U.S. patent application number 10/219937 was filed with the patent office on 2004-02-19 for water resistant tongue and groove flooring.
Invention is credited to Fowler, Gregory.
Application Number | 20040031225 10/219937 |
Document ID | / |
Family ID | 49323813 |
Filed Date | 2004-02-19 |
United States Patent
Application |
20040031225 |
Kind Code |
A1 |
Fowler, Gregory |
February 19, 2004 |
Water resistant tongue and groove flooring
Abstract
The invention provides a new floor covering panel and floor
covering system in which the floor covering panels include first
and second generally planar surfaces, first and second side edges
containing first and second complementary coupling members,
respectively, and a barrier composition selectively applied to at
least a portion of at least one of the first and second coupling
members for providing a moisture barrier to prevent water
penetration below the first surface of the floor covering panel.
The barrier composition may be applied to at least one of the first
or second coupling members during the floor covering manufacturing
process.
Inventors: |
Fowler, Gregory; (Rocky
Face, GA) |
Correspondence
Address: |
NEEDLE & ROSENBERG, P.C.
SUITE 1000
999 PEACHTREE STREET
ATLANTA
GA
30309-3915
US
|
Family ID: |
49323813 |
Appl. No.: |
10/219937 |
Filed: |
August 14, 2002 |
Current U.S.
Class: |
52/578 ;
52/588.1; 52/592.1 |
Current CPC
Class: |
E04F 2201/0115 20130101;
B32B 3/02 20130101; E04F 2201/07 20130101; E04F 15/02 20130101;
E04F 2201/026 20130101; E04F 15/10 20130101; E04F 2201/0153
20130101 |
Class at
Publication: |
52/578 ;
52/588.1; 52/592.1 |
International
Class: |
E04C 003/30; E04C
003/00; E04B 002/46 |
Claims
What is claimed is:
1. A floor covering panel, comprising: a. a first generally planar
surface, b. a second generally planar surface, c. a first side edge
and an opposed second side edge, each respective side edge
extending between said first and second surfaces, respectively, d.
a first coupling member defined within the first edge of the panel
and comprising a protrusion extending therefrom and a first
abutment surface between the protrusion and the first surface, e. a
second coupling member defined within the second edge of the panel
and comprising a recess sized and shaped to receive said protrusion
therein, and further comprising a second abutment surface between
the recess and the first surface, and f. a barrier composition
selectively applied to at least a portion of at least one of the
first abutment surface and the second abutment surface
2. The floor covering panel of claim 1, further comprising a first
and a second one of said floor covering panels, respectively, the
first coupling member of the first panel being received within the
second coupling member of the second panel, and at least a portion
of the first abutment surface of the first panel contacting at
least a portion of the second abutment surface of the second panel,
wherein the barrier composition is positioned between said first
abutment surface and said second abutment surface and creates a
relative barrier against moisture penetrating into the respective
floor covering panels beyond the first surface.
3. The floor covering panel of claim 1, wherein the barrier
composition is applied along substantially all of the first
abutment surface.
4. The floor covering panel of claim 1, wherein the barrier
composition is applied along substantially all of the second
abutment surface.
5. The floor covering panel of claim 1, wherein the barrier
composition is applied along substantially all of the first
abutment surface and along substantially all of the second abutment
surface.
6. The floor covering panel of claim 1, wherein the barrier
composition is selectively applied along a portion of the first
abutment surface adjacent the upper surface.
7. The floor covering panel of claim 1, wherein the barrier
composition is selectively applied along a portion of the second
abutment surface adjacent the upper surface.
8. The floor covering panel of claim 1, wherein the barrier
composition is selectively applied along a portion of the first
abutment surface adjacent the upper surface and along a portion of
the second abutment surface adjacent the upper surface.
9. The floor covering panel of claim 1, wherein the barrier
composition comprises an active ingredient that comprises one or
more of a fluorochemical, metal stearate, oil, wax, acrylate
polymer or a silicone polymer.
10. The floor covering panel of claim 9, wherein the active
ingredient is crosslinkable.
11. The floor covering panel of claim 9, wherein the active
ingredient comprises the fluorochemical.
12. The floor covering panel of claim 11, wherein the
fluorochemical comprises a fluoropolymer.
13. The floor covering panel of claim 12, wherein the fluoropolymer
comprises a fluoroacrylate polymer.
14. A floor covering panel suitable for mating with a second floor
covering panel, wherein the floor covering panel has a
crosslinkable polymer applied to at least part of an area defining
a tongue and groove profile, thereby providing a durable water
barrier when the polymer is at least partially crosslinked and
floor covering panel is mated with at least one second floor
covering panel.
15. The floor covering panel of claim 14, wherein the crosslinkable
polymer is applied to a vertical edge of the profile, wherein the
edge comprises an upper edge of the floor covering panel.
16. The floor covering panel of claim 14, wherein the floor
covering panel is mated with a second floor covering panel, thereby
providing a floor covering system, wherein the system comprises at
least one seam on an upper surface of the system.
17. The floor covering system of claim 16, wherein the second floor
covering panel comprises a crosslinkable polymer applied to a
vertical edge that is complementary to the vertical edge of the
first floor covering panel.
18. The floor covering system of claim 16, wherein the
crosslinkable polymer provides a water barrier, thereby
substantially reducing water seepage into the system in comparison
to seepage in a floor covering system not treated with a
crosslinked polymer barrier composition.
19. The floor covering panel of claim 14, wherein the polymer
comprises one or more of a silicone polymer, an acrylate polymer or
a fluoropolymer.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to floor covering panels
for use in commercial, industrial or residential environments. More
particularly, this invention relates to a floor covering panel
having complementary coupling members with a barrier composition
applied to the side edges of the floor covering panel.
[0003] 2. Background Art
[0004] It is generally known in the art to use various laminates,
including high pressure laminates and fiberboard core laminates, in
flooring applications. Fiberboard core laminates used to
manufacture flooring products typically include a plurality of
layers, including a fiberboard or organic composite core layer, a
decorative layer, and a hard and flat protective wear layer of
resin-impregnated melamine material. These layered constructions
are typically formed into standard-sized panels which are joined
together at an installation site to create a floor covering
system.
[0005] Though the uppermost layer of such flooring systems is
frequently manufactured from a water resistant or water tight
material, the floor covering systems may be vulnerable to water
damage at the joints between adjacent floor covering panels that
make the floor covering system. Slight imperfections in the fit
(seam) between adjacent floor panels may allow water or other
liquids to penetrate into the joints between floor panels, which
may, in turn, result in damage, warpage, accelerated wear, or
deteriorated fit of individual floor panels. Moreover, cleaning
materials generally comprise surfactants that may accelerate the
seepage of water into the seam. Because the materials that make up
the inner layers of the floor panels may not be completely
impervious to water, those layers may absorb water or other fluids,
resulting in damage or decreased product life.
[0006] In actual residential and commercial settings, laminate and
wood floorings are often contacted with liquids, either
deliberately or through accident. Cleaning of floors with a
detergent solution may cause up to as much as a 35% swelling of the
flooring at the seam. Accidental wetting may also occur from spills
or animal or child urine. Each of these liquids has a lower surface
tension than water and will be likely to migrate into the seam
formed by the mating of two floor covering panels so as to cause
swelling.
[0007] Manufacturers commonly apply paraffin-based materials to
floor covering panels in an attempt to improve the water resistance
of these products. However, such materials generally are not
durable and, as such, do not provide a good water resistance for
the useful life of a floor covering system. Moreover, such
materials also do not provide enough barrier when, for example,
cleaning agents are repeatedly used on the floor covering materials
or when low surface tension materials are spilled on the floor.
[0008] As a result, a need exists in the industry for a floor
covering panel and a floor covering panel system having strong and
reliable joints that are resistant to water and other liquids.
Moreover, there is a need for floor covering panels and floor
covering systems that provide a durable water barrier.
SUMMARY OF THE INVENTION
[0009] In accordance with the invention, as embodied and described
herein, this invention, in one aspect, relates to a floor covering
panel. In this aspect, the invention includes a first generally
planar surface and a second generally planar surface opposed to the
first surface. Between the first and second surfaces are a first
side edge and an opposed second side edge, respectively. Within the
first edge of the panel is a first coupling member, which includes
a protrusion extending therefrom and a first abutment surface
between the protrusion and the first surface. A complementary
second coupling member is defined within the second edge of the
panel and includes a recess sized and shaped to receive the first
protrusion therein and a second abutment surface between the recess
and the first surface. A barrier composition may be selectively
applied to at least a portion of at least one of the first and
second abutment surfaces.
[0010] In use, a first coupling member of a first panel is received
within a second coupling member of a second panel such that the
barrier composition is positioned between the respective first and
second abutment surfaces of the two panels. A water resistant
barrier is thereby formed between the two coupling members in
association with the barrier composition applied thereto. A
plurality of panels may be joined together in this manner to form a
floor covering system.
[0011] In particular, the barrier composition may be applied to at
least one of the first or second abutment surfaces at a point in
the floor covering manufacturing process. In a further aspect, a
barrier composition may be applied to the entire surface of one or
both of the first and second abutment surfaces. Still further, the
barrier composition provides a water resistant barrier that
substantially reduces the possibility of water or other liquids
penetrating the seam of two mated floor covering panels under
normal use conditions.
[0012] Additional advantages of the invention will be set forth in
part in the description which follows, and in part may be learned
from the description, or may be learned by practice of the
invention. The advantages of the invention will be realized and
attained by means of the elements and combinations particularly
pointed out in the appended claims. It is to be understood that
both the foregoing general description and the following detailed
description are exemplary and explanatory only and are not
restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a top plan view of a plurality of floor covering
panels connected together to form a floor covering panel
system.
[0014] FIG. 2 is a cross-sectional side view of an embodiment of
the floor covering panel according to the present invention.
[0015] FIG. 3 is a partial cross-sectional side view of a pair of
the floor covering panels according to FIG. 2, particularly
illustrating a first coupling member engaging a second coupling
member.
[0016] FIG. 4 is a schematic illustration of a testing fixture used
to test water resistance associated with the floor covering panel
of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The present invention is more particularly described in the
following examples that are intended as illustrative only since
numerous modifications and variations therein may be apparent to
those skilled in the art. As used in the specification and in the
claims, "a," "an," and "the" can mean one or more, depending upon
the context in which it is used. Several aspects are now described
with reference to the figures, in which like numbers indicate like
parts throughout the figures.
[0018] Referring to FIGS. 1 and 2, the present invention, in one
embodiment, is a floor covering panel 10. The panel 10 includes a
first generally planar surface 11 and a second generally planar
surface 12 opposed to the first surface 11. Extending between the
surfaces 11, 12 are a first side edge 13 and an opposed second side
edge 14, respectively, each of which runs the length of the floor
covering panel. Defined within the first side edge 13 is a first
coupling member 20, which includes a protrusion 21 extending
therefrom. The first coupling member 20 further comprises a first
abutment surface 50 between the protrusion 21 and the first surface
11. The second side edge 14 includes a second complementary
coupling member 22 defined therein that includes a recess 23 sized
and shaped to receive the protrusion 21 of a second one of the
floor covering panels therein. The second coupling member 22 also
includes a second abutment surface 52 between the recess 23 and the
first surface 11. A barrier composition 60, described in greater
detail below, is selectively applied to at least a portion of at
least one of the first or second abutment surfaces 50, 52 as
desired. A plurality of floor covering panels may be joined
together to form a floor covering system 15 as shown in FIG. 1.
[0019] The present invention includes floor covering panels of
various constructions known in the industry or that may be
developed in the furtherer. For example, the floor covering panels
may be manufactured from a laminated material having a fiberboard
core. Additionally, the present invention may be constructed of
other types of laminates such as high pressure laminates, which
have been marketed under such trade names as Formica.RTM. and
Wilson Art.RTM.. Other materials may also be used to construct the
floor panel such as natural organic, recycled or synthetic
materials. Still further, the floor covering panel may be a tongue
and groove wooden flooring material, such as those manufactured by
Bruce Hardwood Floors, a division of Armstrong Flooring, Inc.
(Lancaster, Pa.). Still further, the present invention is suitable
for use on any flooring substrate that may benefit from formation
of a non-refastenable bond as set forth in more detail herein.
[0020] Referring to FIG. 2, a typical laminate floor panel is
constructed of a plurality of discrete layers, which may include
some or all of the following: a backing layer 16, a core layer 17,
a decorative layer 18, and a wear layer 19. The various layers may
be adhered, joined, or coupled to one another by a chemical
adhesive, mechanical connection, or other means known in the art
for forming the panel. In an embodiment including each of the above
listed layers, the first generally planar surface 11 is usually the
upper surface of the wear layer 19 while the second generally
planar surface 12 is typically created by the lower surface of the
backing layer 16 as shown in FIG. 2. When the panel 10 is
installed, the backing layer 16 faces the underlying subfloor (not
shown).
[0021] While the backing layer 16 is optional, it may provide an
improved moisture resistance to the floor panel 10 because the core
layer 17 typically is not completely impervious to moisture or
contaminants. Additionally, the backing layer 16 may improve the
structural integrity of the floor panel 10 by increasing overall
thickness and reducing the warp and wear tendencies of the uncoated
core material. The construction of the backing layer 16 may, for
example, comprise a clear sheet of melamine reinforced with
aluminum oxide (AlO.sub.2) and impregnated with a suitable
thermosetting resin. In other embodiments, backing layers 16 may be
constructed of other materials providing suitable moisture
resistance, such as phenolic resins or other natural, synthetic or
recycled materials.
[0022] The next layer in a typical laminate floor covering panel is
the core layer 17. In one embodiment, the core layer 17 may be
formed from medium density or high density fiberboard, such as
those marketed by companies such as Louisiana Pacific, Georgia
Pacific, Temple Inland, and Weyerhauser. One fiberboard core
material found to produce acceptable results is a high density
fiberboard, which is a hardwood/softwood fiber compound compressed
at 900-960 kg/m.sup.3. Such fiberboard core material is usually
available in 4 or 5 feet widths (1.22-1.52 meters) and lengths of
up to 18 feet (5.49 meters). In other embodiments, core layers 17
constructed of different materials or having different properties
may be utilized, including but not limited to other timber-based
products, such as plywood, chipboard or particleboard.
[0023] In one embodiment, the decorative or "dcor" layer 18
comprises a sheet of paper that substantially covers the top
surface of the core layer 17. The visible side of the decorative
layer 18 displays a desired aesthetic appearance, such as a color
or pattern. For example, some currently contemplated patterns
include simulated hardwood flooring and simulated ceramic tile,
each in a variety of styles, shades and colors. Currently
contemplated simulated hardwood styles include pine, heart pine,
cheny, maple, beech, oak and mahogany. Simulated tile appearances
are contemplated in a range of styles, including a variety of
marble and ceramic tile colors, including grout lines in ceramic
tile styles. Other currently contemplated patterns include floral
patterns, abstract designs, geometric designs and company logos.
Other patterns may be selected by the manufacturer or user
according to their aesthetic preference or design objectives.
[0024] The decorative layer 18 may be manufactured from paper that
is impregnated with a thermosetting resin and provided with the
desired aesthetic color and/or pattern. Other materials may make up
the decorative layer 18, such as real wood veneer, pulverized
stone, or other materials. Additionally, it is possible to achieve
a similar decorative appearance by applying a direct or indirect
printing process onto the top surface of the core layer 17. In such
an embodiment, the decorative layer 18 comprises the ink, dye,
pigment or other marking substances applied to the core layer 17.
Alternatively, the decorative appearance may be provided by
etching, burning or otherwise marring the top surface of the core
layer 17. Any such treatment that supplies such a decorative
appearance on the top surface of the core layer 17 is contemplated
to comprise the decorative layer 18 as defined herein.
Alternatively, a decorative appearance may be imparted directly to
the upper surface of the wear layer 19, which may remove the need
for a decorative layer 18 within the floor panel 10.
[0025] The wear layer 19 may be adhered, joined, or coupled to the
decorative layer 18 to protect the panel from the ambient
environment. In one embodiment, the wear layer 19 is substantially
transparent so that the aesthetic appearance of the decorative
layer 18 is unobstructed by the wear layer 19. Though a wear layer
19 is optional, the resistance of the floor panel 10 to wear,
staining or fading of the aesthetic image imparted to the
decorative layer 18 may be generally improved by the inclusion of a
wear layer 19 in the floor covering panel 10. The wear layer 19 may
comprise a melamine sheet which is reinforced with AlO.sub.2 and
impregnated with a thermosetting resin. Alternately, the wear layer
19 may comprise a layer of varnish or other UV curable scratch
resistant coating. Moreover, the wear layer 19 may be made from any
material providing suitable moisture resistance and resilience to
loads and wear to which a floor is subjected, such as phenolic
resins or other natural, synthetic or recycled materials.
[0026] The coupling members 20 and 22 of the present invention
provide a means for joining two adjacent floor covering panels 10a,
10b together as illustrated in FIGS. 1 and 3. One illustrative
example of such a means for adjoining adjacent panels is set forth
in U.S. Pat. No. 6,006,486 to Moriau et al. (which is incorporated
herein in its entirety by this reference).
[0027] In the embodiment illustrated in FIGS. 2 and 3, the first
edge 13 of the panel 10 includes the first coupling member 20. The
first coupling member 20 includes a protrusion 21 with a rib 30
formed on the underside thereof. On the second edge 14, the second
coupling member 22 includes an upper lip 33, a lower lip 31, and a
detent 32 formed within the lower lip 31. The recess 23 is sized
and shaped to accept the protrusion 21, and the detent 32 is sized
and shaped to accept the rib 30. In this embodiment, the detent 32
and the rib 30 represent a locking structure, which will be
discussed in greater detail below.
[0028] Referring to FIGS. 2 and 3, the coupling of floor covering
panel 10a to adjacent panel 10b is achieved by placing the first
coupling member 20 of panel 10a into the second coupling member 22
of panel 10b. In the illustrated embodiment, the tip of the
protrusion 21 of panel 10a is inserted into the recess 23 of panel
10b at an angle above the horizontal, and the panel 10a is then
rotated clockwise until the panels 10a and 10b are within
substantially the same horizontal plane, as illustrated.
[0029] In the illustrated embodiment, contact is made between the
complementary coupling members 20, 22 of the two panels 10a, 10b in
four contact zones as shown in FIG. 3. The protrusion 21 of panel
10a contacts the upper lip 33 and the lower lip 31 of panel 10b at
contact zones 40 and 41, respectively. Contact zones 40 and 41 help
locate the panels into substantially the same horizontal plane. The
rib 30 (FIG. 2) of panel 10a engages the detent 32 of panel 10b at
contact zone 42. In this embodiment, the contact zone 42 is
substantially planar; however, any contact zone may be formed in
any shape depending on the profile desired. The angle formed by the
substantially planar contact zone 42 and the substantially planar
second surface 12 forms an acute angle therebetween, when measured
from the second surface 12 counterclockwise to the plane of the
contact zone 42. This configuration ensures that the contact force
between the adjacent panels 10a, 10b at the contact zone 42 urges
the panels together and promotes a tight joint. This locking
structure defined by the rib 30 of panel 10a and the detent 32 of
panel 10b prevents substantial separation of the two panels 10a and
10b in a direction perpendicular to the side edges 13, 14 of the
panels 10a, 10b and parallel to the respective first surfaces 11.
An additional contact zone 43 is present in the embodiment
illustrated in FIG. 3, adjacent the first surface 11 of each of the
panels at the juncture between the first abutment surface 50 of
panel 10a and the second abutment surface 52 of panel 10b.
[0030] It should be noted that floor covering panels 10 may be
manufactured in a variety of shapes and sizes, commonly including
square, rectangular and other polygonal embodiments. In the case of
square and rectangular panels, each panel has four side edges.
Thus, according to the invention, each panel 10 may include two
first side edges 13, and two opposed second side edges 14, each
edge extending between the top and bottom surfaces 11, 12 of the
panel 10.
[0031] It should also be noted that the embodiments shown in FIGS.
2 and 3 are for illustrative purposes only, and that the present
invention is equally applicable to other coupling profiles known in
the industry or that may be developed in the future. In other
embodiments, the quantity, size and location of the contact zones
may vary with the profile as desired, but the different profiles
still fall within the scope of the present invention. For example,
a tongue and groove profile without a locking structure would
benefit from, and fall within the scope of the present invention.
As a further example, a tongue and groove profile in which
substantially fill contact is maintained along the entire mating
edges of the panels is also contemplated as being within the scope
of the invention.
[0032] The barrier composition 60 may be selectively pre-applied to
the floor covering panels at the factory, at any desired location
and in any desired amount, using one of a number of methods known
to one of skill in the art. In one illustrative example, the
barrier composition may be applied in spray form at the desired
location. According to the present invention, the barrier
composition 60 may be selectively applied to at least a portion of
at least one of the first or second abutment surfaces 50, 52, as
desired, for example the contact zones 40-43. Still further, the
barrier composition 60 may be selectively applied to at least a
portion of the first abutment surface 50. Yet still further, the
barrier composition 60 may be selectively applied to at least a
portion of the second abutment surface 52. In a still further
aspect, the barrier composition 60 may be selectively applied to at
least a portion of both the first and the second abutment surfaces
50, 52, which portions may correspond with, or be separate of, one
another, as desired.
[0033] In the embodiment shown in FIGS. 2 and 3, the barrier
composition 60 may be selectively applied only to substantially all
of the first abutment surface 50 at a location corresponding to the
contact zone 43. By "selectively applied" it is meant that the
barrier composition 60 is applied only to the intended area of
application, and that the barrier composition 60 is not applied to
neighboring areas or any other areas besides the selected and
intended area of application.
[0034] When adjacent panels 10a, 10b are assembled together as
illustrated in FIG. 3, the barrier composition 60 forms a moisture
barrier between the first and the second abutment surfaces 50, 52,
such that water and other liquids along the first surface 11 of the
adjacent panels 10a, 10b are substantially prevented from seeping
past that moisture barrier. In another embodiment, the barrier
composition 60 may be selectively applied only to substantially all
of the second abutment surface 52 at a location corresponding to
contact zone 43. In yet another embodiment, the barrier composition
60 may be selectively applied to substantially all of both the
first and second abutment surfaces 50, 52 at a location
corresponding to contact zone 43.
[0035] In other embodiments, the barrier composition 60 may be
applied to some portion of, or the entirety of, one or both of the
coupling members 50, 52. As set forth above, in various
embodiments, the barrier composition 60 may be selectively applied
only to locations on the first abutment surface 50. Altematively,
the barrier composition 60 may be selectively applied only to
locations on the second abutment surface 52. In yet another
embodiment, the barrier composition 60 may be selectively applied
to locations on both the first abutment surface 50 and the second
abutment surface 52.
[0036] In yet a further embodiment, the barrier composition 60 may
be applied to substantially the entire first edge 13, second edge
14, or both, as desired.
[0037] Various methods can be used for applying the barrier
composition 60 to the floor covering panels 10, as known. In a
first aspect, a vacuum coating process may be utilized. In this
aspect, a floor covering panel is passed through a machine that
applies the barrier composition under pressure to one side of a
respective edge of a floor covering panel. A vacuum is applied at
an opposite side of the edge of the panel to remove excess barrier
composition from the floor covering panel. Excess barrier
composition is returned to a vessel for re-use. Use of such a
vacuum coating method allows for precise application of the barrier
composition to a floor covering panel by way of adjusting the
pressure/vacuum ratios.
[0038] A further method that may be utilized to apply the barrier
composition to the floor covering panel is the use of a roll coat
applicator. In this method, several large diameter rollers are made
to match the area to be coated on the floor covering panels. The
barrier composition may be applied to the floor covering panels by
a transfer roller that is supplied with the barrier composition
from a supply reservoir. The application of the barrier composition
can be precisely controlled by adjusting the parameters used in the
application.
[0039] A further method of applying the barrier composition to the
floor covering panels is achieved by use of a multi-spray head
applicator. This method will allow application of the amount of
barrier composition to the flooring profile with precision and
accuracy. In this method, multiple spray applicators may be fitted
with nozzles and situated to spray the barrier composition on
selected portions of the side edges of a floor covering panel. The
spray applicators may pulse at a high frequency to apply the
barrier composition to the desired position on the floor covering
panel, which pulsing action may also assist in keeping the spray
head clean. The barrier composition is supplied to the spray head
by means of a conventional pump system that draws the composition
from a supply tank. Such spray application systems are known to
those skilled in the art, and the spray applications are
commercially available from manufacturers including Spraymation,
Inc. (Ft. Lauderdale, Fla.).
[0040] Other methods of applying the barrier composition may be
utilized according to the invention, including other existing
methods of applying the barrier composition, and including methods
of applying the barrier composition that may be developed in the
future.
[0041] The amount of barrier composition applied to the floor
covering material is not critical, as long as the desired water
barrier qualities are provided. Generally, about 0.1, 0.5, 1.0,
2.0, or 5.0 g of composition per 8".times.48" (0.20.times.1.22
meters) board may provide the desired water barrier quality in the
finished floor covering material.
[0042] As used herein, "barrier composition" means the composition
comprising the active ingredient, i.e., the chemical material
providing the primary barrier properties, and any solvent or
diluent and other ingredients. In one aspect where the barrier
composition is to be selectively applied to the floor covering
panel, the active ingredient may be any material that is suitable
for use to provide water resistance or oil resistance to a surface.
To this end, the following non-exclusive list of materials may be
utilized as the active ingredient in the barrier composition: a
fluorochemical, metal stearate, oil, paraffin wax, acrylate (latex)
polymer or a silicone polymer. In a further aspect, the active
ingredient for the barrier composition does not comprise a paraffin
wax. In yet a further aspect, the barrier composition does not
comprise a synthetic isoparaffinic hydrocarbon. Still further, the
active ingredient for the barrier composition consists essentially
of a fluorochemical.
[0043] As would be recognized by one of ordinary skill in the art,
application of a barrier composition comprising one or more of the
active ingredients disclosed herein will result in a reduction of
the wettability of the surface of a floor covering panel. Since the
wettability of the floor covering panel is lower, there will be a
lesser possibility for water or other damaging materials to migrate
through the seam of a mated pair of floor covering panels. This
water barrier property is very important so as to allow floor
covering materials to be used in locations that are commonly
subjected to contact with water, such as bathrooms, kitchens and
other areas.
[0044] In accordance with the present invention, it has been found
that by localizing a barrier composition toward an upper portion of
the vertical edges of a mated pair of floor covering panels that
define a floor covering system, durable and effective water barrier
or water resistance may be obtained. Such selective application of
the barrier composition is not known in the prior art.
[0045] In one aspect, the barrier composition for application to
the floor covering panels comprises a fluorochemical as an active
ingredient. Suitable fluorochemicals are those that can have been
used to provide water repellent qualities to textiles and other
materials. Such materials are well known to one of ordinary skill
in the art. Any fluorochemical that is suitable for use in
imparting stain or oil resistance to textile materials may be used
in the present invention.
[0046] The fluorochemical may comprise unbranded generic
fluoropolymers. Suitable fluorochemical textile treating agents
include, but are not limited to, commercially available
fluorochemical compositions. Commercially available fluorochemical
compositions may be used in the invention herein such as
SCOTCHGUARD FC 255, SCOTCHGUARD FC 214-230, products of 3M Corp.
(St. Paul, Minn.) and TEFLON, TEFLON 8070, and TEFLON 8787 and
Zonyl 8412, available from DuPont (E.I. DuPont de Nemours Corp.,
Wilmington, Del.). Further suitable fluorochemical compounds
include the following: FX-1367F and FX-1355 both from 3M Specialty
Chemicals Division, NRD-372 from DuPont Flooring Systems, TG-232D
from Advanced Polymers, Inc. (Carlstadt, N.J.) and Nuva 3555 from
Hoechst Celanese (Munich, Germany). Other similar fluorochemical
compounds from these and other manufacturers may also be
suitable.
[0047] In one aspect of the present invention, the barrier
composition does not comprise an organic solvent. Still further,
the diluent for the active ingredient of the barrier composition
comprises water or, in a further aspect, consists essentially of
water. Yet further, the barrier composition comprises an emulsion
or dispersion of the active ingredient in water. In a further
aspect, the barrier composition is substantially non-flammable and
may be utilized in an industrial setting without the use of
explosion and fire proof equipment.
[0048] In particular, to obtain a durable barrier composition, use
of a polymeric material may be desirable for use as the active
ingredient. Non-exclusive examples of suitable polymers include
silicone polymers, acrylate (latex) polymers and fluoropolymers.
Such materials will generally have higher molecular weights and, as
such, may allow a more durable deposition of the barrier
composition to the floor covering panels. In separate aspects, the
barrier composition provides a treatment that makes a floor
covering material durable for at least about 6 months, or at least
about 1 year, or at least about 5 years, or at least about 7 years,
or at least about 12 years, or for the entire useful life of the
floor covering system.
[0049] In one suitable aspect of the present invention, the barrier
composition comprises a fluoroalkyl acrylate copolymer. The
fluoroalkyl acrylate polymer may be formulated in an emulsion.
Specific examples of such an emulsion for use in the barrier
composition compositions of the present invention are Unidyne
TG-572 and TG-472 (Daikin America, Signal Mtn., TN). TG-472 is
believed to comprise about 30% by weight fluoroalkyl acrylate
copolymer and emulsifiers, about 5.4% tripropylene glycol, with a
balance of the composition comprising water. The composition of
TG-572 is believed to be similar.
[0050] The barrier composition may comprise about 100% by weight of
a composition comprising the active ingredient as supplied by the
vendor, i.e. neat. The composition as supplied by a vendor may
comprise any amount of active ingredient. However, such
compositions are normally supplied as solutions or dispersions of
water barrier chemicals in water or other solvents. As
contemplated, the concentration of barrier chemicals as supplied by
a vendor is not significant as long as the appropriate dilution may
be obtained to provide the barrier compositions suitable for use in
the present invention. Alternatively, the composition as provided
may be diluted prior to use on the floor covering panels. Any
suitable solvent may be used for the dilution but water results in
a lesser environmental impact from industrial use of the active
ingredient. Accordingly, the barrier composition may comprise water
as a primary solvent.
[0051] The active ingredient for the barrier composition may, in
some aspects, be crosslinkable. "Crosslinkable" means the active
ingredient reacts with or condenses with itself to result in a
final product with a molecular weight of at least about 1.5 times
or about 2 times or about 3 times the molecular weight of the
non-crosslinked active ingredient. The active ingredient may also
be crosslinkable in conjunction with a second material, such as
melamine/formaldehyde resin.
[0052] The active ingredient may be crosslinkable by application of
energy to the barrier composition after application of the barrier
composition to the floor covering panel. The energy can be applied
by heat, infrared lamps or microwave energy. The active ingredient
may also be crosslinkable by inclusion of a crosslinker in the
barrier composition. In separate aspects, the active ingredient is
substantially crosslinked at the conclusion of the application of
heat, however, it will be recognized that with time, some
additional crosslinking may occur.
[0053] The final amount of active ingredient in the barrier
composition may vary within a wide range. In particular, the amount
of active ingredient (that is, the water barrier chemical) in the
barrier composition may be about 1, 2, 5, 10, 15, 20, 25, 30, 40 or
50% or by weight of the barrier composition, with any value forming
the upper and lower endpoint, as appropriate. The balance of
materials in the barrier composition may primarily be water, along
with a minor amount of other materials.
[0054] The barrier composition may include additives as are known
to one of ordinary skill in the art. In particular, the barrier
composition may include one or more of: surfactants, viscosity
modifiers, preservatives, surface tension modifiers or
opacifiers.
[0055] As would be recognized by one of ordinary skill in the art,
any dilution of the active ingredient will depend in large part on
the type and amount of active ingredient in the composition as
supplied by a manufacturer.
[0056] An important aspect of the present invention is that the
barrier composition provides a durable water resistance or barrier
treatment to a floor covering panel or floor covering panel system.
"Durable" is used herein to mean that the barrier composition
provides a treatment that will substantially reduce the possibility
that water or other liquids will penetrate the seam of two mated
floor covering panels. The barrier composition should provide a
water barrier that lasts at least 2 times as long as the barrier
provided by a paraffin-based composition. Still further, the
barrier composition of the present invention should reduce the
amount of water penetrating a top seam by at least 1/2 or 3/4, even
when the water comprises a small amount of surfactant, i.e., 1
weight percent of the water or less. Such reduction should last for
at least about 10, or about 20, or about 40, or about 100 normal
mopping cycles, where "normal mopping" corresponds to the cleaning
that a floor covering panel system will undergo during normal
residential use. Yet still further, the barrier composition of the
present invention will provide a durable water barrier for one
normmal mopping cycle per week for about 1 year, or about 2 years,
or about 5 years, or about 7 years, or about 12 years, or about as
long as the nonnal useful life of the particular floor covering
panel system.
[0057] Moreover, it has been found possible to apply other
materials to the floor covering panels along with this barrier
composition. In particular, prior art methods of application of
water resistance compositions to, for example, tongue and groove
flooring materials, rely on a general and non-specific application
of the water resistance composition to the tongue and groove
profile. This general and non-specific application may prevent the
subsequent application of other materials, such as adhesive,
because the water barrier composition may prevent durable adherence
of the adhesive (or other material) to the surface of the tongue in
groove profile. In some circumstances, it is desirable to have a
floor covering panel that not only has a water barrier property,
but to which an adhesive may also be applied.
[0058] In accordance with such an objective, the present invention
may also be utilized in conjunction with an invention relating to
selective application of an adhesive composition to a floor
covering panel. The invention relating to this adhesive is
described in detail in a U.S. Patent Application filed concurrently
herewith (Attorney Docket Number 19133.0026U1), the disclosure of
which is incorporated herein in its entirety by this reference.
[0059] Upon application of the barrier composition to the floor
covering panels, heat may be applied to remove the solvent from the
barrier composition and/or to provide crosslinking i.e., curing, of
the active ingredient. In separate aspects, the barrier composition
may be dried for about 5 seconds, about 10 seconds, about 30
seconds, about 1 minute, about 3 minutes, about 5 minutes, about 10
minutes, or about 20 minutes, with any value forming an upper or
lower endpoint, as appropriate. The temperature applied to dry
and/or crosslink the active ingredient may be from about
100.degree. F. (37.8.degree. C.), about 120.degree. F.
(48.89.degree. C.), about 140.degree. F. (60.degree. C.), about
160.degree. C.), (71.1.degree. C.), about 180.degree. F.
(82.2.degree. C.), about 200.degree. F. (93.3.degree. C.), or about
220.degree. F. (104.4.degree. F. where any value may form an upper
and lower endpoint, as appropriate. In some aspects, it is
important to heat the floor covering panels to at least about
180.degree. F. (82.2.degree. C.) for at least 10 seconds.
[0060] The barrier composition may include additives as are known
to one of ordinary skill in the art. In particular, the barrier
composition may include one or more of: surfactants, viscosity
modifiers, preservatives, surface tension modifiers or
opacifiers.
[0061] When it is only desired that the floor covering panel be
waterproof and not, for example, pre-glued in the factory, such as
disclosed and claimed in co-pending patent application, Attorney
Docket Number 19133.0026U1, the barrier composition can be applied
to the entire profile of the floor covering panel so as to provide
an exceptionally complete waterproofing to the panel, e.g.,
waterproofing will be applied from both above and below. In such an
aspect, crosslinked polymer forms the active ingredient of the
barrier composition of the present invention, the barrier
composition may be applied to an entire portion of the first or
second abutment.
[0062] In this aspect, the active ingredient of the barrier
composition must be crosslinkable or, put another way, crosslinked
when the floor covering panels are assembled for use in a
commercial or residential establishment. In accordance with this
aspect of the present invention, the crosslinkable material may be
a silicone polymer, an acrylic polymer or a fluoropolymer. When a
fluoropolymer, the crosslinkable material may be a fluoroacrylate
polymer as described elsewhere herein.
EXAMPLES
[0063] The following examples are put forth so as to provide those
of ordinary skill in the art with a complete disclosure and
description of how the apparatus and composition, claimed herein is
made and evaluated, and are intended to be purely exemplary of the
invention and are not intended to limit the scope of what the
inventor regards as the invention. Efforts have been made to ensure
accuracy with respect to numbers (e.g., amounts, temperature, etc.)
but some errors and deviations should be accounted for. Unless
indicated otherwise, parts are parts by weight, temperature is in
.degree. F. (.degree. C.) or is at ambient temperature, and
pressure is at or near atmospheric.
Seam Seepage & Swelling Test
[0064] Equipment:
[0065] 1. Plumber's putty
[0066] 2. Digital caliper
[0067] 3.2% liquid detergent solution Ivory with Red dye 40 (much
lower surface tension than H.sub.2O) (very harsh test)
[0068] 4. 10 ml graduated cylinder
[0069] 5. Flat Horizontal surface
[0070] 6. Saw with a blade for cutting laminates
[0071] Procedure for Seam Test (FIG. 4):
[0072] 1. Mark 12 inch cuts down the length of the panel as samples
to be tested.
[0073] 2. Mark placement for three two-inch rings R about 1.5
inches apart on the edge of the upper lip on the groove side.
[0074] 3. Within each ring R make three marks about half inch
apart.
[0075] 4. With a digital caliper measure the thickness of the panel
at each of the marks.
[0076] 5. Join together two panels 210a, 210b and cut samples
apart.
[0077] 6. Allow to sit in a flat horizontal location for the
desired amount of time.
[0078] 7. Place a ring R of plumber's putty around each set of
marks.
[0079] 8. At the desired time after joining the panels, pour 10 ml
of a red detergent solution S into each ring R and allow to sit
undisturbed in a flat horizontal position until all the solution
has passed through the joint J or evaporated.
[0080] The detergent solution comprises 2% liquid Ivoiry.RTM. or
liquid Ajax.RTM. dishwashing detergent with a small amount of real
food coloring added.
[0081] 9. Separate the two panels and remeasure the same marked
locations. Also observe how far into the joint the red dye solution
has penetrated. A spraymation head was used. About 1 g or less of a
25% TG 472 or 571/75% water composition. Laminate floor covering
material of 8".times.48 (0.20.times.1.22 meters)". Barrier
composition applied at location 50/52
1 Seam Seepage & Swelling 4 Hour % 72 Hour % B Flexipel XPC
Only 9.96 2.98 (comparative) D Unidyne TG-571 16.70 4.31 E Unidyne
TG-472 1.84 0.87 G Virgin Control (comparative) 24.45 23.68 H
Paraffin Control (comparative) 30.66 25.63 I Competitive floor
covering 21.17 21.49 material (comparative believed to be treated
with paraffin wax)
[0082] Flexipel XPC (Innovative Chemical Technologies,
Cartersville, Ga.) is a synthetic hydrocarbon (97-98%) and a
perflorinated polymer (2-3%). Unidyne 571 and 472 are
fluoroacrylate polymer emulsions. After application to the floor
covering panels, the floor covering panels were treated at
180.degree. F. (82.2.degree. C.) for 10-30 seconds.
[0083] Seam seepage and swelling measured as a % change of the
thickness of the flooring material after application of liquid as
indicated.
[0084] From the above results, it is apparent that the
fluoroacrylate polymer provides a markedly improved water barrier
over the other materials tested.
[0085] It will be apparent to those skilled in the art that various
modifications and variations can be made in the present invention
without departing from the scope or spirit of the invention. Other
embodiments of the invention will be apparent to those skilled in
the art from consideration of the specification and practice of the
invention disclosed herein. It is intended that the specification
and examples be considered as exemplary only, with a true scope and
spirit of the invention being indicated by the following
claims.
* * * * *