A deck system and floor panel for a deck system

Abstract

 The invention relates to a deck system, particularly for outdoor use, comprising at least a first and a second, similar, floor panel (1) in lateral interlocking engagement, said floor panels comprising a polymer material, said floor panels comprising a floor panel body (2) having opposite longitudinal edges (9, 10), a top side (3) and a bottom side (4), a first panel coupling part (5) extending along one longitudinal edge of said panel body and a second panel coupling part (6) extending along the opposite longitudinal edge of said panel body, said first panel coupling part of said first panel for coupling to said second panel coupling part of said second panel.

Description

BACKGROUND OF THE INVENTION

[0001] The invention relates to deck system, and a floor panel for a deck system.

[0002] US6637163 describes a deck including a panel, a retainer and a fastener. The panel includes a flange having an aperture therein. The retainer includes an upper leg and a lower leg embracing the flange therebetween, with the lower leg having a fastener receiving opening. The fastener is for attaching the panel to structural framework, with the fastener including a shoulder. The fastener extends through the aperture of the flange and the opening of the lower leg of the retainer. The shoulder extends through the aperture in the flange and abuts against the lower leg of the retainer to secure the retainer. Furthermore, the shoulder is sufficiently tall as to prevent the fastener from tightly clamping the flange. Additionally, the flange embraced between the upper leg and the lower leg of the retainer is adapted to expand between the upper leg and the lower leg.; Therefore, thermal expansion of the panel is accommodated.

[0003] US6324796 describes a decking system for placement on a subassembly having at least two spaced apart joists. A plurality of elongated tubular elements for placement in lateral interlocking engagement with each other transversely of and spanning the distance between the joists. Each of said plurality of elements having a top portion, a bottom portion, and first and second side walls connecting said top and bottom portions. The top portion extends laterally beyond the first side wall and has formed thereon a downwardly extending longitudinal flange. The bottom portion extends laterally beyond the second side wall and has formed thereon an upwardly extending longitudinal wall defining an upwardly opening channel adjacent the second side wall adapted to receive therein in watertight relation the downwardly extending longitudinal flange. The bottom portion having formed therein a plurality of apertures intermediate the second side wall and the upwardly extending longitudinal wall, adapted for the insertion of fasteners therethrough for engagement with the joists

[0004] There is room for improvement of panels for outdoor decks, in particular for instance for terraces.

SUMMARY OF THE INVENTION

[0005] It is an object of the invention to provide an improved panel for outdoor use.

[0006] The invention furthermore or additionally has the object of providing a panel that is easy to produce, easy to place, and with new architectural possibilities.

[0007] The invention further or additionally provides a deck system of panels that are in lateral interlocking engagement but allowing the panels to expand and contract in their transverse direction due to environmental influences, and remain in interlocking engagement.

[0008] For that purpose the invention provides a deck system, particularly for outdoor use, comprising at least a first and a second, similar, floor panel in lateral interlocking engagement, said floor panels comprising a polymer material, said floor panels comprising a floor panel body having opposite longitudinal edges, a top side and a bottom side, a first panel coupling part extending along one longitudinal edge of said panel body and a second panel coupling part extending along the opposite longitudinal edge of said panel body, said first panel coupling part of said first floor panel for coupling to said second floor panel coupling part of said second panel.

[0009] In particular, the invention provides a deck system wherein said first coupling part comprises a first longitudinal ledge extending in transverse direction from the first side wall and at a normal distance from said bottom side, said second coupling part comprises a lower longitudinal ledge extending in longitudinal direction and in transverse direction away from said floor panel body and at a normal distance from said top side, wherein the first longitudinal ledge and the lower longitudinal ledge in transvers direction overlap each other,
wherein one of the first longitudinal ledge and the lower longitudinal ledge comprises a receiving groove having a receiving groove width and the other one of the first longitudinal ledge and the lower longitudinal ledge comprises a snap-lip having a snap-lip width, and
wherein the receiving groove and the snap-lip are provided for snap-fitting into one another, at least one of the receiving groove width and the snap-lip width being flexibly resilient, for allowing said floor panels to expand in transverse direction.

[0010] In particular, when a floor panel is fixed to a substrate along one longitudinal edge, the flexible parts allow floor panels to expand.

[0011] In an embodiment, the first longitudinal ledge comprises the receiving groove opening in the direction of the bottom side and the lower longitudinal ledge comprises the snap-lip extending in the direction of the top side.

[0012] In an embodiment, the receiving groove comprises a resilient, slanted lip extending from a receiving groove wall for providing the flexible, resilient recieving groove width, in particular comprises a resilient, upwardly slanted lip extending from a lower part of said longitudinal edge.

[0013] In an embodiment, the snap-lip comprises comprising a first resilient longitudinal lip and a second resilient longitudinal lip at a transverse distance from said first resilient longitudinal lip, for providing the flexible, resilient snap-lip width.

[0014] In an embodiment, the second coupling part further comprises an upper longitudinal ledge extending in longitudinal direction and in transvers direction away from the floor panel body, the first longitudinal ledge dimensioned for extending in abutment with a lower surface of the upper longitudinal ledge.

[0015] In an embodiment, the first and second resilient longitudinal lips in transvers direction spaced apart 1%-5% of an upper surface width of said floor panels and designed to allow edges of said first and second resilient longitudinal lips to touch one another. The combination of mutual distance, length and flexibility allows the thickness of the combination of lips to change and thus be able to take up at least part of expansion and shrinkage of the floor panels in transvers direction due to temperature fluctuations.

[0016] Thus, the flexible lips provide a second coupling part that allows snap-fitting and take up dimensional fluctuations.

[0017] In an embodiment, an edge of the upwardly slanted lip in transverse direction in unmounted state to the floor panels designed to flex a distance of 1%-5% of an upper surface width in transverse direction towards said floor panel.

[0018] In an embodiment, the first longitudinal ledge comprising a lower abutment rib extending from its lower surface, the lower abutment rib providing a side wall of the receiving groove.

[0019] In an embodiment, the second coupling part further comprises an upper longitudinal ledge extending in longitudinal direction, in transverse direction away from said floor panel body and comprising a lower abutment surface for said first longitudinal ledge.

[0020] In an embodiment, the first coupling part comprises a first longitudinal ledge extending in transverse direction from the first side wall, said first longitudinal ledge comprising an upper abutment rib on its upper surface and a lower abutment rib extending from its lower surface, and a resilient, upwardly slanted lip extending from a lower part of said longitudinal edge.

[0021] In an embodiment, the second coupling part comprises an upper longitudinal ledge extending in longitudinal direction and in transverse direction away from said floor panel body and comprising a lower abutment surface for said upper abutment rib and a lower longitudinal ledge extending in longitudinal direction and in transverse direction away from said floor panel body and at a normal distance from said upper longitudinal ledge and comprising a first resilient longitudinal lip and a second resilient longitudinal lip at a transverse distance from said first resilient longitudinal lip, and wherein said lower longitudinal ledges are fixed to a substructure, and said first coupling part of said first floor panel provides a lateral, interlocking engagement with said second coupling part of said second floor panel.

[0022] In an embodiment, said first longitudinal ledge is dimensioned for extending the upper abutment lip in abutment with said lower surface of said upper longitudinal ledge.

[0023] In an embodiment, the first and second resilient longitudinal lips are in transvers direction spaced apart 1%-5% of an upper surface width of said floor panels and designed to allow edges of said first and second resilient longitudinal lips to touch one another when a force is exerted that pushes the lips together.

[0024] In an embodiment, an edge of said upwardly slanted lip is designed such that in transverse direction in unmounted state to the floor panels it is allowed to flex a distance of 1%-5% of an upper surface width in transverse direction towards said floor panel.

[0025] The invention further relates to a floor panel for a deck system in which the floor panel is in lateral, interlocking engagement with similar floor panels, said floor panel comprising a floor panel body having opposite longitudinal edges, a top side and a bottom side, said floor panel body comprises an upper wall and a lower wall, and a first side wall and a second side wall connecting said upper wall and said lower wall, said floor panel comprising a polymer material, wherein said first coupling part comprises a first longitudinal ledge extending in transverse direction from the first side wall, said first longitudinal ledge comprising an upper abutment rib on its upper surface and a lower abutment rib extending from its lower surface, and a resilient, upwardly slanted lip extending from a lower part of said longitudinal edge, said second coupling part comprises an upper longitudinal ledge extending in longitudinal direction and in transverse direction away from said floor panel body and comprising a lower abutment surface for said upper abutment rib and a lower longitudinal ledge extending in longitudinal direction and in transverse direction away from said floor panel body and at a normal distance from said upper longitudinal ledge and comprising a first resilient longitudinal lip and a second resilient longitudinal lip at a transverse distance from said first resilient longitudinal lip.

[0026] By using similar floor panels that each comprise these first and second coupling parts, and engaging the first coupling part of one floor panel with the second coupling part of a second floor panel, the floor panels are allowed to expand and contract in transvers direction, i.e., their width, and still remain in interlocking engagement.

[0027] The floor panels can be used in particular for constructing for instance boat docks, piers, decks, patios, walkways, pontoon boat floors, and specifically terrace floors.

[0028] As mentioned before, in the past many floor panels were proposed that are made from, or largely consist of, polymer material. Often, the polymer material comprises a filler to make these panels even more weather resistant, and/or even more wear resistant. Many manufacturers were of the opinion that making such panels already provides a durable deck. The amount of expansion and contraction in particular due to thermal expansion and contraction, however, was always underestimated.

[0029] In one embodiment the floor panels further comprises floor panel coupling parts along an edge for coupling to similar panels. The first and second coupling parts of the current invention can also be seen as so-called tongue-and-groove. In that way floor panels can for instance be assembled into a complete deck.

[0030] Further embodiments are described in depending claims.

[0031] The invention further relates to a floor panel as described in this description or according to the claims.

[0032] The invention further relates to a floor panel provided with one or more of the characterising measures described in the attached description and/or shown in the attached drawings.

[0033] It will be clear that the various aspects mentioned in this patent application can be combined and each individually can be eligible for a divisional patent application.

SHORT DESCRIPTION OF THE DRAWINGS

[0034] In the attached figures an embodiment of a floor panel is shown in which:

Figure 1 shows a cross sectional view cross to the longitudinal direction, i.e. in transverse direction, of an embodiment of a floor panel;

Figures 2A-2C show subsequent views of the floor panel of figure 1 showing several steps in coupling two panels along their longitudinal sides.

DETAILED DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 shows a transverse cross section of a floor panel 1. Floor panel 1 has a floor panel body 2. Floor panel body 2 has an upper face 3 and a lower face 4. Floor panel 1 extends in longitudinal direction. Two similar floor panels 1 can be placed such that they engage one another lateral and interlocking. To that end, each floor panel 1 has a first floor panel coupling part 5 along one longitudinal edge and a second floor panel coupling part 6 along its opposite longitudinal edge. The floor panel 1 has a longitudinal axis running normal to the paper, a lateral or transvers axis running here parallel to the layer indicated with reference number 13, and a normal axis running normal to the layer indicated with reference number 13.

[0036] In figure 1, Normal (N), longitudinal (L, normal to the paper) and Transvers (T) are indicated.

[0037] In the embodiment shown in figure 1, the floor panel 1 has a floor panel body 2 that comprises an upper wall 7, and a lower wall 8. The upper wall 7 and the lower wall 8 are here parallel and at a distance from one another. Floor panel body 2 further comprises a first side wall 9 and a second side wall 10 opposite the first side wall 9. The first and second side walls 9, 10 extend in longitudinal direction and in thickness direction, and connect the upper and lower walls 7 and 8. In this embodiment, the floor panel body 2 comprises additional internal walls 11 that connecting the upper wall 7 with the lower wall 8. Longitudinally expending air chambers 12 are enclosed by upper and lower walls 7 and 8 and by the internal walls and the first and second side walls 9, 10. Often, such a floor panel is produced in an extrusion process of a polymer material. Often, the polymer material comprises fillers. These fillers may be silicon-based, and/or cellulose based.

[0038] In the embodiment of figure 1, the floor panel comprises an upper surface layer 13. Such an upper surface layer 13 may be co-extruded with the further floor panel 1. Other processes, however, may also be used, like a two-stage extrusion where the surface layer 13 is applied on the floor panel 2.

[0039] In an embodiment, the surface layer 13 is a material comprising more than 50% by weight of rice husk and less than 50% by weight of polymer material. In particular, it comprises between 70 and 90 % by weight of rice husk and between 30% and 10 by weight of polymer material. In particular, a material sold under the trade name Resysta® was found to be very suitable.

[0040] In an embodiment, the floor panel is mainly (excluding the upper surface layer 13) composed of polyvinyl chloride (PVC). This material is durable and can be recycled. Other materials that may be used are for instance polyethylene (PE), Nylon (polyamide, PA), polyester like for instance PET. These polymer materials may comprise fillers like for instance cellulose base (e.g., wood, or other organic material), silicon based (e.g., sand) or another inorganic material, or fibers. These fillers may be included in volumes of up to 50 % by weight, and in some cases even larger amounts may be possible.

[0041] In the embodiment of figure 1, the first panel coupling part 5 comprises a first longitudinal ledge 14 that further extends in a transverse direction from the first side wall 9. The ledge may also be referred to as a flange.

[0042] A first coupling is provided by a receiving groove 60 and a snap-lip 61. Here, the receiving groove 60 is provided on the first panel coupling part 5. The snap-lip 61 is provided here on the second panel coupling part 6.

[0043] The first longitudinal ledge 14 comprises an upper abutment rib 15 on an upper face of first longitudinal ledge 14 and which extends toward the upper surface direction. Upper abutment rib 15 extends in longitudinal direction. Upper abutment rib 15 is positioned at or near an end portion of first longitudinal ledge 14, in particular at the end of first longitudinal ledge 14. At its bottom surface, first longitudinal ledge 14 comprises a lower abutment rib 16 extending towards the lower surface direction. Lower abutment rib 16 provides an abutment surface directed towards or facing the first side wall 9. This abutment surface is in transvers direction at a distance from the upper abutment rib 15. In this embodiment of figure 1, the upper wall 7 of the floor panel body 2 extends beyond the first side wall 9. In particular, the extended part 19 of the upper wall 7 extends in transvers direction beyond lower abutment rib 16. First longitudinal ledge 14 is positioned below the extended upper wall part 19 end connected to its lower surface via a connecting rib.

[0044] In the embodiment of figure 1, the first panel coupling part 5 further comprises an upwardly slanted lip 17. Upwardly slanted lip 17 extends in longitudinal direction. Furthermore, upwardly slanted lip 17 extends from the lower part of the first side wall 9. In particular, in the embodiment of figure 1, it extends from the first side union of the first side wall 9 and the lower wall 8. The upwardly slanted lip 17 runs toward the upper face at a slope, away from the first side wall 9. The angle between the upwardly slanted lip 17 and the first side wall 9 is between 25° and 55°. In particular, the angle is between 30° and 50°. Upwardly slanted lip 17 has a longitudinal edge 18. The thickness of upwardly slanted lip 17 is selected such in combination with the material from which the upwardly slanted lip 17 is made that it is flexible. The longitudinal edge 18 can be urged in the direction of the side wall 9, in particular its flexibility or resilience is such that the longitudinal edge 18 can be urged against side wall 9 by a force that is exerted by the thermal expansion of the material from which the floor panel 1 is made. A width of upwardly slanted lip 17 is selected such that at its edge 18, it extends between 1% and 5% of the width of upper wall 7 from first side wall 9. In order to be flexible with respect to the upper wall 9, in an embodiment its thickness is less then 60% of the thickness of the upper wall 9.

[0045] In this embodiment, slanted lip 17 and lower abutment rib 16 define the receiving groove 60. In particular, a receiving groove width w1 is defined by abutment surface 50 of abutment rib 16 and the edge of slanted lip 17

[0046] In the embodiment of figure 1, the second floor panel coupling part 6 comprises an upper ledge 20, extending in longitudinal direction and in transvers direction away from the floor panel body 2. In the embodiment of figure 1, the upper ledge 20 has an upper surface that is substantially a continuation of the upper face of the floor panel body. The upper ledge 20 further comprises a lower surface that provides an engagement surface for the upper abutment rib 15 of first longitudinal ledge 14. Upper ledge 20 extends in transverse direction of floor panel body 2 beyond second side wall 10. Upper ledge 20 in this embodiment extends past upper abutment rib 15 when a first floor panel coupling part 5 of one panel engages a second floor panel coupling part 6 of a second, similar floor panel. Such a situation if indicated in figure 2C. In fact, the sum of the transverse extension of the upper ledge 20 and of the extended upper wall part 19 minus the transverse extension of first longitudinal ledge 14 is between 1% and 10% of the width of the upper wall 7. In particular, the width of the groove 26 between adjacent floor panels 1 is between 1% and 5% of the width of the upper wall 7. An advantage of such a groove 26 is that it provides a gutter that can lead water away from the surface. The upper surface 3 can have a slight curvature to facilitate that. Alternatively, the width of remaining groove 26 is selected in such a way that it takes into account a change of width due to a temperature change of 100K. In an embodiment, the upper abutment rib 15 of a first floor panel is positioned to remain below upper ledge 20 of a second floor panel (below in the sense as indicated in figure 2C) when two floor panels are engaging and at a temperature of -40°C, in particular at a temperature of -25°C. In this definition, the floor panels are first fixed to a substructure at a temperature of between 10-25°C without urging the floor panels towards one another, more in particular a temperature of about 15°C.

[0047] Upper ledge 20 in this embodiment can also be defined as an extension of upper wall 7 beyond side wall 10.

[0048] In the embodiment of figure 1, the second floor panel further comprises a lower ledge 21. Lower ledge 21 extends in longitudinal direction and in transvers direction away from the floor panel body 2. Lower ledge 21 or lower flange 21 is positioned at a normal distance from upper ledge 20. Here, the lower ledge 21 runs near the lower face 4 of floor panel body 2. In this embodiment of figure 1, the lower ledge or lower flange 21 can be defined as an extension of lower wall 8 beyond second side wall 10. The lower ledge 21 comprises a first lip 22 and a second lip 23 further away from the first lip 22 in transverse direction. The first lip 22 and second lip 23 are substantially parallel with respect to one another. The transvers distance between the first lip 22 and the second lip 23 is here between 1% and 5 % of the width of upper wall 7. In particular, the transverse distance between these two lips 22, 23 is between 20 and 70 times the thermal expansion coefficient of the material of the upper wall 7, times the width of the upper wall 7. Lips 22 and 23 extend in longitudinal direction.

[0049] In this embodiment, the snap-lip 61 is provided by first lip 22 and a second lip 23. The width w1 of the snap-lip 61 can flexibly resiliently change due to the fact that the lips 22 and 23 can flex toward one another.

[0050] The most remote lip 23 comprises a longitudinal groove 24 in its face facing away from second side wall 10. This longitudinal groove 24 is adapted to receive and engage edge 18 of upwardly slanting lip 17 when a first and second floor panel laterally engage one another. A transverse distance between the abutment surface of lower rib 16 and the edge of upwardly slanted lip 17 and a width of the lips 22 and 23 (a distance between away facing faces) are selected such that when the first coupling part 5 of a first floor panel and the second coupling part of a second floor panel engage, the edge 18 of upwardly slanted lip 17 snaps into longitudinal groove 24.

[0051] The lips 22, 23 are less resilient than upper wall 7. In particular, lips 22, 23 have a thickness that is less than the thickness of the upper wall 7. Specifically, the thickness of the lips 22, 23 is less then 60% of the thickness of the upper wall 7. Usually, the upper wall 7 and lower wall 8 are substantially equal.

[0052] In the embodiment of figure 1, in particular, the upper wall 7 extends in lateral directions past the first and second side walls 9, 10. Lower ledge 21 here extends in transvers direction further from floor panel body than upper ledge 20. Lower ledge 20 in this embodiment is an extension of lower wall 8 beyond side wall 10.

[0053] Upper face 3 of the floor panel often is flat, but it may also be provided with a relief. Alternatively, the upper face may be slightly curved, for instance in transverse direction.

[0054] The various lips, ledges and ribs extend continuously in longitudinal direction. However, interruptions may be provided if that does not compromise the functionality. In the current design, the pnels can provide a deck that prevents water to reach a substructure.

[0055] A first floor panel can be coupled to a second floor panel. The first panel coupling part 5 of the first floor panel can be brought into interlocking engagement with the second floor panel coupling part 6 of a second panel. To that end, the second floor panel coupling part 6 of that second floor panel is inserted into the first floor panel coupling part 5 of that first floor panel while the upper faces 3 are at an angle, and next the upper faces are brought in one plane. These subsequent steps are shown in figures 2A-2C. The first (left) floor panel is first coupled to s substructure (not shown). Subsequently, a second coupling part 6 of a second floor panel is inserted as shown in figures 2A and 2B. Floor coupling parts of adjacent floor panels are snap-locked in their coupled state. Next, the second floor panel in the position of figure 2C is fixed to the substructure at its lower ledge 21. When installed at an average temperature of use, often between 10°C and 20°C, the upwardly slanted lip 17 and remote lip 23 may be slightly under pressure. Thus, the width of the floor panels 1 is able to contract and expand due to temperature changes.

[0056] Floor panels 1 are usually connected to a lower construction or substructure. A series of apertures can be formed in the lower ledge 21 to permit the use of fasteners such as screws to engage a sub assembly beneath the floor panels. Such a sub assembly may be a frame with joists or a subjacent surface.

[0057] In assembling a deck, one panel is applied to a subassembly via the fasteners. Then, a next floor panel is snapped with its first coupling part 5 into the second coupling part 6. Especially for outdoors use or another use where a deck is subjected to large temperature differences between for instance -20°C to 40°C, the current coupling parts allow mounting of a deck that stays properly flat and where floor panels do not crack or deform due to linear expansion or to dilatation. For a panel substantially made of PVC with a thermal expansion parameter α = 24.10^-5 K^-1 and with a width of between 10 and 30 cm, a change in width for a change in temperature of 60 degrees will be about 60x24.10^-5 = 0.014 parts. Thus, the width changes 1.4-4.2 mm. The flexing in transverse direction of lips 17, 22 and 23 should be able to take up about that amount of dimensional change.

[0058] In an embodiment, the floor panel 1 has a total width of 187 mm, and a thickness of 21 mm. the thickness of the upper wall 7 and the lower wall 8 and the first and second side walls 9, 10 in that embodiment is 4 mm. The lips 17, 22 and 23 have a thickness of about 1-1.5 mm. Thus, when the width of the floor panel changes through thermal expansion or thermal shrinkage, the lips 17, 22 and 23 can bend and take up the change in dimension of the floor panel 1 while the rest of the floor panel keeps its form.

[0059] It will be clear that the description above is included to illustrate the operation of preferred embodiments of the invention, and not to limit the scope of the invention. Starting from the above explanation many variations that fall within the spirit and the scope of the present invention will be evident to an expert.

List of reference numbers

[0060] 

1 floor panel

2 floor panel body

3 upper face

4 lower face

5 first panel coupling part

6 second panel coupling part

7 upper wall

8 lower wall

9 first side wall or longitudinal edge

10 second side wall or longitudinal edge

11 internal wall

12 longitudinal chamber

13 upper surface layer

14 longitudinal ledge

15 upper abutment rib

16 lower abutment rib

17 upwardly slanted lip

18 edge of upwardly slanted lip 17

19 extended upper wall

20 upper (longitudinal) ledge

21 lower (longitudinal) ledge

22 first (resilient longitudinal) lip

23 second or remote (resilient longitudinal) lip

24 longitudinal groove (in lip 23)

25 attachment provision in lower ledge

26 gutter or groove between upper walls of adjacent lateral floor panels

50 (lower abutment lip 16) abutment surface

51 lower surface (of the upper longitudinal ledge 20)

52 surface of upper abutment rib 15

53 abutment surface of first lip 22

A insert direction

B snap direction

d upper (sur)face width

d1 spacing/transverse distance of longitudinal lips 22, 23

d2 transverse distance between transverse end of first longitudinal ledge 14 and abutment surface of lower abutment lip 16

d3 transverse distance between end of first longitudinal ledge 14 and first resilient longitudinal lip 22

d4 transverse distance between end of the upper ledge and the second lip

d5 total width of the floor panel

d6 transverse distance between end of the upper ledge and first resilient lip

d7 transverse distance between end or first longitudinal ledge and ....

d8 transverse length of the upper ledge

d9 flexing distance of the upward slanted lip

d10 distance between the end of

w1 receiving groove width

D snap-lip width

60 receiving groove

61 snap-lip

Claims

1. A deck system, particularly for outdoor use, comprising at least a first and a second, similar, floor panel (1) in lateral interlocking engagement, said floor panels (1) comprising a polymer material, said floor panels comprising a floor panel body (2) having opposite longitudinal edges (9, 10), a top side (3) and a bottom side (4), a first floor panel coupling part (5) extending along one longitudinal edge (9) of said floor panel body and a second panel coupling part (6) extending along the opposite longitudinal edge (10) of said floor panel body, said first floor panel coupling part (5) of said first floor panel (1) for coupling to said second floor panel coupling part (6) of said second floor panel (1), wherein

- said first coupling part (5) comprises a first longitudinal ledge (14) extending in transverse direction from the first side wall (9) and provided at a normal distance from said bottom side (4);

- said second coupling part (6) comprises a lower longitudinal ledge (21) extending in longitudinal direction and in transverse direction away from said floor panel body (2) and at a normal distance from said top side (3);

wherein the first longitudinal ledge (14) and the lower longitudinal ledge (21) in transvers direction overlap each other,
wherein one of the first longitudinal ledge (14) and the lower longitudinal ledge (21) comprises a receiving groove (60) having a receiving groove width (w1) and the other one of the first longitudinal ledge (14) and the lower longitudinal ledge (21) comprises a snap-lip (61) having a snap-lip width (D), and
wherein the receiving groove (60) and the snap-lip (61) are provided for snap-fitting into one another, at least one of the receiving groove width and the snap-lip width being flexibly resilient, for allowing said floor panels to expand in transverse direction.

2. The deck system of claim 1, wherein the first longitudinal ledge (14) comprises the receiving groove (60) opening in the direction of the bottom side and the lower longitudinal ledge (21) comprises the snap-lip (61) extending in the direction of the top side(3).

3. The deck system of any one of the preceding claims, wherein the receiving groove (60) comprises a resilient, slanted lip (17) extending from a receiving groove wall for providing the flexible, resilient receiving groove width, in particular comprises a resilient, upwardly slanted lip (17) extending from a lower part of said longitudinal edge (9).

4. The deck system of any one of the preceding claims, wherein the snap-lip (61) comprises comprising a first resilient longitudinal lip (22) and a second resilient longitudinal lip (23) at a transverse distance (d1) from said first resilient longitudinal lip (22), for providing the flexible, resilient snap-lip width.

5. The deck system of any one of the preceding claims, wherein second coupling part further comprises an upper longitudinal ledge (20) extending in longitudinal direction and in transverse direction away from the floor panel body (2), the first longitudinal ledge (14) dimensioned for extending in abutment with a lower surface (51) of the upper longitudinal ledge (20).

6. The deck system of any one of the preceding claims, wherein the first and second resilient longitudinal lips (22, 23) in transvers direction spaced apart (d1) 1%-5% of an upper surface width (d) of said floor panels (1) and designed to allow edges of said first and second resilient longitudinal lips (22, 23) to flex until they touch one another.

7. The deck system of any one of the preceding claims, wherein an edge (18) of the upwardly slanted lip (17) in transverse direction in unmounted state to the floor panels designed to flex a distance (d9) of 1%-5% of an upper surface width (d) of said panel (1) in transverse direction towards said floor panel (1).

8. The deck system of any one of the preceding claims, wherein the first longitudinal ledge (14) comprising a lower abutment rib (16) extending from its lower surface, the lower abutment rib (16) providing a side wall (50) of the receiving groove (60).

9. The deck system of any one of the preceding claims, said second coupling part (6) further comprises an upper longitudinal ledge (20) extending in longitudinal direction, in transverse direction away from said floor panel body (2) and comprising a lower abutment surface (51) for said first longitudinal ledge (14).

10. The deck system according to any one of the preceding claims, wherein a transverse distance (d2) between a transverse end (52) of said first longitudinal ledge (14) and an abutment of said lower abutment lip (16) with said first resilient longitudinal lip (22) is 1%-5% less than a transverse distance (d3) between an end of said first longitudinal ledge (14) and said first resilient longitudinal lip (22).

11. The deck system according to any one of the preceding claims, wherein a transverse distance (d4) between an abutment of said lower abutment lip (16) with said first resilient longitudinal lip (22) and the edge (18) of said upwardly slanted rib (17) between 0.5% and 3% less than a transverse distance (d1) between said first and second resilient longitudinal lips (22, 23).

12. The deck system according to any one of the preceding claims, wherein said floor panels are produced using extrusion, in particular said floor panel comprising an upper surface layer that is coextruded with said further floor panel, more in particular said upper surface layer comprising at least 50 % by weight material derived from rice husk.

13. The deck system according to any one of the preceding claims, wherein said floor panel body (2) comprises an upper wall (7) and a lower wall (8), and a first side wall (9) and a second side wall (10) connecting said upper wall (7) and said lower wall, wherein said upper wall (7) extends beyond said second side wall (10) forming said upper longitudinal ledge (20), and wherein said upper wall (7) extends beyond said first side wall (9) forming at least part of said first longitudinal ledge (14), and wherein said lower wall (8) extends beyond said second side wall (10) forming said lower longitudinal ledge (21), in particular wherein said resilient, upwardly slanted longitudinal lip (17) extends form a lower portion of said first side wall (10), in particular said resilient, upwardly slanted longitudinal lip (17) extends from the first union of the first side wall and the lower wall (8).

14. The deck system according to any one of the preceding claims, wherein said floor panel coupling parts (5, 6) form a tongue on one longitudinal side edge and a groove on the opposite longitudinal side edge and the floor panels form a lath part or tongue-and-groove planking.

15. A floor panel (1) for a deck system of any one of the preceding claims, in which the floor panel (1) is in lateral, interlocking engagement with similar floor panels, said floor panel (1) comprising a floor panel body (2) having opposite longitudinal edges, a top side (3) and a bottom side (4), said floor panel body (2) comprises an upper wall (7) and a lower wall (8), and a first side wall (9) and a second side wall (10) connecting said upper wall (7) and said lower wall, said floor panel (1) comprising a polymer material, and wherein:

- said first coupling part (5) comprises
a first longitudinal ledge (14) extending in transverse direction from the first side wall (9), said first longitudinal ledge comprising an upper abutment rib (15) on its upper surface and a lower abutment rib (16) extending from its lower surface, and a resilient, upwardly slanted lip (17) extending from a lower part of said longitudinal edge;

- said second coupling part (6) comprises
an upper longitudinal ledge (20) extending in longitudinal direction and in transverse direction away from said floor panel body and comprising a lower abutment surface for said upper abutment rib (15) and
a lower longitudinal ledge (21) extending in longitudinal direction and in transverse direction away from said floor panel body and at a normal distance from said upper longitudinal ledge (20) and comprising a first resilient longitudinal lip (22) and a second resilient longitudinal lip (23) at a transverse distance from said first resilient longitudinal lip (22), and
wherein said lower longitudinal ledges allow fixing to a substructure, and said first coupling part (5) of said floor panel provides a lateral, interlocking engagement with said second coupling part (6) of another, similar floor panel, said first longitudinal ledge (14) dimensioned for extending the upper abutment lip (15) in abutment with said lower surface of said upper longitudinal ledge, said first and second resilient longitudinal lips (22, 23) in transvers direction spaced apart 1%-5% of an upper surface width of said floor panels and designed to allow edges of said first and second resilient longitudinal lips (22, 23) to touch one another,
an edge (18) of said upwardly slanted lip (17) in transverse direction in unmounted state to the floor panels designed to flex a distance of 1%-5% of an upper surface width in transverse direction towards said floor panel,
and a transverse distance between a transverse end of said first longitudinal ledge (14) and an abutment of said lower abutment lip (16) with said first resilient longitudinal lip (22) at least 1%-5% less than a transverse distance between an end of said first longitudinal ledge (14) and said first resilient longitudinal lip (22), and a transverse distance between an abutment of said lower abutment lip (16) with said first resilient longitudinal lip (22) and the edge (18) of said upwardly slanted rib (17) between 0.5% and 3% less than a transverse distance between said first and second resilient longitudinal lips (22, 23).

Drawing