Packaging comprising flexible floor covering elements and method of laying

Abstract

A flexible, preferably polymer-based, rectangular floor covering element of double- angling type has six sides: a decorative top face and a bottom face, as well as four edges. The first long edge has a first connection profile with a recess at the bottom face and a tongue overhanging the recess. The second long edge opposite the first long edge has a second connection profile with a protrusion at the bottom face and a groove for receiving the tongue of the first profile. The first short edge is equipped with the first profile and the second short edge is equipped with the second profile. When looking at the floor covering element from above the top face, the edges of the floor covering element are arranged in the following order in the clockwise direction: 1) the first long edge, 2) the first short edge, 3) the second long edge and 4) the second short edge.

Description

Field of the Invention

[0001] The invention generally relates to a flexible (i.e. bendable) rectangular floor covering element (e.g. a plank or a tile) with connection profiles arranged on its four edges.Background of the Invention

[0002] Floor covering elements with conjugate connection profiles are known in the art. Such profiles have first been used on wood floor elements. One of their simplest embodiments comprises a tongue profile (or male profile) and a groove profile (or female profile). Each floor covering element has one long edge with a tongue profile and the opposite long edge with a groove profile. There are layouts, wherein the each floor covering element further has one short edge with a tongue profile and the other short edge with a groove profile. Laying such a wood floor is typically done in the following way. A first row of floor covering elements is installed beginning on the left and adding new floor covering elements on the right of the elements already in place. To connect the new element, the parquet recliner puts it in place and then taps on its right edge with a hammer to obtain a firm engagement of the profiles on the short edges. The next rows are laid as the first row except that the parquet recliner also taps the floor covering element on the long edge next to him in order to obtain a firm engagement also on the long edges. As hammering on the tongue profiles was more likely to lead to damage, the floor covering elements were arranged in the following way: when looking at the top face of the floor covering element and holding it such that the long edge with the tongue profile is in the 12-o'clock position (the long edge with the groove profile is thus in the 6 o'clock position), then the short edge with the groove profile is in the 3-o'clock position (on a conventional clock, not a Bolivian clock, for instance) and the short edge with the tongue profile is in the 9-o'clock position (on the conventional clock). That order of the edges is comfortable for the majority of people who are right-handed and thus prefer to hold the hammer in the right hand. To the knowledge of the inventors that order has never been put into question and was taken over on any later developed floor covering element with connection profiles.

[0003] More recently, tongue-and-groove connection profiles were developed that provide better protection against separation. With so-called angling-type connectors, the tongue profile is angled into the groove profile whereupon the floor covering element with the tongue is hinged down. During this movement, the connection profiles deform resiliently and then snap into place. The tongue profile is thus locked in the groove profile such that a separation thereof requires a higher amount of force or a specific relative movement of the profiles. When the profiles are made of relatively hard material, such as, e.g. wood, a click can be heard when the connection profiles are securely connected. When angling-type connectors are provided on the four edges of each floor covering element, the new element to be laid is first angled into the element on the left already in place. Then, the new element is declined towards the rear and angled into the row behind. The latter step requires that the element(s) on the left follow the movement of the new element. They are thus also raised at their front and hinged down. Installing such floor covering elements requires some coordination, which is however easily acquired through some practice.

[0004] Nevertheless, in order to facilitate the installation of floor coverings especially to do-it-yourselfers (DIYers), so-called angling and drop-down floor covering elements have been developed. On such floor covering elements, the long edges are equipped with a tongue and a groove profile respectively. The new element to be laid is angled into the elements already in place behind it. On the left short edge, each element comprises a connection profile with an overhang that is the counterpart of the connection profile on the right short edge, which has a protrusion at the bottom side. The connection profiles on the short edges are configured in such a way that they can be assembled by simply dropping down the new element to be installed from the angled position into the final horizontal position. Some configurations even have a latch on the right-hand connection profile, which prevents the separation of the floor covering elements on the short edges. Notwithstanding that, compared to the double-angling-type floor covering elements mentioned above, the angling-and-drop-down floor covering elements have the disadvantage of a weaker connection on the short edges, which may also lead to worse durability under strain (assessable using e.g. the castor chair test according to European norm EN 425).

[0005] For flexible polymer-based floor covering elements the double-angling configuration is thus preferred.

[0006] Document WO 03 / 025307 relates to floorboards for installation of floors in herring-bone pattern are formed with two opposite sides inverted relative to each other. The invention further comprises methods for producing and making floorings comprising such floorboards, as well as fitting pieces and sets of parts for such floorings. Said document discloses a packaging according to the preamble of claim 1 and a method according to the preamble of claim 8.

[0007] Document WO 2004 / 079130 relates to floorboards for mechanical joining of floors in a herringbone pattern and in parallel rows with horizontal connecting means which on the short sides have cooperating locking surfaces which are designed differently from the cooperating locking surfaces on the long sides.

[0008] Document WO 2011 / 077311 relates to a floor panel for forming a floor covering, which, at least at two opposite edges, comprises coupling parts of the type allowing to couple two of such panels to each other by means of a downward movement of one panel in respect to the other. These coupling parts form a first locking system, which effects a locking in the plane of the panels and perpendicularly to said edges, as well as form a second locking system, which effects a locking perpendicularly to the plane of the panels.General Description

[0009] The invention relates to a packaging comprising a set of flexible rectangular floor covering elements, such as, e.g., planks or tiles, in particular for the installation of a floating floor. Each floor covering elementhas six sides: a decorative top face and a bottom face for contacting the underfloor, as well as four lateral faces herein referred to as the edges of the floor covering element. The first long edge has a first connection profile with a recess at the bottom face and a tongue overhanging the recess. The second long edge opposite the first long edge has a second connection profile that is complementary (conjugate) to the first connection profile and that has a protrusion at the bottom face and a groove for receiving the tongue of the first connection profile. The first short edge is equipped with the first connection profile and the second short edge is equipped with the second connection profile. When looking at the floor covering element from above the top face (i.e. when looking at the top face in the direction opposite the outwardly pointing normal vector of the top face), the edges of the floor covering element are arranged in the following order in the clockwise direction: 1) the first long edge (with the first connection profile), 2) the first short edge (with the first connection profile), 3) the second long edge (with the second connection profile) and 4) the second short edge (with the second connection profile). The set of floor covering elements (hereinafter: the first set of floor covering elements) has user information associated therewith indicating that the set of floor covering elements is best suited for installation from left to right by double-angling. The user information is provided as a textual or pictorial notice on or in the packaging of the set of floor covering elements. Additionally, the packaging could comprise (on its outside or in its interior) an Internet link (in textual form or in the form of a machine-readable code, such as, e.g., a OR-code or another type of matrix barcode with or without colour coding) pointing to an Internet site on which the user information is available as a text, pictures (including photos and / or pictograms), a sound file or stream, a video file or stream, or any combination thereof.

[0010] It was surprisingly discovered by the inventors that the specified arrangement of the edges greatly facilitates the installation of flexible rectangular floor covering elements of the double-angling type. Indeed, with flexible floor covering elements having the mirrored arrangement the edges, the installation of a new floor covering element on the right of an already installed floor covering element frequently led to a partial loosening of the row being installed from the row behind. That risk could be considerably reduced with floor covering elements as provided in the packaging of the invention, which had originally been produced by error. When investigating the reasons for the unexpected increase in terms of laying comfort, it was found that the protrusion on the bottom side of the second short edge provided better support for the floor covering element on the left of the element being installed, whereby the second angling step became much easier.

[0011] As used herein, the term "flexible" designates a floor covering element that can be bent to a radius of curvature of 50 cm, preferably to a radius of curvature of 25 cm, or even to a smaller radius of curvature, without visible deterioration. It will be understood, however, that a floor covering element as provided in the packaging of the invention is not totally soft (such as a carpet with a foam backing) but has a firmness or rigidity that makes the floor covering element suitable for the secure installation of a floating floor covering by interconnecting the floor covering elements by means of the connection profiles.

[0012] The terms "long" and "short" are used herein to distinguish between the longer and the shorter edges of the floor covering element; they do not imply any particular lengths in absolute figures.

[0013] Preferably, the first connection profile on the first long edge is identical to the first connection profile on the first short edge and the second connection profile on the second long edge is identical to the second connection profile on the second short edge. Alternatively, the first connection profile on the first long edge differs from the first connection profile on the first short edge and the second connection profile on the second long edge differs from the second connection profile on the second short edge. In this case, both first connection profiles are of the same type (first type) and comprise each a recess at the bottom face and a tongue overhanging the recess, the shapes and / or the dimensions thereof being different in the detail, however. Similarly, both second connection profiles are of the same type (second type) and comprise each a protrusion at the bottom face and a groove, the shapes and / or the dimensions thereof being chosen such as to be able to mate with the respective first connection profile.

[0014] The floor covering element is preferably a synthetic (polymer-based) floor covering element, more preferably a vinyl tile, such as, e.g. a vinyl composition tile, a solid vinyl tile or a luxury vinyl tile. A polymer-based floor covering element may be PVC-based or PVC-free.

[0015] Preferably, the decorative top face comprises a decorative pattern representing a wood flooring, a bamboo flooring, a stone flooring, a ceramic flooring or a cork flooring. Any other decorative pattern, e.g. a photograph, a drawing or an abstract design, could of course also be used on the top face.

[0016] According to a preferred embodiment, the height of the floor covering element is comprised in the range from 3 to 7 mm, preferably in the range from 3 to 5 mm.

[0017] The first and second connection profiles are preferably configured for interlocking floor covering elements to be assembled by angling the first connection profile into the second connection profile and then bringing the floor covering elements to be assembled into alignment. The first and second connection profiles are preferably configured in such a way as to deform resiliently and to snap into place when the floor covering elements to be assembled are brought into alignment.

[0018] Another aspect of the invention relates to a method of laying a floor covering using the floor covering elements. The method comprises laying the floor covering elements row by row, each row being laid from left to right and each new row being laid in front of the rows already laid, wherein each element to be laid that has both a left-hand neighbour and a rear row already in place is first angled with its second short edge into the first short edge of the left-hand neighbour and then angled with its first long edge into the second long edge of the element or elements of the rear row.Brief Description of the Drawings

[0019] By way of example, preferred, non-limiting embodiments of the invention will now be described in detail with reference to the accompanying drawings, in which: Fig. 1: is a top view of a floor covering made with flooring tiles in accordance with the invention; Fig. 2: is a transversal cross-sectional view of first and second connection profiles; Fig. 3: is a transversal cross-sectional view illustrating how the second short edge of a flooring tile to be installed is connected with the right short edge of a flooring tile on the left already in place; Fig. 4: is a schematic perspective view of a packaging of flooring tiles best suited for installation from left to right; Detailed Description of Preferred Embodiments of the Invention

[0020] Fig. 1 is a schematic top view of a part of a floor covering 10 made with flexible flooring tiles 12. The flooring tiles 12 are of the double-angling type. Each flooring tile 12 has six sides: a decorative top face 14, a bottom face 16 (see Fig. 2) for contacting the underfloor 22 (see Fig. 2), two long edges 18a, 18b and two short edges 20a, 20b. The long edges comprise a first long edge 18a equipped with a first connection profile and a second long edge 18b opposite the first long edge 18a and equipped with a second connection profile that is complementary (conjugate) to the first connection profile. The short edges comprise a first short edge 20a equipped with the first connection profile and a second short edge equipped with the second connection profile.

[0021] Fig. 2. Shows the first and second connection profiles in cross section. The first connection profile, hereinafter referred to as the male profile M, has a recess 24 at the bottom face 16 of the flooring tile and a tongue 26 overhanging the recess 24. The second connection profile, hereinafter referred to as the female profile F, has a protrusion 28 at the bottom face 16 of the flooring tile and a groove 30 for receiving the tongue 26 of the male profile M. The shapes of the connecting profiles are conjugate to each other meaning that they can be brought into engagement. It should be noted, however, that the contour lines of the male and female profiles in cross section need not be completely identical. In the illustrated example, the male and female profiles can be brought into interlocking engagement. When the tongue 26 of the male profile M is inserted into the groove 30 of the female profile F, a small temporary deformation one or both of the profiles is necessary for the tongue 26 to reach its final position in the groove 30. When the tongue has been completely inserted, there is no or almost no residual deformation. However, the abutments 32 and 34 on the tongue 26 and the protrusion 28, respectively, secure the tongue 26 against slipping out of the groove 30 without application of significant force or carrying out the reverse movement.

[0022] When looking at the floor covering element from above the top face (as in Fig. 1), the order of the edges in the clockwise direction is: 1) the first long edge 18a (with the male profile - at the 12-o'clock position in Fig. 1), 2) the first short edge 20a (with the male profile - at the 3-o'clock position in Fig. 1), 3) the second long edge 18b (with the female profile - at the 6-o'clock position in Fig. 1) and 4) the second short edge (with the female profile - at the 9-o'clock position in Fig. 1). The advantage of that arrangement of the connection profiles can be experienced when laying the floor covering. A floor is typically laid by first laying the rearmost row of flooring times from the left to the right and then installing the next row. Except for the first row and the leftmost tile in each row, a new flooring tile is always added in front and to the right of the tiles already in place.

[0023] The male and female connectors shown in Fig. 2 are so-called angling-type connectors: when a new flooring tile is installed, the user holds it in the orientation described above and shown in Fig. 1. The user then angles the edge on the left of the new flooring tile under the overhanging tongue of the flooring tile on the left already in place (see Fig. 3). When the tongue has thereby entered the groove, the new flooring tile is hinged down. During this movement, the connection profiles deform resiliently and then snap into place. Depending on the stiffness of the polymer material of the flooring tile (and thus the connection profiles) a clicking noise may or may not be heard by the user. The male and female profiles are now interlocked with each other such that their separation would require a high amount of force (potentially leading to damage on the flooring tiles) or the reverse movement of the profiles. The next step is the connection of the new flooring tile with the tile or the tiles in the row behind. The user typically holds the new flooring tile with both hands. The left hand supports the new tile at the corner of the second long edge 18b and the second short edge 20b while the right hand supports it at the corner of the second long edge 18b and the first short edge 20a. The new tile and the tile to its left are already connected with each other. The user now raises the second long edge 18b of the new tile, giving the new tile a decline towards the row behind. The tile to the left has to follow that decline because of its engagement with the new tile. At this point, a conventional flexible double-angling flooring tile would be likely to disengage from the row behind and the user would have to be quite careful to avoid that. With flooring tiles according to the first aspect of the invention, the risk of the already installed tiles to the left disengaging from the row behind is significantly reduced. Keeping the tile to be installed inclined, the user pushes it with the male profile of the first long edge 18a into the female profile of the second long edge of the tile(s) behind it. When the connection profiles are in contact, the user lowers the second long edge 18b of the new tile on the underfloor. By that rotational motion of the new tile, the male and female profiles become interconnected along the long edge.

[0024] Fig. 4 shows an example of a packaging 36a of a set of flooring tiles according to the first aspect of the invention. The packaging 36a comprises several indications that the flooring tiles are most suitable for installation by right-handed persons, in particular a matrix barcode 38a, a pictogram representing a right hand 40a and a textual notice 42a.

[0025] It will be understood that flooring tiles according to the invention are most suitable for installation from left to right, irrespectively of the handedness of the person installing them.

[0026] The particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is defined by the appended claims.

Claims

1. A packaging comprising a set of flexible rectangular floor covering elements, such as e.g. planks or tiles, each floor covering element having a decorative top face and a bottom face for contacting an underfloor, each of the floor covering elements being of double-angling type and having a first long edge with a first connection profile, the first connection profile having a recess at said bottom face and a tongue overhanging said recess, a second long edge with a second connection profile that is complementary to the first connection profile, the second connection profile having a protrusion at said bottom face and a groove for receiving the tongue of the first profile, a first short edge with said first connection profile; and a second short edge with said second connection profile; wherein, when looking at the floor covering element from above the top face, the edges are arranged in the following order in the clockwise direction: 1) the first long edge, 2) the first short edge, 3) the second long edge and 4) the second short edge; characterised in that the packaging has user information associated therewith indicating that the set of floor covering elements is best suited for installation from left to right by double-angling, when looking at the floor covering element from above the top face in the direction of installation of the floor covering elements, the user information being a textual or pictorial notice on or in the packaging.

2. The packaging as claimed in claim 1, wherein each floor covering element is a synthetic, e.g. polymer-based, floor covering element.

3. The packaging as claimed in claim 1 or 2, wherein the decorative top face comprises a decorative pattern representing a wood flooring, a bamboo flooring, a stone flooring, a ceramic flooring or a cork flooring.

4. The packaging as claimed in any one of claims 1 to 3, each floor covering element being a vinyl tile or plank, preferably a vinyl composition tile, a solid vinyl tile or a luxury vinyl tile.

5. The packaging as claimed in any one of claims 1 to 4, wherein each floor covering element has a height comprised in the range from 3 to 7 mm, preferably in the range from 3 to 5 mm.

6. The packaging as claimed in any one of claims 1 to 5, wherein the first and second connection profiles are configured for interlocking floor covering elements to be assembled by angling the first connection profile into the second connection profile and then bringing the floor covering elements to be assembled into alignment.

7. The packaging as claimed in claim 6, wherein the first and second connection profiles are configured in such a way as to deform resiliently and to snap into place when the floor covering elements to be assembled are brought into alignment.

8. A method of laying a floor covering using a set of flexible rectangular floor covering elements, such as e.g. planks or tiles, each floor covering element having a decorative top face and a bottom face for contacting an underfloor, each of the floor covering elements being of double-angling type and having a first long edge with a first connection profile, the first connection profile having a recess at said bottom face and a tongue overhanging said recess, a second long edge with a second connection profile that is complementary to the first connection profile, the second connection profile having a protrusion at said bottom face and a groove for receiving the tongue of the first profile, a first short edge with said first connection profile; and a second short edge with said second connection profile; wherein, when looking at the floor covering element from above the top face, the edges are arranged in the following order in the clockwise direction: 1) the first long edge, 2) the first short edge, 3) the second long edge and 4) the second short edge; characterised in that the method comprises laying the floor covering elements row by row, each row being laid from left to right and each new row being laid in front of the rows already laid, wherein each element to be laid having a left-hand neighbour and a rear row already in place is first angled with its second short edge into the first short edge of the left-hand neighbour and then angled with its first long edge into the second long edge of the element or elements of the rear row.

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