U.S. patent application number 11/479479 was filed with the patent office on 2007-02-01 for plastic flooring with improved seal.
This patent application is currently assigned to The Parallax Group International, LLC. Invention is credited to John Grimm, Bruce Thrush.
Application Number | 20070022689 11/479479 |
Document ID | / |
Family ID | 37692775 |
Filed Date | 2007-02-01 |
United States Patent
Application |
20070022689 |
Kind Code |
A1 |
Thrush; Bruce ; et
al. |
February 1, 2007 |
Plastic flooring with improved seal
Abstract
A floor or wall covering has blocks with mating strips having
multiple ridges and multiple grooves in both mating members. Ridges
and grooves can have different sizes and cross-sectional shapes
from one another, and can mate in a manner that provides expansion
gaps. Male/female positioning pairs can advantageously be included
to facilitate alignment of the blocks during installation and use.
Preferred floor blocks comprise a ribbed support portion that
supports a working surface, and the ribbed support portion defines
a plurality of cells that collectively reduce the weight of the
block by a factor of at least 20% relative to corresponding block
without such cells.
Inventors: |
Thrush; Bruce; (Laguna
Niguel, CA) ; Grimm; John; (Santee, CA) |
Correspondence
Address: |
ROBERT D. FISH;RUTAN & TUCKER LLP
611 ANTON BLVD 14TH FLOOR
COSTA MESA
CA
92626-1931
US
|
Assignee: |
The Parallax Group International,
LLC
|
Family ID: |
37692775 |
Appl. No.: |
11/479479 |
Filed: |
June 30, 2006 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60697466 |
Jul 7, 2005 |
|
|
|
Current U.S.
Class: |
52/392 |
Current CPC
Class: |
E04F 13/18 20130101;
E04F 2201/0138 20130101; E04F 15/10 20130101; E04F 2201/05
20130101 |
Class at
Publication: |
052/392 |
International
Class: |
E04F 13/08 20060101
E04F013/08 |
Claims
1. A system for covering a surface, comprising: a first block with
an edge having a first edge strip along which are disposed at least
two parallel ridges; a second block with an edge having a second
edge strip along which are disposed at least two parallel grooves,
the grooves sized and dimensioned to mate with the ridges; and the
first and second blocks each having a thickness of at least 2
mm.
2. The system of claim 1 wherein the first block has a second edge
with a second edge strip with at least two parallel ridges, and
third and fourth edges each having edge strips with at least two
parallel grooves.
3. The system of claim 1 wherein the first and second blocks
comprise a polymeric material.
4. The system of claim 1 wherein the first strip is at least 10 cm
long.
5. The system of claim 1 wherein first and second of the at least
two ridges are separated by at least 2 mm.
6. The system of claim 1 wherein the first block is at least 5 mm
thick.
7. The system of claim 1 further comprising a propositioned
adhesive disposed upon at least one of the first and second
strips.
8. The system of claim 1 wherein at least one of the ridges
includes a bulbous region.
9. The system of claim 1 wherein at least one of the ridges extends
downwardly at an angle slightly off normal.
10. The system of claim 1, further comprising a third ridge
positioned between the two parallel grooves; and a third groove
positioned between the at least two parallel ridges; wherein the
third ridge is positioned to abut against the third groove as a
barrier to moisture.
11. The system of claim 1, further comprising a three-channel
interface between the first strip of the first block and first
strip of the second block.
12. The system of claim 1 wherein the first edge strip is at least
5% more massive than the second edge strip.
13. The system of claim 10, further comprising gaps between the at
least two ridges and the at least two grooves, allowing expansion
room for the at least two ridges when the two edge strips snap
together.
14. The system of claim 1, further comprising at least one
positioning pair that includes a least one of a locator, slot,
boss, and ring.
15. A floor block comprising a ribbed support portion that supports
a working surface, the ribbed support portion defining a plurality
of cells that collectively reduce the weight of the block by a
factor of at least 20% relative to corresponding block without such
cells.
16. The block of claim 15, wherein the factor is at least 30%.
17. The block of claim 15, wherein the factor is at least 40%.
18. The block of claim 15, wherein the ribbed support portion
defines at least 100 cells.
19. The block of claim 15, wherein the ribbed support portion
defines at least 200 cells.
20. The block of claim 15, wherein the ribbed support portion
defines at least 350 cells.
Description
[0001] This application claims the benefit of our U.S. provisional
patent application with the Ser. No. 60/697,466, which was filed
Jul. 7, 2005.
FIELD OF THE INVENTION
[0002] The field of the invention is floor coverings.
BACKGROUND
[0003] There is a need for modular floor covering systems that are
relatively easy to install, maintain, and provide reasonably good
seal against water infiltration.
[0004] Various types of modular floor covering systems are well
known, including for example systems having edges that mate using a
single ridge and a single groove (see US 2002/0189183, U.S. Pat.
No. 5,630,304). The known single-ridge, single-groove floor
covering blocks (also called tiles) are relatively easy to install
and maintain, but can come apart too easily. In addition, use of
only a single ridge and a single groove on each strip provides a
relatively poor water barrier.
[0005] More sophisticated water barriers have been developed that
use multiple ridges and grooves in only one of the strips, and a
removable seal disposed in one of the multiple grooves. For
example, Flooring Surfaces.TM. markets a floor covering system in
which an upper edge strip mates with a lower edge strip having a
separate seal. Interestingly, there do not appear to be any
flooring or wall covering systems in which both mating strips have
multiple ridges and multiple grooves. Thus, there is still a need
for a modular floor covering system in which both mating strips
have multiple ridges and multiple grooves.
[0006] In addition, there is a long-standing problem with alignment
of ridged mating systems that has never been resolved. Since any
portion of a block edge can mate with any other portion of a mating
block edge, larger installations frequently get out of alignment.
Thus, there is still a need for systems and methods for aligning
blocks having grooved mating systems.
SUMMARY OF THE INVENTION
[0007] The present invention provides apparatus, systems and
methods for covering a floor or wall surface, in which blocks have
mating strips with multiple ridges and multiple grooves in both
mating members.
[0008] In one aspect of preferred embodiments, the ridges on the
various strips can have different cross-sectional shapes from one
another. Accordingly, the ridges on one of the strips can combine
to be more massive than the ridges on the opposing strip, and the
strip having the more massive ridges can be used advantageously as
the upper strip. The strip having the less massive ridges can be
used advantageously as the lower strip.
[0009] In another aspect the various ridges and grooves mate in a
manner that provides expansion gaps. Such gaps allow expansion room
for easier assembly and disassembly.
[0010] In yet another aspect, systems and methods are contemplated
in which at least some of the blocks have both ridged mating strips
and at least one mechanical positioner. Preferred positioners are
male and female pairs, including for example locator and slot
pairs, and boss and hole pairs. Blocks can have multiple
positioners.
[0011] Various objects, features, aspects and advantages of the
present invention will become more apparent from the following
detailed description of preferred embodiments of the invention,
along with the accompanying drawings in which like numerals
represent like components.
BRIEF DESCRIPTION OF THE DRAWING
[0012] FIG. 1 is a vertical cross-section of a mating region of
prior art floor covering blocks, before installation.
[0013] FIG. 2 is a vertical cross-section of a mating region of
prior art floor covering blocks of FIG. 1, after installation.
[0014] FIG. 3 is a vertical cross-section of a mating region
between two modular floor covering blocks, before installation.
[0015] FIG. 4 is a vertical cross-section of the mating region
between the two modular floor covering blocks of FIG. 3, after
installation.
[0016] FIG. 5 is a perspective view of the bottom of a block,
showing a waffle pattern that supports a main or "working
surface".
[0017] FIG. 5A is a perspective view of a portion of block having a
locator in the middle of one of the sides, and a boss at a
corner.
[0018] FIG. 5B is a perspective view of a portion of another block
having a female connector that mates with the boss of FIG. 5A.
[0019] FIG. 5C is a perspective view of a portion of the block of
FIG. 5B, having a slot that mates with the locator of FIG. 5A.
DETAILED DESCRIPTION
[0020] In prior art FIGS. 1 and 2, a modular floor covering system
100 generally comprises blocks 110 and 120, having edge strips 112,
122, respectively. Edge strip 112 has a single ridge 115 and a
single groove 117. Edge strip 122 has two ridges 125A, 125B, and
two grooves 127A, 127B. A resiliently compressible tubular seal 129
is disposed in groove 127B.
[0021] In FIGS. 3 and 4, a floor covering system 200 generally has
a plurality of modular blocks. Here, edge portions of blocks 210
and 220 are shown prior to installation.
[0022] Each block generally has four sides. In a preferred
embodiment, two of the sides have edge strips arranged as strip
212, and two other sides have edge strips arranged as strip 222.
This configuration allows identical blocks to interlock in a manner
that covers a large area. Of course, other embodiments are also
contemplated that have other than four sides. Thus, contemplated
embodiments include those that have three sides (triangular), five
sides (pentagonal), and so forth, as well as embodiments where the
sides do not define a regular geometric shape.
[0023] Floor covering block 200 generally has a thickness of at
least 2 mm, preferably at least 5 mm, more preferably at least 10
mm, most preferably at least 15 mm. In preferred embodiments, block
100 is contemplated to be at least 10 cm long, more preferably at
least 50 cm long, and most preferably at least 80 cm long. The
modular floor covering blocks can be made of any suitable material
common known for floor covering, including clay, stone, wood,
polymeric materials, and especially material selected from the list
consisting of vinyl, rubber, linoleum, and resin. Especially
contemplated materials include PVC, DOP, polypropylene, TPR, TPE,
and blends of these, along with smaller amounts of fillers and
stabilizers.
[0024] Along one edge of block 210 is edge strip 212 having two
parallel ridges 215A, 215B and grooves 217A, 217B. A second block
220 has edge strip 222, with corresponding parallel grooves 227A,
227B sized and dimensioned to mate with the two ridges 215A, 215B.
Edge strip 222 also has two parallel ridges, 225A, 225B, sized and
dimensioned to mate with the two grooves 217A, 217B. Those skilled
in the art will immediately appreciate how any number of such
blocks could be configured together to make a square, rectangular
or other grouping to cover a desired area of floor, lawn, wall,
etc.
[0025] Edge strips can be any practical width, thickness, and
length. The ridges and grooves on edge strips need not be at the
lateral ends of the strips, and indeed in many cases (such as that
shown in FIGS. 3, 4), the most laterally positioned ridge 215A can
be positioned several mm from the lateral-most edge of the
strip.
[0026] The two ridges of each strip 212, 222 are preferably
separated by at least 2 mm, more preferably at least 5 mm, most
preferably at least 8 mm. As used herein the term "parallel" means
substantially parallel, and includes ridges that are wavy or out of
parallel by an amount that does not adversely affect performance to
a significant degree. Thus, ridges that are out of parallel by
5-10% may well fall within the meaning of the term parallel, as
used herein, provided that the arrangements does not adversely
affect performance to a significant degree.
[0027] In preferred embodiments, ridge 225A is sized and
dimensioned to abut groove 217A so as to prevent infiltration of
moisture. All four of the ridges 215A, 215B, 225A, 225B are
sufficiently thick to provided needed strength. In many cases this
would mean that the ridge are at least 2 mm thick, more preferably
at least 4 mm thick, and most preferably 6 mm thick. In a preferred
embodiments, top ridges 215A and 215B are larger than bottom ridges
225A, 225B, preferably at least 5% larger, more preferably at least
15% larger, and most preferably at least 35% bigger. Bigger ridges
are thought to allow relatively easier coupling of the upper and
lower edge strips 220, 222, and relatively better locking
performance.
[0028] With a given strip, the ridges can have same sizes as one
another, or different sizes. Thus, top ridges 215A, 215B can be the
same or different sizes from one another, and bottom ridges 225A,
225B can be the same or different sizes from one another. There is
a potential benefit in having different sized ridges on a given
strip in that different sizes can improve the ease of coupling the
strips together. To that end a more lateral ridge is preferably
larger than a more medial ridge.
[0029] It is also possible, although not desirable from a
manufacturing cost standpoint, for different ridges on a given
strip to be made of different materials, densities, shapes, colors
and so forth. In FIGS. 3 and 4, ridges 215A, 215B project
downwardly at angle slightly off normal, and have a laterally
extending bulbous portion 218 that acts as a lead-in region. Those
features also assist in locking strip 212 in place when mated with
strip 222. Of course, various other shapes, sizes, and
configurations of the ridges are also possible.
[0030] Further contemplated embodiments have edge strips shaped to
create expansion gaps 300A-D when two blocks are installed. These
expansion gaps allows relatively easier installation, relatively
more aggressive snaps, and allows relatively easier disassembly.
Size of the gap is defined by the distance between corresponding
ridges and grooves. Preferred size of the gap is at least 0.05 mm,
more preferably at least 0.5 mm, most preferably at least 1.0
mm.
[0031] It is further contemplated that a propositioned adhesive is
disposed on the strips. Such an adhesive can help in preventing
water and moisture penetration through the seals, and can assist in
preventing unwanted separation of mating strips.
[0032] In FIG. 5, a tile system 300 has a "waffle design" portion
330 that supports a main or working surface 350. The waffle design
portion 330 is shown here as orthogonal ribs 332 that define
substantially square cells 334. In a preferred embodiment there are
20 ribs in each direction, forming 361 cells (a matrix of
19.times.19), but there could be a greater or lesser number of ribs
in either direction. The ribs 332 can be any suitable thickness, or
even have varying thicknesses, but preferably have a uniform
thickness of 0.155 inch (or about 3 mm). The ribs could, of course,
be oriented in some other manner, which would produce cells having
a diamond, round, ovoid, or any other suitable shape. The cells can
have any suitable depth, but are preferably about 4 mm deep, with a
ceiling (the working surface) having a thickness of 0.063 inch (or
about 2-3 mm). There can be any suitable number of cells, including
especially at least 100 cells, more preferably at least 200 cells,
and most preferably at least 300 cells.
[0033] It turns out that using a ribbed ("waffle design") on the
underside of a polymeric floor block provides sufficient structural
integrity to support the weight of normally expected garage-based
or other activity, including supporting the weight of cars, gym
equipment, etc. The ribbed ("waffle design") also provides
significant cost and weight reduction. For example, use of a ribbed
("waffle design") in place of a solid design can reduce the weight
of the block by at least 20%, more preferably at least 30%, and
most preferably at least 40%.
[0034] In FIG. 5A-5C a tile system 300 includes at least two pieces
of block 310. In FIG. 5A, block 310 has a locator 312 in the middle
of one of the sides, and a boss 314 at a corner. Each of the
locator 312 and boss 314 could be placed elsewhere on the block
310, or replaced and/or supplemented with other types, sizes, and
configurations of positioners. The boss 314, for example, could be
rectangular or diamond shaped rather than round. In FIGS. 5B and
5C, a slot 322 on a first of the blocks 310, mates with the locator
312 on a second of blocks 310, and a ring 324 defining a hole on
the first of blocks 310 that mates with the boss 314 on the second
of blockss 310. The mating pairs, (locator 312 and slot 322; and
boss 314 and ring 324), serve to maintain alignment among the
various blocks of system 300 during installation and use.
[0035] Thus, specific embodiments and applications of plastic
flooring with improved seal have been disclosed. It should be
apparent, however, to those skilled in the art that many more
modifications besides those already described are possible without
departing from the inventive concepts herein. The inventive subject
matter, therefore, is not to be restricted except in the spirit of
the appended claims. Moreover, in interpreting both the
specification and the claims, all terms should be interpreted in
the broadest possible manner consistent with the context. In
particular, the terms "comprises" and "comprising" should be
interpreted as referring to elements, components, or steps in a
non-exclusive manner, indicating that the referenced elements,
components, or steps may be present, or utilized, or combined with
other elements, components, or steps that are not expressly
referenced. Where the specification claims refers to at least one
of something selected from the group consisting of A, B, C . . .
and N, the text should be interpreted as requiring only one element
from the group, not A plus N, or B plus N, etc.
* * * * *