IP Library Granted Patent US 11,859,390
Granted Patent B2
US 11,859,390 · App. 17/513,471 · Granted Jan 2, 2024

Method for manufacturing a floor panel

Inventor: Mark Cappelle (Staden, BE)
Assignee: FLOORING INDUSTRIES LIMITED, SARL
E04F15/02038E04F15/10E04F15/105E04F15/107E04F2201/0146E04F2201/0184E04F2201/041
View Patent ↗
Loading inventors, assignments & file history…
Monitor This Case
Get email alerts when status or documents change.
Order Certified Copies
Most orders are placed with the USPTO same day — all within 24 business hours.
Order via The Patent Place →
Pre-filled with this patent's details
Quick Facts
Patent No.
US 11,859,390
App. No.
17/513,471
Granted
Jan 2, 2024
Kind
B2
Abstract

A floor panel for forming a floor covering, wherein this floor panel comprises a substrate, which substrate is manufactured on the basis of synthetic material; wherein this floor panel, on at least one pair of opposite edges, comprises coupling parts, which coupling parts allow that two such floor panels can be coupled to each other by means of a downward movement of one floor panel in respect to the other floor panel.

Claims (33)

1. A method for manufacturing a floor panel for forming a floor covering,

wherein this floor panel comprises a substrate,

wherein the substrate is manufactured on the basis of synthetic material, and comprises fillers;

wherein this floor panel, on at least one pair of opposite edges, comprises coupling parts;

wherein these coupling parts allow a locking in a first direction perpendicular to the plane of the floor panel, as well as in a second direction perpendicular to the edges and in the plane of the floor panel;

wherein at least a portion of said coupling parts is manufactured from the material of said substrate by means of planing or scraping treatments;

wherein the at least a portion of the coupling parts is arranged for locking in the first direction; and

wherein a remainder of the coupling parts is manufactured from the synthetic material by a milling treatments, such that the coupling parts are provided for locking in the second direction by the milling treatments.

2. The method of claim 1 , wherein the planing or scraping treatments are broach or broaching treatment.

3. The method of claim 1 , wherein the fillers of the substrate consist of plasticizers and/or chalk and/or limestone.

4. The method of claim 1 , wherein the at least a portion of the coupling parts arranged for locking in the first direction defines an undercut.

5. A method for manufacturing a floor panel for forming a floor covering,

wherein this floor panel comprises a substrate, wherein the substrate is manufactured on the basis of synthetic material, and comprises fillers;

wherein this floor panel, on at least one pair of opposite edges, comprises coupling parts, which coupling parts allow that two such floor panels can be coupled to each other by means of a downward movement of one floor panel in respect to the other floor panel;

wherein these coupling parts allow a locking in a first direction perpendicular to the plane of the floor panel, as well as in a second direction perpendicular to the edges and in the plane of the floor panel; wherein at least a portion of said coupling parts is manufactured from the material of said substrate by means of planing or scraping treatments;

wherein the at least a portion of the coupling parts is arranged for locking in the first direction; and

wherein a remainder of the coupling parts is manufactured from the synthetic material by milling treatments, such that the coupling parts are provided for locking in the second direction by the milling treatments.

6. The method of claim 5 , wherein the planing or scraping treatments are broach or broaching treatment.

7. The method of claim 5 , wherein said coupling parts consist of a downward-directed upper hook-shaped part, which is situated on the one edge of said pair of opposite edges, as well as an upward-directed lower hook-shaped part, which is situated on the other, opposite edge of said pair of opposite edges, which hook-shaped parts can be engaged behind each other by means of said downward movement;

wherein the upper hook-shaped part consists of a lip which is provided with a downward-directed locking element, whereas the lower hook-shaped part consists of a lip which is provided with an upward-directed locking element;

wherein the locking elements are provided with locking surfaces which at least partially allow the locking in said first direction perpendicular to the plane of the floor panels; and

wherein at least said locking surfaces are manufactured from the material of said substrate by means of planing or scraping treatments.

8. The method of claim 7 , wherein the planing or scraping treatments are broach or broaching treatments.

9. The method of claim 7 , wherein said locking surfaces comprise a first locking surface and a second locking surface, wherein the first locking surface belongs to a proximal side of the downward-directed locking element and wherein the second locking surface belongs to a proximal side of the upward-directed locking element.

10. The method of claim 9 , wherein the first locking surface and the second locking surface define in the coupled condition of two such floor panels a tangent line forming an angle with the plane of the floor panel, wherein said angle is smaller than 90 degrees.

11. The method of claim 9 , wherein the second locking surface defines in proximal direction of the panel an angle smaller than 90 degrees with the plane of the floor panel.

12. The method of claim 7 , wherein the fillers of the substrate consist of plasticizers and/or chalk and/or limestone.

13. The method of claim 7 , wherein the floor panel, on a distal side of the downward-directed locking element, is free from locking parts which, partially or entirely, allow a locking in the aforementioned first direction.

14. The method of claim 7 , wherein the floor panel, on a distal side of the upward-directed locking element, is free from locking parts which, partially or entirely, allow a locking in an aforementioned first direction.

15. The method of claim 7 , wherein a vertical closing surface is formed between two such floor panels in the coupled condition of two of the floor panels;

wherein the lip of the lower hook-shaped part comprises a support surface for supporting the downward-directed locking element; and

wherein in coupled condition of two of the floor panels an interspace is present between said vertical closing surface and the aforementioned support surface.

16. The method of claim 5 , wherein the at least a portion of the coupling parts arranged for locking in the first direction defines an undercut.

Assignments (2)
NUNC PRO TUNC ASSIGNMENT Recorded Mar 18, 2024
From: FLOORING INDUSTRIES LIMITED, SARL
To: UNILIN BV
Reel/Frame 066805/0445 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 28, 2021
From: CAPPELLE, MARK
To: FLOORING INDUSTRIES LIMITED, SARL
Reel/Frame 057952/0813 →