Note: Descriptions are shown in the official language in which they were submitted.
WO 2022/157618 PCT/1B2022/050370
1
Set of floor panels and method for installing this set of floor panels
The present invention relates to a set of floor panels which is suitable for
forming a floor
covering, and to a method for installing this set of floor panels. More
particularly, it
relates to a set of floor panels which are provided with well-defined coupling
parts on
their edges.
The set may be composed of floor panels which, according to a first
possibility, are all
the same or similar with regard to the coupling parts on the edges thereof,
and which,
according to a second possibility, consist of floor panels which include two
or more types
per set with regard to the configuration of the coupling parts, a typical
example being
floor panels which comprise two types, so that they can be laid in a
herringbone pattern,
in which case the distribution of male and female coupling parts along the
periphery of
the floor panels for the two types of floor panels then differs, more
particularly is
mutually mirrored.
The floor panels are preferably elongate rectangular and therefore comprise a
pair of long
edges and a pair of short edges. Both the long and the short edges are
provided with
mechanical coupling parts which allow the floor panels to be coupled together.
Preferably, the coupling parts on all four edges are integrally formed from
the material
of the floor panel, preferably by means of a machine operation, for example a
milling
process. The expression "integrally formed from the material of the floor
panel- is
understood to mean that no essential separate parts, such as interlocking
strips or the like,
still have to be provided on the already machine-processed edges during
production.
However, this does not rule out that this may be a floor panel whose substrate
has an
edge portion which consists of a material which differs from the material
which is mainly
used in the floor panel, wherein the integrally formed coupling part is then
entirely or
partly formed in this edge portion. This may be the case, as is known, with
the so-called
"engineered wood" panels.
CA 03202306 2023-6- 14
WO 2022/157618 PCT/IB2022/050370
2
The type of sets of floor panels as referred to in the present invention are
known, inter
alia, from W02017/187298 and from W02019/138365A1.
It is first and foremost the objective of the present invention an alternative
set of floor
panels which, at least in a specific embodiment thereof, is suitable to form a
floor
covering in a herringbone pattern. In particular, it is an object of the
invention to provide
floor panels which can easily be laid in a herringbone pattern, wherein these
panels can
be coupled together securely in such a way that the risk of differences in
height,
formation of gaps or cracks between the mutually coupled floor panels can be
minimized.
The invention provides various independent aspects which fulfill the intended
objectives.
The first aspect of the invention is a set of floor panels, wherein these
floor panels are
elongate rectangular and therefore comprise a pair oflong edges and a pair of
short edges;
wherein both the long and the short edges are provided with mechanical
coupling parts
which allow the floor panels from the set to be coupled together; wherein the
one long
edge is provided with a male coupling part and the other long edge is provided
with a
female coupling part; wherein the one short edge is provided with a male
coupling part
and the other short edge is provided with a female coupling part; wherein the
male
coupling part on the long edge can be fitted into the female coupling part on
the long
edge of a floor panel of the set by means of a rotating movement; wherein the
male
coupling part on the long edge can also be fitted into the female coupling
part on the
short edge of a floor panel from the set by means of a rotating movement; and
wherein
the male coupling part on the short edge can be fitted into the female
coupling part on
the long edge in one and the same rotating movement which is used to fit the
male
coupling part on the long edge into the female coupling part on the long or
short edge;
wherein the male coupling part on the short edge and the female coupling part
on the
long edge comprise interlocking parts which, in a mutually coupled position of
such a
short edge and long edge, bring about an interlocking in a horizontal
direction and an
interlocking in a vertical direction; wherein the female coupling part on the
long edge
and on the short edge comprises a lateral groove which is delimited by an
upper lip and
a bottom lip, the bottom lip of which extends distally beyond the upper lip
and is provided
CA 03202306 2023-6- 14
WO 2022/157618 PCT/IB2022/050370
3
with an upwardly pointing interlocking part; wherein the male coupling part on
the long
edge is provided with a tongue which, in the coupled position, can cooperate
with the
abovementioned lateral groove in order to bring about a vertical interlocking;
and
wherein the set of floor panels comprises at least one pair of interlocking
portions in
order to bring about the abovementioned vertical interlocking of the male
coupling part
on the short edge into the female coupling part on the long edge,
characterized in that the
male coupling part on the long edge may be fitted into the female coupling
part on the
short edge of a floor panel from the set by means of a horizontal sliding
movement with
snap-fit effect; preferably wherein the male coupling part on the long edge
may be fitted
into the female coupling part on the long edge of a floor panel of the set by
means of a
horizontal sliding movement with snap-fit effect.
The panels can be installed by means of the so-called "fold down" method. Due
to the
fact that the set of panels of the first aspect of the invention may al so be
coupled together
by means of a horizontal sliding movement, the ease of installation increases,
in
particular along the edges of the room in which the panels are being laid, for
example in
a herringbone pattern. Furthermore, the first aspect of the invention also
makes it easier
to lay panels in a herringbone pattern from the center of a room, since, with
the "fold-
down" method, panels can only be used efficiently in one direction. The
invention makes
2 0 it possible to couple the panels together in the other direction by
means of a horizontal
sliding movement with snap-fit effect. This is explained further in Fig. 3
which illustrates
the "fold-down" method as used when installing panels in one direction; and
Fig. 11
shows the installation of panels in the other direction by means of the
sliding effect with
snap-fit effect.
A preferred embodiment of the first aspect of the invention is characterized
in that the
male coupling part on the long edge and the female coupling part on the short
edge are
configured in such a way that when horizontally sliding a first panel from the
set of floor
panels with respect to a second panel from the set of floor panels in order to
couple the
male coupling part on the long edge of the first panel to the female coupling
part on the
short edge of the second panel, when sliding the bottom side of the tongue of
the male
coupling part on the long edge over the upwardly pointing interlocking part of
the female
CA 03202306 2023-6- 14
WO 2022/157618 PCT/IB2022/050370
4
coupling part on the short edge, the tongue of the male coupling part on the
long edge is
guided in the groove of the female coupling part on the short edge.
A preferred embodiment of the first aspect of the invention is characterized
in that the
male coupling part on the long edge and the female coupling part on the short
edge are
configured such that, when horizontally sliding a first panel from the set of
floor panels
with respect to a second panel from the set of floor panels to couple the male
coupling
part on the long edge of the first panel to the female coupling part on the
short edge of
the second panel, when sliding the bottom side of the tongue of the male
coupling part
on the long edge over the upwardly pointing interlocking part of the female
coupling part
on the short edge, the tongue of the male coupling part on the long edge is
guided in the
groove of the female coupling part on the short edge, wherein no deformation
of the
tongue of the male coupling part on the long edge and no deformation of the
bottom lip
of the female coupling part on the short edge is required in order to insert
this tongue into
this groove.
A preferred embodiment of the first aspect of the invention is characterized
in that, when
coupling the male coupling part on the long edge of a panel from the set by
means of a
horizontal sliding movement with snap-fit effect into the female coupling part
on the
short edge of a floor panel, a bending and returning of the bottom lip of the
female
coupling part on the short edge takes place.
The second aspect of the invention relates to a set of floor panels,
optionally as in any
embodiment of the first aspect of the invention, wherein these floor panels
are elongate
rectangular and therefore comprise a pair of long edges and a pair of short
edges; wherein
both the long and the short edges are provided with mechanical coupling parts
which
allow the floor panels from the set to be coupled together; wherein the one
long edge is
provided with a male coupling part and the other long edge is provided with a
female
coupling part; wherein the one short edge is provided with a male coupling
part and the
other short edge is provided with a female coupling part; wherein the male
coupling part
on the long edge can be fitted into the female coupling part on the long edge
of a floor
panel of the set by means of a rotating movement; wherein the male coupling
part on the
CA 03202306 2023-6- 14
WO 2022/157618 PCT/IB2022/050370
long edge can also be fitted into the female coupling part on the short edge
of a floor
panel from the set by means of a rotating movement; and wherein the male
coupling part
on the short edge can be fitted into the female coupling part on the long edge
in one and
the same rotating movement which is used to fit the male coupling part on the
long edge
5 into the female coupling part on the long or short edge; wherein the male
coupling part
on the short edge and the female coupling part on the long edge have
interlocking parts
which, in a mutually coupled position of such a short edge and long edge,
bring about an
interlocking in a horizontal direction and an interlocking in a vertical
direction; wherein
the female coupling part on the long edge and on the short edge comprises a
lateral
groove which is delimited by an upper lip and a bottom lip, the bottom lip of
which
extends distally beyond the upper lip and is provided with an upwardly
pointing
interlocking part; wherein the male coupling part on the long edge is provided
with a
tongue which, in the coupled position, can cooperate with the abovementioned
lateral
groove in order to bring about a vertical interlocking; and wherein the set of
floor panels
comprises at least one pair of interlocking portions in order to bring about
the
abovementioned vertical interlocking of the male coupling part on the short
edge into the
female coupling part on the long edge, characterized in that the upwardly
pointing
interlocking part of the female coupling part on the long edge and/or the
upwardly
pointing interlocking part of the female coupling part on the short edge, in
cross section
2 0 at right angles to the respective edge, comprises a point which is
situated closest to the
top side of the panel, and wherein, when running through the section of this
interlocking
part proximally from this point, from proximally from this interlocking part
to the distal
end of this interlocking part, the distance to the level of the surface of the
floor panel
becomes continuously smaller.
The feature that the upwardly pointing interlocking part of the female
coupling part on
the long edge and/or the upwardly pointing interlocking part of the female
coupling part
on the short edge, in cross section at right angles to the respective edge,
comprises a point
which is situated closest to the top side of the panel, and wherein, when
running through
the section of this interlocking part proximally from this point, from
proximally from this
interlocking part to the distal end of this interlocking part, the distance to
the level of the
surface of the floor panel becomes continuously smaller, has surprising
advantages. The
CA 03202306 2023-6- 14
WO 2022/157618 PCT/IB2022/050370
6
milling process is simplified, resulting in smaller tolerances. Consequently,
the coupling
is made more secure, both in terms of the ease of coupling and of the correct
coupling of
the panels to each other. In addition, the same face may be provided
proximally on the
upwardly pointing interlocking part of the female coupling part on the long
edge and/or
of the female coupling part on the short edge for horizontal interlocking with
both a male
coupling part on the long edge and with a male coupling part on the short
edge.
A preferred embodiment of the second aspect of the invention is characterized
in that the
slope of this section always runs distally, thus making coupling of the floor
panels easier.
A preferred embodiment of the first aspect and/or of the second aspect of the
invention
is characterized in that the angle between the bottom lip of the female
coupling part on
the long edge and the proximal flank of the interlocking part of the female
coupling part
on the long edge is greater than 90 everywhere ¨ and is preferably greater
than 1000
everywhere ¨, wherein this angle is the angle outside the material of the
floor panel,
preferably wherein this angle is between 1000 and 135 in the bending point of
this
proximal flank. Such embodiments have the advantage that coupling by means of
rotation can be performed more easily.
More preferably, the angle between the bottom lip of the female coupling part
on the
short edge and the proximal flank of the interlocking part of the female
coupling part on
the short edge is greater than 90 everywhere ¨ and is preferably greater than
100
everywhere ¨, wherein this angle is the angle outside the material of the
floor panel.
Preferably, this angle is between 100 and 135 in the bending point of this
proximal
flank.
A preferred embodiment of the first aspect and/or of the second aspect of the
invention
is characterized in that the at least one pair of interlocking portions, in
order to bring
about the abovementioned vertical interlocking of the male coupling part on
the short
edge into the female coupling part on the long edge, comprises a first
interlocking portion
on this male coupling part and a second interlocking portion on the female
coupling part
which cooperates with the former in the coupled position; wherein the
abovementioned
CA 03202306 2023-6- 14
WO 2022/157618 PCT/IB2022/050370
7
second interlocking portion which is present on the female coupling part is
situated on
the proximal side of the abovementioned upwardly pointing interlocking part.
Preferably,
the abovementioned second interlocking portion consists of an undercut,
preferably in
the form of a sloping surface under which the first interlocking portion may
engage.
Preferably, the male coupling part on the short edge and the female coupling
part on the
long edge are configured in such a way that the first interlocking portion can
be brought
behind the second interlocking portion by means of a downward movement of the
male
coupling part of the short edge, more particularly by means of a downward snap-
fit
movement.
Such embodiments ensure effective interlocking in a vertical direction, while
still
allowing easy coupling.
A preferred embodiment of the first aspect and/or of the second aspect of the
invention
is characterized in that the male coupling part on the short edge comprises a
flange which
extends laterally at the top and which has a downwardly extending interlocking
part, and
in that, for the abovementioned vertical interlocking, an additional pair of
interlocking
portions is provided, one interlocking portion of which is situated on the
distal end of the
abovementioned flange and/or downwardly extending interlocking part, while the
other
interlocking portion is then situated on the opposite floor panel. Such
embodiments make
2 0 it possible to achieve an interlocking in a horizontal direction in an
effective way, and
actually offer the possibility to provide effective interlocking portions.
Preferably, there is a pretension in the contact surface between the proximal
end of the
downwardly extending interlocking part of the male coupling part on the short
edge and
the upwardly pointing interlocking part of the female coupling part on the
long edge
between the male coupling part on the short edge and the female coupling part
on the
long edge in the coupled position, preferably by an overlap of the profiled
sections of
these interlocking parts in the uncoupled position.
A preferred embodiment of the first aspect and/or of the second aspect of the
invention
is characterized in that, for the abovementioned vertical interlocking of the
male coupling
part on the short edge into the female coupling part on the long edge, at
least one pair of
interlocking portions is provided, namely a first interlocking portion on this
male
CA 03202306 2023-6- 14
WO 2022/157618 PCT/IB2022/050370
8
coupling part and a second interlocking portion on the female coupling part
which
cooperates with the former in the coupled position, wherein the abovementioned
second
interlocking portion which is present on the female coupling part is situated
on the distal
end of the bottom lip and/or of the upwardly pointing interlocking part,
whereas the other
abovementioned first interlocking portion is situated on the opposite floor
panel. Such
embodiments make it possible to achieve a vertical interlocking in an
effective way.
More preferably, the interlocking portion which is situated on the distal end
of the
abovementioned bottom lip and/or of the upwardly pointing interlocking part
consists of
a projection or recess, whereas the interlocking portion which cooperates with
the latter
then consists of a recess or projection, respectively, in which case such a
projection may
consist, for example, of a bulge-shaped portion.
A preferred embodiment of the first aspect and/or of the second aspect of the
invention
is characterized in that the coupling parts on all four edges are integrally
formed from
the material of the floor panels.
A preferred embodiment of the first aspect and/or of the second aspect of the
invention
is characterized in that the female coupling part on the short edge and the
female coupling
part on the long edge are substantially congruent and are preferably identical
to each
other.
A preferred embodiment of the first aspect and/or of the second aspect of the
invention
is characterized in that, on the underside of the female part of the long edge
and/or of the
short edge, a recess is present which makes elastic bending during assembly
easier. As a
result thereof, the installation of the floor panels is simplified.
In preferred embodiments of the first aspect and/or of the second aspect of
the invention,
the floor panels are at least composed of a substrate which comprises at least
a substrate
layer which is produced on the basis of a composition which has one or more
one or more
of the following features, in so far as they do not conflict with each other:
- the composition comprises at least a thermoplastic;
CA 03202306 2023-6- 14
WO 2022/157618 PCT/IB2022/050370
9
- the composition comprises at least a plastic, such as polyvinyl chloride,
polyethylene, polypropylene, polyethylene terephthalate, polyurethane and/or
elastomer;
- the composition comprises one or more plasticizers in an amount of less
than
20 phr and preferably in an amount of between 5 and 15 phr;
- the composition comprises one or more plasticizers in an amount of at
least
20 phr;
- the composition comprises an inorganic filler, such as chalk, talc and/or
limestone;
- the composition comprises an organic filler, such as wood particles, bamboo
and/or cork particles;
- the composition comprises a mineral filler, such as ceramics; and/or
- the composition comprises mineral fiber structures, such as fibers of
glass, talc
and/or wolla stonite;
- the composition contains a mineral binder, for example of Portland cement,
plaster or magnesium oxide.
A preferred embodiment of the first aspect and/or of the second aspect of the
invention
is characterized in that the floor panels are so-called "resilient" or,
alternatively, so-called
"rigid" plastic-based floor panels ¨ preferably these floor panels are based
on polyvinyl
chloride ¨, optionally containing fillers or other constituents, with the
amount by weight
of plastic preferably being less than 50 %.
The thickness of the floor panels is preferably between 2 and 9 mm, and more
preferably
between 3 and 6 mm. This makes it possible to make the floor panels
sufficiently thin,
while still being sufficiently strong and stable.
Preferably, the floor panels are decorative. To this end, they may be composed
of a
substrate and a top layer which is situated on top of the substrate and which
comprises a
decor layer. This decor layer preferably has a design or pattern which may
simulate, for
example, a natural product, such as wood, stone or ceramics. This may then
consist of,
CA 03202306 2023-6- 14
WO 2022/157618
PCT/1B2022/050370
for example, a wood design or pattern. This design or pattern may then
simulate, for
example, wood grain or wood pores.
The decor layer preferably consists of a print which is applied, optionally
directly, onto
5 an underlying layer of the floor panel. If the print is not applied
directly, it is typically
applied onto a carrier sheet. This carrier sheet may involve, for example, a
plastic film,
such as a polyvinyl chloride film, polyurethane film, polypropylene film,
polyethylene
terephthalate film or polyethylene film. Preferably, the carrier sheet is
attached to the
substrate or another layer of the top layer by means of a thermal lamination
process.
10 When the print is applied directly onto an underlying layer of the floor
panel, the so-
called direct print, it is not ruled out that it is applied onto a base layer
or primer provided
on the underlying layer. Preferably, a digital printer, such as an inkjet
printer, is used
when printing directly.
Preferably, the top layer also comprises a transparent or translucent wear
layer which is
situated on top of the decor layer. This wear layer then forms a protection
for the decor
layer. This may involve, for example, a plastic-based wear layer which is
applied either
as a film, optionally together with the abovementioned printed film, for
example by
means of a thermal lamination process, or in liquid form and then cured on the
substrate
2 0 or another layer of the top layer. In case the wear layer comprises a
film, this is preferably
a thermoplastic film, in particular a polyvinyl chloride film, a polyurethane
film, a
polypropylene film, a polyethylene terephthalate film or a polyethylene film.
The top layer may be finished with a lacquer layer which is applied as a
liquid layer onto
the abovementioned wear layer and/or the abovementioned decor layer and is
subsequently cured. Preferably, this is a lacquer layer which can be cured by
UV light or
excimer radiation or a layer which can be cured by means of raising the
temperature.
This latter layer may use, for example, blocked isocyanates as crosslinkers.
Preferably, a
lacquer layer is applied on top of the possible wear layer, but, according to
an alternative,
the lacquer layer may act as a wear layer.
CA 03202306 2023-6- 14
WO 2022/157618
PCT/1B2022/050370
11
The top layer may also be provided with impressions which are optionally in
register
with the decor layer. To this end, a roller is used such as described as such
in
W02016/016864. The impressions provide the floor panels with a relief in such
a way
that they simulate a natural structure such as a wood structure even better.
The
impressions may, for example, be made in accordance with a wood grain pattern.
In addition to the substrate and the top layer, the floor panels may also
comprise a backing
layer which is situated under the substrate. The backing layer may, for
example, be based
on cork or based on a thermoplastic, which is preferably of the flexible type.
Such a
rather soft backing layer may give the floor panels new properties, for
example with
regard to comfort and sound absorption. In particular, the backing layer forms
a layer
with acoustic properties. The backing layer may contribute, for example, to a
reduction
in the production of sound by the floor panels, for example when someone walks
over
the latter
As the above makes clear, the invention firstly provides floor panels which
are composed
of a substrate which is based on a plastic, such as polyvinyl chloride,
polyethylene,
polypropylene, polyethylene terephthalate and/or polyurethane. However, the
invention
is not limited to such floor panels. In general, it can be applied in any type
of floor panel.
Thus, it is for example not ruled out that the invention is used in floor
panels having a
wood-based substrate, such as an MDF or HDF substrate, which may be provided
with a
top layer of any kind, for example a laminate layer. The invention may also be
used on
floor panels with a wood-based substrate and a wooden top layer situated on
top thereof,
such as a top layer of wood veneer. In this case, the floor panels are
referred to as being
of the engineered wood type.
A preferred embodiment of the first aspect and/or of the second aspect of the
invention
is characterized in that the set of floor panels comprises two types of floor
panels which
are configured in such a way that a herringbone pattern may be produced, in
which the
coupling parts of the two types of floor panels are preferably mirrored with
respect to
each other.
CA 03202306 2023-6- 14
WO 2022/157618
PCT/1B2022/050370
12
In a preferred embodiment of the first aspect or of the second aspect of the
invention, the
bottom lip of the female coupling part on the long edge comprises a first
support surface
and a second support surface. In a coupled position with another panel, these
support
surfaces are both situated proximally from an open space between this bottom
lip and
either the bottom side of the tongue or the bottom side of the downwardly
extending
interlocking part. The first support surface is situated proximally from the
second support
surface. The first support surface is provided in order for making contact
with the bottom
side of the tongue of a male coupling part on the long edge of a coupled
panel. The second
support surface is a potential or actual support surface for the bottom side
of the
downwardly extending interlocking part of the male coupling part on the short
edge. The
term support surface is understood to mean that actual support is provided or
that support
may be provided. Such embodiments make it possible to optimize the ease of
coupling.
Alternatively, it is possible for the bottom lip to comprise a similar support
surface both
for the bottom side of the tongue of a male coupling part on the long edge of
a coupled
panel and for the bottom side of the downwardly extending interlocking part of
the male
coupling part on the short edge; wherein this support surface is proximal to
an open space
between this bottom lip and either the bottom side of the tongue or the bottom
side of the
downwardly extending interlocking part.
2 0 The third aspect of the invention relates to a method for installing a
set of floor panels,
wherein a set of panels such as in the first aspect and/or such as in the
second aspect of
the invention is used, wherein the set of panels comprises two types of floor
panels which
are configured in such a way that a herringbone pattern may be produced. The
method
comprises the feature that a herringbone pattern is produced.
In the resulting floor covering, the risk of differences in height, formation
of gaps or
cracks between the mutually coupled floor panels is minimized. This is due to
the fact
that a satisfactory interlocking is provided not only between the mutually
coupled long
edges but that a secure interlocking may also be provided between the mutually
coupled
short and long edges.
In addition, installation may be easy to perform.
CA 03202306 2023-6- 14
WO 2022/157618
PCT/1B2022/050370
13
The present invention ¨ in its various aspects ¨ can be applied particularly
advantageously in floor panels comprising a substrate which is based on a
plastic, such
as polyvinyl chloride, polyethylene, polypropylene, polyethylene terephthalate
and/or
polyurethane. After all, these floor panels have been found to experience
drastic
dimensional changes as the temperature changes. These may result in
compression of the
floor covering and even to a moving apart of the coupled floor panels.
However, the
present invention is able to minimize this risk due to the secure interlocking
which may
be provided between the edges with respect to each other.
The substrate of the floor panels in the set of floor panels according to the
first aspect
and/or of the second aspect of the invention may optionally be multi-layered,
but
preferably comprises at least a substrate layer which is produced on the basis
of a
composition which has one or more of the following features insofar as these
are not
contradictory:
- The composition comprises at least a thermoplastic.
- The composition comprises at least a plastic, such as polyvinyl chloride,
polyethylene, polypropylene, polyethylene terephthalate, polyurethane and/or
an
elastomer.
- The composition comprises one or more plasticizers in an amount of less than
20
phr and preferably in an amount between 5 and 15 phr. In case such an amount
of plasticizers is used, a substrate layer of the rigid or stiff type is
involved.
- The composition comprises one or more plasticizers in an amount of at
least 20
phr. In this case, a substrate layer of the elastic or flexible type is
involved.
- The composition comprises an inorganic filler, such as chalk, talc and/or
limestone.
- The composition comprises an organic filler, such as wood particles,
bamboo
and/or cork particles.
- The composition comprises a mineral filler, such as ceramics.
- The composition comprises mineral fiber structures, such as fibers of glass,
talc
and/or wollastonite.
CA 03202306 2023-6- 14
WO 2022/157618
PCT/1B2022/050370
14
It should be noted that the presence of a substrate layer of the rigid type,
i.e. containing
an amount of plasticizer of less than 20 phr, benefits the dimensional
stability of the floor
panels. Together with the secure interlocking, this rigid substrate layer then
provides an
extremely stable floor covering.
If desired, the substrate layer may be foamed. This has the advantage that the
density of
the substrate layer can be reduced. Thus, it is possible to achieve a saving
in raw materials
and energy. Foaming may also provide the substrate layer with new properties,
such as
with regard to comfort and, more importantly, with regard to dimensional
stability.
It should also be noted that the substrate layer may be produced in accordance
with
various possibilities. Thus, the substrate layer may be produced by means of
spreading,
extrusion, injection-molding, calender and/or coating techniques.
The substrate may be composed of several substrate layers. These substrate
layers may
be produced on the basis of a composition such as those mentioned above, but
they do
not have to be identical to each other. The substrate layers may differ, for
example, on
the basis of the amount of plasticizers used. In this case, it may involve the
combination
of an elastic substrate layer with a rigid substrate layer.
In a particularly preferred embodiment, the floor panels are of the so-called
Luxury Vinyl
Tile (LVT) or Wood Plastic Composite (WPC) type. For example, these are the
floor
panels which are configured as described in document US9,156,233B2.
Possibly, the substrate is provided with a reinforcing layer, such as a glass
fiber cloth or
a glass fleece or a glass fiber mesh. This reinforcing layer is then
preferably incorporated
in the substrate. This means that the reinforcing layer is then delimited by
the material of
the substrate on both its top and bottom side. This reinforcing layer helps to
increase the
dimensional stability of the floor panels and thus contributes in preventing
the formation
of gaps and cracks in the floor covering in a herringbone pattern. It should
be noted that
the substrate may be provided with several, optionally incorporated,
reinforcement
layers.
CA 03202306 2023-6- 14
WO 2022/157618
PCT/1B2022/050370
The thickness of the floor panels is preferably substantially, i.e. for half
or more, formed
by the substrate.
5 In
summary, the independent aspects of sets of floor panels of the invention are
not
limited to specific types of materials of floor panels, but may be applied in
all kinds of
floor panels.
It should be noted that the expression "mechanical coupling parts" is
understood to mean
10
coupling parts which make it possible to bring about a mechanical
interlocking. No
adhesive or the like is thus required for the interlocking, but the use of
adhesive is not
ruled out.
Tn order to show th e features of the invention in more detail, some preferred
embodiments
15 are
described below by way of example and without being limited thereto, with
reference
to the accompanying drawings, in which:
- Fig. 1 shows a top view of two floor panels from a set according to the
invention;
- Fig. 2 diagrammatically shows a partly constructed floor covering,
comprising
floor panels from Fig. 1 which have been fitted in a herringbone pattern;
- Fig. 3 diagrammatically and on a larger scale shows the portion which is
denoted
as F3 in Fig. 2, however during assembly of the floor panels;
- Fig. 4 shows a panel from a set of panels according to the invention
along its long
edges, panel as may be used in the floor covering of Fig. 1;
- Fig. 5 shows a panel from a set of panels according to the invention along
its short
edges, panel as may be used in the floor covering of Fig. 1;
- Fig. 6 shows a cross section along line VI-VI from Fig. 1;
- Fig. 7 shows a cross section along line VII-VII from Fig. 1;
- Fig. 8 illustrates the coupling of the male coupling part on the long
edge by means
of a horizontal sliding movement with snap-fit effect into the female coupling
part on the short edge;
CA 03202306 2023-6- 14
WO 2022/157618
PCT/1B2022/050370
16
- Fig. 9 illustrates the coupling of the female coupling part on the short
edge into
the male coupling part on the long edge by means of a horizontal sliding
movement with snap-fit effect;
- Fig. 10 illustrates the coupling by means of a rotating movement;
- Fig. 11
illustrates the fitting in a herringbone pattern, in which panels according
to the invention may be fitted by means of a horizontal sliding movement;
- Fig. 12 illustrates a block motif in which the invention may also be
applied;
- Fig. 13 shows ¨ in an identical view to that from Fig. 7 ¨ another
embodiment of
the invention;
- Figs. 14 and 15 show another embodiment of a set of panels according to the
invention in the coupled position of the panels.
Fig. 1 shows a top view of two floor panels 1A, 1B from a set of floor panels
according
to the invention, which are different from each other and which are to this
end denoted,
more specifically, as lA and 1B. These floor panels 1A-1B are suitable for
forming a
floor covering in a herringbone pattern, as will become clear from the
following. The
coupling parts of the two types of floor panels 1A, 1B are mirrored with
respect to each
other along the longitudinal axis of the panels.
In Fig. 2 a portion of the floor covering in a herringbone pattern is shown.
In this floor
covering, several of the floor panels 1A-1B from Fig. 1 have been used.
Fig. 4 shows a panel from a set of panels according to the invention on its
long edges,
panel as may be used in the floor covering from Fig. 1. Fig. 5 shows a panel
from a set
of panels according to the invention on its short edges, panel as may be used
in the floor
covering from Fig. 1.
Fig. 6 shows a cross section along line VI-VI from Fig. 1. Fig. 7 shows a
cross section
along line VH-VII from Fig. 1.
The reference numerals have the same meaning throughout the various figures.
CA 03202306 2023-6- 14
WO 2022/157618
PCT/1B2022/050370
17
The floor panels 1A-1B are elongate rectangular and therefore comprise a pair
of long
edges 2-3 and a pair of short edges 4-5. Both the long and the short edges 2-3-
4-5 are
provided with mechanical coupling parts 6-7-8-9 which allow several of such
floor
panels 1A-1B to be coupled together. The one long edge 2 is provided with a
male
coupling part 6 and the other long edge 3 is provided with a female coupling
part 7. The
one short edge 4 is provided with a male coupling part 8 and the other short
edge 5 is
provided with a female coupling part 9.
It is clear from Fig. 1 that the floor panel IA is of a different type than
the floor panel
1B. The reason for this is that the position of the coupling parts 6-7-8-9 in
the floor panel
lA is mirrored with respect to the position of the coupling parts 6-7-8-9 in
the floor panel
1B.
Fig. 3 shows how the floor panels 1 A and 1 II can be assembled systematically
to form a
herringbone pattern. The aim in Fig. 3 is that the floor panel 1B shown in an
upwardly
rotated position is connected to the horizontal floor panels 1A and 1B. The
edge 2
comprising the male coupling part 6 of the floor panel 1B which is in the
upwardly
rotated position is in this case presented to the edge 3 of the horizontal
floor panel 1B,
following which these floor panels 1B are connected along the edges 2 and 3 by
rotation
by means of the rotating movement W. Due to the rotating movement W, a
downward
movement M is created on the short edge 4 which, according to the invention,
results in
a male coupling part 8 situated on the short edge 4 being coupled in an
interlocking
manner to the female coupling part 7 of the long edge 3 of the transverse
floor panel 1A.
This method of installation is known as a "fold-down" installation.
Fig. 4 shows a panel from a set of panels according to the invention on its
long edges,
panel as may be used in the floor covering from Fig. 1. Fig. 5 shows a panel
from a set
of panels according to the invention on its short edges, panel as may be used
in the floor
covering from Fig. 1.
Fig. 6 shows a cross section along line VI-VI from Fig. 1 in which panels as
in Figs. 4
and 5 have been used. Fig. 7 shows a cross section along line VII-VH from Fig.
1 in
which panels as in Figs. 4 and 5 have been used.
CA 03202306 2023-6- 14
WO 2022/157618
PCT/1B2022/050370
18
The floor panels 1A, 1B, illustrated in Figs. 4-7, are elongate rectangular
and therefore
comprise a pair of long edges 2-3 and a pair of short edges 4-5; wherein both
the long
and the short edges are provided with mechanical coupling parts 6-7-8-9 which
allow the
floor panels from the set to be coupled together; wherein the one long edge 2
is provided
with a male coupling part 6 and the other long edge 3 is provided with a
female coupling
part 7; wherein the one short edge 4 is provided with a male coupling part 8
and the other
short edge 5 is provided with a female coupling part 9. The male coupling part
6 on the
long edge 2 can be fitted into the female coupling part 7 on the long edge 3
of a floor
panel of the set by means of a rotating movement W. This rotating movement is
illustrated in Fig. 10.
The male coupling part 6 on the long edge 2 can also be fitted into the female
coupling
part 9 on the short edge 5 of a floor panel from the set by means of a
rotating movement.
The male coupling part on the short edge 4 can be fitted into the female
coupling part
7 on the long edge 3 in one and the same rotating movement W which is used to
fit the
male coupling part 6 on the long edge 2 into the female coupling part 7 or 9
on the long
or short edge 3 or 5, as is illustrated in Fig. 3.
The male coupling part 8 on the short edge 4 and the female coupling part 7 on
the long
edge 3 comprise interlocking parts which, in a mutually coupled position of
such a short
edge and long edge, bring about both an interlocking in a horizontal direction
H and an
interlocking in a vertical direction V; wherein the female coupling part on
the long edge
and on the short edge comprises a lateral groove 10 which is delimited by an
upper lip
11 and a bottom lip 12, the bottom lip 12 of which extends distally beyond the
upper lip
11 and is provided with an upwardly pointing interlocking part 13; wherein the
male
coupling part on the long edge is provided with a tongue 14 which, in the
coupled
position, can cooperate with the abovementioned lateral groove 10 in order to
bring about
a vertical interlocking; and wherein the set of floor panels comprises at
least one pair of
interlocking portions in order to bring about the abovementioned vertical
interlocking of
the male coupling part on the short edge into the female coupling part on the
long edge.
As is illustrated in Fig. 8, the male coupling part 6 on the long edge 2 can
be fitted into
the female coupling part 9 on the short edge 5 of a floor panel from the set
by means of
a horizontal sliding movement S with snap-fit effect. As is illustrated in
Fig. 9, this also
CA 03202306 2023-6- 14
WO 2022/157618
PCT/1B2022/050370
19
means that ¨ due to the relativity of movements ¨ the female coupling part 9
on the short
edge 5 can be fitted into the male coupling part 6 on the long edge 2 by means
of a
horizontal sliding movement S with snap-fit effect.
The male coupling part 6 on the long edge 2 may be fitted into the female
coupling part
7 on the long edge 3 of a floor panel of the set by means of a horizontal
sliding movement
S with snap-fit effect.
The panels illustrated in Figs. 4-7 ¨ see also Figs. 8 and 9 ¨ are configured
in such a way
that the male coupling part on the long edge 2 and the female coupling part on
the short
edge 5, when horizontally sliding a first panel from the set of floor panels
with respect
to a second panel from the set of floor panels in order to couple the male
coupling part
on the long edge 2 of the first panel to the female coupling part on the short
edge 3 of the
second panel, when sliding the bottom side 30 of the tongue 14 of the male
coupling part
on the long edge 2 over the upwardly pointing interlocking part 13 of the
female coupling
part on the short edge 5, the tongue 14 of the male coupling part on the long
edge 2 is
guided in the groove 10 of the female coupling part on the short edge. When
sliding the
bottom side 30 of the tongue 14 of the male coupling part on the long edge 2
over the
upwardly pointing interlocking part 13 of the female coupling part on the
short edge 5,
in which case the tongue 14 of the male coupling part on the long edge 2 is
guided in the
groove 10 of the female coupling part on the short edge, no deformation of the
tongue 14
of the male coupling part on the long edge 2 and no deformation of the bottom
lip 12 of
the female coupling part on the short edge 5 is required in order to insert
this tongue 14
into this groove 10. The coupling parts are configured in such a way that when
coupling
the male coupling part 6 on the long edge 2 of a panel from the set by means
of a
horizontal sliding movement S with snap-fit effect into the female coupling
part 9 on the
short edge 5 of a floor panel, a bending and returning of the bottom lip 12 of
the female
coupling part 9 on the short edge 5 may take place.
In the panels illustrated in Figs. 4-7, the upwardly pointing interlocking
part 13 of the
female coupling part 7 on the long edge 3 and the upwardly pointing
interlocking part 13
of the female coupling part 9 on the short edge 5, in cross section at right
angles to the
CA 03202306 2023-6- 14
WO 2022/157618
PCT/IB2022/050370
respective edge, comprise a point 31 which is situated closest to the top side
of the panel,
wherein, when running through the section 32 of this interlocking part 13
proximally
from this point, from proximally from this interlocking part 13 to the distal
end of this
interlocking part 13, the distance D to the level of the surface of the floor
panel becomes
5 continuously smaller. The slope of this section 32 always runs distally.
The panels illustrated in Figs. 4-7 illustrate an example in which the angle A
between the
bottom lip 12 of the female coupling part 7 on the long edge 3 and the
proximal flank of
the interlocking part 13 of the female coupling part 7 on the long edge 3 is
greater than
10 900 everywhere, in the example, this angle A is 115 in the bending
point of this proximal
flank. In addition, the angle B between the bottom lip 12 of the female
coupling part 9
on the short edge 5 and the proximal flank of the interlocking part 13 of the
female
coupling part 9 on the short edge 5 is greater than 90 everywhere; in the
example, this
angle A is 1 15 in the bending point of this proximal flank
With the panels illustrated in Figs. 4-7, the male coupling part 8 on the
short edge 4
comprises a flange 21 which extends laterally at the top and which has a
downwardly
extending interlocking part 22, wherein, for the abovementioned vertical
interlocking, an
additional pair of interlocking portions 17-18 is provided, one interlocking
portion 17 of
which is situated on the distal end of the abovementioned flange 21 and/or
downwardly
extending interlocking part 22, while the other interlocking portion 18 is
then situated on
the opposite floor panel.
In order to bring about the abovementioned vertical interlocking of the male
coupling
part 8 of the short edge 4 into the female coupling part 7 on the long edge 3,
the panels
illustrated in Figs. 4-7 comprise a first interlocking portion 19 on this male
coupling part
8 and a second interlocking portion 20 on the female coupling part 7 which
cooperates
with the former in the coupled position, wherein the abovementioned second
interlocking
portion 20 which is present on the female coupling part is situated on the
distal end of
the upwardly pointing interlocking part 13, wherein the abovementioned other
first
interlocking portion 9 is situated on the opposite floor panel. The
interlocking in a
CA 03202306 2023-6- 14
WO 2022/157618
PCT/1B2022/050370
21
vertical direction by these interlocking portions 19, 20 in the coupled
position may take
place with or without contact between these interlocking portions 19, 20.
In the examples shown in Figs. 4-7, the coupling parts on all four edges are
integrally
formed from the material of the floor panels. In these examples, the female
coupling part
on the short edge and the female coupling part on the long edge are of
identical design.
In the examples shown in Figs. 4-7, a recess 23 is present on the underside of
the female
part of the long edge 3 and of the short edge 5, which recess 23 makes elastic
bending
during assembly easier.
In the examples shown in Figs. 4-7, an identical surface 33 proximally to the
upwardly
pointing interlocking part of the female coupling part 7 on the long edge 3
and to the
female coupling part 9 on the short edge 5 is used, intended for horizontal
interlocking
with both a male coupling part 6 on the long edge 2 and a male coupling part 8
on the
short edge 4.
Preferably, there is a pretension in the contact surface between the proximal
end of the
downwardly extending interlocking part 22 and the upwardly pointing
interlocking part
13 between the male coupling part 8 of the short edge 4 and the female
coupling part 7
of the long edge 3 in the coupled position, this pretension being caused by an
overlap of
the profiled sections of these interlocking parts in the uncoupled position.
Fig. 11 illustrates the installation of a set of panels 1A, 1B in a
herringbone pattern, for
example such as in Fig. 1. The reference numerals have the same meaning as in
the other
figures. The panel 49, a panel of type IA, could simply be added by means of
the "fold
down" method. However, due to the position of the coupling parts, this is not
possible
with the panel 50. Nevertheless, this panel may be coupled by horizontally
sliding with
a snap-fit movement in the direction of arrow 51, in which case both the
female coupling
part on the short edge 5 of the panel 50 is coupled into the male coupling
part on the long
edge 2 of an already fitted panel, and the female coupling part on the long
edge 3 of the
panel 50 may be coupled into the male coupling part on the long edge 2 of
another already
CA 03202306 2023-6- 14
WO 2022/157618
PCT/IB2022/050370
22
fitted panel and also on the male coupling part on the short side 4 of yet
another already
fitted panel. In this way, it is possible to start laying a herringbone
pattern in the center
of a room, in which panels are laid in the various directions by means of the
fold-down
method or via horizontal sliding. The advantage is that the herringbone
pattern can easily
be laid accurately centered in a room.
The manner of coupling by means of horizontal sliding can also be used in an
advantageous way along the edges of the room.
Fig. 12 illustrates how such floor panels according to the first aspect and/or
according to
the second aspect of the invention may also be fitted in a block motif For the
illustrated
block motif, one type of panels lA is sufficient; and it is not necessary to
use two types
lA and 1B as is the case when laying in a herringbone pattern.
Fig. 13 shows ¨ in the same view from Fig. 7 ¨ another embodiment of the
invention.
These panels are largely similar to the panels illustrated in Figs 4-7 In
order to bring
about the vertical interlocking of the male coupling part 8 of the short edge
4 into the
female coupling part 7 on the long edge 3, these panels from Fig. 13 comprise
a first
interlocking portion 15 on this male coupling part 8 and a second interlocking
portion 16
on the female coupling part 7 which cooperates with the former in the coupled
position;
wherein the abovementioned second interlocking portion 16 which is present on
the
female coupling part 7 is situated on the proximal side of the abovementioned
upwardly
pointing interlocking part 13. This second interlocking portion 16 consists of
an undercut
in the form of a sloping surface under which the first interlocking portion 15
may engage.
The male coupling part 8 of the short edge 4 and the female coupling part 7 on
the long
edge 3 are configured in such a way that the first interlocking portion 15 can
be brought
behind the second interlocking portion 16 by means of a downward movement of
the
male coupling part 8 of the short edge 4, more particularly by means of a
downward
snap-fit movement Ml. The contact between this first interlocking portion 15
and the
second interlocking portion 16 preferably takes place under pretension.
Figs. 14 and 15 show another embodiment of a set of panels according to the
invention
in the coupled position of the panels. In a view similar to that from Fig. 6,
Fig. 14 shows
the coupling of a panel lA along its long edge 2 with its male coupling part 6
into the
CA 03202306 2023-6- 14
WO 2022/157618
PCT/IB2022/050370
23
female coupling part 7 on the long edge 3 of such another panel 1A. In a view
similar to
that from Fig. 7, Fig. 15 shows the coupling of a panel 1A along its short
edge 4 with its
male coupling part 8 into the female coupling part 7 on the long edge 3 of
such another
panel 1B. The reference numerals have the same meaning as in the other
figures. The
bottom lip 12 of the female coupling part 7 on the long edge 3 comprises a
first support
surface 60 and a second support surface 61, both situated at a different
distance from the
bottom side of the panel. In the coupled position with another panel, the
first support
surface 60 and the second support surface 61 are both situated proximally to
an open
space 62, 63 between the bottom lip 12 and either the bottom side of the
tongue 14 or the
bottom side of the downwardly extending interlocking part 22 of the other
panel. The
first support surface 60 is situated proximally to the second support surface
61, wherein
the first support surface 60 is provided to make contact with the bottom side
of the tongue
14 of a male coupling part 6 on the long edge 2 of a coupled panel. The second
support
surface 61 i s a potential or actual support surface for the bottom side of
the downwardly
extending interlocking part 22 of the male coupling part 8 on the short edge
4. The term
support surface is understood to mean that actual support is provided or that
support may
be provided.
With the examples shown in Figs. 6 and 7, the bottom lip 12 comprises an
identical
support surface ¨ situated proximally to an open space ¨ both for the bottom
side of the
tongue 14 of a male coupling part 6 on the long edge 2 of a coupled panel and
for the
bottom side of the downwardly extending interlocking part 22 of the male
coupling part
8 on the short edge 4.
In the example from Fig. 15, the interlocking in the vertical direction is
performed by the
interlocking portions 19, 20, with these interlocking portions 19, 20 being in
contact in
the coupled position.
It should be noted that, in the invention, the coupling parts 6-7 may be
configured in such
a way that they provide a tensioning force in the coupled position which
pushes the top
sides of the coupled edges 2-3 towards each other. The principle from Fig. 23
of
document WO 97/47834 may be used for this purpose. The bottom lip 25 may then
be
permanently bent slightly downwards, for example in the coupled position.
CA 03202306 2023-6- 14
WO 2022/157618
PCT/IB2022/050370
24
In the examples, the female coupling part 9 on the short edge 5 is identical
to the female
coupling part 7 on the long edge 3. However, it should be clear that this
female coupling
part 9 does not necessarily have to have the same shape as the female coupling
part on
the long edges, but that it is sufficient if the functionalities discussed
above are present
in order to bring about the respective aspects of the invention.
It will be clear that the bottom lip 12, where necessary, will be sufficiently
flexible to
allow interlocking or unlocking, respectively, during the inward and/or
outward rotating
movement. In specific embodiments, it may also be provided that the tongue 14
can be
snap-fitted horizontally into the groove 10, which is the case, for example,
in Fig. 13.
It should be noted that where reference is made to the "upwardly pointing
interlocking
part of the bottom lip", this may refer to both an interlocking part which
actually
protrudes above the average level of the top side of the lip, and an
interlocking part which
is situated partly or even entirely below this level, but which has a recess
in the top side
of the bottom lip proximally thereto. Since, in the latter case, a recess is
situated in front
of the interlocking part, the adjacent interlocking part is automatically also
"upwardly
pointing".
2 0 It is also clear that the term "interlocking portion" may relate both
to the material portion
or the zone which results from the respective interlocking and to the
interlocking surface
thereof which brings about the interlocking.
The present invention is by no means limited to the above-described
embodiments, but
such methods and floor panels may be produced according to different variants
without
departing from the scope of the present invention.
CA 03202306 2023-6- 14
