Floor panel having coupling parts allowing assembly with vertical motion
AssigneeFlooring Industries Limited, Sarl
InventorsMark Cappelle, Lode De Boe
Life of this patent
Estimating the term…
Abstract
A method for manufacturing floor panels, wherein boards of laminate material are formed by means of a press treatment and wherein these boards are divided into several panels, from which the actual floor panels are formed. In a press treatment of the method, at least one impression is provided in the board, which at least is employed as a guiding groove for guiding the aforementioned board or the subsequently obtained panels in further treatments.
Claims39
A floor panel having a core, a decorative upper surface and at least two opposite edges, wherein said two opposite edges are provided with a first profiled edge area and a second profiled edge area, respectively, said first and second profiled edge areas comprising:
- coupling parts substantially forming a tongue having a tongue tip and a groove limited in downward direction by a lower lip, the coupling parts, in a coupled condition of two of such floor panels, having contact surfaces to lock in a vertical direction;
- said contact surfaces including an upper vertically locking contact surface formed at the upper side of said tongue;
- locking parts, which, in a coupled condition of two of such floor panels, having contact surfaces arranged to lock in a horizontal direction;
- said contact surfaces including a horizontally locking contact surface formed at a protrusion of said lower lip, said lower lip having a thickness at said protrusion and said thickness being less than 0.4 times a thickness of the floor panel;
- wherein, in a coupled condition of two of such floor panels, said decorative upper surfaces of said two of such floor panels meet along a vertically extending first plane;
- wherein a first one of said profiled edge areas is essentially located inwardly from said first plane and underneath said decorative upper surface of said floor panel;
- said first one of said profiled edge areas comprising said tongue and an upwardly extending surface above said tongue;
- said upwardly extending surface defining a point furthest away from said tongue tip in a proximal direction at a corner located as the most inward point of an upper surface of the tongue tip and the upwardly extending surface;
- said point defined along a vertically extending second plane generally parallel to the vertically extending first plane;
- said tongue extending outside from the second plane;
- the second one of said profiled areas is located substantially outside of the first plane;
- wherein said upper vertically locking contact surface is located entirely distally from said second plane and extends a first length in a first direction from said second plane towards said tip of the tongue;
- wherein said lower lip is located substantially distally from said first plane and extends for a second length beyond said first plane in a second direction opposite said first direction;
- said first length being substantially less than said second length;
- wherein said upper vertically locking contact surface is entirely located above the lower lip relative to the decorative upper surface;
- wherein the tongue has a first surface sloping downwardly relative to the decorative upper surface and inwardly from said tongue tip to the second plane;
- wherein said coupling parts and said locking parts are sized and shaped to couple two floor panels by bringing the floor panels towards each other with a substantially vertical movement, wherein said first one of said profiled edge areas is arranged to be brought down to said second one of said profiled edge area and coupled therewith by a snap-on effect, and wherein said coupling parts define overlapping and corresponding contours forming a pretensioned joint when the floor panel is in the coupled condition;
- wherein a depth of the groove as measured perpendicular to the first plane is larger than half the thickness of the floor panel.
A floor panel having a core, a decorative upper surface and at least two opposite edges, wherein said two opposite edges are provided with a first profiled edge area and a second profiled edge area, respectively, said first and second profiled edge areas comprising:
- coupling parts substantially forming a tongue having a tongue tip and a groove limited in downward direction by a lower lip, the coupling parts, in a coupled condition of two of such floor panels, having contact surfaces to lock in a vertical direction;
- said contact surfaces including an upper vertically locking contact surface formed at the upper side of said tongue;
- locking parts, which, in a coupled condition of two of such floor panels, having contact surfaces arranged to lock in a horizontal direction;
- said contact surfaces including a horizontally locking contact surface formed at a protrusion of said lower lip, said lower lip having a thickness at said protrusion and said thickness being less than 0.4 times a thickness of the floor panel;
- wherein, in a coupled condition of two of such floor panels, said decorative upper surfaces of said two of such floor panels meet along a vertically extending first plane;
- wherein a first one of said profiled edge areas is essentially located inwardly from said first plane and underneath said decorative upper surface of said floor panel;
- said first one of said profiled edge areas comprising said tongue and an upwardly extending surface above said tongue;
- said upwardly extending surface defining a point furthest away from said tongue tip in a proximal direction at a corner located as the most inward point of an upper surface of the tongue tip and the upwardly extending surface;
- said point defined along a vertically extending second plane generally parallel to the vertically extending first plane;
- said tongue extending outside from the second plane;
- wherein a second one of said profiled areas is located substantially outside of the first plane;
- said second one of said profiled edge areas comprising said groove;
- wherein said upper vertically locking contact surface is located entirely distally from said second plane and extends a first length in a first direction from said second plane towards said tip of the tongue;
- wherein said lower lip is located substantially distally from said first plane and extends for a second length beyond said first plane in a second direction opposite said first direction;
- said first length being substantially less than said second length;
- wherein said upper vertically locking contact surface is entirely located above the lower lip relative to the decorative upper surface;
- wherein the tongue has a first surface sloping downwardly relative to the decorative upper surface and inwardly from said tongue tip to the second plane;
- wherein said coupling parts and said locking parts are sized and shaped to couple two floor panels by bringing the floor panels towards each other upon choice either with a substantially vertical movement wherein said first one of said profiled edge areas is arranged to be brought down to said second one of said profiled edge area and coupled therewith by a snap-on effect, or by turning the floor panels into each other along said two edges;
- wherein a depth of the groove as measured perpendicular to the first plane is larger than half the thickness of the floor panel.
A floor panel having a core, a decorative upper surface and at least two opposite edges, wherein said two opposite edges are provided with a first profiled edge area and a second profiled edge area, respectively, said first and second profiled edge areas comprising:
- coupling parts substantially forming a tongue having a tongue tip and a groove limited in downward direction by a lower lip, the coupling parts, in a coupled condition of two of such floor panels, having contact surfaces to lock in a vertical direction;
- said contact surfaces including an upper vertically locking contact surface formed at the upper side of said tongue;
- locking parts, which, in a coupled condition of two of such floor panels, having contact surfaces arranged to lock in a horizontal direction;
- said contact surfaces including a horizontally locking contact surface formed at a protrusion of said lower lip, said lower lip having a thickness at said protrusion and said thickness being less than 0.4 times a thickness of the floor panel;
- wherein, in a coupled condition of two of such floor panels, said decorative upper surfaces of said two of such floor panels meet along a vertically extending first plane;
- wherein a first one of said profiled edge areas is essentially located inwardly from said first plane and underneath said decorative upper surface of said floor panel;
- said first one of said profiled edge areas comprising said tongue and an upwardly extending surface above said tongue;
- said upwardly extending surface defining a point furthest away from said tongue tip in a proximal direction at a corner located as the most inward point of an upper surface of the tongue tip and the upwardly extending surface;
- said point defining a vertically extending second plane generally parallel to the vertically extending first plane;
- said tongue extending outside from the second plane;
- wherein a second one of said profiled edge areas is located substantially outside of the first plane;
- said second one of said profiled edge areas comprising said groove;
- wherein said upper vertically locking contact surface is located entirely distally from said second plane and extends a first length in a first direction from said second plane towards said tip of the tongue;
- wherein said lower lip is located substantially distally from said first plane and extends for a second length beyond said first plane in a second direction opposite said first direction;
- said first length being substantially less than said second length;
- wherein in coupled condition of two of such floor panels the horizontal distance between the tongue tip and the distal end of the lower lip is smaller than 1.5 times the thickness of the floor panel;
- wherein said upper vertically locking contact surface is entirely located above the lower lip relative to the decorative upper surface;
- wherein the tongue has a first surface sloping downwardly relative to the decorative upper surface and inwardly from said tongue tip to the second plane;
- wherein the first profiled edge area is free from surfaces substantially horizontal and downwardly facing outside said first plane;
- wherein said coupling parts and said locking parts are sized and shaped to couple two floor panels by bringing the floor panels towards each other with a substantially vertical movement, wherein said first one of said profiled edge areas is arranged to be brought down to said second one of said profiled edge area and coupled therewith by a snap-on effect;
- wherein a depth of the groove as measured perpendicular to the first plane is larger than half the thickness of the floor panel.
A floor panel having a core, a decorative upper surface and at least two opposite edges, wherein said two opposite edges are provided with a first profiled edge area and a second profiled edge area respectively, said first and second profiled edge areas comprising:
- coupling parts substantially forming a tongue having a tongue tip and a groove limited in downward direction by a lower lip, the coupling parts, in a coupled condition of two of such floor panels, having contact surfaces to lock in a vertical direction;
- said contact surfaces including an upper vertically locking contact surface formed at the upper side of said tongue;
- locking parts, which, in a coupled condition of two of such floor panels, having contact surfaces to lock in a horizontal direction;
- said contact surfaces including a horizontally locking contact surface formed at a protrusion of said lower lip, said lower lip having a thickness at said protrusion and said thickness being less than 0.4 times a thickness of the floor panel;
- wherein, in a coupled condition of two of such floor panels, said decorative upper surfaces of said two of such floor panels meet along a vertically extending first plane;
- wherein a first one of said profiled edge areas is essentially located inwardly from said first plane and underneath said decorative upper surface of said floor panel;
- said first one of said profiled edge areas comprising said tongue and an upwardly extending surface above said tongue;
- said upwardly extending surface defining a point furthest away from said tongue tip in a proximal direction at a corner located as the most inward point of an upper surface of the tongue tip and the upwardly extending surface;
- said point defined along a vertically extending second plane generally parallel to the vertically extending first plane;
- said tongue extending outside from the second plane;
- wherein a second one of said profiled edge areas is located substantially outside of the first plane;
- said second one of said profiled edge areas comprising said groove;
- wherein said upper vertically locking contact surface is located entirely distally from said second plane and extends a first length in a first direction from said second plane towards said tip of the tongue;
- wherein said lower lip is located substantially distally from said first plane and extends for a second length beyond said first plane in a second direction opposite said first direction;
- said first length being substantially less than said second length;
- wherein said upper vertically locking contact surface is entirely located above the lower lip relative to the decorative upper surface;
- wherein the tongue has a first surface sloping downwardly relative to the decorative upper surface and inwardly from said tongue tip to the second plane;
- wherein said coupling parts and said locking parts sized and shaped to couple two floor panels by bringing the floor panels towards each other with a substantially vertical movement wherein said first one of said profiled edge areas is arranged to be brought down to said second one of said profiled edge areas and coupled therewith by a snap-on effect;
- wherein a depth of the groove as measured perpendicular to the first plane is larger than half the thickness of the floor panel.
Dependencies are inferred from the claim text.