U.S. patent application number 10/210469 was filed with the patent office on 2002-12-26 for multipanel floor system with sealing elements.
Invention is credited to Heisserer, Jamie, Nelson, Thomas J., Rosenthal, Guy L., Stolarski, Victoria L., Stone, James W., Suopys, Algis.
Application Number | 20020194807 10/210469 |
Document ID | / |
Family ID | 27411911 |
Filed Date | 2002-12-26 |
United States Patent
Application |
20020194807 |
Kind Code |
A1 |
Nelson, Thomas J. ; et
al. |
December 26, 2002 |
Multipanel floor system with sealing elements
Abstract
A disengageable interconnecting floor system comprises two or
more flooring panels, a connector and a sealant. Each flooring
panel comprises a top wear surface and a bottom surface for contact
with a support structure and at least two edges having identical
recesses formed therein for receipt of an extension from a
connector. The connector comprises a base and an extension
extending vertically from the base. The extension is shaped to be
received in a disengageable connected fashion into at least one
recess of at least one panel. Sealant is disposed on the flooring
panel, the connector, or both. The invention also includes flooring
panels and sealants for use in a disengageable interconnecting
floor system, and methods for sealing laminate flooring panels
joined by connectors.
Inventors: |
Nelson, Thomas J.; (Belton,
TX) ; Stone, James W.; (Northbrook, IL) ;
Rosenthal, Guy L.; (Wheaton, IL) ; Suopys, Algis;
(Lindenhurst, IL) ; Heisserer, Jamie; (Alsip,
IL) ; Stolarski, Victoria L.; (Georgetown,
TX) |
Correspondence
Address: |
WILSONART INTERNATIONAL, INC.
C/O BAKER BOTTS L.L.P.
ONE SHELL PLAZA
910 LOUISIANA STREET
HOUSTON
TX
77002-4995
US
|
Family ID: |
27411911 |
Appl. No.: |
10/210469 |
Filed: |
July 31, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10210469 |
Jul 31, 2002 |
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09662388 |
Sep 14, 2000 |
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6449918 |
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10210469 |
Jul 31, 2002 |
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09661705 |
Sep 14, 2000 |
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09661705 |
Sep 14, 2000 |
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09436317 |
Nov 8, 1999 |
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6460306 |
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Current U.S.
Class: |
52/582.1 |
Current CPC
Class: |
E04F 2201/05 20130101;
E04F 2201/07 20130101; E04F 15/04 20130101 |
Class at
Publication: |
52/582.1 |
International
Class: |
E04B 002/00 |
Claims
What is claimed is:
1. A disengageable interconnecting floor system comprising: two or
more flooring panels, each flooring panel comprising a top wear
surface and a bottom surface for contact with a support structure,
said panel further comprising at least two edges having identical
recesses formed therein for receipt of an extension from a
connector; at least one connector comprising a base and an
extension extending vertically from the base, said extension shaped
to be received in a disengageable connected fashion into at least
one recess of said at least one panel; and at least one sealant,
said sealant disposed on said flooring panel or said connector.
2. The system of claim 1, wherein said sealant comprises a foamed
elastomer cord.
3. The system of claim 2, wherein said cord is extruded and further
comprises a skin layer.
4. The system of claim 2, wherein said cord further comprises a
pressure sensitive adhesive to hold the cord in place.
5. The system of claim 1, wherein said sealant comprises a material
selected from the group consisting of an elastomer cord, a flexible
cord, a film, a tape, a wax, a paste, or a liquid which solidifies
with time.
6. The system of claim 1, wherein said sealant is attached to the
flooring panel or the connector during installation of a floor.
7. The system of claim 1, wherein said sealant is disposed in said
recess of said flooring panel.
8. The system of claim 1, wherein said edges of said flooring panel
each comprise an upper portion adjacent the top wear surface, and
said sealant is disposed on said upper portion.
9. The system of claim 8, wherein the sealant comprises a material
selected from the group consisting of an elastomer cord, a flexible
cord, a film, a tape, a wax, a paste, or a liquid which solidifies
with time.
10. The system of claim 1, wherein said extension comprises a top
surface and said sealant is disposed on said top surface of said
extension.
11. The system of claim 1, wherein said extension comprises a
vertical support and two horizontal flanges each having a distal
end, and said sealant is disposed on said distal end of at least
one of said flanges.
12. A flooring panel for use in a disengageable interconnecting
floor system comprising: a top wear surface and a bottom surface
for contact with a support structure, said panel further comprising
at least two edges, said edges each having an identical recess
formed therein for receipt of an extension from a connector and an
upper portion adjacent said top wear surface; and at least one
sealant, said sealant disposed in said recess of said flooring
panel or on said upper portion.
13. The flooring panel of claim 12, wherein said sealant comprises
an extruded foamed elastomer cord.
14. The flooring panel of claim 13, wherein said cord further
comprises a pressure sensitive adhesive to hold the cord in
place.
15. The flooring panel of claim 12, wherein said flooring panel
comprises at least three edges having identical recesses formed
therein for receipt of the extension from the connector.
16. The flooring panel of claim 12, wherein said sealant comprises
a material selected from the group consisting of an elastomer cord,
a flexible cord, a film, a tape, a wax, a paste, or a liquid which
solidifies with time.
17. The flooring panel of claim 12, wherein said sealant is
disposed on said upper portion.
18. A method for sealing laminate flooring panels joined by
connectors comprising: providing at least two flooring panels, said
panels each having a top wear surface and a bottom surface for
contact with a support structure, said panels each further
comprising an edge having a recess formed therein and an upper
portion adjacent the top wear surface; providing a connector having
a base and an extension attached to the base, said extension having
a mating member for mating with said recess in said flooring panel;
and disposing a sealant in said recess, on said upper portion, or
on said mating member.
19. The method of claim 18 wherein said sealant comprises a foamed
elastomer cord.
20. The method of claim 18, wherein said sealant is disposed in
said recess of said flooring panel.
21. The method of claim 18, wherein said sealant is disposed on
said upper portion of said edge of said flooring panel.
22. The method of claim 18, wherein said sealant is disposed on
said mating member of said extension.
23. The method of claim 18, wherein said cord is extruded and
further comprises a skin layer.
24. The method of claim 18, wherein said cord comprises a pressure
sensitive adhesive to hold the cord in place.
25. The method of claim 18, wherein said cord is disposed on said
flooring panel or said connector during installation of the
floor.
26. The method of claim 18, wherein said sealant comprises a
material selected from the group consisting of an elastomer cord, a
flexible cord, a film, a tape, a wax, a paste, or a liquid which
solidifies with time.
27. The method of claim 21, wherein said sealant comprises a
material selected from the group consisting of an elastomer cord, a
flexible cord, a film, a tape, a wax, a paste, or a liquid which
solidifies with time.
28. A sealant for sealing edges of flooring panels of a
disengageable flooring system comprising a cord, said cord
comprising an extruded foamed elastomer cord having an exterior
surface and a pressure sensitive adhesive disposed on at least a
portion of said exterior surface.
29. The sealant of claim 28, wherein said edges of said flooring
panels have a first color, and said sealant has at least one second
color to visibly distinguish it from said flooring panels.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 09/662,388, filed Sep. 14, 2000, and a
continuation-in-part of U.S. patent application Ser. No.
09/661,705, filed Sep. 14, 2000, both of which are a
continuation-in-part of U.S. patent application Ser. No.
09/436,317, filed Nov. 8, 1999, all of which are incorporated
herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to systems for constructing a
flooring surface. More specifically, the present invention relates
to components, systems, and methods for constructing a
disengageable decorative laminate flooring surface using individual
flooring panels and connector elements having novel sealing
elements and sealants on the panels or connectors.
BACKGROUND OF THE INVENTION
[0003] Various systems have been proposed in an attempt to provide
a means for easily constructing a flooring surface; however, none
to date have found overwhelming acceptance in the market place,
especially in relation to disengageable thin laminate "floating
floor" surfaces.
[0004] Typically, manufacturers of laminate flooring panels have
produced a flooring product that contains both a tongue and a
groove profile within the same flooring panel. The tongue profile
is machined into one side and one end of the panel with the groove
being machined into the opposite side and end of the same panel.
When panels of this type are assembled, a seam is created between
adjacent panels.
[0005] The manufacturers of laminate flooring panels have used
various methods in an attempt to seal the seam between the panels
of an installed floor. To obtain a seal between panels, known
methods have involved the practice of applying a sealant such as
wax, lacquer, silicon or some other sealant directly onto the
flooring attachment profile (tongue or groove) during the
manufacturing process. This method is detrimental to the
manufacturing process due to the inherent problems associated with
the application of a liquid sealant (which must be dried) to a high
speed linear manufacturing process. It complicates the
manufacturing process and causes numerous problems with the sealant
contaminating all downstream manufacturing equipment.
[0006] A number of the known proposed systems are discussed to
provide a background for the present invention.
[0007] U.S. Pat. No. 3,310,919 titled "Portable Floor," discloses a
floor comprising a plurality of like panels having straight sides,
coupling elements at the sides for coupling arrangement with
cooperating coupling elements on adjacent panels, and means
operatively associated with the coupling elements for releasably
locking adjacent panels in a side-by-side contiguous relationship.
As illustrated in FIG. 2, the panels are coupled together using
locking screws 19 and nails 15.
[0008] U.S. Pat. No. 3,657,852 titled "Floor Tiles," discloses a
floor or tile consisting either of a single piece composed of any
one of a range of different materials or a plurality of
superimposed laminations each composed of any one of a range of
materials. The floor tiles are formed with a plurality of
identical, laterally projecting tongues and, in their underside,
with an equal number of identical pockets which open to the
periphery of the tiles and alternate around the periphery with the
tongues. The tongues and pockets being so shaped that any tongue of
any one of the tiles is adapted to engage and fit within any pocket
of any one of the other tiles and when so engaged, it is held
against endwise withdrawal from the pocket so that, when the two
tiles are located in a common plane, relative movement therebetween
in the plane is prevented.
[0009] U.S. Pat. No. 4,449,346 titled "Panel Assembly," discloses a
panel assembly including at least two panels and a connector member
for mounting the panels to a support surface, the panels being
positioned edge-to-edge in coplanar relationship with the
respective confronting edges thereof spaced apart, and the
connector member between the confronting panel edges and
interlocking the panels together by being fixedly secured to the
support surface. Each panel has first and second surfaces in first
and second parallel planes and each has on its respective edge a
tongue and a groove. The tongue and groove extend along the panel
edge in between the first and second planes, and respectively
project an opening outwardly angularly towards the first plane. The
connector member comprises an elongated body filling the space
between the confronting panel edges and having on each side thereof
a tongue and a groove respectively projecting an opening outwardly
angularly towards the second plane. The tongue and groove on either
side are complimentary to lockingly engage with the respective
groove and tongue on the adjacent respective confronting edges of
the panel. The connector member cooperates with the panels to urge
the panels toward one another in a tight locking engagement as a
result of a compressive force being exerted on the member in the
direction toward the support surface when the member is secured to
the support surface. The patent states that the provision of such a
connector member does away with the heretofore known practice of
driving nails or screws in the panel edges to fix the panels to the
support surface, while still providing a tight locking engagement
between the panels. As shown in FIG. 2, the connecting member is
fixedly secured to the support surface using screw 86. In addition,
"the top surface 56 of the connector member 14 is coplanar with the
top planar surfaces 16 and 18 of panels 10 and 12" and therefore,
forms a part of the top wear surface--which is readily visible.
[0010] U.S. Pat. No. 4,135,339 titled "Slatted Floor System,"
discloses a slatted floor system which is said to be easily
assembled, provides firm footing and comfort to confined animals,
resists corrosion, discourages accumulation of animal waste, is
easily cleaned, and can be used to span significantly greater
distances than prior art slats. The slatted floor system is stated
to comprise a plurality of elongated, spaced, generally parallel
slats. Each slat has a top, load-carrying surface with spaced
apart, opposite outer edges. Each slat also has a bottom surface
substantially parallel to the top surface and a pair of side
surfaces integral with the top surface and the bottom surface. The
side surfaces are joined with the top surface along lines recessed
from the outer edges of the top surface. The side surfaces are said
to further taper toward each other in first positions, adjacent to
the top surface, then extend substantially parallel to each other
and vertically relative to the bottom surface in second portions.
It is stated that this forms with the top and bottom surfaces a
generally Y-shaped, enclosed main compartment. The patent discloses
that each slat also includes a first pair of projection receiving
means extending longitudinally along the tapered first portion of
its side surfaces and a second pair of projection receiving means
extending longitudinally along the second portion of the side
surfaces. Adjacent slats are said to be connected and locked in
spaced-apart relationship in a plurality of connectors. Each
connector has a pair of projections, with each projection being
receivable by one of the first pair of projection receiving means
on each of two adjacent slats, and the second pair of projection
receiving means on each of two adjacent slats. At least one of the
first and second pairs of projections on the connectors are adapted
to interlock with its corresponding projection receiving means on
adjacent slats. As stated above, and shown in FIGS. 1 and 4, the
upper wear surface of the slats are spaced apart to provide a gap
to facilitate the object of the invention, i.e., for discouraging
the accumulation of animal waste. In addition, as shown in the same
figures, the projections and connector means can only be assembled
by sliding the edges of the slats and connector together when held
in parallel coplanar relationship to one another. As shown, the
connector member does not extend the entire length of the slat
members.
[0011] U.S. Pat. No. 4,461,131 titled "Panel Interconnection
System," discloses an assembly of panels of rectangular shape, as
for example, a floor, in which the panels comprise upper and lower
ridged sheets separated by a core, elongated fittings extending
along adjacent edges of adjacent panels and having lateral
extension receipt means between edge portions of the sheets of the
panels. Each fitting has an upwardly open channel located beyond
the edge of the associated panel. Adjacent fittings and adjacent
panels are secured together by elongated connector strips which
have parallel elongated lugs received in the channels of the
adjacent fittings. As shown in FIG. 3, strips 40 form a portion of
the top wear surface and are thus, visibly distinct from the upper
surface 10 of flooring panels P.
[0012] U.S. Pat. No. 4,796,402 titled "Step Silencing Parquet
Floor," discloses a step silencing parquet board, in which the
sound of steps which are perceivable from one room to another are
silenced by using a surface-press non-homogeneous fiber board in
the supporting construction layers provided underneath the wear
surface layer of the parquet board. The patent discloses that the
board has longitudinal sides and ends formed with a tongue and
groove whereby said board will cooperate with adjacent boards to
form a self-silencing parquet floor.
[0013] U.S. Pat. No. 5,022,200 titled "Interlocking Sections for
Portable Floors and the Like," discloses an alleged improved
locking mechanism including first and second members which fit
together for locking purposes. The second locking member has pins
mounted therein for motion along defined paths between first and
second positions, referred to in the patent as closed and open
positions. The patent discloses means for normally urging the pins
to their closed positions. The first locking member is stated to
have means for moving the pins to their open positions when the two
lock members are moved together and for permitting the pins to
return to their closed positions after engagement of the first and
second lock members. The first lock member has engagement surfaces
which contact the pins when forces are applied to move the first
and second lock members apart. The shape or slope of these
engagement surfaces relative to the paths of the defined motion of
the pins is such as to cause substantial interference of the first
lock member with the pins which prevents movement of the pins to
the open position and therefore, prevents removal of the lock
member. A separate unlocking mechanism is provided to move the pins
to the open position and thereby permit disengagement of the
mechanism. According to a preferred embodiment disclosed in the
patent, the first locking member includes a flange and the second
locking member includes means to define a recess to receive the
flange. The pins are positioned generally within the receiving
space, and the flange includes surfaces on its outer edge for
moving the pins to the open position, and hook-like portions having
engagement surfaces which engage the pins in a locked position. The
patent also discloses an alleged improved panel construction
wherein a panel is formed in a single molding process which
encapsulates a core member in urethane, molds the edge tongue and
groove portions with recesses formed therein to receive the locking
members, and bonds the decorative endurable floor surface.
[0014] U.S. Pat. No. 5,157,890 titled "Floor," discloses a flooring
system of individual panel assemblies that may be cooperatively
interengaged. The patent discloses that the periphery of each panel
is bound by frame members having two spaced generally parallel
flanges and a generally perpendicular web extending therebetween.
On one side of the web, between the upper and lower flanges, the
frame members include a track for receiving a key block. The key
block comprises a generally rectangular base with a key tongue
extending therefrom. The base is slottably received in the track of
one frame member and the tongue is received in the track of an
adjacent frame member. The frame members may be miter cut to a
desired length and the corners fastened together by a corner
fastener.
[0015] U.S. Pat. No. 5,179,812 titled "Flooring Product," discloses
a flooring product comprising a wood panel having an L-shaped
surround the base of which is located below the wood panel. The
patent discloses the use of a plurality of parallel aluminum
battens which are connected to the base of the panel. These battens
are said to comprise a groove. In practice, the patent discloses
that two flooring products having similar joint arrangements are
secured together by locating the base of the surround of each
product in the groove and the elongated members of the other
product. The connection cannot be disengaged unless one of the
flooring panels is tilted relative to the other.
[0016] U.S. Pat. No. 5,295,341 titled "Snap-Together Flooring
System," discloses a flooring system having a base member having a
top side, an underside, and four circumferentially spaced outer
edges, a tongue connector secured to one outer edge by an
interlocking rib and groove, a groove connector secured to another
outer edge by an interlocking rib and groove, a tongue connector
having forwardly converging compressible side walls terminating in
rear transverse locking surfaces, the groove connector having a
large inner opening and a small outer opening. The tongue sidewalls
in a compressed position are smaller than said groove outer opening
to pass through the outer opening but are elastically expandable to
be larger than said outer opening to lock a tongue and a groove.
The patent discloses that preferably the connectors are attached to
the base members and recesses of the outer edges by additional
tongues and grooves and that they are attached to the base members
at the factory during manufacture.
[0017] U.S. Pat. No. 5,736,227 titled "Laminated Wood Flooring
Product and Wood Floor," discloses a flooring product which
includes a top decorative layer, an intermediate layer bonded to
the top layer, and a base layer bonded to the intermediate layer.
The top, intermediate, and base layers are bonded to define a
laminated elongated wood flooring strip. A tongue and groove are
formed on respective side edges of the flooring strip. The tongue
and groove extend along the length of the flooring strip, and lock
adjacent flooring strips together side-to-side to form an assembled
wood floor. The base layer has a multiplicity of closely
spaced-apart scores cut transverse to the length of the flooring
strip along substantially the entire length of the flooring strip.
The scores relieve stress and increase flexibility in the wood
strip for more closely adhering to irregularities of the sub
floor.
[0018] U.S. Pat. No. 3,694,983 titled "Pile or Plastic Tiles for
Flooring and the Like Applications," discloses tiles adapted to
constitute by juxtaposition a continuous, plain or diversified
carpet or revetment of textile, plastic or other material. Each
tile is secured to a backing of the same dimensions but having
projections along two adjacent edges of the tile to form an
embedded strip. Each strip is provided with means permitting the
mutual engagement of fastening means provided in embedded condition
under the edges of two sides of the adjacent tile. The fastening
means have a thickness inferior to that of said backing so that in
assembled condition no extra thickness is produced in relation to
the normal backing thickness.
[0019] U.S. Pat. No. 3,859,000 titled "Road Construction and Panel
for Making Same," discloses a road construction comprised of a
plurality of identical invertible polygonal panels. Each panel
comprises a plurality of single piece peripheral frame members
fixed together to define a polygonal configuration and each of the
members having a roughly L-shaped projection extending therefrom.
The projection is adapted to be interlocked with an identical
projection of an associated member. Each panel also has a pair of
load carrying sheets fixed on opposite sides of its frame
members.
[0020] U.S. Pat. No. 5,706,621 titled "System for Joining Building
Boards," discloses a system for laying and mechanically joining
building panels, especially thin, hard, floating floors. The patent
discloses that adjacent joint edges of two panels engage each other
to provide a first mechanical connection locking the joint edges in
a first direction perpendicular to the principal plane of the
panels. In each joint, the patent states that there is provided a
strip which is integrated with or integrally formed with one joint
edge and which projects behind the other joint edge. The patent
discloses that the strip has upwardly protruding locking elements
engaging in a locking groove in the rear side of the other joint
edge to form a second mechanical connection locking the panels in a
second direction parallel to the principal plane of the panels and
at right angles to the joint. Both the first and second mechanical
connections allow mutual displacement of joined panels in the
direction of the joint. The patent discloses that the strip is
mounted at the factory on the underside of the panel and extends
throughout the joint edge. The patent discloses the strip may be
made of flexible, resilient aluminum, and can be affixed
mechanically, by means of glue or any other suitable way. The
patent discloses that alternatively, the strip may be integrally
formed with the strip panel. According to the patent, "at any rate,
the strip 6 should be integrated with the panel 1, i.e., it should
not be mounted on the strip panel in connection with laying."
[0021] U.S. Pat. No. 5,860,266 titled "Method for Joining Building
Boards," discloses a method for laying and mechanically joining
rectangular building panels in parallel rows. The patent discloses
the following steps: (a) placing a new one of the panels adjacent
to a long edge of a previously laid first panel in a first row and
to a short edge of a previously laid second panel in an adjacent
second row, such that the new panel is in the second row while
holding the new panel at an angle relative to a principal plane of
the first panel, such that the new panel is spaced from its final
longitudinal position relative to the second panel and such that
the long edge of the new panel is provided with a locking groove
which is placed in contact with a locking strip at the adjacent
long edge of the first panel; (b) subsequently angling down the new
panel so as to accommodate a locking element of the strip of the
first panel in a locking groove of the new panel, whereby the new
panel and the first panel are mechanically connected with each
other in a second direction with respect to the thus connected long
edges, wherein the long edges, and the angled down position of the
new panel, are engaged with each other and thereby mechanically
locked together in a first direction also; and (c) displacing one
of the new panels in its longitudinal direction relative to the
first panel towards a final longitudinal position and to a locking
element of one of the short edges of the new panel and the second
panel snaps up into a locking groove of the other one of the short
edges, whereby the new panel and the second panel are mechanically
connected with each other in both the first and second directions
with respect to the connected short edges. The patent states that
the strip 6 projects horizontally from a panel and is mounted at
the factory on the underside of the panel and extends the entire
edge of the panel. The patent discloses that strip 6 may be made of
flexible, resilient sheet aluminum, and can be affixed
mechanically, by means of glue or any other suitable way. The
patent discloses that other strip material can be used, such as
sheets of other metals, as well as aluminum or plastic sections.
Alternatively, the patent teaches that the strip 6 may be
integrally formed with the strip panel. The patent states that "at
any rate, the strip 6 should be integrated with a strip panel,
i.e., it should not be mounted on the strip panel in connection
with laying."
[0022] Japanese Patent Application No. 56-5347 titled "A Method for
Partially Recovering Floor Plates," discloses floor plates laid on
a floor bed with tongue joints engaged with groove joints. The
patent teaches a saw is inserted into gap A between both the side
floor plates of a floor plate to be replaced and the tongue joints
are cut off, thereby the connection between the floor plates is cut
and the floor plate to be replaced is removed. The patent teaches
that the subsequently left tongue joints in the groove joints of
the adjacent floor plates are removed. The portion where there were
tongue joints before in the floor plates is cut off and groove
joints are newly formed. The patent states that FIG. 4 shows a new
floor plate and that along both sides of the floor plate are formed
relatively shallow and wide slots in relatively deep concaved
portions. The bottom of the concaved portion is dented so as to
hold a foaming synthetic resin. The new floor plate is then
inserted into the position where the removed floor plate was
located and at a status wherein the new floor plate is level with
the adjacent floor plate. The foaming resin is foamed and hardened.
The hardened foaming resin expands into the groove joints to form a
tongue joint. It is also noted that the new floor plate in contact
with the floor bed is secured by adhesive.
[0023] Japanese Patent Application No. 1-30691 titled "Floor
Plates," discloses floor plates to be laid on a ground floor
characterized by having a thin wooden decorative plate laminated
onto the surface layer of a base material in a sheet shape. An
engaging protrusion is formed on one side of the base material
while an engaging concave portion to which the above engaging
protrusion may be engaged is formed on the other end thereof while
an engaging concave portion to which the above engaging protrusion
may be engaged is formed on the end of the other side thereof. The
patent teaches that the floor plates include a stopper protrusion
formed on one side of the engaging protrusion and on one side of
the engaging concave portion. And a stopper concave portion to
which the stopper protrusion is engaged is formed on the other side
of the engaging protrusion and on the other side of the engaging
concave portion.
[0024] Patentschrift No. 200949 discloses in FIGS. 1 and 2 flooring
panels having four edges wherein two edges include an upper groove
for insertion thereunder of an adjacent panel, while the other two
edges include an extension including a tooth formed to be inserted
under the upper groove portion of an adjacent panel when
assembled.
[0025] Patentschrift No. 1 534 278 discloses in FIGS. 1-3 to
assemble two adjacent structures wherein the first structure
includes a groove and a notch for receipt of a corresponding tongue
and tooth of an adjacent structure to be connected thereto.
[0026] Offenlegungsschrift 25 02 992 discloses a flooring panel
especially suitable for use in making a temporary floor, as for
example, in a camping tent. The flooring panel is disclosed to have
a flat thread surface bent back on at least two edges, one of which
is given a distinct profile and the other having a fitting
counterprofile. The patent teaches that these bent sections are
preferably on two opposite sides, one being roughly U-shaped with
its outer shank and the resultant slot-type opening facing upwards
and the counterprofile consisting of a shank at right angles to the
thread surface. The patent teaches that such profiles may be
provided alternatively, on all four edges of the panel. It is
disclosed that the panels may be of plastic, and formed in a single
piece, corrugated projections underneath preferably of a softer
material. As shown in FIG. 3, the panels are assembled together
using a tongue and groove arrangement.
[0027] Offenlegungsschrift DE 3041781A1 discloses the inner
connection of two panels wherein the panels include a tongue on one
edge and a groove in another edge to provide interlocking
connections between two panels used especially for constructing a
skating rink or skittle alley. The patent discloses at the root of
the tongue there are two parallel sides with faced pieces aligned
at right angles to the edge of equal thickness. The patent
discloses that the groove has two initial parallel sidewalls
against which the tongue side face pieces come to rest. It is
disclosed that this part of the groove is succeeded by a
semi-trapezoidal shaped recess or a fully trapezoidal shaped
recess. The patent discloses that the tongue may be rounded on the
side opposite to its acute-angled side face.
[0028] Offenlegungsschrift DE 35 44 845 A1 discloses a board used
for the manufacture of solid wood panels which consists of glued
boards engaging complimentary profiles. Longitudinal edges of the
boards have a joint profile which sections extend at an angle to
the vertical board edge. The application discloses that the joint
profile has two parallel straight sideward displaced upright flanks
which are connected at their inner ends via straight transverse
flanks. The inward upward flank encloses an acute angle with the
board surface, while the other flank forms an obtuse angle with the
associated board surface. Upright flanks and transverse flanks
enclose acute angles.
[0029] European Patent Application No. 0248127 titled "A Table Top
for a Motor Lorry" discloses a motor lorry table top consisting of
a plurality of planks which are fixed to at least two beams forming
part of the motor lorry chassis. The planks consist of extruded
aluminum and are fixed to the chassis by means of clips with the
planks interlocking to secure the planks from relative movement
therebetween.
[0030] Patenttihakemus-Patentansokan 843067 (PCT/SE 83/00423)
discloses a means for interconnecting adjacent panels wherein the
edges of panels to be connected include tongues and grooves. In
addition, located to either side of the tongue and groove joint of
two connected panels are recesses formed in said panels for receipt
of a U-shaped metal clamp means for holding the two panels together
at the tongue and groove joint.
[0031] French Application No. 2 697 275 discloses the formation of
a surface from rectangular shaped slabs placed on a flat horizontal
surface. The application discloses that the body of the slab has
shaped sections on all four sides and that the slabs can be
mechanically joined together via a number of ribs running
lengthwise along the slab which are shaped so that they slide into
a matching groove in the adjacent slab. FIG. 2 appears to disclose
a member 33 for connecting two adjacent slabs. As shown, the top
surface of the member 33 forms a portion of the top wear surface of
the resulting floor. This also can be seen in FIG. 1 where members
5 and 6 form a portion of the top wear surface.
[0032] Japanese Application No. 54-65528 shows in FIGS. 1-3 a
particular tongue and groove arrangement for interconnecting two
adjacent panels.
[0033] French Application 2 568 295 discloses a prefabricated
flooring system consisting of a series of flat panels which are
laid directly on the ground. The panels are made, for example, from
a resin compound either containing reinforcing elements or
incorporating granules of a durable material such as quartz or
carborumdum. The patent discloses that the panels have interlocking
joints on all their edges, made in the form of projections and
recesses, and the under surface of each panel can be covered with a
layer of non-decomposing cellular and flexible material which is
able to compensate for irregularities in the surface of the ground.
UK Patent Application No. 424,057 discloses a method of
constructing a parquet floor which comprises the use of reversible
rectangular blocks each having protruding flanges forming
sphenoidal grooves on each of its four sides, each groove extending
across the whole of the side in which it is situated. The patent
teaches the grooves on two co-terminus sides having their mouths
facing upwards when the mouths of the other two grooves on the
other two sides face downwards, whereby a plurality of such blocks
may be built up into a floor covering in which each block is locked
on each side which lays contiguous with the side of another such
block. The method is stated to also comprise the use of connecting
members having flanges adopted to engage beneath the overhanging
flanges of two adjacent blocks where a change in direction of
laying is required.
[0034] UK Patent No. 1,237,744 titled "Improved Building
Structure," discloses that it relates to a building structure
composed of panels joined at their edges by first tongue and groove
connections having elements located in the plane of the building
structure as well as by second tongue and groove connections having
elements located perpendicular to said plane.
[0035] UK Patent No. 1,430,423 titled "Joint Structure," discloses
in FIGS. 1 and 2 a specific tongue and groove/notch and tooth joint
structure for interconnecting plastic and metal materials.
[0036] UK Patent Application No. 2 117 813A titled "Pivotal
Assembly for Simulated Wall Panels," discloses a joint assembly
comprising a pair of strips secured to the edges of the respective
panels by folding the outer skins of the panels and by a dovetail
joint in the foam insulation material inside the panels. The
application discloses the connecting strips provide a curved tongue
and groove. The groove strip has a pivotal body of part-cylindrical
shape so that one strip can be pivoted relative to the other for a
tongue to enter the groove. The application discloses that a
locking strip is provided to be inserted into a groove to lock the
panels together.
[0037] UK Patent Application No. 2 256 023A titled "Joint,"
discloses a joint between the joining side edges of two similar
panels in which one panel has a channel-section recess open towards
the front face and the other panel has a rib facing towards the
rear face for reception in the recess to restrict separation of the
panels to provide a predetermined expansion gap between the
adjacent side edges. The application discloses that the panels may
be tongue and groove boards for construction of, for example, a
door. The application discloses in the figures a particular tongue
and groove/notch and tooth joint.
[0038] Utlengningsskrift No. 157871 discloses in the figures the
connection of two adjoining members utilizing a tongue and groove
joint at the edges and which includes recesses formed in said
panels spaced from the joint for receipt of a U-shaped member for
holding the two panels together at the tongue/groove joint.
[0039] Utlaggningsskrift No, 7114900-9 discloses in FIGS. 1-3 means
for connecting two adjacent members utilizing connection blocks 2,
5 and 9 wherein said blocks form a part of the top wear surface.
The application further discloses a U-shaped member for insertion
on the backside of the panels to hold the two panels together at
the joint where the joint block exists.
[0040] WO 84/02155 titled "Device for Joining Together Building
Boards, Such as Floor Boards," discloses a device for joining
together building boards, such as floor boards, edge surface to
edge surface. The application discloses a system wherein the boards
comprise a groove in the rear side of each board, the groove
running over the entire length of the board parallel to its joining
edge, and a substantially U-shaped spring device, the legs of which
are each adapted to engage the groove of one board, and which is
prestressed so that, upon engagement, the boards are tightly
clamped together edge surface to edge surface.
[0041] Patentschrift 200949 discloses in FIGS. 1-6 panels for
joinder one to another wherein the panels include on two
intersecting edges extending tongue strips and on the other
intersecting edges an extending groove strip.
[0042] WO 93/13280 titled "A Device for Joining Floor Boards,"
discloses a device for joining floor boards comprising elongated,
flat-shaped body with legs adapted to engage a longitudinal groove
in each of the joining floor boards. The legs are shaped at a
distance from the ends of the plate-shaped body in such a manner
that the plate-shaped body supports the boards on each side of the
grooves.
[0043] U.S. Pat. No. 3,538,665 titled "Parquet Flooring," discloses
a floating parquet flooring comprising rectangular-shaped two-layer
flooring units composed of a parquet layer and a backing layer. The
bottom face of the backing layer being provided with marginal
recesses along the four sides of the unit and a strip of backing
layer material being inserted in the space formed by such marginal
recesses for bridging the joint between adjacent units. The patent
discloses that the backing layer material has a modulus of
elasticity in tension not exceeding 5000 kg/cm.sup.2.
[0044] Offenlegungsscrift 26 16 077 A discloses a connection web
with a flange for connecting plates resting flat on a supporting
substrate. The patent application discloses the arrangement is
especially useful for connecting prefabricated parquet floor
elements. The application discloses that a pliable connection
arrangement is provided which replaces rigid connectors such as
adhesives or nails. The application states that the system is
advantageous because it accommodates expansion and shrinking
stresses which thus, prevents cracking. It is stated that the
connecting web prevents overlapping of the plate edges on uneven
substrates and in use the connection web is loaded in tension when
the plates expand. On contraction of the plates, the connection web
pulls the plates together and prevents gap formation.
[0045] French Application No. 1 293 043 discloses in FIGS. 1-3 a
tile having four edges wherein one set of intersecting edges
includes a tongue extending therefrom and the other two
intersecting edges includes a groove open in the direction of the
bottom side of the tile. FIGS. 4-6 disclose tiles having four edges
wherein two intersecting edges include a notch and a groove open
toward the top side of the panel and the other two intersecting
edges have a notch and a groove open toward the bottom of the
panel.
[0046] Utlaggningsskrift No. 8206934-5 discloses the joining of two
panels wherein a tongue and groove arrangement is utilized. The
drawings further disclose a U-shaped clip for insertion into the
panels on either side of the joint for holding the two panels
together at said joint.
[0047] WO 97/47834 titled "Floor Covering, Consisting of Hard Floor
Panels and Methods for Manufacturing Such Floor Panels," discloses
a floor covering consisting of hard floor panels which, at least at
the edges of two opposite sides, are provided with coupling parts
cooperating with each other. The coupling parts are substantially
in the form of tongues and grooves characterized in that the parts
are provided with integrated mechanical locking means. The locking
means prevent the drifting apart of two coupled floor panels into a
direction perpendicular to the related edges and parallel to the
underside of the coupled floor panels.
[0048] In view of the prior art, there is a need for a connector
that is separate from the floor panels and joins or assembles floor
panels to each other. There is a further need for a connector,
floor panels and/or a floor panel system which has a seal or
sealant for seams between panels which is easily manufactured.
SUMMARY OF THE INVENTION
[0049] Accordingly, one embodiment of the invention is directed to
a disengageable interconnecting floor system with a novel sealant
which may be used to form temporary or permanent flooring surfaces
from individual flooring panels on top of a support structure. The
system preferably comprises two or more flooring panels, at least
one connector, and a sealant. Each flooring panel comprises a top
wear surface and a bottom surface for contact with the support
structure. The panel preferably further comprises at least two
edges having identical recesses formed in the edges for receipt of
an extension or other projection from a connector. More preferably,
the panel comprises at least three edges having such identical
recesses, and, even more preferably, the panel is rectangular,
square, or any shape and comprises four or more of such edges. Each
of the edges has an upper portion disposed adjacent the top wear
surface of the flooring panel. The connector preferably comprises a
base and an extension extending vertically from the base. The
extension is spaced above the base, and, preferably, extends
vertically so that it is spaced from and substantially parallel to
the base. Preferably, the distance from the base of the connector
to the top surface or uppermost point of the extension is less than
the distance from the bottom surface to the top wear surface of the
panels. The extension is shaped to be received in a disengageable
horizontal/vertical connected fashion into at least one recess of
the panel. As such, the extension of the connector disengageably
mates with the recess in the panels.
[0050] The sealant is preferably a foamed elastomer cord and is
disposed or adapted to be disposed on the flooring panel or the
connector. For instance, it may be applied to the panel or
connector by the manufacturer. Alternately, it may be applied or
attached by the purchaser or consumer to the panel or connector
during installation of the floor.
[0051] Preferably, the cord is pre-extruded and may further
comprise a skin layer on the exterior surface. Optionally, the cord
may have a pressure sensitive adhesive on its exterior surface to
hold the cord in place.
[0052] The sealant may be attached to the recess of the flooring
panel. Alternately, or additionally, it may be attached or disposed
on the upper portion of the edge. Alternately, or additionally, the
sealant may be attached to the extension of the connector.
Preferably, the extension comprises a top surface, a vertical
support and two horizontal flanges. The sealant may be disposed or
adapted to be disposed on a top surface of the extension.
[0053] Alternately, the sealant may be disposed or adapted to be
disposed on a distal end of at least one of the flanges. In one
embodiment, the base of the connecting element further comprises a
groove or recess, and the panel edge is shaped to be received in a
disengageable horizontal/vertical connected fashion into the groove
or recess of the base of the connecting element. Alternately, the
base may comprise a node, ridge or other protrusion or projection,
and the flooring panels have notches, recesses or channels in their
bottom surfaces shaped to receive the protrusion or projection on
the base.
[0054] In a preferred embodiment, the floor panel has both a recess
in the edge to receive the flange portion of the extension of the
connector and a channel in the bottom surface to receive a
protrusion in the base of the connector. Preferably, the recesses
in the edges and the channels on the bottom surfaces of the
flooring panels extend substantially the entire length of their
respective edges and bottom surfaces.
[0055] Another embodiment of the invention is directed to a
flooring panel for use in a disengageable interconnecting floor
system comprising: a top wear surface and a bottom surface for
contact with a support structure, the panel comprising at least two
edges, said edges each having an identical recess formed therein
for receipt of an extension from a connector, and an upper portion
adjacent to the top wear surface; and at least one sealant, the
sealant disposed in the recess of the flooring panel or on the
upper portion of the edge. More preferably, the flooring panel
comprises at least three edges having identical recesses formed
therein for receipt of extensions from connectors. Although various
sealants may be used in this embodiment, in a preferred embodiment,
the sealant comprises an extruded foamed elastomer cord and a
pressure sensitive adhesive on at least a portion of the exterior
surface of the cord to hold the cord in place. Other sealants
include flexible cords, films, tapes, waxes, pastes, or liquids
which solidify with time.
[0056] Another embodiment of the invention is directed to a method
for sealing laminate flooring panels joined by connectors
comprising the steps of: providing at least two flooring panels,
the panels each having a top wear surface and a bottom surface for
contact with a support structure, the panels each further
comprising an edge having a recess formed therein for receipt of a
mating member on an extension from a connector, and an upper
portion disposed adjacent the top wear surface; providing a
connector having a base and an extension attached to the base, the
extension having the mating member for mating with the recess in a
flooring panel; and disposing a sealant in the recess, on the upper
portion, or on the mating member. The sealant may be disposed in
the recess of the flooring panel, on the upper portion of the edge,
or both. Alternately, or additionally, the sealant may be disposed
on the mating member of the extension. Preferably, the sealant
comprises a foamed elastomer cord. The cord is preferably extruded
and may further comprise a skin layer. The cord may optionally
comprise a pressure sensitive adhesive to hold the cord in place.
Alternately, the sealant may comprise flexible cords, films, tapes,
waxes, pastes, or liquids which solidify with time.
[0057] Still another embodiment is directed to a sealant for
sealing edges of flooring panels of a disengageable flooring system
comprising a cord comprising an extruded foamed elastomer cord
having an exterior surface and a pressure sensitive adhesive
disposed on at least a portion of the exterior surface. Preferably,
the edges of the flooring panels have a first color, and the
sealant has at least one second color to visibly distinguish it
from the flooring panels.
[0058] Advantages to placing the sealant in the recess of the
flooring panel include protection of the sealant during packaging
and during handling prior to installation. In addition, advantages
may include: elimination of the need to minimize drying time in the
manufacturing process; elimination of and/or prevention of
contamination of processing equipment down stream from the
application of the sealant; and allowing for the application of a
sealant without slowing the manufacturing speed.
[0059] Advantages to placing the sealant on the upper portion of
the edge of the flooring panel may include complete exclusion of
fluids from the seam area.
[0060] In those embodiments where the sealant is disposed on the
connector, a number of advantages may be obtained. The connector,
which is separate from the panels, allows for a different approach
to the application of a sealant to the seam area of a laminate
floor and eliminates the problems associated with current methods
for applying the sealant. The application of a sealant directly to
the connector has the following advantages: (1) depending on the
manufacturing process, it may be easier to apply the sealant to the
connector than directly on the flooring panels; (2) drying problems
associated with applying a wet sealant to a high-speed, linear,
panel manufacturing process are eliminated, i.e., the sealant
contaminates the manufacturing equipment and attracts dirt and dust
during the drying process, and sealant application results in
slower processing speeds due to the application method and/or
required drying times; (3) the sealant may be placed in areas
beyond the normal attachment profile (between the panel bottom
surface and the connector); (4) the sealant may be applied in
various forms (e.g., as flexible cords, films, tapes, waxes,
pastes, or liquids which solidify with time) with varying
thicknesses in specific areas, and various methods of application
may be used without disrupting or interfering with the flooring
manufacturing processes; and (5) a more uniform coverage of the
sealant in the seam area of an installed flooring panel is
assured.
[0061] According to another preferred embodiment, the preferred
connector of the system of the present invention further includes
an extension that is shaped to be received in a disengageable
horizontal connected fashion into at least one groove or recess of
the panels.
[0062] According to another embodiment of the present invention,
the base of the novel connecting element has grooves or other
recesses formed therein, and at least one panel edge is shaped to
be received in a disengageable horizontal connected fashion into
the groove or recess of the base of the connecting element. The
groove or recess may be formed in the base or in part of the
above-described extension.
[0063] According to yet another embodiment of the present
invention, an extension of the connector according to the present
invention has a groove or other recess formed therein, and at least
one panel is shaped to be received in a disengageable horizontal
connected fashion in the groove or other recess of the
extension.
[0064] According to a further embodiment of the present invention,
the distance from the base of the connector to the top or uppermost
point of the extension, preferably tongue-shaped, of the connector
is less than the distance from the bottom surface to the top wear
surface of the panels.
[0065] According to another embodiment of the present invention, a
disengageable interconnecting flooring system is provided for use
in forming temporary or permanent flooring surfaces on top of a
support structure from individual flooring panels. The system
comprises two or more flooring panels, preferably laminated, and at
least one elongated connector, e.g., a track. The flooring panels
preferably have a top wear surface, a middle reinforcing substrate
material, and a bottom surface for contact with a support floor
structure. The panels preferably have four edges with identical
grooves formed therein, preferably in all edges, for receipt of a
vertically extending extension of the track. The panels also have
notches or other recesses, e.g. channels, formed in their bottom
surfaces shaped for receipt of nodes, ridges, or other protrusions
from the connector. Preferably, the grooves and the channels extend
substantially the entire length of the edges of the panels.
[0066] The connector, according to one embodiment of the present
invention, has a base with preferably a single extension extending
vertically therefrom shaped to be received in a disengageable
vertical connected fashion into grooves or other recesses in the
edges of the panels. Preferably, the connector is substantially the
same length as the panel edges to be connected. Preferably, the
extension extends the entire length of the connector. The base of
the connector further has two nodes, ridges, or two other
protrusions extending vertically from either side of the base
spaced from the single extension. The protrusions or ridges are
shaped to be received in a disengageable horizontal connected
fashion into the notches or other recesses, e.g., channels, in the
bottom surface of the panels. Preferably, the protrusions or ridges
extend substantially the entire length of the edges of the panels.
When the panels are connected using the connector, the resultant
visible flooring surface consists of only the top wear surface of
the panels.
[0067] According to another embodiment of the present invention, a
vertical and horizontal interconnecting flooring system for use in
forming a flooring surface on top of a support surface is provided.
The system comprises two or more individual flooring panels,
preferably laminated floor panels, having a thickness, and at least
one connecting track. The flooring panels have a top wear surface
and a bottom surface for contact with a support surface. The panels
have at least three edges wherein all edges have first identical
recesses or grooves formed therein. The first recesses or grooves
are shaped to receive a first connection projection or flange from
the connector. The panels also have second recesses, e.g.,
channels, located along the bottom surfaces of the panels open in
the direction of the ground or support surface for receipt of a
second connection projection or ridge from the track. The track,
according to this embodiment, has a base, a first connection
projection or flange, and a second connection projection or ridge.
The first connection projection or flange is connected to and
extends vertically a distance from the base and then extends
horizontally relative to the base and is shaped to be received in
the first recesses or grooves of the panels to form a vertical
connection between the panels. The second connection projection or
ridge is connected to and extends vertically a distance from the
base, preferably a distance less than the vertical portion of the
first projection, and shaped to be received in the second recesses
or channels of the panels to form a horizontal connection between
the panels. According to this embodiment, the distance from the
base of the track to an uppermost vertical portion of the first
projection or flange is less than the distance between the top wear
surface and the bottom surface of the panel in contact with the
support surface such that when two panels are connected, said first
and second connections form a flooring surface consisting of only
the top wear surface of the panels.
[0068] According to a further embodiment of the present invention,
a disengageable decorative laminate flooring system for application
to an existing floor surface without the use of adhesives or
traditional fastening devices is provided. The system comprises a
plurality of identical individual floor panels and connectors. The
individual floor panels have a top decorative wear surface and
comprise at least three edges each having an identical receiver
located in the edges, i.e., each edge of each panel comprises the
same configuration. The connectors, preferably comprise rails, of
substantially the same length as the edges of the panels. The rails
have extending vertically therefrom a first projection and a second
pair of projections. The first projection is shaped for insertion
into the receivers for disengageable vertical interconnection of
the individual flooring panels at their edges. The second pair of
projections is shaped for insertion into the receivers for
disengageable horizontal interconnection of the individual flooring
panels at their edges. Preferably, the first projection and second
pair of projections extend substantially the entire length of the
rail. And when the panels are interconnected using the connectors,
according to this embodiment, the visible resultant flooring
surface only consists of the top decorative wear surface, i.e., no
portion of the connector forms a part of the visible flooring
surface.
[0069] According to one embodiment, the present invention is
directed to a disengageable connector for vertically and
horizontally interconnecting individual flooring panels to form a
laminate flooring surface on top of a support structure. The
connector preferably comprises a base for contact with the support
structure. The base, according to one embodiment, has a projection
or extension extending vertically therefrom in a direction away
from the support structure. The projection or extension has top and
bottom portions consisting of identical right and left halves, each
half preferably comprising a tongue-like extension or flange
extending a distance substantially parallel to and spaced above
said base. Optionally, according to a particularly preferred
embodiment, the base includes two additional protrusions or ridges
extending vertically therefrom. These protrusions or ridges are
spaced apart and located on either side of the projection or
extension.
[0070] According to yet another embodiment, the present invention
is directed to individual flooring panels for use in forming a
flooring surface on a support structure, the flooring surface
comprised of the panels disengageably interconnected horizontally
and vertically. The panels, according to this embodiment, comprise
a top surface, a bottom surface, and edges between the top and
bottom surfaces. The top surface comprises a decorative wear
surface. The edges comprise identical grooves and/or recesses
extending substantially the entire length of the edges. The bottom
surface comprises identical channels formed therein and open toward
the support structure or away from the top surface. These channels
are parallel to, spaced from, and preferably extend substantially
the entire length of the edges.
[0071] According to one aspect of the invention, there is provided
a connector for assembling and sealing laminate flooring panels
which are separate from the connector, the connector comprising: a
base; an extension attached to the base and having a mating member
for mating with a flooring panel; and a seal attached to a member
selected from the base and the extension.
[0072] According to a further aspect of the invention, there is
provided a method for manufacturing a connector for assembling and
sealing laminate flooring panels which are separate from the
connector, the method comprising: extruding a connector having a
base and an extension attached to the base, wherein the extension
has a mating member for mating with a flooring panel; and attaching
a seal to the connector.
[0073] The present invention is directed to a unique and novel
system for easily joining and disjoining a flooring surface,
preferably a thin (less than an inch thick) laminate flooring
surface of the "floating" type. The system is designed such that
additional traditional fastening means are not needed, e.g., nails,
screws, adhesives, tacks, staples, etc. are unnecessary. The
present inventive system accomplishes this task without the need of
special tools or floor laying experience. The present inventive
system accomplishes its advantages utilizing preferably identical
joining panels with preferably identical novel edges making
assembly easy and flexible, even for the novice. Moreover, the
present inventive system provides a single connecting means for use
in relation to all edges of the novel panels--again, making
assembly and disassembly easy. More importantly, due to the fact
that at least two edges of the panels have recesses formed therein
during manufacture, either less reinforcing middle substrate
material is needed to manufacture the panels and thus, saving
resources and/or less decorative top surface material is wasted,
i.e., it is not necessary to remove as much of the top wear surface
portions to provide for the interconnecting system of the
invention.
[0074] A further advantage of the invention is that the panels may
be oriented in any direction (during installation) without the need
to mechanically modify a factory produced tongue or groove profile.
These panels may be manufactured in a cost-effective manner (no
tongue profile to machine). The amount of material (approximately
1/8 inch in width) needed to mechanically create the tongue profile
does not have to be machined off. The result is a significant cost
reduction due to the elimination of the tooling needed to produce
the tongue profile. Also, this results in an additional 1/8 inch
net saleable surface area. The material previously machined away to
form a tongue profile (approximately 1/8 inch in width) is now
machined into a groove profile. The creation of a groove, as
opposed to a tongue, yields additional surface area. Greater
surface area results in greater revenue because the surface area is
available to be sold, rather than machined away and disposed.
[0075] The system of the present invention also eliminates "seam
swell" or "peaking" caused by the typical tongue and groove
systems. When moisture (water) penetrates the seam from above the
floor or reaches the seam from the underside of the flooring panel
the seam profile swells. By way of explanation, the tongue profile
will grow in size and the groove profile will shrink in size. This
causes the entire panel thickness to change (grow in thickness) in
the seam area. The result is "peaking" directly above the seam
area. Since the present invention uses a connector having flanges
to make the joint between two panels, the flange is no longer made
of a material that absorbs moisture. Thus, there is no tongue which
expands upon absorbing moisture so that "peaking" is no longer a
problem when using the present inventive system.
[0076] Also, the seal which is attached to the connector or panel
prevents moisture from entering the seam or from entering the
connector/panel interface from the back or bottom of the panels.
Since the seals provide a moisture barrier, the moisture has no
opportunity to damage the panels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0077] The present invention is better understood by reading the
following description of non-limitative embodiments with reference
to the attached drawings wherein like parts in each of the several
figures are identified by the same reference characters, and which
are briefly described as follows:
[0078] FIG. 1 illustrates one embodiment of the connector and seal
of the present invention;
[0079] FIG. 2 illustrates one embodiment of the connector and seal
of the present invention;
[0080] FIG. 3 illustrates one embodiment of the connector and seal
of the present invention;
[0081] FIG. 4 illustrates one embodiment of the connector and seal
of the present invention;
[0082] FIG. 5 illustrates one embodiment of the connector and seal
of the present invention;
[0083] FIG. 6 illustrates a preferred embodiment of the connector
and seal of the present invention;
[0084] FIG. 7 illustrates one embodiment of the connector and seal
of the present invention;
[0085] FIG. 8 illustrates one embodiment of the connector and seal
of the present invention;
[0086] FIG. 9 illustrates one embodiment of the connector and seal
of the present invention;
[0087] FIG. 10 illustrates one embodiment of the connector and seal
of the present invention;
[0088] FIG. 11 illustrates one embodiment of the connector and seal
of the present invention;
[0089] FIG. 12 illustrates one embodiment of the connector and seal
of the present invention;
[0090] FIG. 13 illustrates one embodiment of the connector and seal
of the present invention;
[0091] FIG. 14 illustrates a particularly preferred embodiment of
the connector and seal of the present invention (Scale: 1.00=1
inch);
[0092] FIG. 15 illustrates a shaded view of a preferred embodiment
of the connector of the present invention;
[0093] FIG. 16 illustrates one embodiment of the connector and seal
of the present invention;
[0094] FIG. 17 illustrates one embodiment of the connector and seal
of the present invention;
[0095] FIG. 18 illustrates a preferred embodiment of the connector
and seal of the present invention and a preferred embodiment of the
panels of the present invention;
[0096] FIG. 19A is a top view of a panel having truncated grooves
in the backing layer;
[0097] FIG. 19B is an end view of the panel of FIG. 19A;
[0098] FIG. 20A is a top view of a connector having angled ends and
an extension seal;
[0099] FIG. 20B is an end view of the connector and seal shown in
FIG. 20A;
[0100] FIG. 20C is a side view of the connector and seal shown in
FIGS. 20A and 20B;
[0101] FIG. 21 is a top view of a partially assembled section of
floor covering comprising square panels and connectors with angled
ends;
[0102] FIG. 22 is a top view of a partially assembled section of
floor covering comprising square and triangular panels and
connectors with angled ends;
[0103] FIG. 23 is a top view of a partially assembled section of
floor covering comprising rectangular panels, transverse connectors
and longitudinal connectors;
[0104] FIG. 24A is a top view of a transverse connector having an
extension seal and a ridge seal;
[0105] FIG. 24B is an end view of the transverse connector shown in
FIG. 24A;
[0106] FIG. 24C is a side view of the transverse connector shown in
FIGS. 24A and 24B;
[0107] FIG. 25 is a side view of a transverse connector assembled
with two longitudinal connectors and seals, wherein end views of
the longitudinal connectors are shown, and wherein all of the
connectors have extension and ridge seals;
[0108] FIG. 26A is a top view of a rectangular panel having
complete grooves;
[0109] FIG. 26B is an end view of the panel shown in FIG. 26A;
and
[0110] FIG. 27 is a top view of a partially assembled floor system
having hexagon and triangle shaped panels.
[0111] FIG. 28 illustrates one embodiment of a connector, panels
and seals of the present invention.
[0112] FIG. 29A illustrates one embodiment of a connector, panels
and seals, before assembly.
[0113] FIG. 29B illustrates the embodiment of FIG. 29A after
assembly.
[0114] FIG. 30A illustrates one embodiment of a connector, panels
and seal.
[0115] FIG. 30B illustrates the embodiment of FIG. 30A after
assembly.
[0116] FIG. 31 illustrates one embodiment of a floor panel and seal
of the present invention.
[0117] It is to be noted, however, that the appended drawings
illustrate only typical embodiments of this invention and are
therefore not to be considered limiting of its scope, as the
invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION OF THE INVENTION
[0118] In a preferred embodiment, the present inventive system is
directed to decorative laminate flooring panels, squares, tiles,
rectangles or any monolithically connectable shape, etc. each
having a top wear surface, a middle substrate or reinforcing
material below the top surface, and optionally, a backing layer
surface attached to the middle substrate material for contact with
the supporting or existing floor or ground surface.
[0119] The top wear surface of the panels of the present invention
preferably comprises decorative laminates or laminates prepared by
heat and pressure consolidation. These panels have been produced
commercially for a number of years, and have found widespread
acceptance in the building and furniture industry as counter and
table tops, bathroom and kitchen work surfaces, wall paneling,
partitions and doors. Such decorative laminates can be described as
containing a number of laminae that are consolidated to form a
composite or unitary structure carrying a surface decoration which
can range from something as simple as a solid color to something as
complex as an embossed simulated wood grain finish.
[0120] More specifically, a decorative laminate, useful in the
present invention, generally comprises a plurality of layers of
synthetic resin impregnated paper sheets consolidated or bonded
together into a unitary structure under heat and pressure. In
normal practice, the decorative laminate assembly, from the bottom
up, consists of a core of one or more sheets impregnated with
phenolic resin, above which lies a decorative sheet impregnated
with melamine resin and/or an overlay impregnated with melamine
resin. The core or base member functions to impart rigidity to the
laminate and usually comprises a solid substrate which may or may
not be formed prior to the initial laminating step. Prior to
stacking, the sheets of the core member are impregnated with a
water alcohol solution of phenol and formaldehyde or a formaldehyde
precursor, dried and partially cured in a hot air oven, and finally
cut into sheets. Examples of such a base or core member include:
(1) a plurality of sheets of 90 to 150 pound ream kraft paper
impregnated throughout and bonded with a substantially completely
cured phenolic resin which has been converted to the thermoset
state during the initial laminating step; (2) a precured plastic
laminate such as glass fiber-reinforced thermoset polyester resin
laminates or the like; (3) a wood product such as hardboard,
fiberboard, woodwaste, particle boards, plywood or the like; (4) a
mineral base board such as cement-asbestos board, sheet rock,
plaster board or the like; (5) plastic impregnated boards; (6)
plastic/wood compositions; (7) plastic compositions; (8)
closed-cell polyurethane foam, e.g., RIM foam; (9) urethane
impregnated boards; (10) a combination of these substrates; or (11)
any material suitable to perform the desired function of the base
or core member.
[0121] The decorative sheet, useful in the panels of the present
invention, generally functions to give an attractive appearance to
the laminate, and also gives the panel its surface characteristics
(i.e., resistance to chemical agents, to heat, to light, to shock
and to abrasion). The decorative sheet typically is a high quality
50 to 125 ream weight, pigment filled, alpha cellulose paper that
has been impregnated with a water-alcohol solution of
melamine-formaldehyde resin, dried and partially cured, and finally
cut into sheets. The decorative sheet may be of a solid color or
may comprise a decorative design or pattern, or a photo
reproduction of natural materials, such as, wood, marble, leather,
etc. As stated above, the decorative sheet and/or an overlay sheet
may be impregnated with melamine resin.
[0122] The decorative laminate useful in the manufacture of the
panels of the present invention, is generally obtained by, but not
limited to, placing the resin impregnated core and decorative
sheets between steel coated, steel, or stainless steel plates and
subjecting the laminate stack to temperatures ranging from about
150.degree. F. to about 500.degree. F. and pressures ranging from
about 800 to about 1600 psi for a time sufficient to consolidate
the laminate and cure the resins (generally about 25 minutes to an
hour). This causes the resin in the paper sheets to flow, cure, and
consolidate the sheets into a composite or unitary laminated mass
referred to in the art as a high pressure decorative laminate
(HPDL). More than one laminate can be formed at one time by
inserting a plurality of assembled sheets in a stack with each
assembly being separated by a release sheet which allows the
individual laminates to be separated after consolidation. Finally,
the decorative laminates are further processed and are generally
bonded to a reinforcing substrate, such as medium to high density
fiber board, wood/plastic compositions, woods, plywood, hardboard,
asbestos board, particleboard, ceramics, filled and unfilled
plastics, closed-cell rigid foams, or the like. If a cushioning
effect is desired, the reinforcing substrate may be comprised of
open-cell foam.
[0123] The decorative laminate useful in the practice of the
present invention may also be obtained by placing the resin
impregnated core and decorative sheets between steel coated, steel,
or stainless steel plates and subjecting the laminate stack to
temperatures ranging between about 150.degree. F. to about
500.degree. F. and pressures ranging below about 800 to about 1600
psi for a sufficient time to consolidate the laminate and cure the
resins. This causes the resin in the paper sheets to flow, cure,
and consolidate the sheets into a composite or unitary laminated
mass known in the art as a low pressure decorative laminate
(LPDL).
[0124] In addition, according to one embodiment, the reinforcing
substrate of the present invention may be prepared from any
suitable extrudable thermoplastic, so long as it has the structural
and mechanical properties necessary for the end use desired. In
particular, it is preferred that the substrate have a compression
set that is approximately the same or better than conventional
medium or high density fiberboard or particle board (wherein
compression set is measured in accordance with ASTM F970, as
thickness decreases as a function of compressive stress).
Preferably, this thickness decrease at 2000 psi is at most 0.01
inch, more preferably at most 0.005 inch, and most preferably at
most 0.001 inch.
[0125] Possibly, the reinforcing substrate useful in the practice
of the present invention comprises one or more members selected
from the group consisting of rigid urethanes (e.g., RIM foam),
poly(acrylonitrile/butadi- ene/styrene) (hereafter referred to as
ABS) resins such as flame retardant ABS resins and glass filled ABS
resins; polycarbonate; high impact polystyrene (HIPS), polystyrene,
polyphenylene oxide (PPO), and polyvinyl chloride (PVC).
Preferably, the reinforcing substrate is prepared from a commingled
resin system containing, but not limited to, one or more of the
above listed polymers. Further, these polymers can be filled or
unfilled, although from an impact resistance and physical property
standpoint, the filled polymers are best. Preferred fillers include
calcium carbonate, talc, silica, glass fibers, alumina and
wollastonite, with the more preferred being calcium carbonate and
wollastonite, and the most preferred being calcium carbonate.
Non-limiting examples of reinforcing agents include inorganic or
organic products of high molecular weight, including glass
microspheres, glass fibers, asbestos, boron fibers, carbon and
graphite fibers, whiskers, quartz and silica fibers, alumina
fibers, fused fiber materials and organic fibers. When such
conventional ingredients are utilized, they will generally be
present in a range from about 0.01 to about 50 weight percent of
the total weight of the reinforcing substrate member, preferably in
a range from about 1 to about 25 weight percent of the total weight
of the member.
[0126] Additional optional layers may be inserted between the core
member and the decorative surface member, on the back of the
reinforcing substrate member, or on the decorative surface member.
It should be understood that backing layers and/or decorative
layers may be coextruded with the reinforcing substrate member, or
may be applied after the extrusion step by any suitable method.
[0127] The panels, according to one embodiment of the present
invention, are preferably water repellant and most preferably
substantially waterproof. As with conventional flooring panels, the
present panels include a decorative layer, a substrate, and a
backing layer. The decorative layer and the backing layer are
respectively bound to the substrate in a conventional manner to
form the present panel. In accordance with a preferred embodiment
of the present invention wherein the reinforcing substrate material
is fiberboard, the backing layer includes, from bottom up, a
hydrophobic waterproof layer and three layers of phenol
formaldehyde resin impregnated kraft paper. As with the bottom
resin impregnated layer of the decorative layer, the top resin
impregnated layer of the backing layer is sanded for bonding with
the substrate. The hydrophobic waterproof layer may be a
DYLARK-like compound. DYLARK is a styrene-maleic anhydride
copolymer manufactured by NOVA Chemicals, Inc. DYLARK exhibits
outstanding bonding characteristics with the phenolic resin
impregnated kraft paper. The excellent bonding characteristics are
thought to be a result of the carboxyl groups found on the maleic
anhydride of the DYLARK copolymer. The carboxyl groups bind with
the phenolic resin to produce a very stable laminate. Although
DYLARK is disclosed as the preferred material for the bottom layer
of the backing, other functionally and structurally equivalent
polymers may be used without departing from the spirit of the
present invention. It is not only desirable to prevent moisture
from penetrating the backing layer but also to maintain the
original as-manufactured moisture content of the panel to prevent
panel warpage.
[0128] In addition, although phenol formaldehyde resin impregnated
kraft paper is used in accordance with a preferred embodiment of
the present invention, other resin impregnated papers (or similar
materials) may be used without departing from the spirit of the
present invention. The resin impregnated layers are maintained in
the present backing layer to balance the resin impregnated layers
commonly found in decorative layers which may be used in
conjunction with the backing layer. That is, the resin impregnated
layers in the decorative layer and the backing layer similarly
expand and contract as a result of temperature to maintain the
substantially flat configuration of the flooring panel. If the
resin impregnated layers in the backing layer were not included,
the decorative panel would expand and contract at a different rate
than the backing layer. This would cause the flooring panel to warp
in an undesirable manner. As such, it should be appreciated by
those of ordinary skill in the art that the phenolic layers may be
varied to maintain a balanced relation between the backing and the
decorative layers.
[0129] As stated according to one embodiment of the invention, the
substrate is poly(acrylonitrile-c-butadiene-c-styrene) (ABS) foam.
The construction of the backing layer and the substrate results in
a waterproof flooring panel which is not susceptible to the harmful
environmental conditions commonly found in certain environments.
Specifically, the ABS substrate and styrenemaleic anhydride
copolymer layer create a moisture barrier which protects the resin
impregnated layers from the undesirable effects of moisture.
[0130] The above-described flooring panels are manufactured
utilizing techniques known in the art. During manufacturing, panels
may be machined to form the appropriate recesses in the edges or
preferably, may be manufactured wherein at least two edges have
recesses formed therein during manufacture of the panel and thus,
reduce the amount of material needed to manufacture the panel. In
addition, the panel of the present invention, according to one
embodiment, may be manufactured utilizing injection molding
techniques wherein all edges are formed.
[0131] The connector of the present invention is illustrated with a
number of embodiments. Referring now to FIGS. 1-18, wherein the
same numerals are used to identify the components of the connector
of the present invention, end views of various embodiments of the
connector 1 are shown.
[0132] The connector 1 comprises a base 2 and an extension 15. The
base 2 is a substantially flat portion for resting on the floor or
surface to be covered by the assembled panels and connectors. The
extension 15 is a projection shaped substantially like a "T" having
a vertical support 3 and two horizontal flanges 4 and 5. The
support 3 is the vertical portion of the "T" and the flanges 4 and
5 are those portions that extend horizontally at the top of the
"T". As shown in many of the exemplary embodiments, the connector 1
has ridges 6 and 7 which extend vertically from the base 2 near the
distal extremities of the base 2 distant from the center where the
support 3 is attached to the base 2. In further embodiments, the
connector 1 has depressions 8 and 9 in the upper surface of the
base 2 immediately adjacent opposite sides of the support 3. At the
distal ends of the flanges 4 and 5 of the T-shaped extension 15,
some embodiments of the connector 1 have vertically extending
projections 10 and 11. In some embodiments, a slot 12 is formed in
the top of the T-shaped extension 15 between the vertically
extending projections 10 and 11. Embodiments of the connector 1
further comprise notches 13 and 14 that are located in the
underside of the proximal ends of the flanges 4 and 5 where they
are connected to the support 3. Preferably, the system of the
present invention comprises a connector 1 having a substantially
T-shaped extension and ridges 6 and 7, and the panels having
recesses and channels such that two panels can be disengageably
interconnected using the connector in a horizontal and vertical
fashion without the use of glue or other adhesives.
[0133] The seal is manufactured in conjunction with the connector
1, wherein the sealant is strategically attached to the connector
1. In different embodiments, sealant materials include a foamed
elastomer or other flexible cords, films, pastes, tapes, liquids,
or waxes, etc. The sealant material is applied to the connector 1
with varying thicknesses and/or shapes in specific areas and
various methods of application.
[0134] Referring to FIG. 6, a cross-sectional, end view of a
connector 1 of the present invention is shown with a seal attached
thereto. In this embodiment, the seal is an extension seal 40. The
extension seal 40 is positioned in the slot 12 in the top of the
extension 15 of the connector 1 and runs the entire length of the
connector 1. As shown in FIG. 18, when the connector of FIG. 6 is
used to assemble two panels 20, the extension seal 40 becomes
deformed and squeezed between the panels 20 and the connector 1 to
seal the seam 50 between the panels 20. The volume of the sealant
in the extension seal is just the right amount so that the sealant
fits within the space defined by the connector 1 and the two panels
20 immediately below the seam 50 without pushing the edges of the
panels in an upward direction (peaking).
[0135] In alternative embodiments, seals are attached to other
portions of the connector 1. As shown in FIG. 1, a flange seal 41
is attached to the distal end of the flange 4. Upon assembly, this
seal provides a seal between the flange 4 and the groove 24 of the
panel 20 (see FIG. 18).
[0136] As shown in FIG. 2, several base seals 43 are attached to
the top surface of the base 2 of the connector 1. Depending on the
material used and the intended application, one or more base seals
are applied. Upon assembly, the base seals 43 form a seal between
the top of the base 2 of the connector 1 and the backing layer
surface 23 of the panel 20 (see FIG. 18).
[0137] As shown in FIG. 3, a support seal 45 is attached to the
support 3 of the extension 15 of the connector 1. Upon assembly,
this seal provides a seal between the support 3 and the distal end
of the portion of the panel 20 forming the lower side of the groove
24 (see FIG. 18). Of course, the volume of the support seal 45 must
be small enough so that the panel 20 may fully mate with the
connector 1 to prevent a gap in the seam 50 of the final
assembly.
[0138] Referring to FIG. 7, a ridge seal 47 is shown attached to
the ridge 6 of the connector 1. Upon assembly, this seal provides a
seal between the ridge 6 and the channel 25 formed in the backing
layer surface 23 of the panel 20 (see FIG. 18). The ridge seal 47
may be attached to either side of the ridge 6, or to both sides of
the ridge 6. A proper amount of seal material should be used to
complete the seal and to allow the ridge 6 to "snap" into the
channel 25 upon assembly.
[0139] As shown in FIG. 8, a depression seal 44 is attached to the
depression 8 in the connector 1 between the base 2 and the support
3. Upon assembly, this seal provides a seal between the depression
8 and the lower corner of the panel 20 (see FIG. 18). The
depression 8 ensures that a sufficient amount of the sealant
material may fill the space without disrupting the complete mating
of the panel 20 to the connector 1.
[0140] As shown in FIG. 11, a notch seal 46 is attached to the
notch 13 in the connector 1 between the flange 4 and the support 3.
Upon assembly, this seal provides a seal between the notch 13 and
the lower lip of the groove 24 of the panel 20 (see FIG. 18). The
notch 13 ensures that a sufficient amount of the sealant material
may fill the space without disrupting the complete mating of the
panel 20 to the connector 1.
[0141] It is to be understood that FIGS. 1-18 are not meant to
limit the scope of the invention but are provided to give example
embodiments, including the preferred embodiment, of various
components of the novel connector of the present invention. Indeed,
various combinations of different embodiments of various individual
components of the connector can be utilized, i.e., various base 2
configurations illustrated in, e.g., but not limited to, FIGS. 1,
2, 7, 8, 9, 10, 11, 12, etc. can be utilized with various
embodiments of the extension, e.g., but not limited to FIGS. 1, 2,
3, 5, 6, 16, 17, 18, etc., even though the exact combination
configuration may not be graphically shown in the figures.
Preferably, the connector is less than 0.240 inches in height.
[0142] The connector of the present invention may be manufactured
from materials selected from the group consisting of filled and
unfilled plastics, rubbers, wood compositions, ceramics, metals,
and combinations thereof. Preferably, in use with the preferred
laminate flooring panels, the connector of the present invention is
manufactured from metal or plastic. Depending upon the material and
size, the connector may be manufactured using techniques known in
the art, e.g., the connector is preferably manufactured from
aluminum.
[0143] The panels of the present invention include recesses formed
therein shaped to receive a connector such that when the panels are
connected, the top visible flooring surface only consists of the
top wear surface, i.e., preferably, a decorative layer. The
connector projections and panel recesses are formed such that when
two panels are joined together using a connector of the present
invention, the panels are vertically connected together, i.e., if
two panels are connected at their edges, the edges of the opposing
panels do not move up or down (vertically) relative to each other
and thus, provide a level uniform seam between the two. For
example, in a preferred embodiment, once connected the panels are
engaged against movement relative to each other in the direction of
a plane extending vertically from the support surface and
perpendicular thereto.
[0144] In a particularly preferred embodiment, in addition to
vertical connection, the panels and connectors are so shaped to
provide a horizontal connection between adjacent panels at their
edges, i.e., if two panels are connected at their edges, the edges
cannot move any from each other horizontally resulting in a gap
between adjacent panels. For example, and according to one
embodiment, once connected, the panels are engaged against movement
relative to each other in a direction horizontal to the support
surface and parallel thereto.
[0145] Various non-limiting embodiments of the connector of the
present invention have been described and while not shown, the
panels of the present invention are necessarily configured, for
example, to correspond to these connectors to achieve the
advantages of the present invention. It being understood that the
panels can be configured to provide an exact fit with the
connectors or a non-exact fit, as long as the advantages of the
present invention are achieved. For example, where a permanent
structure is desired, an embodiment allowing space for glue to
accumulate between the panels and the connectors may be
appropriate. In addition, when utilizing certain reinforcing
substrate materials it might be undesirable for the panels and
connectors to fit together exactly, especially when a temporary
structure is desired. For example, some space between certain
portions of the connector projections and the recesses of the
panels can be tolerated as long as the advantages of the invention
are achieved, especially a resultant floor having only the top wear
surface visible with level uniform seams.
[0146] The panels are constructed such that they disengageably
interconnect with the connectors of the present invention, i.e.,
while the connectors and panels are securely connected to perform
the function of a flooring surface, the panels can, if desired, be
removed by lifting a panel and pulling the panel away from the
connector--disengaging the panel/connector interconnection.
[0147] The panels of the present invention, according to one
embodiment, are constructed such that when connected together
utilizing a connector of the present invention, they always form a
tight uniform level seam between the panels. The panels, according
to a preferred embodiment, are constructed such that the depth of
the recess or channel in the bottom surface of each panel is always
a certain distance from the top wear surface. As stated above,
these recesses or channels are shaped to receive a protrusion
projecting from the base of a connector (preferably a track) to
disengageably interconnect two panels together horizontally. Thus,
at the interconnection point, both panels rest on the connector.
Consequently, even when the support structure or ground floor is
uneven or not level, the seam is always tight, uniform and level.
Thus, even if the thickness of the panels vary, a uniform level
seam is provided when two panels are interconnected because the
depth of the recesses or channels in the bottom surface of each
panel is formed to be a certain distance from the top wear surface.
Therefore, the top wear surfaces of two adjacent panels will always
come to rest at the same level, i.e., a certain distance from the
base protrusions of the connector. The seals attached to the
connector should not be so large as to interfere with the proper
alignment of the connected panels. Preferably, the panels of the
present inventive system, range in thickness from about 0.240
inches to about 0.320 inches. According to another embodiment, the
panels are less than an inch thick.
[0148] The system of the present invention also provides panels
which utilize substantially all of the manufactured laminate top
wear surface and thus, provides an economic advantage over many
prior art systems. Utilizing the system of the present invention,
the amount of top wear surface of the panels that needs to be
machined to remove any part of the already manufactured and paid
for decorative top wear surface is greatly reduced. Substantially
all of the manufactured decorative top wear surface is sold to the
end user--eliminating waste experienced in prior art systems. As a
result, the total square footage of saleable flooring produced by a
plant is increased and costs are reduced.
[0149] In addition, the connectors of the present invention are not
fixed to the panels at the factory and thus, no adhesive or other
fastening means is required to be applied--again, reducing material
costs, labor costs, and time to manufacture. In a preferred
embodiment, the panels are manufactured having all of the necessary
recesses formed therein utilizing injection molding techniques. In
another preferred embodiment, wherein the middle reinforcing
substrate of the panel is extruded, only two edges have to be
machined to form recesses therein--the other two edges running in
machine direction are formed during extrusion. Both of the above
provide additional savings due to the fact that the amount of
middle reinforcing substrate material used is reduced, i.e., never
produced.
[0150] The system of the present invention also provides panels
which are less susceptible to damage than prior art tongue and
groove systems. For example, it is known that the tongues of panels
are susceptible to damage during shipping, handling, and even
assembly and disassembly. If a tongue is broken off or
substantially deformed, it will not be able to engage the groove of
an adjacent panel and therefore, is rendered useless. The panels of
the present invention do not include tongues--they only have
recesses or grooves formed therein. It is difficult, if not
impossible, to damage a recess or groove during shipping, handling,
assembly and disassembly. Thus, the panels of the present invention
are more durable than many prior art panels. This is a significant
advantage in relation to the use of the panels for "floating floor"
surfaces and temporary flooring constructions which will be removed
and reassembled many times. The system of the present invention
provides connectors (preferably made from metal) which are fairly
tough, and easy and economical to replace, when compared to the
cost of a new panel. The present inventive systems substantially
reduce, if not eliminate, the risk of damaging a panel to the
extent that it is inoperable.
[0151] The flooring system of the present invention provides a
flooring surface which is easy to repair and/or change. The panels
of the present inventive system do not require a single directional
laying sequence, so that a damaged panel may be removed and
replaced by first removing adjacent panels in any direction.
Adjacent panels may be removed in a direction having the fewest
number of panels, so as to simplify the removal and replacement
process. The present inventive system substantially reduces the
time and aggravation of removing and replacing panels. Further,
since the floor may be constructed in multiple directions, more
than one person can construct different portions of a single
flooring surface simultaneously. According to one process for
assembly, panels are laid in a central portion of the floor space
and panels are added outwardly from the center. This is especially
advantageous in relation to the installation of large flooring
surfaces, e.g., retail spaces.
[0152] The panels of the present inventive system also provide
substantially more aesthetic flexibility than prior art panels. For
example, since the panels are not right or left handed, i.e., one
or unidirectional, but instead are multidirectional due to each
edge being identical, each individual panel can be placed into a
flooring surface being constructed in the most eye-appealing
manner. Moreover, the panels of the present inventive systems allow
for flexibility in designing and constructing parquet-type flooring
surfaces. For example, it is known that a panel is usually
manufactured wherein the grain runs in the machine direction;
however, since the panels of the present invention are
multidirectional, the direction of the grain on the flooring
surface can be easily alternated to form a parquet floor, or a
floor of any grain design.
[0153] The panels of the present inventive system also reduce waste
during floor construction. With the panels of the present
invention, i.e., each panel is constructed with grooves on all
edges so that any panel portion remaining after completing the
floor up to a portion of the end wall is also possibly useable to
complete another portion of the floor up to the end wall.
[0154] The panels of the present inventive system are constructed
such that to assemble two panels together it is not necessary to
hold one panel at an angle relative to the other panel and angle
down the new panel into place. The fact that the panels can be
interconnected by forcing two together while they are lying in the
same plane is very advantageous in relation to constructing certain
portions of flooring surfaces challenged by various physical
boundaries, e.g., the interface between a flooring surface and a
fireplace.
[0155] Referring now to FIG. 6, the preferred embodiment of
connector 1 of the present invention is comprised of a base 2, an
extension 15, ridges 6 and 7 spaced apart from and on either side
of the extension 15 and projecting vertically from base 2. Ridges 6
and 7 are preferably rounded on the top portion as shown, and taper
away, i.e., decrease in height as you move away from the center of
the base 2 toward the end of said base. Thus, the portion of the
ridges closest to the center of the base 2 and extension 15 extend
the greatest distance vertically.
[0156] A particularly preferred embodiment of the connector 1 of
the present inventive system is shown in FIG. 14. It is also to be
understood however, while not shown, that base 2 of connector 1 may
be constructed such that it does not touch the support structure,
i.e., wherein the connector is fully encompassed by the two
connecting panels.
[0157] Referring to FIGS. 19A and 19B, top and end views,
respectively, of a square panel 20 are shown. The panel 20 has a
top wear surface 21, a middle substrate 22 and a backing layer
surface 23. In the embodiment shown, the panel 20 has four grooves
24 in the middle substrate 22 in each of the four sides of the
panel 20. Further, the panel 20 has four channels 25 in the backing
layer surface 23 that run parallel to and slightly distanced from
each of the four sides of the panel 20.
[0158] In an alternative embodiment (not shown), two or more
channels 25 are formed in the backing layer surface 23 adjacent to
each side of the panel 20. Of course, in this embodiment, the
connector 1 has two or more corresponding ridges (6 or 7) on each
side of the connector.
[0159] A connector is shown in FIGS. 20A-20C for joining panels as
illustrated in FIGS. 19A and 19B. Top, end and side views of the
connector 1 are shown, respectively. The connector 1 has a base 2
and an extension 15 as previously described. The base 2 has two
ridges 6 and 7 on the upper surface. The extension 15 has a support
3 and two flanges 4 and 5. The extension 15 has a slot 12 in its
top. In the slot 12, there is attached an extension seal 40. The
extension seal 40 extends the entire length of the connector 1, and
in some embodiments extends slightly beyond the ends to ensure a
good seal at the joint between connectors upon final assembly of
the floor system (see FIG. 21, described below). The ends of the
connector 1 are angled at 45 degrees (see FIG. 20A) to create end
faces 16. Since the end faces 16 on the same end are each cut at 45
degrees, a 90 degree angle point is formed in the middle of the
connector 1 at each end. In alternative embodiments, a seal is
attached to the end faces 16 of the connectors.
[0160] As shown in FIG. 21, an assembled section of floor comprises
square panels 20 joined to each other by connectors 1. The end
faces 16 of two connectors 1 are placed in contact with each other
wherein the connectors are secured to adjacent sides of a single
panel 20. A benefit of this configuration is that the top wear
surfaces of the panels 20 are completely supported by the
connectors 1, even at the corners where the connectors 1 meet.
Also, because the extension seals 40 extend from end to end of the
connectors 1, the extension seals 40 are brought into mutual
contact so as to merge with each other at the corners to provide a
complete seal at the corners.
[0161] In an alternative embodiment, some of the panels 20 are
manufactured in triangular shapes. Triangle shapes increase the
decorative possibilities for the assembled floor covering. One
possible arrangement of an assembled portion of floor is shown in
FIG. 22. Of course, different connectors 1 are required to join the
triangular panels. They must have end faces cut at 22.5 degrees in
some cases and 45 degrees in others.
[0162] In further embodiments, the panels have square, rectangle,
triangle, pentagon, hexagon and octagon geometries. According to
the assembly systems of the present invention, it is possible to
assemble panels having these geometries because the panels and
connectors are assembled while the panels are laid flat on the
subfloor support. For example in FIG. 27, a top view of hexagon
panels 20 in a partially assembled floor system are shown. While
connectors 1 are used to make the connections between the panels
20, the connectors 1 are not shown for simplicity. The panel 20b is
in position for connection to panels 20f and 20g. Since panels 20f
and 20g are already assembled, they are laying flat on the subfloor
support. Panel 20b is connected by laying panel 20b flat on the
subfloor and sliding panel 20b toward panels 20f and 20g. Contact
with panels 20f and 20g is made simultaneously and the panel 20b is
snapped into mating connection with the connectors (not shown)
between the panels. Similarly, panel 20a is shown in position for
connection to panels 20c, 20d and 20e. Panel 20a is placed on the
subfloor adjacent the other panels so as to be in the same plane as
the other panels. Panel 20a is then slid toward panels 20c, 20d and
20e until contact is made simultaneously with the panels. Since
each of the connectors 1 have one or more seals, the seals become
deformed and compressed between the connectors 1 and the panels 20
during the assembly process.
[0163] FIG. 18 best illustrates a panel/connector assembly. The
panels 20 become attached to the connectors 1 by "snapping" a
flange 4, 5 of a connector 1 into a groove 24 of a panel 20.
Initial contact is made be inserting flange 4, 5 into a groove 24.
As the panel 20 and connector 1 are further moved toward each
other, the ridge 6, 7 slides across the backing layer surface 23 of
the panel. The top edges of the grooves 24 of the opposite panels
20 engage the extension seal 40 from opposite sides. As the panels
20 move closer together to form the seam 50, the extension seal 40
is deformed within the space defined by the upper sides of the
grooves 24 and the slot 12 in the connector 1. When the panel 20
and connector 1 are completely moved together, the flange 4, 5
completely extends into the groove 24 and the ridge 6, 7 "snaps"
into the channel 25. Upon final assembly, the extension seal 40 is
sufficiently deformed and molded to form a seal within the seam 50.
Throughout the entire process, the base 2 of the connector 1 and
the panel 20 remain substantially in the same plane. Since the
connectors 1 and panels 20 remain in the same plane during
assembly, it is possible to simultaneously connect a panel to
multiple other panels. This single-plane, "snap" assembly process
enables the use of panels of various geometries, as described
above.
[0164] Referring to FIG. 23, another configuration is shown for a
floor covering of the present invention comprising panels which are
rectangularly shaped. In this embodiment, the panels 20 are joined
by two separate types of connectors: longitudinal connectors 30 and
transverse connectors 31. In one embodiment of the invention, the
longitudinal connectors 30 span several panels 20 and are therefore
much longer than any given panel 20 in the longitudinal direction.
In another embodiment of the invention, the longitudinal connectors
30 are approximately the same length as panels 20 in the
longitudinal direction. The transverse connectors 31 are
approximately the same length as the width of the panels 20. The
transverse connectors 31 extend at right angles between two
adjacent, parallel, longitudinal connectors 30. In the
configuration shown in FIG. 23, each set of panels 20 extending end
to end in the longitudinal direction are offset from each adjacent
set of panels running end to end in the longitudinal direction.
Since the panels end at different locations on either side of a
particular longitudinal connector, the assembly is significantly
stronger as the joints are more evenly dispersed throughout the
assembly. If the ends of all panels were not offset from one row to
the next, weaknesses in the floor at a "four corners" area would
occur where the adjacent transverse connectors 31 attach to a
single longitudinal connector 30. Also for similar reasons, in some
embodiments of the invention, the ends of the longitudinal
connectors 30 do not coincide with the longitudinal ends of the
panels 20 so that the connectors span at least two consecutive
panels 20.
[0165] Referring to FIGS. 24A through 24C, top, and side views,
respectively, of a transverse connector 31 are shown. Similar to
the previously described connectors, this transverse connector 31
has a base 2 and an extension 15. The extension 15 is comprised of
a support 3 and flanges 4 and 5. An extension seal 40 is attached
to the top of the extension 15. The transverse connector 31 further
comprises ridges 6 and 7 located at opposite ends of the base 2. A
ridge seal 47 is attached to the tops of each of the ridges 6 and
7. A significant feature of the transverse connector 31 is that the
extension 15 is longer than the base 2. Thus, at both ends, the
extension 15 extends beyond the base 2. As shown in FIG. 24C, at
both ends of the extension 15, there are cutouts 32 and 33. The
shape and dimensions of the cutouts 32 and 33 are negative images
of the ridges 6 and 7. This enables the transverse connector 31 to
mate at a right angle with a longitudinal connector 30.
[0166] A view of a transverse connector 31 assembled to two
longitudinal connectors 30 is shown in FIG. 25. Longitudinal
connectors 30 are viewed from the end while the transverse
connector 31 is viewed from the side. The longitudinal connectors
30 are in parallel while the transverse connector 31 is positioned
between and at right angles to the longitudinal connectors 30. The
cutouts 32, 33 of the transverse connector 31 are positioned
immediately over the ridges 6, 7 of the longitudinal connectors 30.
The ridge seals 47 form seals between the cutouts 32, 33 of the
transverse connector 31 and a ridge 6, 7 of each of the
longitudinal connectors 30. As previously discussed, the extension
15 of the transverse connector 31 extends over portions of the
bases 2 of the longitudinal connectors 30. Both the transverse and
longitudinal connectors 31 and 30 have extension seals 40 attached
thereto. Upon assembly of panels to the connectors shown, a seal is
provided in the seams 50 (see FIG. 18) between panels almost
entirely around the perimeters of the panels, in particular, the
corner areas of the panels. This complete seal of the scam 50 is
possible because the extension 15 of the transverse connector 31
extends beyond its base 2 to nearly contact the flange 4, 5 of the
longitudinal connector 30 to which it is attached. This allows the
extension seal 40 of the transverse connector 31 to extend nearly
entirely to the extension seal 40 of the longitudinal connector
30.
[0167] Referring to FIGS. 26A through 26B, top and end views of a
rectangular panel are shown. This panel 20 is particularly suited
for assembly with the longitudinal and transverse connectors
described in FIGS. 23 through 25. Similar to the previously
described panels, this panel has a top wear surface 21, a middle
substrate 22, and a backing layer surface 23. The panel 20 also has
a groove 24 for mating with the flanges 4 and 5 of the connectors
30 and 31. The groove 24 extends entirely around the perimeter of
the panel 20. The panel 20 also has four channels 25 running
parallel to each of the four sides of the panel. The channels 25
are cut or formed in the bottom or backing layer surface 23 of the
panel 20. The channels 25 extend entirely from side to side of the
panel. The channels 25 of the panel 20 are adapted to mate with
ridges 6 and 7 of the longitudinal and transverse connectors 30 and
31.
[0168] The present invention is also directed to the use of novel
sealants or sealing elements disposed on the flooring panels or the
connector elements of interconnected disengageable flooring
systems. The sealants provide an effective moisture barrier between
connected flooring panels. A preferred embodiment of one such
flooring system is shown in FIG. 28. FIG. 28 depicts two flooring
panels and a connector after assembly according to one embodiment
of the invention.
[0169] As shown in FIG. 28, flooring panel 220 comprises a top wear
surface 221, a middle substrate 222, a bottom surface 223, a
plurality of edges 219, and a recess 224 running longitudinally
along at least one edge of the flooring panel. A groove 225 may be
provided on the bottom surface. Most preferably, all edges of the
flooring panel have identically-shaped recesses and grooves. Recess
224 is shaped or adapted to receive an extension 215 of connector
201. Groove 225 is adapted or shaped to receive projection 207 on
the base of the connector.
[0170] Connector 201 comprises a base 202 and an extension 215.
Extension 215 preferably comprises a vertical support 203 and a
mating member comprising two horizontal flanges 206, which are
disposed parallel, or substantially parallel to base 202. As shown
in FIG. 28, preferably, the flanges have an angled portion sloped
in relation to the base. The extension has a top surface 230 which
may have a groove 232 in the center. Each flange 206 has a distal
end 236. Base 202 has two projections 207, each of which are shaped
to engage with a groove 225 in panel 220. Although the extension
and base of the connector and the profile of the flooring panels
are preferably shaped as shown in FIG. 28, the connectors and
panels may assume any of the shapes described herein, including
those shown in FIGS. 1-27 and FIGS. 29-31, without departing from
the spirit and scope of the invention.
[0171] As shown in FIG. 28, pre-extruded foamed elastomer cord 250
is disposed in recess 224. The cord may have a skin layer on the
exterior surface. If desired, the cord may optionally be coated
with an adhesive, such as a light tack pressure sensitive adhesive,
to hold the cord in place. In addition, the cord may be colored
with great intensity or as otherwise desired to show the feature to
the consumer or installer. Preferably, the cord has a color which
is distinctive from the color of the flooring panel or connector.
The cord may be applied to the panel during installation of a floor
by a consumer, but more preferably, is applied to the recess by the
manufacturer.
[0172] The pre-extruded cord allows the extrusion of the cord to be
performed separately from the wood processing operations, thereby
providing minimal risk to existing production operations. The
foamed cord can be applied at high speeds, without regard to
curing. It can be easily applied to one or more sides of a flooring
panel that provide a recess or groove to hold it. As such, the ends
of flooring panels may be sealed even though a connector is not
used there. Further, the foamed elastomer is more forgiving, i.e.,
it is less sensitive to dimensional tolerance requirements than
solid coating materials.
[0173] In addition to foamed elastomer cords, the sealant or
sealing element may be a cord, bead or strip made of any suitable
material that provides an effective moisture barrier. Materials may
be foamed or unfoamed and include, but are not limited to, paraffin
and other waxes, silicon, rubber, and other elastomers, polymers
(such as polyethylene, polypropylene and polyurethanes), plastics,
chemically reactive resins, soft metals, caulking and other like
materials. Preferred materials provide a waterproof or
substantially waterproof barrier or seal without creating a tight,
inflexible bond between the panels and connectors. Such materials
allow for easy disassembly of the flooring elements for repair and
other purposes. These preferred materials also prevent undue
constraint and the resulting stresses that may occur during
expansion or shrinking of the laminate floor panels.
[0174] In addition to providing an effective moisture barrier
between flooring panels, the sealant deters movement in the joint
which may be caused by poor installation technique. The combination
thereby reduces joint noise and serves to cushion the transmission
of a noise shock wave from one plank to the next. Further, by using
a pre-extruded foamed elastomer cord according to the invention, an
effective seal is obtained that does not interfere with existing
manufacturing processes for the flooring panels.
[0175] In an alternate embodiment, cord 240 is mounted in groove
232 on the top surface of the connector or on the distal ends 236
of flanges 206. If desired, the cord may be mounted to the
connector during the manufacturing process. Alternately, the cord
may be provided as a separate component which is applied to the
connector later, such as by the consumer during installation.
[0176] Other preferred embodiments of the invention are shown in
FIGS. 29-30. In these embodiments, the extension has a vertical
support 203 and two horizontal flanges 206, and recesses 224 in the
wood panels adapted to receive the flanges of the extension of the
connectors. Preferably, the flanges comprise an angled portion
sloped in relation to the base, shaped to disengageably mate with
the recesses in the panels. As shown in FIGS. 29A and B, a sealant
250 may be provided in recess 224 of the flooring panel.
Alternately, or additionally, as shown in FIGS. 30A and 30B, the
sealant 260 may be provided on the top center portion of the
extension, or on the distal ends 236 of flanges 206.
[0177] Still another embodiment of the invention is shown in FIG.
31. In this embodiment, a sealant is disposed on the upper portion
of the edge of the floor panel. Specifically, as shown in FIG. 31,
flooring panel 220 comprises a top wear surface 221, a middle
substrate 222, a plurality of edges 219, and a recess 224 running
longitudinally along at least one of the edges 219 of the flooring
panel. Groove 225 is provided on bottom surface 223. Edges 219 each
comprise an upper portion 219a disposed adjacent top wear surface
221. Sealant 300 is disposed on upper portion 219a of edge 219.
Sealants may be any desired form, such as the cords, films, tapes,
waxes and pastes described herein. Alternately, the sealant may be
applied as a liquid which solidifies via drying or chemical
reaction to a flexible material. Preferably, the panel is
rectangular (4 edges) and the sealant is on the upper portion of
all four edges.
[0178] Other embodiments and uses of the invention will be apparent
to those skilled in the art from consideration of the specification
and practice of the invention disclosed herein. Although the
invention has been described with respect to preferred embodiments,
the foregoing description and examples are intended to be merely
exemplary of the invention. Not all embodiments of the invention
will include all the specified advantages. The true scope and
spirit of the invention is not intended to be limited by the
foregoing description and examples, but instead is intended to be
commensurate with the scope of the following claims. Variations and
modifications on the elements of the claimed invention will be
apparent to persons skilled in the art from a consideration of this
specification or practice of the invention disclosed herein.
* * * * *