Covering Panel and Method for Assembling a Plurality of Same

Abstract

A covering panel. The panel includes multiple lips disposed around the edges of the panel. Each lip projects from a corresponding edge of the panel and extends along at least a portion of the edge. Each lip also includes the features of at least one flange, which projects from the lip. Each lip also includes at least one groove, which receives the at least one flange of a separate, or the same lip. The groove is substantially contiguous with the flange. The panel can also include an elastomeric core, made of PVC or uPVC material. The groove and the flange can be mushroom shaped, and can be complementary such that they share the same shape, but are inversed.

Description

FIELD OF THE INVENTION

The present invention relates to panels for covering surfaces. More particularly, the present invention relates to a covering panel and a method for assembling a plurality of the same.

BACKGROUND OF THE INVENTION

Panels for covering surfaces such as walls, floors, ceilings, etc. are known in the art. In the field of floor panels in particular, the concept of glueless click vinyl flooring is also known.

For example, known to the Applicant are the products of Windmöller Flooring GmbH, Välinge Innovation and Flooring Industries (Unilin Group). In general, these products consist of floor panels or planks, typically rectangular in shape, provided with channels along their edges for receiving protrusions from a corresponding plank, such that the protrusions mate with the channel and allow the two panels or planks to be connected. FIGS. 1 and 2 illustrate such flooring.

Examples of such floor planks are described in U.S. Pat. No. 7,484,337 B2 to Hecht; U.S. Pat. No. 7,543,418 B2 to Weitzer; and U.S. Pat. No. 7,980,043 B2 to Moebus.

Another example of such a floor plank is U.S. Pat. No. 6,006,486 to Moriau et al., which relates to hard floor panels having coupling parts that cooperate with each other. The coupling parts are in the form of a tongue and a groove, the coupling parts having integrated mechanical locking elements which prevent the drifting apart of two coupled floor panels.

U.S. Pat. No. 3,694,983 to Couquet relates to plastic tiles for flooring. Each tile is secured to a backing of same dimensions but projecting along two adjacent edges of the tile to form an embedded strip provided with means permitting the mutual engagement of fastening means.

Also known to the Applicant are the following patent documents: U.S. Pat. Nos. 7,895,805; 7,797,890 B2; 7,516,588 B2; 7,188,456 B2; 6,536,178 B1; 1,476,485; 2,690,082; 2,114,430; 2,094,349; 325,654; 314,818; US 2011/0247285 A1; US 2011/0094178; US 2010/0000172; US 2009/0249731 A1; US 2007/0130872; US 2007/0068110 A1; WO 2008/110112 A1; WO 2006/043893 A1; WO 2003/012224 A1; and DE 3214207 A1.

Also known to the Applicant are the substantial drawbacks associated with such conventional floor planks/panels and systems, for example: a) the tongue/groove connection often does not provide sufficient retentive force such that the planks separate after a certain period of time; b) the ends of different floor planks are not often at the same level (i.e. are not flush) when the sub-floor is uneven due to the fact that the locking system does not lock both ends together, or if an object on the floor (i.e. the leg of a chair) is sitting on one end of a plank, then the other end will lift; c) known vinyl locking systems often require installation of the locking system at a 45 degree angle, which increases installation times and makes installation more difficult (i.e. a tapping block is needed for the installation) because vinyl flooring is a soft product (unlike High-Density Fiberboard, or HDF, which is used for laminate flooring), and the plank will bend while trying to click the planks together; d) other vinyl click flooring that have vertical locking systems often do not have vertical retention (compression and locking of the two pieces), therefore the sides and ends unclick when exposed to heat or high levels of traffic; e) conventional floor systems often do not function as well or are not as appealing when the temperature in rooms in which they are installed exceeds or drops below a certain range, which can reduce the utility of these systems in many circumstances.

Hence, in light of the aforementioned, there is a need for an improved device which, by virtue of its design and components, would be able to overcome or at least minimize some of the aforementioned prior art problems.

SUMMARY OF THE INVENTION

The present invention relates to a covering panel, such as a floor panel, which by virtue of its design and components, satisfies some of the above-mentioned needs and is thus an improvement over other related planks, panels, assemblies, and/or methods known in the art.

According to an aspect of the present invention, there is provided a floor panel comprising:

• • an elongated core;
  • a plurality of edges disposed about the core; and
  • a plurality of lips, each lip projecting from a corresponding edge of the core and extending along at least a portion of said edge, each lip comprising:
    • at least one flange projecting from the lip and being provided with a flange base and a flange cap; and
    • at least one groove being configurable for receiving the flange base and the flange cap of a separate lip, the at least one groove being substantially complementary with at least one of the flange base and the flange cap of the same lip.

In some optional configurations, the flange base and the flange cap form a mushroom-shaped projection which can be elastically deformed so as to fit into the at least one groove. Optionally, the mushroom-shaped projection is compressed via an external force applied by the user into the at least one groove of another floor panel. The at least one groove can also be mushroom-shaped.

In other optional configurations, the elongated core is rectangular, making the panel rectangular as well. The core, as well as the flange and the groove, may be made from a flexible material such as a macromolecule material, polyvinyl chloride (PVC), vinyl, and unplasticized polyvinyl chloride (uPVC).

According to another aspect of the present invention, there is provided a covering panel comprising:

• • a plurality of lips, each lip projecting from a corresponding edge of the panel and extending along at least a portion of said edge, each lip comprising:
    • at least one flange projecting from the lip; and
    • at least one groove being configurable for receiving the at least one flange of a separate lip, the at least one groove being substantially contiguous with the flange of the same lip.

In an optional implementation, a connection noise is produced when compressively receiving the at least one flange in the at least one groove. This alerts the installer or user that a secure connection has been established.

According to yet another aspect of the present invention, there is provided a floor panel comprising:

• • an elongated core;
  • a plurality of edges disposed about the core; and
  • a plurality of lips, each lip projecting from a corresponding edge of the core and extending along at least a portion of said edge, each lip comprising:
    • at least one flange projecting from said lip and being provided with a flange base and a flange cap, the flange cap and flange base forming a mushroom-shaped projection; and
    • at least one groove provided with a groove passage and a groove bottom, the groove passage and the groove bottom forming a mushroom-shaped depression;
      wherein the mushroom-shaped projection is substantially contiguous with the mushroom-shaped depression, both the mushroom-shaped projection and the mushroom-shaped depression having the same form.

According to yet another aspect of the present invention, there is provided a floor panel assembly comprising:

• • a floor cover; and
  • a plurality of panels, each panel comprising:
    • a plurality of lips, each lip projecting from a corresponding edge of the panel and extending along at least a portion of said edge, each lip comprising:
      • at least one flange projecting from the lip and being provided with a flange base and a flange cap; and
      • at least one groove being configurable for receiving the flange base and the flange cap of a separate panel, the at least one groove being substantially contiguous with at least one of the flange base and the flange cap of the same panel.

According to yet another aspect of the present invention, there is provided a method of assembling a plurality of floor panels, the method comprising the steps of:

a) providing the floor panels, each floor panel comprising at least one lip projecting from a corresponding edge of the floor panel and extending along at least a portion of said edge, each lip being provided with at least one flange projecting from the lip and at least one groove being substantially contiguous with the flange;

b) placing the at least one lip of a first floor panel over the at least one lip of a second floor panel; and

c) applying a compressive force to the first or second floor panel so that the at least one flange and groove of the first floor panel frictionally engages the at least one groove and flange of the second floor panel, respectively, thereby assembling the first and second floor panels.

In an optional implementation of the method, step b) includes inserting the lip of the first panel at an angle, such as ninety degrees, with respect to the lip of the second panel which remains laid out against the floor. This may form a pivot point about which the first panel may be rotated downward (for applying a compressive force and thus assembling the first and second panels), or upward (thereby allowing the first and second panels to disassemble).

According to another aspect of the present invention, there is provided a method for manufacturing a panel for compressively engaging with another similar plank, the method comprising the steps of:

a) providing a plank with at least first and second lips protruding from opposed respective edges of the plank;

b) profiling the first lip so as to create a groove/flange configuration facing in a first direction; and

c) profiling the second lip so as to create a substantially similar groove/flange configuration facing in a second direction opposite the first direction.

According to yet another aspect of the present invention, there is also provided a kit with components for assembling the above-mentioned panels.

The objects, advantages and other features of the present invention will become more apparent upon reading of the following non-restrictive description of optional embodiments thereof, given for the purpose of exemplification only, with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 are views of flooring systems known in the art.

FIG. 3 is a perspective view of a covering panel, according to an optional embodiment of the present invention.

FIG. 3A is an enlarged view of lips of the covering panel of FIG. 3.

FIG. 4 is a side elevational view of a first lip and a second lip being aligned, according to another optional embodiment of the present invention.

FIG. 5 is a side elevational view of the lips of FIG. 4, the first lip shown angled with respect to the second lip.

FIG. 6 is a side elevational view of the lips of FIG. 4, the lips shown as compressed together.

FIG. 7 is a side elevational view of a different set of lips, according to another optional embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

In the following description, the same numerical references refer to similar elements. Furthermore, for sake of simplicity and clarity, namely so as to not unduly burden the figures with several references numbers, only some of the figures have been provided with reference numbers, and components and features illustrated in other figures can be easily inferred therefrom. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the figures are preferred, for exemplification purposes only.

Moreover, although the present invention was primarily designed for being used for assembling covering panels so as to cover or install them on a planar surface, it may be used with other types of materials and objects and in other fields. For this reason, expressions such as “floor”, “planar surface”, “plank”, “panel”, etc., as used herein should not be taken as to limit the scope of the present invention, which includes all other kinds of materials, objects and/or purposes with which the present invention could be used and may be useful.

In addition, although the optional implementations of the present invention as illustrated in the accompanying drawings comprises various components, and although the optional embodiments of the panel and method as shown consists of certain geometrical configurations as explained and illustrated herein, not all of these components and geometries are essential to the invention and thus should not be taken in their restrictive sense, i.e. should not be interpreted so as to limit the scope of the present invention. Other suitable components and cooperations thereinbetween, as well as other suitable geometrical configurations may be used for the panel, and corresponding parts, as explained and as can be easily inferred, without departing from the scope of the invention.

Broadly described, the present invention relates to a covering panel. The covering panel can be any plank, slat, board, strip, etc. of any shape which is capable of overlaying, concealing, protecting, etc. a surface, such as a planar surface. Some of these surfaces can include a floor, a wall, a ceiling, etc. For the sole purpose of describing the optional embodiments of the invention, and without limiting the applications of the covering panel to only overlaying floors, the covering panel will be referred to in this description as a “floor panel” for being applied to floors.

FIGS. 3 and 3A illustrate an example of a floor panel 10 (or simply “panel”). The panel 10 can be of any shape suitable for the surface to which the panel 10 can be applied. For example, when being applied to floors, it is often useful that the panel 10 be rectangular in shape, and thus the panel 10 will be longer than it is wide. In such a rectangular configuration, the panel 10 may have a plurality of edges 12, such as four edges 12, which can be arranged in opposed and perpendicular relation to each other.

The panel 10 can be made of any number of materials including, but not limited to, PVC and vinyl. Each panel 10 may include a core 14 which can have different densities and chemical properties depending on the application for which the panel 10 will be used. The material make-up of the core 14 and/or panel 10 can also depend on other factors, such as durability, cost effectiveness, material availability, environmental qualities, etc. Some examples of materials used to make the core 14 can include elastomeric materials such as a macromolecule material, polyvinyl chloride (PVC), vinyl, and unplasticized polyvinyl chloride (uPVC).

At least one surface of the panel 10, such as the usable surface 16, can be laminated. The usable surface 16 refers to the surface of the panel 10 with which the user interacts. Where the panel 10 is used to cover floors, for example, the usable surface 16 would be the surface upon which the user places his/her feet. The usable surface 16 can be laminated with a finishing layer (with or without a wear layer), for example, and a base layer serving as a waterproof or insulation coating. Other types of laminations are within the scope of the present invention, and depend upon the applications for which the panel 10 would be used. For example, the usable surface 16 can be laminated and/or coated with a fire-retardant film so as to improve the fire resistance of the panel 10.

The panel 10 has a plurality of lips 20. Each lip 20 can serve as the interface between two panels 10, allowing both panels 10 to connect with each other so as to cover more of the surface to which they are applied. By “plurality”, it is understood that there is more than one lip 20 on each panel 10, although a panel 10 having only one lip 20 is within the scope of the present invention. For example, in the optional configuration of the panel 10 shown in FIG. 3, four lips 20 are shown, the lips 20 being in opposed spaced and perpendicular relation to each other.

The disposition of the lips 20 about the panel 10 can vary. In one optional configuration, the panel 10 has at least two lips 20, each lip 20 being opposed to another lip 20. For example, where a panel 10 has two lips 20, one lip 20 can be situated on one longitudinal side of the panel 10, and the other lip 20 can be situated on the other, opposed longitudinal side of the panel 10. In another optional configuration, opposed lips 20 can face in opposite directions. Returning to the example where a panel 10 has two lips 20, one of the lips 20 can be facing downward (i.e. toward a floor, for example) and the other, opposed lip 20 can be facing upward (i.e. toward the user, or away from the surface being covered). This configuration of lips 20 allows for a mostly seamless connection of adjacent panels 10 because the downward-facing lip 20 can be covered with the usable surface 16 and placed over the upward-facing lip 20, and the two lips 20 can be connected together, thus connecting the panels 10. Thus, to the user, the appearance of continuity in the usable surface 16 is undisturbed at the connection point of adjacent panels 10.

Each lip 20 is any thin, flat surface which extends or projects from a corresponding edge 12 of the panel 10 and runs along either some, or all, of the length of the edge 12. In so doing, the lip 20 can be parallel to the edge 12. The lip 20 can have a lip thickness that is thinner than the thickness of the panel 10 and/or core 14 to which it is attached. The distance the lip 20 extends, which is also known as its width W, depends on the application for which the lip 20 and/or panel 10 is to be used, and can vary based on the strength of the connection required between corresponding lips 20, the surface upon which the panel 10 is laid, and other such factors. The lip 20 can extend perpendicularly from its corresponding edge 12, although extensions at an angle or circumferentially are possible, depending on, among other things, the area in which the panel 10 will be installed and the configuration of the panel 10 itself.

Each lip is configured for compressively engaging with a corresponding lip 20 of another or same panel 10, thus joining both panels 10. As used herein, the expression “compressively engage” can signify the application of a compressive, clamping, pinch-like, etc. force to one lip 20, or both lips 20 of two panels 10, so that the lips 20 securely engage or connect with each other, thus joining both panels 10, as further explained below. Therefore, each lip 20 can be made of elastically deformable materials such as, but not limited to a macromolecule material, PVC, vinyl and/or unplasticized polyvinyl chloride (uPVC), which allow the lip 20 to temporarily deform in response to a compressive applied pressure. In order to facilitate compressive engagement, the each lip 20 is provided with at least one flange 24 and at least one groove 22. By “at least one”, it is understood that each lip 20 can be provided with one or more flange 24 or groove 22. For example, in the configuration exemplified in FIG. 7, each lip 20 has two flanges 24, and two grooves 22. The flange 24 and the groove 22 are substantially contiguous, which can mean that they share a common border. This contiguity may facilitate securing of the flanges 24 with the grooves 22 through the complementary nature of their respective profiles. Such contiguous complementary profiles allow compression of the flanges 24 for insertion and securing in the corresponding grooves 22 under a given pressure, while resisting unlocking of the interface as a significantly higher force is required to unlock the interface. For example, in the configuration shown in FIG. 3A, the flange 24 is shown as neighbouring or abutting against the groove 22, such that the flange 24 ends where the groove 22 begins.

The groove 22 can run along at least a portion of the length of the lip 20, and optionally along the entire length of the lip 20. The groove 22 may be any channel or depression in the lip 20 which runs parallel to the edge 12 of the panel 10, and which receives a corresponding flange 24, as explained below. The groove 22 may be preferably situated directly next to the edge 12 of the panel 10. The groove 22 can be made of elastically deformable materials such as, but not limited to, a macromolecule material, PVC, vinyl and/or unplasticized polyvinyl chloride (uPVC), which allow the groove 22 to temporarily deform when it compressively receives a corresponding flange 24, as explained below. Once the flange 24 is removed from the groove 22, the groove 22 can thus return to its original shape, thus allowing the groove 22 to be continuously re-used because its shape is not significantly degraded once deformed.

Each lip 20 is also provided with a flange 24, which can run parallel and next to the groove 22 of the lip 20. The flange 24 may run the same length as the adjacent groove 22, and may be situated further away from the edge 12 than the groove 22. The flange 24 may be any projection or protrusion from the lip 20 which can be inserted into a corresponding groove 22 so as to compressively engage the groove 22. The flange 24 may be also made of elastically deformable materials such as, but not limited to, a macromolecule material, PVC, vinyl and/or uPVC, which allow the flange 24 to temporarily compress when being compressively received by a corresponding groove 22, and to expand when reaching the end of said groove 22.

Examples of profiles of the flange 24 and adjacent groove 22 are now described, with reference made to FIGS. 4 to 6. A first panel 10a and a second panel 10b are shown. The terms “first” and “second” and “a” and “b” as used herein do not limit the number of panels 10 that can be applied to a surface to only two panels 10, and are used simply to facilitate the explanation of the optional interaction of two panels 10a,10b.

The profile of the flange 24 can be a substantially mushroom-shaped projection 25a,25b protruding from the lip 20 (or cut into the lip 20), and running the length of the flange 24. The expression “mushroom-shaped” as used to describe the shape and/or profile of the flange 24 can mean that the mushroom-shaped projection 25a,25b consists of a substantially linear flange base 26a,26b which is topped by a flange cap 28a,28b which extends slightly beyond the flange base 26a,26b, or is wider than the flange base 26a,26b. This profile allows the flange 24 to be inserted into a corresponding groove 22, and secured therein, as explained below. As mentioned above, such a profile allows compression of the flange 24 for insertion and securing in the groove 22 under a given pressure, while resisting unlocking of the interface as a significantly higher force is required to unlock the interface.

The groove 22 next to the mushroom-shaped projection 25a, as well as the groove 22 of another panel 10b, may be configured to have a profile that is substantially similar or complementary, to the mushroom-shaped projections 25a,25b. Thus the groove 22a is substantially complementary to either the flange base 26a or the flange cap 28a of the same lip 20a. The groove 22a can also be substantially complementary to both the flange base 26a and the flange cap 28a of the same lip 20a. In such a configuration, the groove 22 includes a groove passage 30a,30b and a groove bottom 32a,32b. Such a groove profile is referred to herein as a mushroom-shaped depression 23, and there can be two such mushroom-shaped depressions 23a,23b. The expression “substantially complementary” can mean that a mushroom-shaped projection 25a and a mushroom-shaped depression 23a can be of the same shape or profile, such that they compressively combine so as to form a secure, frictional fit. For example, in the optional configuration shown in FIG. 4, the mushroom-shaped depression 23a and the mushroom-shaped projection 25a are inverse, mirror images of one another. In this same configuration, they are also contiguous, as explained above. As explained above with regard to the mushroom-shaped projections 25a,25b, the mushroom-shaped depressions 23a,23b can be any mushroom-shaped channel running along a portion, or the entire length, of the groove 22. The profile of the groove 22 can align with that of the corresponding flange 24 being inserted therein. By “align”, it is understood that the flange caps 28a,28b of mushroom-shaped projections 25a,25b substantially line up with the groove passages 30a,30b of the mushroom-shaped depressions 23a,23b into which they are inserted, as explained below.

It is to be noted that the profile of the flange 24 and/or groove 22 is not limited to a substantially mushroom shape, and can consist of other shapes, profiles and/or configurations, or have different dimensions, that perform the same function and/or have the same attributes which include, but are not limited to, providing a compressive engagement of one lip 20 to another which produces an audible clicking noise once the user applies a compressive force to one of the lips 20.

An optional implementation of the connection of multiple panels 10 will now be described with reference to the exemplified configuration of the two panels 10a,10b of FIGS. 4 to 6. The user first places the lip 20b of the second panel 10b over the lip 20a of the first panel 10a. This technique can allow for the lips 20a,20b to align such that the second flange 24b is substantially over the first groove 22a, and the second groove 22b is substantially over the first flange 24a. This technique can be referred to as the “horizontal configuration” since the lips 20a,20b are overlayed in a horizontal manner. Of course, it is understood that the grooves/flanges do not have to be perfectly aligned because the alignment can autocorrect when the user applies a force.

Once in alignment or near alignment, the user applies a downward or compressive force F to the second panel 10b, or to both panels 10a,10b, thereby pushing the second flange 24b into the first groove 22a, and to have the first flange 24a be compressively received into the second groove 22b. The application of force by the user can be performed by the user's hand, or with a tapping block, rubber hammer, elastomer roller and/or other similar tools. When the second flange 24b is pushed into, or compressively received within, the first groove 22a, the flange cap 28b of the mushroom-shaped projection 25b compressively and elastically deforms as it moves downward through the groove passage 30a of the mushroom-shaped depression 23a. The compressed flange cap 28b eventually expand once it reaches the groove bottom 32a of the mushroom-shaped depression 23a, which temporarily deforms the mushroom-shaped depression 23a/groove bottom 32a into which it is inserted, thus providing a tight fit or frictional engagement. This expansion and its impact against the walls of the groove bottoms 32a,32b can produce a connection noise, such as a click, alerting the user that a secure connection has been established. It is understood that the first mushroom-shaped projection 25a and the second mushroom-shaped depression 23b undergo a similar compression/expansion, and produce a similar connection noise. Thus, the lips 20a,20b of the panels 10a,10b, and consequently, the panels 10a,10b themselves, are securely connected to each other, as illustrated in FIG. 6.

In one optional configuration, the expansion of the mushroom-shaped projections 25a,25b once they reach the ends of the mushroom-shaped depressions 23a,23b releases a spring-like force which secures the flanges 24a,24b in their corresponding grooves 22a,22b because the abutting, inversely-adjacent flange caps 28a,28b of respective flanges 24a,24b prevent vertical displacement of the flanges 24a,24b. Horizontal or separating displacement is equally prevented because the flange bases 26a,26b and flange caps 28a,28b are tightly fitted and/or frictionally engaged to one another.

The engagement of the lips 20a,20b described above is not limited to two panels 10, and may comprise connecting lips 20 on multiple panels 10. For example, a lip 20 on an opposite edge 12 of the lip 20a of the first panel 10a shown in FIG. 4 may be compressively engaged with the lip 20 of a third panel 10. Other panel 10/lip 20/edge 12 configurations and engagements are also possible, and within the scope of the present invention.

An optional alternative technique for connecting multiple panels 10 is now described with reference to FIG. 5. The lip 20b of the second panel 10b can also be inserted at an angle {circle around (-)} to the lip 20a of the first panel 10a, where the first panel is placed on the planar surface (i.e. floor) to be covered. This insertion at angle {circle around (-)} may facilitate entry of the mushroom-shaped projection 25b of the second lip 20b into the corresponding first groove 22a by allowing the second flange cap 28b to be more easily inserted into the mushroom-shaped depression 23a. The user can then easily “snap” or “click” the second lip 20b onto the first lip 20a to join the lips 20a,20b and the panels 10a,10b.

In an example of such an operation, the second flange cap 28b is entered at angle {circle around (-)} into the corresponding first groove 22a, and the second flange 24b may rest on any one of the following surfaces: the mushroom-shaped depression 23a, the first flange 24a and/or anywhere else on the first lip 20a. This provides a fulcrum or pivot point about which the second panel 10b may pivot. Therefore, the second panel 10b is transformed into a moment arm having a length roughly equal to the width of the second panel 10b, and the second panel 10b can be rotated downwards in direction D (i.e. clockwise in FIG. 5) to “snap” or “click” the second lip 20b onto the first lip 20a by the application of a compressive force. This moment arm greatly reduces the force needed by the user to compressively engage the lips 20a,20b together. In order to further facilitate installation by reducing the force required of the user, the angle {circle around (-)} can be increased significantly up to roughly 90 degrees. This configuration is known as the “vertical position” because the second panel 10b is roughly perpendicular to the first panel 10a. In the vertical position, the moment arm is increased, which facilitates the connection of the first and second lips 20a,20b by “snapping” or rotating the second panel 10b in direction D with increased angular momentum.

FIG. 6 shows the lips 20a,20b in substantially compressed engagement, as described above. Once compressively engaged, the panels 10a,10b are substantially seamlessly connected so that a user will not feel or perceive their junction, thus providing a smooth and continuous floor panel assembly and/or flooring.

The assembly of panels 10 has been described above, but it is within the scope of the present invention to easily disassemble connected panels 10 as well. Thus, the panels 10 described herein are both easily installed, and easily removed. The removal of the panels 10 does not necessitate complex and expensive hand tools. In order to remove the panels 10, the user can simply rotate the second panel 10b upwards, opposite direction D in FIG. 5 (or counter clockwise), which causes the second flange 24b and second groove 22b to disengage from the first groove 22a and the first flange 24a, respectively. The second panel 10b is then easily removed from the first panel 10a, and this process is repeated for all panels 10 that require removing.

It can thus be appreciated that, broadly described, the covering panel according to the present invention is a device which, in its some of its optional implementations, is a panel 10 for compressively and securely engaging with a plurality of other panels 10, so as to form a floor panel assembly installed onto a planar surface.

Furthermore, the present invention is a substantial improvement over the prior art in that, by virtue of its design and components, the panel 10 is simple and easy to install onto another panel 10, as well as simple and easy to manufacture and/or assemble, without compromising the reliability of its functions. Hence, it may now be appreciated that the present invention represents important advantages over other floors and/or flooring systems known in the art, in that the panel 10 can be used, though not necessarily exclusively, as a component of a flooring system that is easily installed without the use of tools, as briefly explained hereinabove.

More particularly, the panels 10 described herein can be assembled together without tools (also referred to as a “DIY click vinyl floor”) in both commercial and residential environments, thereby greatly facilitating the task of the lay user.

Indeed, the flange 24 and groove 22 are capable of temporarily plastically deforming when compressed to fit together, which provides for a secured connection when the flange 24 returns to its shape in the groove 22. The substantially mushroom-shaped flange 24 allows for a rapid and tools-free installation and/or removal which reduces costs and labour, provides a secure connection between panels 10, and allows the panels 10 to be easily removed should the need arise. The groove 22 is also temporarily deformable such that when the flange 24 is removed therefrom, the groove 22 can advantageously return to its original shape, which preserves the durability of the panel 10 and allows for its reuse.

The installation of the panel 10 is further advantageously aided by the ability to install a second panel 10 at an angle, which reduces the force needed by the user to secure or click the second panel 10b to the first 10a. Furthermore, the panel 10 can be applied on any floor and/or flooring system. The clicking noise that can be produced when installing the panels 10 together beneficially allows the user to know when the panel 10 is correctly and securely installed. A further advantage that arises when connecting the panels 10 vertically is that it allows for the use of thinner core, in the order of about 3 to about 4 millimetres, when compared to conventional horizontally-connected panels which have a thickness of about 5 millimetres. This reduction of about 20% in the thickness of the core can reduce the material and manufacturing cost per panel.

Furthermore, the laminated PVC panels 10 allow for their use in a multitude of environments such as moist, dry, high-impact, etc. Equally beneficially, the groove 22/flange 24 configuration allows for the rapid alignment of two panels 10 and allows for their interlocking by applying a light pressure.

Of course, the scope of the claims should not be limited by the optional configurations set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole. Numerous modifications could be made to the above-described configurations without departing from the scope of the claims.

Claims

1. A floor panel comprising: wherein the at least one flange and the at least one groove of each lip form a lip profile, the lip profile of a first floor panel being the same as the lip profile of a separate floor panel being connectable to the first floor panel.

an elongated core;

a plurality of edges disposed about the core; and

a plurality of lips, each lip projecting from a corresponding edge of the core and extending along at least a portion of said edge, each lip comprising: at least one flange projecting from the lip and being provided with a flange base and a flange cap; and at least one groove being configurable for receiving the flange base and the flange cap of a separate lip, the at least one groove being substantially complementary with the at least one flange of a same lip

2. A floor panel according to claim 1, wherein the flange cap and flange base form a mushroom-shaped projection.

3. A floor panel according to claim 2, wherein the mushroom-shaped projection is elastically deformable.

4. A floor panel according to claim 2, wherein the at least one groove forms a mushroom-shaped depression, the mushroom-shaped depression being configured for compressively receiving the mushroom-shaped projection of a separate lip.

5. A floor panel according to claim 4, wherein the mushroom-shaped depression is elastically deformable upon compressively receiving the mushroom-shaped projection.

6. A floor panel according to claim 4, wherein a snap fit is produced upon compressively receiving the mushroom-shaped projection in the mushroom-shaped depression, thereby indicating that a secure connection has been established.

7. (canceled)

8. A floor panel according to claim 1, wherein the elongated core is substantially rectangular, and wherein the rectangular elongated core comprises four edges, each edge being disposed substantially perpendicularly to two other edges.

9. A floor panel according to claim 1, wherein the core is made from a flexible material selected from the group consisting of a macromolecule material, polyvinyl chloride (PVC), vinyl, and unplasticized polyvinyl chloride (uPVC).

10. (canceled)

11. (canceled)

12. A floor panel according to claim 1, wherein the plurality of lips comprises at least two lips in opposed relation, and wherein the at least two lips face in opposite directions.

13. (canceled)

14. A floor panel according to claim 1, wherein each lip has a lip thickness and the elongated core has a core thickness, the lip thickness being less than the core thickness.

15. A floor panel according to claim 1, comprising at least one surface, the at least one surface being laminated.

16. (canceled)

17. A floor panel according to claim 1, wherein the at least one groove is disposed closer to the corresponding edge than the at least one flange.

18. (canceled)

19. (canceled)

20. (canceled)

21. (canceled)

22. (canceled)

23. (canceled)

24. A floor panel comprising:

an elongated core;

a plurality of edges disposed about the core; and

a plurality of lips, each lip projecting from a corresponding edge of the core and extending along at least a portion of said edge, each lip comprising: at least one flange projecting from said lip and being provided with a flange base and a flange cap, the flange cap and flange base forming a mushroom-shaped projection; and at least one groove provided with a groove passage and a groove bottom, the groove passage and the groove bottom forming a mushroom-shaped depression;

wherein the mushroom-shaped projection is substantially contiguous with the mushroom-shaped depression, both the mushroom-shaped projection and the mushroom-shaped depression having a same form.

25. (canceled)

26. (canceled)

27. (canceled)

28. (canceled)

29. (canceled)

30. (canceled)

31. (canceled)

32. (canceled)

33. (canceled)

34. (canceled)