surface 2 and an excavation 26 formed in the side of the portion 25 opposite the major upper surface 2, while a second one of the pair of opposite long edges 5 at least comprises a portion 27 that horizontally extends beyond the edge 15 of the major bottom surface 3, and an excavation 28 formed in the side of the portion 27 opposite the major bottom surface 3, wherein in a coupled condition of two such floor panels 1, the following features are available:
horizontally locking surfaces 29-30 are available on material portions bordering the excavations 26-28 in a horizonal direction H outwardly; the horizontally locking surfaces 29-30 are in contact and extend at an angle A with the major upper surface 2 of 30 to 60°. The horizontally locking surfaces 29-30 extend at least about midway in the thickness of the floor covering elements 1, i.e. having a portion located on the central plane C2 of the floor covering element 1;
vertically locking surfaces 31-32 are available on one or more material portions bordering one or more of the excavations 26-28 in a vertical direction V; one pair of the vertically locking surfaces 31-33 is in contact, while a gap S1 is present between a second pair 32-34 of the vertically locking surfaces. Both pairs of vertical locking surfaces 31-33; 32-34 extend at an angle A2-A3 with the major upper surface 2 of 20 to 45°;
the angle A at which the horizontally locking surfaces 29-30 extend is larger than one or both angles A2-A3 at which the vertically locking surfaces 31-33; 32-34 extend;
the angle A4-A5 enclosed between the vertical and the imaginary line 35-36 connecting the edges of the major surfaces, including possible lowered surfaces 9, is at both opposite edges 4-5 comprised between 10 and 30°. Preferably, as is the case here, the imaginary lines 35-36 at both opposite edges 4-5 are parallel or about parallel, i.e. have a difference in inclination smaller than 5°, or even smaller than 2°.
the portions 25-27 extending beyond the respective major surfaces 2-3 both have a horizontal extension E1-E2 between 10 and 30% of the panel thickness T. In this case the horizontal extension E1-E2 of both portions is about equal;
in a connected condition all locking surfaces 29 30 31 32 33 34 37 38 are arranged in an area which extends horizontally to a lesser extent than vertically. In this case the horizontal extension E3 is less than 75% of the vertical extension V3, namely about half the vertical extension V3.
FIGS. 11 to 13 show that the floor covering element 1, more particularly floor panel, of FIGS. 8 to 10 is at the short pair of edges 23-24 provided with coupling means 6 that allow for a connection by means of a downward movement D of either of the edges 23-24 towards the other.
The embodiment of FIGS. 8 to 13 thus forms an example of a floor covering element 1 that may be connected to the long edge 5 of a previous row of floor panels, and to the short edge 24 of a floor panel in the same row, simultaneously, by means of a so-called fold-down movement, irrespective of the orientation of the major surfaces 2-3.
As is apparent from FIGS. 11 to 13 , a first one of the pair of opposite short edges 23 at least comprises a portion 39 that horizontally extends beyond the edge 15 of the major upper surface 2 and an excavation 40 formed in the side of the portion 39 opposite the major upper surface 2, while a second one of the pair of opposite short edges 24 at least comprises a portion 41 that horizontally extends beyond the edge 15 of the major bottom surface 3, and an excavation 42 formed in the side of the portion 41 opposite the major bottom surface 3, wherein in a coupled condition of two such floor panels, the following features are available:
horizontally locking surfaces 43-44 are available on material portions bordering the excavations 40-42 in a horizonal direction outwardly; the horizontally locking surfaces 43-44 are in contact and extend at an angle A with the major upper surface 2 of 60° to 100°; the horizontally locking surfaces 43-44 extend at least about midway, in the thickness of the floor covering elements 1, i.e. having a portion located on the central plane C2 of the floor covering element 1;
vertically locking surfaces 45-46 are available on one or more material portions bordering one or more of the excavations 40-42 in a vertical direction; one pair of the vertically locking surfaces 45-47 is in contact, while a gap S3 is present between a second pair of the vertically locking surfaces 46-48. The vertically locking surfaces 45-46-47-48 all extend at an angle A2-A3 with the major upper surface 2 of 20 to 45°;
the angle A at which the horizontally locking surfaces 43-44 extend is larger than one or both angles A2-A3 at which the vertically locking surfaces 45-47;46-48 extend;
the angle A4-A5 enclosed between the vertical and the imaginary lines 49-50 connecting the edges 15 of the major surfaces 2-3 is at both opposite edges 23-24 comprised between 35° and 60°; Preferably, as is the case here, the imaginary lines 49-50 at both opposite edges 23-24 are parallel or about parallel, i.e. have a difference in inclination smaller than 5°, or even smaller than 2°.
the portions 39-41 extending beyond the respective major surfaces 2-3 both have a horizontal extension E1-E2 between 0.5% and 5% of the panel thickness T. In this case the horizontal extension E1-E2 of both portions is about equal.
in a connected condition all locking surfaces 43 44 45 46 47 48 51 52 are arranged in an area which extends horizontally over a distance E2 which is about 85% of the distance V3 over which it extends vertically.
FIG. 13 illustrates the obtained connected condition in the orientation of FIG. 11 . It is clear that the connected condition in the orientation of FIG. 12 is the same, though upside down.
FIG. 14 shows a variant for the coupling means 6 of FIGS. 11 to 13 , wherein the guiding during coupling by means of the downward movement D has been enhanced, by the introduction of a more pronounced guiding portion 53 at the entrance of the excavations 40-42.
FIG. 15 shows a further variant, wherein an elastically bendable portion 10 has been introduced in the coupling means 6, by providing a flexibility groove 54 at one of the edges 23. In so doing a more fluid downward movement D in combination with a more pronounced locking, especially in the vertical direction V, in the connected condition may be obtained. It is of course possible that one or more flexibility grooves 54 are provided at either or both edges 23-24, in order to further enhance the installation and the obtained locking.
While the previously described embodiments all have coupling means 6 with contours which are basically formed out of one and the same material, either because they have been formed in the material of the panel, as is the case in the embodiments of FIGS. 1 to 4 , and 10 to 15, or because they have been essentially form on one and the same insert 22, as is the case in the embodiments of FIGS. 5 and 6 . It is clear to the skilled person that, although this is preferred, the invention can also be put to practice in other ways.
FIG. 16 shows a variant for the coupling means 6 at e.g. the short edges 23-24, where the coupling means 6 have contours which are formed out a plurality of materials. In the illustrated example, at least one pair of vertical locking surfaces 45-47; 46-48, and in this case each pair of vertical locking surfaces 45-47; 46-48 comprises a surface 45-46 formed on a separate spring element 55.
It is further noted that the embodiments of FIGS. 13 to 16 illustrate particularly preferred coupling means 6 for the short edges 23-24 of floor covering elements 1 in accordance with the invention. Other forms of coupling means 6 are of course possible. For example, the embodiments illustrated for the long edges 4-5 may also be used at the short edges 23-24, or coupling means 6 allowing a connection by means of a downward movement D but having only one pair of vertical locking surfaces 45-47 are also possible. An embodiment in accordance with this latter possibility is illustrated by means of the dashed lines 56 in FIG. 14 . Two pairs of vertical locking surfaces 45-47; 46-48 are however preferred in order to enable at least some kind of vertical alignment between both the major top surfaces 2 and the major bottom surfaces 3 of adjacent floor covering elements 1.
FIG. 17 gives an enlarged view of FIG. 10 . In this view, it can be seen that the circle C1 having its center at the edge 15 of the major upper surfaces 2 and through the most distal point of the vertical locking surfaces 34 has a tangent coinciding with the vertical locking surfaces 34 on the portion 27, or a tangent deviating from the inclination A3 of the vertical locking surfaces 34 by no more than 10°, or even no more than 5°. The circle C1 does not intersect with any other part of the portion 27, on the contrary a space S4 is present between the parts extending outwardly from the vertical locking surfaces 34. The circle C2 having its center at the edge 15 of the major bottom surfaces 3 and through the most distal point of the vertical locking surfaces 33 has a tangent coinciding with the vertical locking surfaces 33 on the portion 25, or a tangent deviating from the inclination A2 of the vertical locking surfaces 33 by no more than 10°, or even no more than 5°. The circle C2 does not intersect with any other part of the portion 25, on the contrary a space S5 is present between the parts extending outwardly from the vertical locking surfaces 33.
FIG. 18 shows a cross-section in accordance with the line VIII-VIII indicated on FIG. 7 of an embodiment of the invention. FIG. 19 , in a similar view, illustrates the reversed application of the floor panel of FIG. 18 . FIG. 20 in a view similar to that of FIGS. 1 to 5 shows the connected condition of the coupling means illustrated in FIGS. 18 and 19 .
FIGS. 18 and 19 illustrate that the long edges 4-5 may be provided with coupling means 6 that allow for connection by means of a rotational movement W about the edges 15 of the respective major upper surfaces 2, as well as by means of a rotational movement W about the edges 15 of the respective major bottom surfaces 3. The embodiment of FIGS. 18 and 19 hence allows to connect the respective edges 4-5 by means of a standard angling down operation W irrespective of which major surface 2-3 is oriented towards the room. FIGS. 18 and 19 illustrate the two possible orientations and the respective angling down operation W. FIG. 18 further illustrates that the present coupling means 6 may also be connected by means of a substantial horizontal shifting movement S of the edges 4-5 towards each other. It is clear that this is also possible in the orientation of FIG. 19 .
FIG. 20 illustrates the obtained connected condition in the orientation of FIG. 18 . It is clear that the connected condition in the orientation of FIG. 19 is the same, though upside down.
The embodiment of FIGS. 18 to 20 also fulfils the first, second, fourth, fifth and eighth listed features, and may be provided with an elastically bendable portion 10 in accordance with the third listed feature, as illustrated here. Although not shown in this exemplary embodiment, lowered surfaces can be provided at one and/or both surfaces, e.g. bevel shaped; e.g. in a similar way as shown in FIGS. 8-10 , or as described in other embodiments of the invention.
FIGS. 18 to 20 further illustrate that a first one of the pair of opposite long edges 4 at least comprises a portion 25 that horizontally extends beyond the edge 15 of the major upper surface 2 and an excavation 26 formed in the side of the portion 25 opposite the major upper surface 2, while a second one of the pair of opposite long edges 5 at least comprises a portion 27 that horizontally extends beyond the edge 15 of the major bottom surface 3, and an excavation 28 formed in the side of the portion 27 opposite the major bottom surface 3, wherein in a coupled condition of two such floor panels 1, the following features are available:
horizontally locking surfaces 29-30 are available on material portions bordering the excavations 26-28 in a horizonal direction H outwardly; the horizontally locking surfaces 29-30 are in contact and extend at an angle A with the major upper surface 2 of 45°. The horizontally locking surfaces 29-30 extend at least about midway in the thickness of the floor covering elements 1, i.e. having a portion located on the central plane C2 of the floor covering element 1;
vertically locking surfaces 31-32-33-34 are available on one or more material portions bordering one or more of the excavations 26-28 in a vertical direction V; in the embodiment shown in FIG. 20 , both pairs of the vertically locking surfaces 31-33 and 32-34 are in contact, and extend at an angle A2-A3 with the major upper surface 2 of 20 to 45°, in the example shown the angles A2 and A3 are 30°;
the angle A (45° in the example) at which the horizontally locking surfaces 29-30 extend is larger than both angles A2-A3 (which are 30° in this example) at which the vertically locking surfaces 31-33; 32-34 extend;
the angles A4-A5 enclosed between the vertical and the imaginary line 35-36 connecting the edges of the major surfaces is at both opposite edges 4-5 comprised between 10 and 30°, in the example 15°. Preferably, as is the case here, the imaginary lines 35-36 at both opposite edges 4-5 are parallel or about parallel, i.e. have a difference in inclination smaller than 5°, or even smaller than 2°.
the portions 25-27 extending beyond the respective major surfaces 2-3 both have a horizontal extension E1-E2 between 10 and 30% of the panel thickness T. In this case the horizontal extension E1-E2 of both portions is equal, and 15% of the thickness T of the panel;
in a connected condition all locking surfaces 29-30-31-32-33-34-37-38 are arranged in an area which extends horizontally to a lesser extent than vertically. In this case the horizontal extension E3 is less than 75% of the vertical extension V3, namely about half the vertical extension V3.
The coupling means 6 are provided such that in coupled condition in a floor covering of a first such floor covering element with a second such floor covering element both with their top surface 2 facing to the room, at the coupled edges of the first such floor covering element with the second such floor covering element, a point of symmetry P at the middle of the height of the floor covering element is provided such that the coupling means 6 of the first coupled floor covering element are symmetrical with respect to the point of symmetry with the coupling means 6 of the second coupled floor covering element. This symmetry involves the portions 25, 27 (it is meant that the portion 25 is symmetrical to the portion 27); excavations 26, 28 (it is meant that the excavation 26 is symmetrical to the excavation 28); and all the locking surfaces 29 30 31 34 37 38 of the first and the second coupled panels. The floor panels (1) shown in FIGS. 18 — 20 are reversible in the sense that the user may, upon choice, install a plurality of such floor covering elements (1) to form a floor covering, wherein in the floor covering at least one of the floor covering elements (1) is installed with its major top surface (2) facing to the room; as well as wherein in the floor covering at least one of the floor covering elements (1) is installed with its major bottom surface (3) facing to the room.
The floor panels shown in FIGS. 18-20 can be provided at their short pair of edges with coupling means that allow for connection by means of a downward movement, e.g. as shown in FIGS. 11 to 13 , or as shown in FIG. 14, 15 or 16 , or as shown in any embodiment disclosed in WO2016/113721. The combination of the coupling means shown in FIGS. 18-20 at the long pair of edges of a floor panel with coupling means at the short pair of edges that allow connection by means of a downward movement allow to install such floor panels using the “fold down” technique.
The invention has been illustrated here with a so-called SPC panel. This is a panel having a core 7 of filled thermoplastic material, in this case PVC (polyvinylchloride), preferably having a filler content higher than 50 weight percent. The plasticizer content in the PVC is preferably below 5 phr, or even zero. At both major surfaces 2-3 a decoration layer 8 has been provided. In this case the decoration layer 8 comprising a print, such as a printed PVC foil, with thereupon a wear layer, such as a layer of transparent PVC. Other decoration layers 8, such as wooden layers below or above 1 mm thickness, or melamine based layers, such as layers comprising one or more melamine impregnated paper layers, are not excluded.
It is clear that the invention can be practiced with many different types of panels, such as with traditional laminate flooring panels, with panels of engineered wood, or with panels having a mineral based core, such as a core of cement fiber board, or magnesiumoxide (MgO) board, or gypsum board.
The present invention is in no way limited to the forms of embodiment described above and shown in the figures, however, such floor covering elements may be realized in various forms and dimensions without leaving the scope of the present invention.

Claims

1.-17. (canceled)

18. A floor covering element having a major top surface and a major bottom surface and having at least two edges comprising coupling means,

wherein these coupling means allow to create a mutual locking with a similar floor covering element at the respective edges,

wherein said locking is active in a horizontal direction perpendicular to the respective edge and in the plane of the floor covering elements, and is active in a vertical direction perpendicular to the plane of the floor covering elements,

wherein said floor covering element further shows one or a combination of two or more of the following features:

at least one of the top surface and the bottom surface is, at the respective edge, provided with a lowered surface, such as a bevel;

only one of the top surface and the bottom surface is, at the respective edge, provided with a lowered surface, such as a bevel, the other surface being free from lowered surface at the respective edge, such that the joint between two adjacent floor covering elements is flush at said other surface, or at least with height differences lower than 0.15 mm;

said coupling means are basically shaped as a tongue-in-groove joint, wherein said tongue comprises one or more elastically bendable parts that bend upon forming the joint, wherein the elastically bendable part remains in a bent condition when connected;

said coupling means are configured to allow for a closed connection, i.e. without intermediate space or with a space smaller than 0.15 mm between the coupled edges, at only one of the top surface and the bottom surface, while at the other major surface a space is available larger than the possible space at the one surface;

said coupling means allow for a disassembly by angling out upwardly and downwardly;

said coupling means are basically shaped as a tongue-in-groove joint, wherein the groove and/or the tongue are partially or wholly formed by a separate, plastic, insert, e.g. made by extrusion or injection molding, wherein said insert is made of a material harder or more flexible or less filled than the basic material of the floor covering element, wherein the insert is provided;

said coupling means have a varying geometry along the respective edge; and are discontinuous along said edge;

said floor covering element has a decorative surface at the top surface and at the bottom surface.

19. The floor covering element of claim 18, wherein said floor covering element has a decorative surface at the top surface and at the bottom surface.

20. The floor covering element of claim 19, wherein said decorative surface comprises a wear layer provided over a decorative print.

21. The floor covering element of claim 20, wherein said floor covering element is panel-shaped, such as a laminate floor panel, a panel of LVT (luxury vinyl tile), a panel having a core of, whether or not filled, thermoplastic material with one or two decorative surface layers.

22. The floor covering element of claim 18, wherein said floor covering element is sheet-shaped, such as a cushion or compact vinyl sheet or polyolefin or polyurethane sheet.

23. The floor covering element according claim 18, wherein said floor covering element is reversible in the sense that the user may, upon choice, install the floor covering element with any of the major surfaces facing to the room.

24. The floor covering element of claim 18, wherein the coupling means are configured such that said floor covering element is reversible in the sense that the user may, upon choice, install a plurality of such floor covering elements to form a floor covering,

wherein in the floor covering at least one of the floor covering elements is installed with its major top surface facing to the room;

coupled with its coupling means to the coupling means of at least one of the floor covering elements installed with its major bottom surface facing to the room.

25. The floor covering element of claim 18, wherein said coupling means allow for connection by means of a mainly horizontal shifting movement of the respective edges towards each other.

26. The floor covering element of claim 18, wherein said coupling means allow for connection by means of a downward movement of one of the edges towards the other.

27. The floor covering element of claim 18, wherein said floor covering element has a thickness of 3 mm or more.

28. The floor covering element of claim 18, wherein said coupling means allow for connection by means of a rotational movement about the edges of the respective major upper surfaces, as well as by means of a rotational movement about the edges of the respective major bottom surfaces.

29. The floor covering element of claim 28, wherein said floor covering elements are rectangular with a pair of opposing long edges and a pair of opposing short edges,

wherein said coupling means are available at said pair of opposing long edges, and wherein said pair of opposing short edges is provided with coupling means as well.

30. The floor covering element of claim 29, wherein said coupling means at said pair of opposing short edges allow for a connection by means of a downward movement of either of the edges towards the other.

31. The floor covering element of claim 28, wherein a first one of said pair of opposite long edges at least comprises a portion that horizontally extends beyond the edge of said major upper surface and an excavation formed in the side of said portion opposite said major upper surface, while a second one of said pair of opposite long edges at least comprises a portion that horizontally extends beyond the edge of said major bottom surface, and an excavation formed in the side of said portion opposite said major bottom surface,

wherein in a coupled condition of two such floor covering elements, one or more of the following features are available:

horizontally locking surfaces are available on material portions bordering said excavations in a horizonal direction outwardly;

said horizontally locking surfaces are in contact and/or said horizontally locking surfaces extend at an angle A with said major upper surface of 30 to 60°; said horizontally locking surfaces extend at least about midway in the thickness of said floor covering elements;

vertically locking surfaces are available on one or more material portions bordering one or more of said excavations in a vertical direction;

said vertically locking surfaces are in contact and/or extend at an angle A2-A3 with said major upper surface of 20 to 45°;

the features of the previous two paragraphs combined, wherein the angle A at which said horizontally locking surfaces extend is larger than the angle A2-A3 at which said vertically locking surfaces extend;

the angle A4-A5 enclosed between the vertical and the imaginary line connecting the edges of the major surfaces is at both opposite edges is comprised between 10 and 30°;

said portions extending beyond the respective major surfaces both have a horizontal extension between 10 and 30% of the floor covering element thickness; the horizontal extension of both portions is about equal, i.e. have a ratio between 1:0.7 and 0.7:1;

in a connected condition all locking surfaces are arranged in an area which extends horizontally to a lesser extent than vertically;

said horizontal extension is less than 75% of the vertical extension.

32. The floor covering element of claim 30, wherein a first one of said pair of opposite short edges at least comprises a portion that horizontally extends beyond the edge of said major upper surface and an excavation formed in the side of said portion opposite said major upper surface, while a second one of said pair of opposite short edges

at least comprises a portion that horizontally extends beyond the edge of said major bottom surface, and an excavation formed in the side of said portion opposite said major bottom surface,

said horizontally locking surfaces are in contact and/or said horizontally locking surfaces extend at an angle A with said major upper surface of 60° to 100°;

said horizontally locking surfaces extend at least about midway in the thickness of said floor covering elements;

the angle A4-A5 enclosed between the vertical and the imaginary line connecting the edges of the major surfaces is at both opposite edges comprised between 35° and 60°;

said portions extending beyond the respective major surfaces both have a horizontal extension between 0.5% and 5% of the thickness of the floor covering element;

the horizontal extension of both portions is about equal, i.e. have a ratio between 1:0.7 and 0.7:1;

in a connected condition all locking surfaces are arranged in an area which extends horizontally about equally as vertically;

said horizontal extension is within 80 to 120% of the vertical extension.

33. The floor covering element of claim 18, wherein the coupling means are provided such that in coupled condition in a floor covering of a first such floor covering element with a second such floor covering element both with their top surface facing to the room, at the coupled edges of the first such floor covering element with the second such floor covering element, a point of symmetry at the middle of the height of the floor covering element is provided such that the coupling means of the first coupled floor covering element are symmetrical with respect to the point of symmetry with the coupling means of the second coupled floor covering element.

34. A floor covering element having a decorative surface at both the major top surface and the major bottom surface,

wherein the floor covering element has straight edges and/or is provided with a tongue and groove joint only locking in the horizontal direction, or, only locking in the vertical direction.