U.S. patent application number 10/352184 was filed with the patent office on 2003-08-21 for floor panel for finished floors.
Invention is credited to Schwartz, Levanna.
Application Number | 20030154676 10/352184 |
Document ID | / |
Family ID | 27626532 |
Filed Date | 2003-08-21 |
United States Patent
Application |
20030154676 |
Kind Code |
A1 |
Schwartz, Levanna |
August 21, 2003 |
Floor panel for finished floors
Abstract
A floor panel having a structural core and a finished surface
layer disposed on a top side of the structural core. A
substantially water-impervious sheet having a plurality of
projections for providing an air gap between the core and a
concrete foundation is affixed to a bottom side of the structural
core. The finished surface may be carpet, carpet underlayment, or a
finished wood or wood-like surface. The floor panel minimizes the
effort required to construct a sub-floor whilst dealing with
moisture problems typically encountered in installing wooden
sub-floors over a concrete foundation.
Inventors: |
Schwartz, Levanna; (Rexdale,
CA) |
Correspondence
Address: |
TORYS LLP
79 WELLINGTON ST. WEST
SUITE 3000
TORONTO
ON
M5K 1N2
CA
|
Family ID: |
27626532 |
Appl. No.: |
10/352184 |
Filed: |
January 28, 2003 |
Current U.S.
Class: |
52/391 ; 52/177;
52/385; 52/403.1; 52/506.01; 52/592.1 |
Current CPC
Class: |
A47G 27/0293 20130101;
B32B 3/28 20130101; E04F 15/225 20130101; E04F 15/02138 20130101;
E04F 15/041 20130101; E04F 15/02 20130101; E04F 15/022
20130101 |
Class at
Publication: |
52/391 ; 52/385;
52/592.1; 52/403.1; 52/506.01; 52/177 |
International
Class: |
E04F 013/08; E04B
002/08; E04B 002/18; E04B 002/32; E04B 002/46 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 29, 2002 |
CA |
2,369,602 |
Claims
1. A floor panel, comprising: a structural core; a finished surface
layer disposed on a top side of the structural core; and a
substantially water-impervious sheet affixed to a bottom side of
the structural core, the sheet having a plurality of projections
for providing an air gap between the panel and a mounting
surface.
2. The panel according to claim 1, including means for
interconnecting the panel to another said panel in abutting
relationship.
3. The panel according to claim 2, wherein the water-impervious
sheet is constructed from semi-rigid polyethylene.
4. The panel according to claim 3, wherein the projections are
somewhat deformable under a load.
5. The panel according to any of claim 1-4, wherein the finished
surface layer is carpet
6. The panel according to any of claims 14 wherein the finished
surface is a finished wood or wood-like surface.
7. The panel according to any of claims 14, wherein the structural
core is an unfinished wooden board and finished wood or wood-like
strips, planks or tiles affixed to the top side of the wooden board
provide said finished surface.
8. The panel according to any one of claims 14, wherein the
structural core is provided by finished wood or wood-like strips,
planks or tiles, said strips, planks or tile also providing said
finished surface.
9. The panel according to claims 7 or 8, wherein said strips,
planks or tiles further include means for interconnecting to
corresponding strips, planks or tiles located on another of said
panels.
10. A floor panel, comprising: a wooden core; a carpet underlayment
layer affixed to a top side of the wooden core; and a substantially
water-impervious sheet affixed to a bottom side of the structural
core, the sheet having a plurality of projections for providing an
air gap between the panel and a mounting surface.
11. The panel according to claim 11, further comprising a carpet
attachment strip affixed to the top side thereof.
12. A kit, comprising: a plurality of floor panels, each floor
panel having: a wooden core; a carpet underlayment layer affixed to
a top side of the wooden core; a substantially water-impervious
sheet affixed to a bottom side of the structural core, the sheet
having a plurality of projections for providing an air gap between
the panel and a mounting surface; and means for interconnecting
means for interconnecting the panel to another said panel in
abutting relationship; and a carpet for disposition over the floor
panels when interconnected.
Description
BACKGROUND OF THE INVENTION
[0001] There are a number of places in a dwelling or office where
moisture and/or humidity can affect the structural properties of
wooden floors. One such example is the concrete foundation typical
of basement floors. Not only does water have a tendency to seep
into basement floors, but also the temperature difference between
the cool concrete and the warm top surface of the wooden floor can
cause condensation on the bottom surface of the wooden floor. This
problem must be dealt with in many flooring applications.
[0002] In the prior an, floors have typically been constructed by
applying a number of flooring layers, i.e., sub-floors, prior to
installing the finished wood, carpet or vinyl surface. This process
often requires a fair degree of manual labour to carry out. It
would be beneficial if the labour requirements were minimized,
especially if the floor is intended to be installed by
non-professionals, as will be encountered in the "do-it-yourself"
or "handyman" market. In any such application moisture and
condensation problems must also be dealt with.
SUMMARY OF THE INVENTION
[0003] According to one aspect of the invention a floor panel is
provided which includes a structural core and a finished surface
layer disposed on a top side of the structural core. A
substantially water-impervious sheet is affixed to a bottom side of
the structural core. The sheet has a plurality of projections for
providing an air gap between the panel and a mounting surface, such
as a concrete foundation. The panel also preferably includes means
for interconnecting the panel to another said panel in abutting
relationship.
[0004] In one embodiment, the finished surface layer is carpet. In
another embodiment, the finished surface is a finished wood or
wood-like surface. The structural core can be an unfinished wooden
board with finished wood or wood-like strips, planks or tiles
affixed to the top side of the wooden board provide the finished
surface of the panel. Alternatively, the wooden board may be
omitted such that the structural core is provided by finished wood
or wood-like strips, planks or tiles which provide the finished
surface of the panel.
[0005] According to another aspect of the invention a floor panel
is provided which includes a wooden core; a carpet underlayment
layer affixed to a top side of the wooden core; and a substantially
water-impervious sheet affixed to a bottom side of the structural
core. The sheet includes a plurality of projections for providing
an air gap between the panel and a mounting surface.
[0006] According to yet another aspect of the invention a kit is
provided, comprising a plurality of floor panels and a carpet. Each
floor panel has a wooden core; a carpet underlayment layer affixed
to a top side of the wooden core; a substantially water-impervious
sheet affixed to a bottom side of the structural core, the sheet
having a plurality of projections for providing an air gap between
the panel and a mounting surface; and means for interconnecting
means for interconnecting the panel to another said panel in
abutting relationship. The carpet may then be disposed over the
floor panels when they are interconnected and installed over a
mounting surface such a concrete foundation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The foregoing and other aspects of the invention will become
more apparent from the following description of illustrative
embodiments thereof and the accompanying drawings which illustrate,
by way of example, the principles of the invention. In the
drawings, in which certain features are not drawn to scale for the
purpose of description:
[0008] FIG. 1A is a perspective view, taken from the top, of a
flooring panel according to a first embodiment having a finished
surface composed of carpet; FIG. 1B is a perspective view, taken
from the bottom, of the flooring panel shown in FIG. 1A;
[0009] FIG. 1C is a cross-sectional view of the flooring panel
shown in FIG. 1A;
[0010] FIG. 2 is an cross-sectional view of a series of
interconnected floor panels according to a second embodiment upon
which a non-sectioned layer of carpet may be overlaid;
[0011] FIG 2A is a cross-sectional view of a variant of the panel
shown in FIG. 2 further including a carpet attachment strip;
[0012] FIG. 3 is a cross-sectional view of a flooring panel
according to a third embodiment having a finished wood or wood-like
surface;
[0013] FIG. 4 is a cross-sectional view of a flooring panel
according to a fourth embodiment having a finished wood or
wood-like surface including an interconnect structure;
[0014] FIG. 5 is a cross-sectional view of a flooring panel
according to a fifth embodiment having a beveled finished wood or
wood-like surface;
[0015] FIG. 6 is a cross-sectional view of a flooring panel
according to a sixth embodiment having a finished wood or wood-like
surface without an intermediate core layer; and
[0016] FIG. 7 is a cross-sectional view of a flooring panel
according to a seventh embodiment having a painted or varnished
wood or wood-like surface.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0017] Referring to FIGS. 1A-1C, a first embodiment of a flooring
panel 10 is shown. The panel 10 comprises a core 12 which provides
the panel with structural rigidity. This layer is preferably formed
from an engineered wood product such as 1/2inch, 5/8inch or 3/4inch
oriented strand board (OSB), waferboard or one of the many
commercially available plywoods. Other dimensions and/or other
materials may be used in the alternative for the core 12, depending
on load handling or stiffness requirements.
[0018] A water-impermeable membrane 14 is fixed to the underside of
the core layer 12, preferably by adhesive bonding. The membrane 14
is preferably formed from polyethylene and includes a plurality of
projections such as frusto-conical cones 16 for spacing the panel
10 from the (typically concrete) foundation and enabling air to
circulate underneath the panel. The cones 16 are also somewhat
deformable thus providing some cushioning effects when walking over
the panel. The membrane 14 protects the wood core from warping,
deforming or delaminating as a result of excess humidity or
moisture that may arise in basements or as a result from
temperature differentials between the foundation and wooden core.
As such, the air gap provided by the membrane 14 also functions as
a thermal insulation barrier. The membrane is especially useful
when OSB is used as the core material since it is more susceptible
to damage from moisture than plywood. The membrane 14 is preferably
sourced from Delta FL.TM. polyethylene sheets manufactured by
Cosella Dorken of Beamsville, Ontario, Canada. Alternatively, a
similar product (which appear to be less deformable) may be sourced
from Platon.TM. polyethylene sheet distributed by Armtec Limited of
Orangeville, Ontario, Canada Other types of dimpled, bossed, or
cleated sheets of substantially water-impervious material may be
used in the still further alternative. The shape of the projections
on the water-impervious sheet is not as important as the fact that
the projections and the panel can withstand a reasonable load and
the projections provide an air gap through which a reasonable flow
of air can circulate.
[0019] In the illustrated embodiment, a sectioned piece of carpet
22 is affixed to the top surface of the core 12 by adhesive
bonding, stapling, nailing, or other such fastening means as known
in the carpet-laying art. Hook and loop fasteners are also
contemplated. Because the preferred membrane 14 has some
shock-absorbing qualities, a carpet underlayment may not be
necessary. However, a shock-absorbing carpet underlayment may be
disposed between the core 12 and carpet 22, if desired.
[0020] The side-walls or perimeters of the core layer 12 include
one or more tongues and grooves 18, 20 for interconnecting panels
in abutting relationship. The carpet 22 is preferably selected with
sufficiently long hairs so as to hide any seam lines or
imperfections in the tongue & groove joints that may arise when
the panels 10 are interconnected or that may arise as a result of
the panels shifting somewhat over time.
[0021] The panel 10 preferably has a breadth of about 2 feet by 2
feet. This size enables the panels 10 to be conveniently handled
and installed, especially by non-professionals. The panels may be
installed as a floating floor system, i.e., without nailing or
otherwise fastening them to the foundation. Because the panel 110
has a finished surface, installing a fully finished floor can be
accomplished quickly. Imperfections in the surface level of the
foundation can be compensated for by disposing one or, more extra
layers of the membrane 14 under select panels. Alternatively,
because the preferred membrane 14 is somewhat deformable, select
panels can be nailed or more preferably sewed into the foundation
under various tensions or depths to achieve a level finished
surface.
[0022] If desired, the carpet 22 may be replaced with a carpet
underlayment 30 as shown in panels 25 of FIG. 2. In this case, a
non-sectioned layer of carpet 32 may be disposed over the floor
panels 10 to completely hide any seam lines presented by the tongue
and groove joints. If desired, the panels may be fitted with one
component 34 (shown in phantom) of a hook and loop fastener system
(e.g., Velcro.TM.) and the underside of the carpet layer 32 may
have the other component 36 (shown in phantom) of the fastener
system affixed thereto. Furthermore, certain panels may be provided
with integrated carpet attachment strips 37 as shown in the
fragmentary view of FIG. 2A which have upright nails upon which the
carpet 32 may be attached.
[0023] FIG. 3 shows the embodiment of another panel 40 which
features the preferably wooden core 12 and the waterproof membrane
14. A finished wooden top floor or wood like surface 42, such as
hardwood flooring, laminated flooring, or melamine wood flooring,
is affixed to the top surface of the core 14, preferably by
adhesive bonding, Because the wood flooring 42 is itself comprised
of multiple strips, planks or parquet tiles 42a, 42b, . . . , 42n,
any seam lines that may arise between the tongue and groove joints
18,20 of the panel appear to be part of the finished wood flooring
42.
[0024] If desired, the strips, planks or parquet tiles 42a, 42n
located on the periphery of the panel 40 may also have tongues and
grooves 44, 46, as shown in FIG. 4. This provides a double
interlocking structure for interconnecting adjacent panels.
Alternatively, as shown in FIG. 5, the strips, planks or parquet
tiles 42a, 42n located on the periphery of the panel 40 may have
beveled edges 48 to thereby simulate grout lines. The beveled edges
48 may be painted to provide a contrast relative to the surface
colour of the strips, planks or parquet tiles 42a, 42b, . . . ,
42n.
[0025] In the further alternative, the wooden core 14 may be
omitted altogether as shown in FIG. 6. In this embodiment, a
plurality of the strips, planks or parquet tiles 42a, 42b, . . . ,
42n used in conventional wood flooring systems are interconnected
and bonded to the water impervious membrane 14 to form a panel 50.
The tongue and grooves 44, 46 of the strips, planks or parquet
tiles 42a, 42n located on the periphery of the panel 50 are used to
interconnect adjacent panels 50. In this embodiment, the strips,
planks or parquet tiles have a thickness sufficient to function as
the structural core of the flooring panel.
[0026] In a still further embodiment as shown in FIG. 7, a panel 60
may comprise the wooden core 12 and the water impervious membrane
14. In this case, the core 12 is painted or varnished so as to
provide a finished surface.
[0027] Those skilled in the art will understand that numerous other
variations and modifications may be made to the embodiments
disclosed herein without departing from the spirit of the
invention.
* * * * *