U.S. patent application number 12/397449 was filed with the patent office on 2009-09-10 for connecting system for surface coverings.
This patent application is currently assigned to MANNINGTON MILLS, INC.. Invention is credited to Hao A. Chen, John M. Whispell.
Application Number | 20090223162 12/397449 |
Document ID | / |
Family ID | 41052166 |
Filed Date | 2009-09-10 |
United States Patent
Application |
20090223162 |
Kind Code |
A1 |
Chen; Hao A. ; et
al. |
September 10, 2009 |
Connecting System For Surface Coverings
Abstract
A plank is provided that has opposing first and second ends
extending along a width of the plank, opposing first and second
longitudinal sides extending along a length of the plank, and
opposing top and bottom surfaces. The plank can have a tongue edge
at the first end and a groove edge at the second end. The tongue
edge can be detachably lockable into the groove edge of an
adjacent, identical plank. Surface covering systems having a
plurality of the planks connected together are also provided.
Inventors: |
Chen; Hao A.; (Chaddsford,
PA) ; Whispell; John M.; (Woodstown, NJ) |
Correspondence
Address: |
KILYK & BOWERSOX, P.L.L.C.
400 HOLIDAY COURT, SUITE 102
WARRENTON
VA
20186
US
|
Assignee: |
MANNINGTON MILLS, INC.
Salem
NJ
|
Family ID: |
41052166 |
Appl. No.: |
12/397449 |
Filed: |
March 4, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61033979 |
Mar 5, 2008 |
|
|
|
Current U.S.
Class: |
52/588.1 |
Current CPC
Class: |
E04F 2201/0115 20130101;
E04F 2201/0153 20130101; E04F 15/042 20130101; E04F 13/08 20130101;
E04F 15/02 20130101 |
Class at
Publication: |
52/588.1 |
International
Class: |
E04F 15/16 20060101
E04F015/16 |
Claims
1. A floor plank having a length and a width comprising: a top
surface; a bottom surface; a first longitudinal side; a second
longitudinal side opposing the first longitudinal side; a first end
extending along the width of the floor plank and comprising a
tongue edge, and; a second end opposing the first end, extending
along the width of the floor plank, and comprising a groove edge,
wherein the tongue edge comprises: a vertical distal surface,
substantially vertical to the top and bottom surfaces, a top planar
slanted surface extending away from the vertical distal surface
toward the top surface, a vertical lip extending downwardly from
the top surface, a channel disposed substantially between the top
planar slanted surface and the top surface, the channel comprising
a channel bottom and a channel back, the channel back extending
away from the channel bottom toward the vertical lip, a pinnacle
rail connecting the top planar slanted surface and the channel,
wherein the channel bottom extends vertically below the pinnacle
rail, and the channel back extends laterally further away from the
vertical distal surface than does the vertical lip, a bottom planar
slanted surface extending away from the vertical distal surface
towards the bottom surface, and a vertical shoulder extending from
the bottom planar slanted surface to the bottom surface.
2. The floor plank as claimed in claim 1, wherein the vertical
shoulder comprises an inclined top portion, the inclined top
portion merging into the bottom planar slanted surface.
3. The floor plank as claimed in claim 1, wherein the channel
bottom comprises a flat surface and the channel back comprises a
curved surface.
4. The floor plank as claimed in claim 1, wherein the channel
further comprises an angled surface that extends from the vertical
lip to the channel back and forms an angle relative to the vertical
lip that is between 40.degree.-50.degree..
5. The floor plank as claimed in claim 1, wherein the pinnacle rail
comprises a flat top surface that is parallel to the top surface of
the plank.
6. The floor plank as claimed in claim 1, wherein the vertical
distal surface has a height that is from about 40% to about 50% of
the height of the plank.
7. The floor plank as claimed in claim 1, wherein the vertical
shoulder is spaced further from the vertical distal surface than
the vertical lip.
8. The floor plank as claimed in claim 1, wherein the groove
comprises a profile that is substantially complementary to the
shape of the tongue.
9. The floor plank as claimed in claim 1, wherein the first
longitudinal side comprises the tongue edge and the second
longitudinal side comprises the groove edge.
10. The floor plank as claimed in claim 1, wherein the first
longitudinal side comprises a tongue profile that is different from
the first end and the second longitudinal side comprises a groove
profile that is different from the second end.
11. A floor plank having a length and a width comprising: a top
surface; a bottom surface; a first longitudinal side; a second
longitudinal side opposing the first longitudinal side; a first end
extending along the width of the floor plank and comprising a
tongue edge, and; a second end opposing the first end, extending
along the width of the floor plank, and comprising a groove edge,
wherein the groove edge comprises: a vertical distal surface,
substantially vertical to the top and bottom surfaces, a top planar
slanted surface extending away from the vertical distal surface
toward the top surface, a vertical lip extending downwardly from
the top surface, a latch disposed substantially between the top
planar slanted surface and the top surface, the latch comprising a
latch bottom and a latch back, the latch back extending away from
the latch bottom toward the vertical lip, a slanted surface
connecting the top planar slanted surface and the latch, wherein
the latch bottom extends vertically below the slanted surface, and
the vertical lip extends laterally further away from the vertical
distal surface than does the latch back, a bottom planar slanted
surface extending away from the vertical distal surface towards the
bottom surface, and a vertical shoulder extending from the bottom
planar slanted surface to the bottom surface.
12. The floor plank as claimed in claim 11, wherein the latch
bottom comprises a flat surface and the latch back comprises a
curved surface.
13. The floor plank as claimed in claim 11, wherein the latch
further comprises an angled surface that extends from the vertical
lip to the channel back and forms an angle relative to the vertical
lip that is between 40.degree.-50.degree..
14. The floor plank as claimed in claim 11, wherein the slanted
surface comprises a flat top surface that is parallel to the top
surface of the plank.
15. The floor plank as claimed in claim 11, wherein the vertical
distal surface has a height that is from about 40% to about 50% of
the height of the plank.
16. The floor plank as claimed in claim 11, wherein the vertical
shoulder is spaced further from the vertical distal surface than
the vertical lip.
17. The floor plank as claimed in claim 11, wherein the tongue
comprises a profile that is substantially complementary to the
shape of the groove.
18. The floor plank as claimed in claim 11, wherein the first
longitudinal side comprises the tongue edge and the second
longitudinal side comprises the groove edge.
19. The floor plank as claimed in claim 11, wherein the first
longitudinal side comprises a tongue profile that is different from
the first end and the second longitudinal side comprises a groove
profile that is different from the second end.
20. A flooring system comprising at least two floor planks that
detachably interlock together, each of the planks comprising: a top
surface; a bottom surface; a first longitudinal side; a second
longitudinal side opposing the first longitudinal side; a first end
extending along the width of the floor plank and comprising a
tongue edge, and; a second end opposing the first end, extending
along the width of the floor plank, and comprising a groove edge,
wherein the tongue edge comprises: a vertical distal surface,
substantially vertical to the top and bottom surfaces, a top planar
slanted surface extending away from the vertical distal surface
toward the top surface; a vertical lip extending downwardly from
the top surface, a vertical shoulder extending from the bottom
planar slanted surface to the bottom surface, and the groove edge
comprises: a vertical distal surface, substantially vertical to the
top and bottom surfaces, a top planar slanted surface extending
away from the vertical distal surface toward the top surface; a
vertical lip extending downwardly from the top surface, and a latch
disposed substantially between the top planar slanted surface and
the top surface, the latch comprising a latch bottom and a latch
back, the latch back extending away from the latch bottom towards
the vertical lip, a slanted surface connecting the top planar
slanted surface and the latch, wherein the latch bottom extends
vertically below the slanted surface, and the vertical lip extends
laterally further away from the vertical distal surface than does
the latch back, a bottom planar slanted surface extending away from
the vertical distal surface towards the bottom surface, and a
vertical shoulder extending from the bottom planar slanted surface
to the bottom surface, and the tongue edge of a first of the at
least two floor planks is detachably lockable into the groove edge
of a second of the at least two floor planks such that the latch of
the second plank is secured between the vertical lip and the
pinnacle rail of the first plank.
21. The flooring system as claimed in claim 20, wherein the
vertical shoulder comprises an inclined top portion, the inclined
top portion merging into the bottom planar slanted surface.
22. The floor plank as claimed in claim 20, wherein the channel
bottom comprises a flat surface and the channel back comprises a
curved surface.
23 The floor plank as claimed in claim 20, wherein the channel
further comprises an angled surface that extends from the vertical
lip to the channel back and forms an angle relative to the vertical
lip that is between 40.degree.-50.degree..
24. The floor plank as claimed in claim 20, wherein the pinnacle
rail comprises a flat top surface that is parallel to the top
surface of the plank.
25. The floor plank as claimed in claim 20, wherein the vertical
distal surface has a height that is from about 40% to about 50% of
the height of the plank.
26. The floor plank of claim 20, wherein the vertical shoulder is
spaced further from the vertical distal surface than the vertical
lip.
27. The floor plank as claimed in claim 20, wherein the latch
bottom comprises a flat surface and the latch back comprises a
curved surface.
28. The floor plank as claimed in claim 20, wherein the latch
further comprises an angled surface that extends from the vertical
lip to the channel back and forms an angle relative to the vertical
lip that is between 40.degree.-50.degree..
29. The floor plank as claimed in claim 20, wherein the slanted
surface comprises a flat top surface that is parallel to the top
surface of the plank.
30. The floor plank as claimed in claim 20, wherein the vertical
distal surface has a height that is from about 40% to about 50% of
the height of the plank.
31. The floor plank system as claimed in claim 20, firther
comprising a first gap formed between the latch back of the second
plank and the channel back and channel bottom of the first
plank.
32. The floor plank system as claimed in claim 20, further
comprising a second gap formed between the top planar slanted
surface of the first plank and the top planar slanted surface of
the second plank.
33. The floor plank system as claimed in claim 20, wherein the gap
thickness of the second gap is about 0.01 mm.
34. The floor plank system as claimed in claim 20, further
comprising a third gap formed between the vertical distal surface
of the first plank and the vertical distal surface of the second
plank.
35. The floor plank system as claimed in claim 20, further
comprising a fourth gap formed between the bottom planar slanted
surface of the first plank and the bottom planar slanted surface of
the second plank.
36. The floor plank system as claimed in claim 20, further
comprising a fifth gap formed between the vertical shoulder of the
first plank and the vertical shoulder of the second plank.
Description
BACKGROUND OF THE INVENTION
[0001] This application claims the benefit under 35 U.S.C.
.sctn.119(e) of prior U.S. Provisional Patent Application No.
61/033,979, filed Mar. 5, 2008, which is incorporated in its
entirety by reference herein.
[0002] The present invention relates to surface-coverings, like
flooring, and methods of installing the same.
[0003] Various types of glueless mechanical locking systems
(including straight tongue and groove arrangements) have been
utilized in the flooring industry. Flooring with glueless
mechanical locking systems (tongue and groove arrangements) are
becoming increasingly popular, as they are easy to lay, and, thus,
it is not necessary to utilize highly trained personnel to lay such
floor tiles.
[0004] Current floor systems have suffered, however, from
disadvantages. One disadvantage experienced with current floor
systems is that if each of the side edges of a plank includes a
mechanical locking tongue or groove, once one of the side edges is
connected to another similar plank, it is difficult to connect the
other side edges of the plank with yet another similar plank.
Lifting portions of the connected flooring is necessary to create a
proper angle to connect the plank. This problem particularly
accentuates itself while installing a click system floor in a very
limited-free-space and/or confined area such as in corners of a
room, under or around a door jamb, or under or around closets or
kitchen islands, and the like. In these areas there is no room for
lifting portions of the connected flooring to create the necessary
angle to connect the plank.
[0005] Some current flooring systems have a mechanical locking
tongue and groove on the first opposing side edges and a straight
edge on the other opposing side edges. This type of flooring
system, however, also includes certain disadvantages. For example,
the straight side edges that are connected to one another may not
be water tight and could potentially slide open to form a gap. If
an adhesive is used, the adhesive can be pressed out of the seams
and create messy seams.
[0006] Other flooring systems have flexible grooves that have some
"give" to permit connecting without angling. The integrity of such
systems, however, is questionable and there is difficulty in making
such a joint.
[0007] Accordingly, there is a need to provide a connecting system
for flooring and other surface-coverings, which is relatively
inexpensive, provides an excellent connection between the planks,
is easy to connect along each of the side edges of the planks,
and/or is moisture resistant and provides an overall acceptable
bond strength between two joined planks.
SUMMARY OF THE INVENTION
[0008] A feature of the present invention is to provide a plank or
a plank comprising a tongue at a first end of the plank and a
groove at an opposing second end of the plank, and the tongue and
groove have profiles as described herein. The tongue can be
defined, at least partially, by a vertical distal surface that is
substantially vertical to the top and bottom surfaces, a top planar
slanted surface extending away from the vertical distal surface
toward the top surface, a vertical lip extending downwardly from a
top surface of the floor plank, and a slanted tongue bottom
extending away from the vertical distal surface toward the bottom
surface.
[0009] In some embodiments, the tongue can comprise a channel
disposed substantially between the top planar slanted surface and
the top surface. A pinnacle rail can be provided that connects, or
can be at the intersection of, the top planar slanted surface and
the channel. The channel can comprise a channel bottom and a
channel back. In some embodiments, the channel bottom can comprise
a flat surface and the channel back can comprise a curved surface.
The channel back can extend away from the channel bottom toward the
vertical lip. According to various embodiments, the channel can
comprise an angled surface that extends from the vertical lip to
the channel back and forms an angle relative to the vertical lip
that is from about 40.degree. to about 50.degree.. In some
embodiments, the channel bottom can extend vertically below the
pinnacle rail. In at least one embodiment, the channel back can
extend laterally further away from the vertical distal surface than
does the vertical lip. According to some embodiments, the pinnacle
rail can comprise a flat top surface that can be parallel to the
top surface of the plank.
[0010] According to various embodiments, a vertical shoulder can be
provided that extends from the slanted tongue bottom to the bottom
surface. According to some embodiments, the vertical shoulder can
comprise an angled transition that merges into the bottom planar
slanted surface.
[0011] According to various embodiments, the vertical distal
surface can have a height that is from about 30% to about 60%, or
from about 40% to about 50% of the height of the plank. In some
embodiments, the vertical shoulder can be spaced further from the
vertical distal surface than the vertical lip.
[0012] According to various embodiments, the groove can comprise a
vertical distal surface that is substantially vertical with respect
to the top and bottom surfaces, a top planar slanted surface
extending away from the vertical distal surface toward the top
surface, a vertical lip extending downwardly from the top surface,
and a bottom planar slanted surface extending away from the
vertical distal surface towards the bottom surface. In some
embodiments, a latch can be disposed substantially between the top
planar slanted surface and the top surface. The latch can comprise
a latch bottom and a latch back. In some embodiments, the latch
bottom can comprise a flat surface and the latch back can comprise
a curved surface. In some embodiments, the latch can comprise an
angled surface that extends from the vertical lip to the channel
back and forms an angle relative to the vertical lip which can be
from about 30.degree. to about 60.degree., or from about 40.degree.
to about 50.degree..
[0013] In some embodiments, the latch back can extend away from the
latch bottom toward the vertical lip. A slanted surface can be
provided between the top planar slanted surface and the latch. The
latch bottom can extend vertically below the slanted surface.
[0014] The vertical lip of the groove can extend laterally further
away from the vertical distal surface than does the latch back.
According to some embodiments, the vertical distal surface can have
a height that is from about 30% to about 60%, or from about 40% to
about 50% of the height of the plank. A vertical shoulder can
extend from the bottom planar slanted surface to the bottom
surface. According to various embodiments, the vertical shoulder
can be spaced firther from the vertical distal surface than the
vertical lip. The tongue can comprise a profile that is
substantially complementary to the shape of the groove edge.
[0015] Another feature of the present invention is to provide a
flooring system for flooring planks and other surface-coverings
that do not require any connecting accessories such as an insert,
spline, metal clip, or the like, and which permits easy and fast
installation and flexibility.
[0016] Still another feature of the present invention is to provide
a flooring system that has significant improvements with respect to
ease of installation at confined areas, and includes a foolproof
installation design and technique.
[0017] Another feature of the present invention is to provide a
plank that can be easily connected to other planks.
[0018] Another feature of the present invention is to provide a
flooring system that can avoid the use of the application of a wet
adhesive composition.
[0019] Also, a feature of the present invention is to provide a
surface-covering system that has the ability to withstand water
damage, such as swelling, delamination, and weakening, can
withstand heavy traffic wear, tearing, and gouging, and exhibits
stain resistance, chemical resistance, and ease of maintenance.
[0020] Also, a feature of the present invention is a method for
joining together plank joints.
[0021] Another feature of the present invention is to provide a
joint system that combines mechanical locking and chemical welding
to provide improved joint strength, ease of installation, and water
sealability.
[0022] Also, a feature of the present invention is to provide a
joining system that enables tongue into groove installation or
groove into tongue installation.
[0023] Additional features and advantages of the present invention
will be set forth in the description that follows, and, in part,
will be apparent from the description that follows, or may be
learned by practice of the present invention. The features and
other advantages of the present invention will be realized and
attained by means of the elements and combinations particularly
pointed out in the written description and the claims.
[0024] To achieve these and other advantages, and in accordance
with the purposes of the present invention as embodied and broadly
described herein, the present invention, in some embodiments,
relates to structural features of planks along interconnecting
edges and/or surfaces of planks that comprise a tongue along a
first edge thereof and a mating groove along a second edge
thereof.
[0025] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory only and are intended to provide further
explanation of the present invention, as claimed.
[0026] The accompanying drawings, which are incorporated in and
constitute a part of this application, illustrate several
embodiments of the present invention and, together with the
description, serve to explain the principles of the present
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a perspective view of a flooring system according
to various embodiments of the present invention;
[0028] FIG. 2 is a cross-sectional view taken along line II-II
shown in FIG. 1.
[0029] FIG. 3 is an enlarged view of the tongue edge of the planks
shown in FIG. 2.
[0030] FIG. 4 is an enlarged view of the channel shown in FIG.
3.
[0031] FIG. 5 is an enlarged view of the groove edge shown in FIG.
2.
[0032] FIG. 6 is an enlarged view of the latch shown in FIG. 5.
[0033] FIG. 7 is a cross-sectional view through two planks of a
flooring system according to various embodiments of the present
teachings.
[0034] FIG. 8 is an enlarged view of the connecting region edge
profiles of the flooring system shown in FIG. 7.
[0035] FIG. 9 is an enlarged view showing a scale for the tongue
edge shown in FIGS. 2, 3, and 4.
[0036] FIG. 10 is an enlarged view of the groove edge depicted in
FIGS. 2, 5, and 6.
DETAILED DESCRIPTION OF THE PRESENT INVENTION
[0037] According to various embodiments, the plank can comprise a
generally rectangular shape, having opposing first and second ends
extending along the width of the plank, opposing first and second
longitudinal sides extending along the length of the plank, and
opposing top and bottom surfaces. In some embodiments, the plank
comprises a tongue edge at a first end of the floor plank and a
groove edge at an opposing second end of the floor plank. The
tongue edge can be defined, at least partially, by a vertical
distal surface that is substantially vertical with respect to the
top and bottom surfaces, and a top planar slanted surface extending
away from the vertical distal surface toward the top surface of the
plank. A vertical lip can be included that extends downwardly from
the top surface of the plank, and a slanted tongue bottom extending
away from the vertical distal surface towards the bottom surface. A
channel can be disposed substantially between the top planar
slanted surface and the top surface. A pinnacle rail can be
provided that connects the top planar slanted surface and the
channel and/or that can comprise an intersection of the top planar
slanted surface and the channel. The channel can comprise a channel
bottom and a channel back. In some embodiments, the channel bottom
can comprise a flat surface and the channel back can comprise a
curved surface. The channel back can extend away from the channel
bottom toward the vertical lip. According to various embodiments,
the channel can comprise an angled transition that extends from the
vertical lip to the channel back and forms an angle relative to the
vertical lip that is in the range of from about 40.degree. to about
50.degree.. In some embodiments, the channel bottom can extend
vertically below the pinnacle rail. In some embodiments, the
channel back can extend laterally further away from the vertical
distal surface than does the vertical lip. According to some
embodiments, the pinnacle rail can comprise a flat top surface that
is parallel to the top surface of the plank.
[0038] According to various embodiments, the tongue can comprise a
vertical shoulder that extends from the slanted tongue bottom to
the bottom surface. According to some embodiments, the vertical
shoulder can comprise an angled transition that merges into the
slanted tongue bottom.
[0039] According to various embodiments, the vertical distal
surface can have a height that is from about 40% to about 50% of
the height of the plank. In some embodiments, the vertical shoulder
can be spaced further from the vertical distal surface than is the
vertical lip.
[0040] According to various embodiments, the groove edge can
comprise a profile that is substantially or fully complementary to
the shape of the tongue edge. The groove edge can comprise a
vertical distal surface that is substantially vertical with respect
to the top and bottom surfaces, a top planar slanted surface
extending away from the vertical distal surface toward the top
surface, a vertical lip extending downwardly from the top surface,
and a bottom planar slanted surface extending away from the
vertical distal surface toward the bottom surface. In some
embodiments, a latch can be disposed substantially between the top
planar slanted surface and the top surface. The latch can comprise
a latch bottom and a latch back. The latch bottom can comprise a
flat surface and the latch back can comprise a curved surface. In
at least one embodiment, the latch can comprise an angled surface
that extends from the vertical lip to the channel back and that
forms an angle relative to the vertical lip, which angle can be
from about 40.degree. to about 50.degree..
[0041] The latch back can extend away from the latch bottom toward
the vertical lip. A slanted surface can be provided between the top
planar slanted surface and the latch. The latch bottom can extend
vertically below the slanted surface.
[0042] The vertical lip can extend laterally further away from the
vertical distal surface than does the latch back. According to some
embodiments, the vertical distal surface can have a length that is
from about 40% to about 50% of the height of the plank.
[0043] A vertical shoulder can extend from the bottom planar
slanted surface to the bottom surface. According to various
embodiments, the vertical shoulder can be spaced further from the
vertical distal surface than is the vertical lip. The tongue edge
can comprise a profile that is substantially or fully complementary
to the shape of the groove edge.
[0044] According to some embodiments the first longitudinal side
can include the tongue edge and the second longitudinal side can
include the groove edge.
[0045] According to various embodiments, a flooring system is
provided that can comprise at least two floor planks that
detachably interlock together. Each of the planks can comprise a
top surface, a bottom surface, opposing first and second ends
extending along the width of the plank, and opposing first and
second longitudinal sides extending along the length of the plank.
The first end of each plank can comprise a tongue edge. The second
end of each plank can comprise a groove edge. According to some
embodiments, the first longitudinal side can also comprise a tongue
edge and the second longitudinal side can also comprise a groove
edge. According to some embodiments, the plank can include a
protruding lip along the first longitudinal side of the plank and a
shoulder extending along the second longitudinal side of the plank
opposite from the first longitudinal side, as discussed in U.S.
patent application Ser. No. 11/190,452, incorporated by reference
in its entirety herein. The shoulder along one longitudinal side of
one plank can be adapted to receive the protruding lip along a
longitudinal side of a similar plank. Alternatively, the first
longitudinal side and the second longitudinal side can comprise any
of the tongue and groove profiles described in U.S. patent
application Ser. No. 11/190,452.
[0046] In some embodiments, the first longitudinal side and the
second longitudinal side of the plank can be a straight edge such
that the edges of two mating planks can be butted together to be
substantially coplanar or flush with each other. A chemical welding
agent such as THF can then be applied on the butted joint to melt
the plastic together (when the planks are thermoplastic) at the
contact to provide excellent joint integrity in strength and
water-sealability. Other joining materials can be used, like
adhesives, especially when the plank is made from laminates like
fiberboard, e.g., HDF or MDF.
[0047] The tongue edge of the first longitudinal side can comprise
a vertical distal surface that is substantially vertical to the top
and bottom surfaces, a top planar slanted surface extending away
from the vertical distal surface toward the top surface of the
floor plank, a vertical lip extending downwardly from a top surface
of the floor plank, and a slanted tongue bottom extending away from
the vertical distal surface towards the bottom surface. According
to some embodiments, the vertical distal surface can have a height
that is from about 40% to about 50% of the height of the plank.
[0048] In some embodiments, if a groove edge is provided in a
second longitudinal side of the plank, the groove edge can comprise
a channel. The channel can be disposed substantially between the
top planar slanted surface and the top surface. The channel can
comprise a channel bottom and a channel back that extends away from
the channel bottom toward the vertical lip. A pinnacle rail can be
provided which connects the top planar slanted surface and the
channel. The channel bottom can extend vertically below the
pinnacle rail. The channel back can extend laterally further away
from the vertical distal surface towards the bottom surface. A
vertical shoulder can be provided which extends from the slanted
tongue bottom to the bottom surface. According to some embodiments,
the channel bottom can comprise a flat surface and the channel back
can comprise a curved surface. In some embodiments, the channel can
comprise an angled surface that extends from the vertical lip to
the channel back and forms an angle relative to the vertical lip
that is in a range of from about 40.degree. to about 50.degree.. In
some embodiments, the pinnacle rail can comprise a flat top surface
that is parallel to the top surface of the plank. The vertical
shoulder can comprise an angled transition. The angled transition
can merge into the bottom planar slanted surface. According to some
embodiments, the vertical shoulder can be spaced further from the
vertical distal surface than the vertical lip. According to various
embodiments, the vertical distal surface can have a height that is
from about 40% to about 50% of the height of the plank.
[0049] The groove edge along the longitudinal side can comprise a
vertical distal surface that is substantially vertical to the top
and bottom surfaces, a top planar slanted surface extending away
from the vertical distal surface toward the top surface, a vertical
lip extending downwardly from the top surface, and a latch disposed
substantially between the top planar slanted surface and the top
surface. The latch can comprise a latch bottom and a latch back.
The latch back can extend away from the latch bottom towards the
vertical lip. The latch bottom can comprise a flat surface and the
latch back comprises a curved surface. According to some
embodiments, the latch bottom comprises a flat surface and the
latch back comprises a curved surface. In some embodiments, the
latch can further comprise an angled surface that extends from the
vertical lip to the latch back and forms an angle relative to the
vertical lip that is in the range of from about 40.degree. to about
50.degree..
[0050] The groove edge along the longitudinal side can comprise a
slanted surface between the top planar slanted surface and the
latch. The latch bottom can extend vertically below the slanted
surface. According to some embodiments, the slanted surface can
comprise a flat top surface that is parallel to the top surface of
the plank. The vertical lip can extend laterally further away from
the vertical distal surface than does the latch back. A bottom
planar slanted surface can extend away from the vertical distal
surface towards the bottom surface. A vertical shoulder can extend
from the bottom planar slanted surface to the bottom surface.
[0051] According to various embodiments of a system comprising a
plurality of planks connected together, a first gap can be formed
between the latch back of the second plank and the channel back and
channel bottom of the first plank. In some embodiments, the span of
the first gap can be in a range of from about 0.075 mm to about
0.20 mm, from about 0.10 mm to about 0.15 mm, or about 0.18 mm.
According to some embodiments, a second gap can be formed between
the top planar slanted surface of the first plank and the top
planar slanted surface of the second plank. In some embodiments,
the gap thickness of the second gap can be about 0.15 mm, or within
a range of from about 0.05 mm to about 0.40 mm or from about 0.25
mm to about 0.30 mm.
[0052] According to various embodiments, a third gap can be formed
between the vertical distal surface of the first plank and the
vertical distal surface of the second plank. According to some
embodiments, a fourth gap can be formed between the slanted tongue
bottom of the first plank and the bottom planar slanted surface of
the second plank. In at least one embodiment, a fifth gap can be
formed between the vertical shoulder of the first plank and the
vertical shoulder of the second plank. Each of the third, fourth,
and fifth gaps can have a span in the range of from about 0.55 mm
to about 0.025 mm, from about 0.04 mm to about 0.05 mm, or of about
0.50 mm.
[0053] In some embodiments of a flooring system, the tongue edge of
a first of at least two floor planks is detachably lockable into
the groove edge of a second of the at least two floor planks such
that the latch of the second floor plank is secured between the
vertical lip and the pinnacle rail of the first floor plank.
[0054] According to various embodiments, a plank can be extruded,
or otherwise formed, in a manner to include a tongue on a first end
and a groove on a second end. Other techniques can also be used to
create the tongue and groove of the present teachings. In some
embodiments, the tongue and groove can be milled or cut into, or
molded onto, ends and/or sides of the plank. Other techniques known
to one skilled in the art can also be used to provide the tongues
and grooves of the present teachings.
[0055] An exemplary flooring system according to various
embodiments of the present teachings is illustrated in FIG. 1.
Three planks 20 can be joined to one another along their ends and
edges to form a surface covering system, for example, a flooring
system. Each plank 20 can be generally rectangular and have a first
end 26, a second end 28 that opposes first end 26, a first
longitudinal side 27, and a second longitudinal side 29 that
opposes first longitudinal side 27. First end 26 and second end 28
can each extend the entire width of plank 20. First longitudinal
side 27 and second longitudinal side 29 can each extend the entire
length of plank 20.
[0056] FIG. 2 is a cross-sectional view of plank 20 taken through
line II-II shown in FIG. 1. According to various embodiments, first
end 26 can comprise a tongue edge 30 and second end 28 can comprise
a mating groove edge 32 that is complimentary to tongue edge 30.
Tongue edge 30 and groove edge 32 can be disposed between opposing
top surface 22 and bottom surface 24 of plank 20.
[0057] FIG. 3 is an enlarged view of tongue edge 30, of plank 20
shown in FIG. 2. Tongue edge 30 can be defined, at least partially,
by a vertical distal surface 34, a top planar slanted surface 36
extending from vertical distal surface 34 toward top surface 22 of
plank 20, a vertical lip 38 extending downwardly from top surface
22, and a slanted tongue bottom 35 extending away from vertical
distal surface 34 towards bottom surface 24. Vertical distal
surface 34 can be substantially vertical with respect to top
surface 22 and bottom surface 24. A channel 40 can be disposed
substantially between top planar slanted surface 36 and top surface
22. A pinnacle rail 52 can be provided that connects top planar
slanted surface 36 and channel 40. Pinnacle rail 52 can have a flat
top surface 54 as shown. Tongue edge 30 can comprise a vertical
shoulder 56 that extends from slanted tongue bottom 35 to bottom
surface 24. According to some embodiments, vertical shoulder 56 can
comprise an angled transition 58 that extends to an intersection
with slanted tongue bottom 35.
[0058] According to various embodiments, vertical distal surface 34
can have a height that is from about 30% to about 60% or from about
40% to about 50% of the height of plank 20. In some embodiments,
vertical shoulder 56 can be spaced further from vertical distal
surface 34 than is vertical lip 38.
[0059] FIG. 4 is an enlarged view of channel 40 shown in FIG. 3.
Channel 40 can comprise a channel bottom 42 and a channel back 44.
In some embodiments, channel bottom 42 can comprise a flat surface
46 and channel back 44 can comprise a curved surface 48. Channel
back 44 can extend away from channel bottom 42 toward vertical lip
38. According to various embodiments, channel 40 can comprise an
angled surface 50 that extends from vertical lip 38 to channel back
44 and forms an angle relative to vertical lip 38 that is in a
range of from about 30.degree. to about 60.degree. or from about
40.degree. to about 50.degree.. In some embodiments, channel bottom
42 can extend horizontally below pinnacle rail 52. In at least one
embodiment, channel back 44 can be spaced further away from
vertical distal surface 34 than is vertical lip 38. According to
some embodiments, pinnacle rail 52 can comprise a flat top surface
54 that can be parallel to top surface 22 of plank 20.
[0060] FIG. 5 is an enlarged view of groove edge 32 shown in FIG.
2. Groove edge 32 can comprise a profile that is substantially or
fully complementary to the shape of tongue edge 30. Groove edge 32
can comprise a vertical wall 60, a top planar slanted surface 62
extending away from vertical wall 60 toward top surface 22, a
vertical lip 64 extending downwardly from top surface 22, a bottom
planar slanted surface 80 extending away from vertical wall 60
toward bottom surface 24, and a vertical bottom wall 82. According
to various embodiments, vertical shoulder 82 can be spaced further
from vertical wall 60 than is vertical lip 64. The vertical wall 60
can be substantially vertical with respect to top surface 22 and
bottom surface 24. A latch 66 can be disposed substantially between
top planar slanted surface 62 and top surface 22. Latch 66 can
comprise a slanted surface 76.
[0061] FIG. 6 is an enlarged view of latch 66 shown in FIG. 5. As
can be seen in FIG. 6, latch 66 comprises a latch bottom 68 and a
latch back 72. In some embodiments, latch bottom 68 can comprise a
flat surface 70 and latch back 72 can comprise a curved surface 71.
In some embodiments, latch 66 can comprise an angled surface 74
that extends from vertical lip 64 to latch back 72 and forms an
angle, relative to vertical lip 64, that is in a range of from
about 20.degree. to about 80.degree. or from about 50.degree. to
about 70.degree.. According to some embodiments, angled portion 74
can have an angle that is from about 40.degree. to about
50.degree..
[0062] Latch back 72 can extend away from latch bottom 68 toward
vertical lip 64. The slanted surface 76 can be provided between top
planar slanted surface 62 and latch 66. Flat surface 70 can
intersect slanted surface 76. According to some embodiments, the
slanted surface 76 can comprise a curved top surface 78 that is
parallel to top surface 22 of plank 20.
[0063] Vertical lip 64 can be spaced further away from vertical
wall 60 than is latch back 72. According to some embodiments,
vertical wall 60 can have a height that is from about 30% to about
60% or from about 40% to about 50% of the height of plank 20.
[0064] With reference again to FIG. 1, according to various
embodiments, first longitudinal side 27, like first end 26
discussed above, can comprise a tongue edge, and second
longitudinal side 29, like second end 28 discussed above, can
comprise a mating groove edge. In another embodiment of the present
invention, plank 20 can include a protruding lip along first
longitudinal side 27 and a shoulder extending along second
longitudinal side 29 opposite first longitudinal side 27, as
discussed in U.S. patent application Ser. No. 11/190,452,
incorporated by reference in its entirety herein. In another
embodiment, the first longitudinal side 27 and the second
longitudinal side 29 can comprise a tongue and groove profile
different from the first end 26 and the second end 28, such as the
tongue and groove profiles described in U.S. patent application
Ser. No. 11/190,452. Essentially, any combination of groove and
tongue profiles of the present invention can be present on each
plank 20. According to various embodiments, plank 20 can have a
tongue edge at a first end, as described above, a groove edge at a
second end, as discussed above, and the remaining two longitudinal
sides can have straight edges with no mechanical lock or connecting
system or conventional tongue/groove or conventional spline and
groove connections or other connecting means. For purposes of the
present invention, in at least one embodiment, the planks of the
present invention have at least the tongue profile on at least a
first end of each plank and a groove profile on at least a second
end each of plank 20 (e.g., the opposing side), whereas first
longitudinal side 27 and second longitudinal side 29 can have other
connecting means, such as tongue/groove systems, mechanical lock
systems, adhesive systems, and/or spline systems, and the like. In
at least one embodiment, the tongue profile of the present
invention is on one short edge of a plank and the groove profile of
the present invention is on an opposing short edge of the same
plank.
[0065] In accordance with various embodiments, the plank of the
present teachings can have any length or width. The length of the
plank can be defined as the distance between the first end of the
plank and the second end of the plank. In some embodiments, the
length of the plank can be, for example, from about 32 inches to
about 52 inches, or about 48 inches. The width of the plank can be
defined as the distance between the first longitudinal side of the
plank and the second longitudinal side of the plank. In some
embodiments, the width of the plank can be, for example, from about
5 inches to about 16 inches, or about 8 inches. The plank can have
a height that is defined as the distance from the top surface of
the plank to the bottom surface of the plank. In some embodiments,
the height of the plank can be from about 0.25 inch to about 0.75
inch, or about 0.50 inch. The plank can be manufactured as a solid
piece, can be extruded, can be injection molded, or can otherwise
be formed, for example, with interior channels or voids of various
dimensions.
[0066] With reference to the surface covering system shown in FIGS.
7 and 8, groove edge 32 of a first plank can be configured to
receive tongue edge 30 of a second plank in a first relative
orientation. Upon joining, no gaps or one or more gaps can exist
between the connected edges. One of the two planks can be moved
toward the other in a direction substantially perpendicular to the
first and second ends of the planks. The opening of groove edge 32
receives the tongue edge 30 as the two planks are connected. The
tongue edge 30 and groove edge 32 can be configured to ensure that
two connecting planks can be firmly coupled to each other in a
manner that avoids lateral movement in the horizontal plane (in a
direction along the plane of the core) and in a manner that avoids
movement in a vertical plane (in a direction perpendicular to the
plane of the core). The joining of the planks using the profiles of
the present invention can be achieved by laterally joining with no
or slight angling the two planks by sliding them together. A little
pushing force (e.g., tapping) may be used to accomplish this
joining. The slight angling can be by lifting one non-joining edge
of one plank (e.g., the plank where the tongue profile is entering
the groove profile of another plank). The angle can be from
1.degree. to 40.degree., such as 1.degree. to 30.degree., 1.degree.
to 25.degree., 1.degree. to 20.degree., 5.degree. to 20.degree.,
5.degree. to 15.degree., 3.degree. to 10.degree., and like, with
the angle relative to the surface of the floor or substrate where
the planks rest on.
[0067] FIG. 7 is a cross-sectional enlarged view of the connection
between a first floor plank 86 and a second floor plank 88 in an
exemplary flooring system 84 according to the present teachings. In
flooring system 84, two floor planks, 86 and 88, are designed to
mate with one another, and when mated, cannot move in a vertical or
horizontal direction with respect to each other. Tongue edge 30 can
comprise a profile that is substantially or fully complementary to
the shape of groove edge 32. As used herein, the phrase
"substantially complementary" means that when operatively
connected, the groove edge and the tongue edge can have one or more
gaps therebetween, wherein, if gaps are provided, each gap provides
a spacing between adjacent surfaces of the tongue edge and the
groove edge and the spacing is no more than 11% of the thickness of
the plank, such as from 1% to 11%, from 1.25% to 8%, from 1.4% to
6%, from 1.5% to 4%, from 1.7% to 3%, or from about 1.7% to 2% of
the thickness (height) of the plank. The joined planks can have no
play or can have play (e.g., lateral movement once connected).
[0068] As can be seen in FIG. 7, the tongue profile of plank 86 and
the groove profile of plank 88 are not identical or even nearly
identical with respect to mating surfaces. In other words, the
tongue profile and the outline of the groove profile do not match
each other like a square cube going into a recess having the same
square dimensions. According to some embodiments, the planks of the
present invention can have a tongue profile and a groove profile
such that when the tongue profile and groove profile are connected
to form a mechanical lock, a significant void volume is created by
the gaps between the connected tongue and groove, especially
compared to conventional tongue and groove profiles. This void
volume, for instance, reflects the amount of open space that exists
once the tongue edge and the groove edge are connected together and
further shows the amount of open space which permits the tongue to
engage the groove or vice versa in an easy fashion, and yet obtain
and maintain a good mechanical lock. According to various
embodiments, the groove profile does not at all mimic the tongue
profile and the two profiles are significantly different or are not
mirror images or perfect compliments of each other.
[0069] FIG. 8 is an enlarged view of one embodiment of the two
connected planks, 86 and 88, of flooring system 84 depicted in FIG.
7. As can be seen in FIG. 8, with reference to FIGS. 3-6, tongue
edge 30 and groove edge 32 connected, vertical lip 64 of groove
edge 32 can abut vertical lip 38 of tongue edge 30, and a gap or
void volume can exist between one or more of the remaining mating
surfaces of tongue edge 30 and groove edge 32. The gaps between the
mating surfaces of tongue edge 30 and groove edge 32 for one
embodiment are identified in FIG. 8. According to various
embodiments, a first gap 90 can be formed between latch back 72 of
second plank 88 and channel back 44 and channel bottom 42 of first
plank 20. A second gap 92 can be formed between top planar slanted
surface 36 of first plank 86 and top planar slanted surface 62 of
second plank 88. In some embodiments, the gap thickness of second
gap 92 can be from about 0.05 mm to about 0.40 mm. In at least one
embodiment, the gap thickness of second gap 92 can be about 0.15
mm.
[0070] According to various embodiments, a third gap 94 can be
formed between vertical distal surface 34 of first plank 86 and
vertical wall 60 of second plank 88. According to some embodiments,
a fourth gap 96 can be formed between slanted tongue bottom 35 of
first plank 86 and bottom planar slanted surface 80 of second plank
88. In at least one embodiment, a fifth gap 98 can be formed
between the vertical shoulder 56 of first plank 86 and vertical
shoulder 82 of second plank 88.
[0071] According to some embodiments, the void volume of first gap
90 can be at least 0.13 mm.sup.2.times.L (e.g., 0.13
mm.sup.2.times.L to 0.19 mm.sup.2.times.L or more), wherein L is
the length (in mm) of the tongue or groove along the end of the
plank. Thus, the void volume (in mm.sup.3) would be at least 0.13
mm.sup.2 multiplied by the length of the tongue or groove (in mm)
along the side of the plank. The length of the tongue and the
length of the groove should be the same. For example, L can be from
50 mm to 200 mm. Preferably, the void volume (in mm.sup.3) for the
area designated 90 in FIG. 8 is at least 0.19 mm.sup.2.times.L or a
void volume of from 0.13 mm.sup.2.times.L to about 0.19
mm.sup.2.times.L. The void volume of second gap 92 can be in the
amount of at least 0.13 mm.sup.2.times.L, or at least 0.40
mm.sup.2.times.L, or at least 1.0 mm.sup.2.times.L, for example,
from about 0.20 mm.sup.2.times.L to about 0.90 mm.sup.2.times.L, or
from about 0.40 mm.sup.2.times.L to about 0.85 mm.sup.2.times.L.
The void volume of third gap 94 can be in the amount of at least
0.58 mm.sup.2.times.L, or at least 1 mm.sup.2.times.L, or at least
1.3 mm.sup.2.times.L, for example, from about 0.58 mm.sup.2.times.L
to about 2.13 mm.sup.2.times.L, or from about 0.75 mm.sup.2.times.L
to about 2 mm.sup.2.times.L. The void volume of fourth gap 96 can
be about 0.32 mm.sup.2.times.L, or at least 0.5 mm.sup.2.times.L,
or at least 1 mm.sup.2.times.L, for example, from about 0.4
mm.sup.2.times.L to 2.85 mm.sup.2.times.L, or 0.8 mm.sup.2.times.L
to about 2.2 mm.sup.2.times.L. The void volume of fifth gap 98 can
be in the amount of at least 0.07 mm.sup.2.times.L or at least 0.2
mm.sup.2.times.L, or a void volume of from about 0.07
mm.sup.2.times.L to about 0.45 mm.sup.2.times.L or from about 0.1
mm.sup.2.times.L to 0.3 mm.sup.2.times.L.
[0072] Again with reference to FIGS. 3-6 and 8, tongue edge 30 of a
first of the at least two floor planks is detachably lockable into
groove edge 32 of a second of the at least two floor planks such
that latch 66 of second plank 88 is secured between vertical lip 38
and pinnacle rail 52 of first plank 86. In some embodiments, the
tongue profile and the groove profile are designed such that tongue
edge 30 and groove edge 32 can be connected multiple times without
a decrease in locking strength and also, or alternatively, without
a decrease in the tightness of the mechanical lock between tongue
edge 30 and groove edge 32. With many previous conventional tongue
and groove systems, the connecting of the tongue with the groove
can only be done once or twice before the integrity of the tongue
and/or groove dramatically decreases, resulting in a mechanical
lock that is loose or faulty. In some embodiments of the present
teachings, however, multiple connecting between tongue edge 30 and
groove edge 32 is enabled while retaining connecting strength and
tightness of the mechanical lock, for example, which is the same or
better as compared to the first time that tongue edge 30 and groove
edge 32 are connected together.
[0073] In some embodiments of the present invention, the planks can
have a tongue profile and a groove profile that can be joined
together by inserting tongue edge 30 of one plank into groove edge
32 of another plank or inserting groove edge 32 of a plank onto a
tongue edge 30 of another plank, for example, while one plank is
(or both planks are) lying flat on a surface.
[0074] Tongue edge 30 and groove edge 32 can be configured to have
any suitable dimension, as long as tongue edge 30 is prevented from
moving horizontally relative to the plane of the connected planks,
once tongue edge 30 enters the cavity of groove edge 32. FIG. 9
shows exemplary measurements for various parts of tongue edge 30,
which measurements are designated H1, H2, H3, H4, and H5. According
to various embodiments, H1 can be 0.087 inch, H2 can be 0.010 inch,
H3 can be 0.031 inch, H4 can be 0.151 inch, H5 can be 0.063 inch,
H6 can be 0.128 inch, and H7 can be 0.065 inch. As an example, any
one or more of these measurements can be (or vary) .+-.20%,
.+-.15%, .+-.10%, .+-.5%, .+-.2%, .+-.1% from one or more of these
particular measurements.
[0075] FIG. 10 shows exemplary measurements for various parts of
groove edge 32, which measurements are designated H8, H9, H10, H11,
H12, and H13. According to various embodiments, H8 can be 0.024
inch, H9 can be 0.163 inch, H10 can be 0.050 inch, H11 can be 0.123
inch, H12 can be 0.039 inch, and H13 can be 0.040 inch. As an
example, any one or more of these measurements can be (or vary)
.+-.20%, .+-.15%, .+-.10%, .+-.5%, .+-.2%, .+-.1% from one or more
of these particular measurements. It should be understood that the
measurements shown are exemplary and for illustrative purposes
only, and that other measurements can be used without departing
from the scope of the invention.
[0076] The surface-covering of the present invention can be for
flooring surfaces. The connecting and surface-covering system of
the present invention can be used in a variety of applications,
including, but not limited to, wall planks, ceiling planks, decks,
patios, furniture surfaces, shelves, and other surface-coverings or
parts thereof. The connecting system of the present invention can
be used to connect a variety of surface-covering products. Any
surface-covering product capable of being formed into a plank such
that the surface-covering of the present invention can be used as
part of this invention to form the surface-covering. For instance,
laminate floor products can be connected by the connecting system
of the present invention. Other floor products that can be
connected together by the connecting system of the present
invention include, but are not limited to, plastic-containing
products, such as, for example, hard surface products. The plank of
the present invention having a groove, optional shoulder, tongue,
and optional protruding lip can be formed by milling/cutting
techniques, extrusion, injection molding, and the like. In
cellulosic-type products, the groove and optional shoulder can be
machined into dimensions to receive the tongue and optional
protruding lip of a similar plank. The planks of the present
invention can also be formed by other molding techniques or other
conventional technology used to form polymeric materials having
designed shapes and forms.
[0077] The planks of the present invention can be made from a
polymeric material. The polymeric material of the plank of the
present invention can comprise a thermoplastic material, although
other types of polymers can also be used. Examples of polymeric
materials that can be used to form the plank of the present
invention include, but are not limited to, vinyl-containing
thermoplastics, such as polyvinyl chloride, polyvinyl
chloride/rubber blends, polyvinyl acetate, polyvinyl alcohol, and
other vinyl and vinylidene resins and copolymers thereof;
polybutyleneterephthalate (PBT), polyethylenes such as low density
polyethylenes and high density polyethylenes,
polyethyleneterephthalate (PET), and copolymers thereof; styrenes,
such as acrylonitrilebutadiene styrene (ABS), SAN, and polystyrenes
and copolymers thereof; polypropylene and copolymers thereof;
saturated and unsaturated polyesters; acrylics; polyamides, such as
nylon containing types; engineering plastics, such as acetal,
polycarbonate, polyamide, polysulfone, and polyphenylene oxide and
sulfide resins and the like. One or more conductive polymers can be
used to form the plank that has applications in conductive flooring
and the like. The thermoplastic polymers set forth in Kirk Othmer
(3.sup.rd Edition, 1981) at pp. 328 to 848 of Vol. 18 and pp.
385-498 of Vol. 16, (incorporated in their entirety by reference
herein) can also be used as long as the resulting plank has
sufficient strength for its intended purpose. The planks can
contain optional ingredients like filler(s), like wood flour,
cellulosic fibers, and/or conventional polymeric additives, like
flame retardants, UV protectors, stabilizers, plasticizers, and the
like. The polymeric planks of U.S. Pat. No. 6,617,009 B1
(incorporated herein in its entirety by reference) can be used
herein, with the profiles of the present invention.
[0078] The plank of the present invention can also be made from
other materials, such as solid wood, engineered wood, wood based
material, like fiberboard (e.g., MDF, HDF), particle board,
plywood, oriented strand board, chip board, various types of
laminates, such as high-pressure laminates, natural, organic,
recycled, or synthetic materials, solid wood, engineered wood, and
the like. The planks can be made from any conventional materials
used in the laminate or plank flooring industry.
[0079] With respect to the mechanical lock between the tongue edge
and groove edge in the present invention, in one embodiment, there
is no play between the tongue edge and groove edge once the tongue
is locked into the groove or vice versa. Furthermore, in one
embodiment, there is no biasing or spring force in the tongue edge
and/or groove edge or tension created by the tongue edge locking
into the groove edge or vice versa. In at least one embodiment of
the present invention, the tongue profile and/or the groove profile
are rigid enough such that the flexing of the profiles that mate
with one another is essentially zero or is zero. In other
embodiments, there can be a biasing or spring force or tension
created when the tongue edge engages the groove edge or vice
versa.
[0080] The planks of the present invention can include a top
layer(s) on the core. For example, the top layer can include (a) a
high pressure laminate construction that is comprised of an
impregnated underlayer Kraft paper, a printed decorative layer, and
an impregnated protective overlay compressed together with heat and
pressure to become one single layer; (b) a wood veneer; or (c) a
vulcanized cellulose layer that is made from a number of plies of
paper treated with zinc chloride (or other agent), an acid to make
the surfaces of the paper gummy and sticky, wherein the gummy plies
are then pressed together. The plank of the present invention does
not require a backing layer. Preferably, in at least some
embodiments, the planks have no backing layer. In other
embodiments, a conventional backing layer(s) can be present.
[0081] In addition, the decorative element such as wood grains
and/or knots texture can be embossed (e.g., mechanical or
engraved), wherein the design can then be directly printed on the
surface using, for example, a non-contact type digital printing
technology. Another option is to incorporate the pigments into an
extrusion operation to create a wood grain look on the surface of
the planks by disturbing the material flow in the extruder. The
decorative element can be any design, like natural appearances,
stone, brick, tile, ceramic, wood, marble, and the like or can be
other designs common to or used by the floor industry. The design
and overall upper layers can be textured, such as embossed in
register with the design.
[0082] In one example, the top layer is a laminate on top of the
core; a print layer can be affixed to the top surface of the core,
wherein the print layer has a top surface and a bottom surface. The
print layer can be a resin layer(s), or a resin impregnated printed
paper, such as an aminoplast resin. The print layer can have a
printed design. The printed design can be any design which is
capable of being printed onto the print layer. The print layer can
also be known as a decor print layer. The print layer can be
prepared by rotogravure printing techniques or other printing means
such as digital printing. Once a design is printed on the paper,
the paper can then be impregnated with one or more resin(s) or
mixtures thereof. The resin can be aminoplast. The resin can
contain formaldehyde, such as urea formaldehyde or melamine
formaldehyde, or a blend thereof. With respect to the optional
laminate on top of the core, a print or design or decorative layer
can be affixed to the top surface of the core, wherein the print
layer has a top surface and a bottom surface. The print layer can
be a resin impregnated printed paper. The print layer can have a
printed design. The printed design can be any design which is
capable of being printed onto the print layer. The print layer is
also known as a decor print layer. Generally, the print layer can
be prepared by rotogravure printing techniques or other printing
means such as digital printing. Once the paper has the design
printed on it, the paper can then be impregnated with a resin or
mixtures thereof. The resin can be an aminoplast resin or can
contain urea formaldehyde and/or a melamine formaldehyde, or other
formaldehydes or other amines. The design or print layer can
simulate any natural surface, such as wood, ceramic, concrete,
tile, brick, stone, or non-natural looking surfaces. Essentially,
any type of design, whether natural in appearance or not, can be
used as the design on the print layer or can be the design located
on the plank by methods described below or methods conventional in
the area of surface coverings.
[0083] The print paper, also known as the Deco paper, can have the
ability to have liquids penetrate the paper such as a melamine
liquid (or other liquid resin or polymer) penetrating in about 3 to
4 seconds and also maintain a wet strength and even fiber
orientation to provide good reinforcement in all directions. The
type of paper used can be 50 to 75 g/m.sup.2 weight and having a
thickness of 0.05 to 0.25 mm. The saturation of the coating can be
from about 50 g/m.sup.2 to 75 g/m.sup.2 or above or below these
ranges.
[0084] Located optionally on the top surface of the print layer can
be an overlay. The overlay which can also be known as the wear
layer is an overlay paper, which upon being affixed onto the print
layer, is clear in appearance. The overlay paper is, preferably, a
high abrasive overlay which can contain wear resistant particles,
such as aluminum oxide embedded in the surface of the paper. In
addition, the paper can be impregnated with a resin(s) just as with
the print layer. Various commercial grades of high abrasive
overlays are, preferably, used such as those from Mead Specialty
Paper with the product numbers TMO 361, 461 (70 gram/m.sup.2
premium overlay from Mead), and 561 wherein these products have a
range of Taber values of 4000 to 15000. The type of paper
preferably used is about 46 g/m.sup.2 and having a thickness of
about 0.13 mm.
[0085] With respect to the print layer and the overlay, the amount
of resin can be from about 60 to about 140 g/m.sup.2, such as from
about 100 to about 120 g/m.sup.2.
[0086] As an option, an underlay can be located and affixed between
the bottom surface of the print layer and the top surface of the
core. The underlay can be paper impregnated with a resin(s) as
described above with respect to the print layer and overlay. The
underlay can be Kraft paper impregnated with a resin(s) (e.g.,
aminoplast, phenolics, phenolic formaldehyde resin, melamine
formaldehyde resin, and the like), which is present in an amount of
from about 60 g/m.sup.2 to about 145 gm.sup.2, such as from about
100 g/m.sup.2 to about 120 g/m.sup.2 paper. The type of paper used
can be about 145 g/m.sup.2 and having a thickness of about 0.25 mm.
Other paper can be used.
[0087] Other types of layers, which can be used in the present
invention, such as wood veneer and vulcanized cellulose layers, can
include the same components with respect to the conventional
laminate surfaces. Wood veneers used as the top layer can be any
type of species such as oak, maple, cherry, hickory, beech, pine,
walnut, mahogany, chestnut, and teak and the like. The thickness of
the veneer can be in the range of 0.005 inch to 0.250 inch.
Preferably, the thickness of the veneer is in the range of 0.080
inches to 0.160 inches. The veneer on the top can be decorated with
a printed design to highlight the grains or knots or to mimic
certain wood species or to emboss the surface to create vintage
appearance and the like. A radiation curing coating, like a
urethane acrylate coating(s) or other protective coating(s), can be
applied on the surface to provide surface properties such as
scratch and wear resistance, scuff resistance, stain and/or
chemical resistance. The coating can incorporate the abrasive
resistance particles in the urethane or other coating for better
surface protection. The coating can have an abrasion level of
500-1500 cycles per the NALFA test.
[0088] In addition, excellent moisture resistance and/or sound
deadening qualities of this product can eliminate the need for
underpadding, though use of underpadding is an option.
[0089] A further embodiment of the present invention relates to a
plank which comprises the same plank described above but, in lieu
of a top layer on top of the plank, a design is printed directly on
the top surface of the plank using any number of printing
techniques such as gravure printing, transfer printing, digital
printing, flexo printing, and the like. Or, a printed thermoplastic
film (e.g., PVC) or a wood veneer and the like can be laminated to
a thermoplastic plank. A protective coating can then be placed on
top of the printed design. Any type of protective coating or wear
layer can be used, such as a polyurethane type coating with or
without wear resistant particles in the coating. Thus, a plank
would have a core, where the core has a top surface and bottom
surface as well as opposing sides and a printed design directly on
the top surface of the plank and optionally at least one protective
coating on top of the printed design. The top surface of the plank
as described earlier can have a textured surface as described
above.
[0090] This type of plank can be made by extruding a material
containing at least one polymeric material into the shape of the
core and then printing a design directly on the top surface of the
plank and then, optionally, applying at least one protective
coating on top of the printed design and curing the protective
coating. The protective coating can be applied by conventional
techniques, such as with a curtain coater, direct roll coater,
vacuum coater, differential roll coater, air knife coater, or spray
apparatus.
[0091] In another embodiment of the present invention, a plank for
surface coverings, such as flooring, has a core and an extruded
layer on the top surface of the core, wherein the extruded layer
includes at least one thermoplastic material with one or more
pigmented compounds. The extruded layer on top of the extruded core
can simulate various designs such as wood grain and the like.
[0092] The plank in this embodiment can be made by co-extrusion
techniques which involve extruding the core and extruding either
simultaneously or subsequently a layer containing at least one
thermoplastic material with one or more pigmented compounds on top
of the extruded core.
[0093] Another embodiment involves a plank having the same design
as described above with a printed polymeric film, such as a PVC
film placed on the top surface of the extruded core. The printed
polymeric film can be a polymeric film having a printed design on
the film wherein the film can be from about 10 to about 20 mil
thick. One or more wear layers or protective coatings can be placed
on top of the printed polymeric film. The polymeric film can be
placed on top of the extruded core by typical lamination
techniques, such as heating the printed film, then pressing the
film to the extruded core to bond them together, or using glue to
bond them together.
[0094] In one embodiment, where the core material is thermoplastic,
like polyvinyl chloride, the core material, in this case, can be
produced by metering the appropriate quantities of vinyl compound
(or other polymer, like a rigid polymer, like a rigid vinyl
chloride) and optional color concentrate into the feed end of an
extruder. The extruder imparts the appropriate properties on the
material through the manipulation of heating zones, cooling zones,
screw temperature and rpm. The material then exits the extruder
through a metal die which is machined with the intended profile
design. As the material passes through the die the exiting mass
(continuous in length) takes the shape of the machined profile. The
profiled material exiting the extruder then enters a calibration
unit which controls and if necessary manipulates critical
dimensions through the cooling process. The calibration unit
utilizes water temperature and flow rate to control profile
measurements. The material exiting the calibration unit is a cooled
continuous plank with specific profile dimensions. The cooled
continuous plank is then fed into a cutter device which cuts the
planks into specific lengths.
[0095] The wrapping unit can be utilized to adhere a decorative
wear layer, or overlay (for example, a decorative paper with an
electron beam cured acrylic resin or other curable EB resin) to a
specific area of the extruded profile plank surface by means of
heat, adhesive (for example, PU hot melt solid), pressure, and
cooling. Extruded planks stacked in the appropriate orientation can
be guided through multiple sections of a profile wrapping unit. As
planks proceed through the unit, specific areas of the profile can
be surface treated with plasma jets or other surface treatment
(such as the bottom of the plank). At the same time, the PU hot
melt solid is being subjected to sufficient temperatures, such as
from 250.degree. F. to 275.degree. F. resulting in an output of
melted PU adhesive. Additionally, the overlay, which is dispensed
via roll form, is fed into the wrapping unit and subjected to low
levels of heat (below 120.degree. F.). After pre-heating, the
overlay is then coated with roughly 9 grams/ft.sup.2 of adhesive.
In this case, the adhesive is maintained to a temperature of
250.degree. F. in an applicator pan and dispensed evenly with an
applicator roll. The wrapping unit combines overlay, adhesive and
base plank together under pressure by means of rollers. Multiple
sections of rollers continue to apply pressure with rolls and mate
the overlay material to the surface of the profile in a gradual
progression. Additional heat is applied in two additional sections,
for instance, at temperatures of 100.degree. F. and 121.degree. F.
respectively. As the wrapped intermittent planks exit the wrapping
unit, the continuous overlay material is cut by saw to the
corresponding plank lengths. Wrapped planks are then stacked on
pallets until staging for the next process.
[0096] A trimming process can be used and trims back any excess
overlay material and completes the plank width sizing step. Wrapped
planks are stacked into an automated feed unit face down. The
tongue side of the plank is used as a guide as the planks proceed
through the cutting tools. A total of four cutting tools (2 tools
per plank side) are used to trim off excess overlay. The trimming
tools remove the overlay and the exposed ledge together, leaving a
smooth vertical surface. Planks proceed through the trimming
equipment to the end cut section. In this case the planks are cut
to a specific length of 48'' with a clean vertical cut for the end
seam. As planks exit the trimming unit they are staged for
packaging.
[0097] With reference again to the drawings, the present teachings
further relate to a method of connecting planks of the present
teachings, to one another. The method of connecting planks 20 of
the present teachings can include joining a plurality of planks 20
together as shown in FIG. 1. The method can comprise moving a first
plank 20, depicted at the top left of FIG. 1, laterally to the
right, in the direction indicated by the directional arrows, toward
a second plank 20 depicted at the top right of FIG. 1. The first
plank is moved in a direction substantially perpendicular to its
first end and substantially perpendicular to the second end of the
second plank. The tongue edge along the first end of the first
plank can enter the groove edge along the second end of the second
plank. A third plank 20, depicted below the first and second
planks, can then be joined with the first and second planks by
moving the third plank 20 toward the first and second plank 20, in
a direction substantially perpendicular to the first and second
longitudinal sides of the first and second planks. In this manner,
the groove edge along the second longitudinal side of the third
plank 20 can engage and overlap the tongue edge along the first
longitudinal sides of the first plank and the second plank, without
having to lift or otherwise change the orientation of the first and
second planks 20. Alternatively, the third plank can be joined to
the first plank and the second plank as described above, except
that the first plank and the second plank can be moved toward the
third plank, for example, by sliding. As discussed above, the first
and second longitudinal sides of the planks can alternatively be
provided with a different tongue/groove profile, or the edges can
be connected in a conventional tongue/groove manner when
tongue/groove connectors are present on these edges, or connected
by using a spline, or the like.
[0098] Although use of a bonding agent is not necessary, a bonding
agent/composition can, optionally, be applied or be used to connect
two or more planks together.
[0099] With respect to the longitudinal sides or the short sides of
the floor planks, which are joined together in some fashion, the
floor planks of the present invention can have straight edges or
can have a tongue and groove design or there can be some
intermediate connecting system used to join the floor planks
together such as a spline or other connecting device. Again, any
manner in which floor planks can be joined together is embodied by
the present application with respect to these two sides. For
purposes of the present invention, the floor plank can have a
tongue and groove design or similar connecting design on the side
edges of the floor plank. Examples of floor planks that can have
the connecting system(s) of the present invention include, but are
not limited to, the floor planks described in U.S. Pat. Nos.
6,101,778; 6,023,907; 5,860,267; 6,006,486; 5,797,237; 5,348,778;
5,706,621; 6,094,882; 6,182,410; 6,205,639; 3,200,553; 1,764,331;
1,808,591; 2,004,193; 2,152,694; 2,852,815; 2,882,560; 3,623,288;
3,437,360; 3,731,445; 4,095,913; 4,471,012; 4,695,502; 4,807,416;
4,953,335; 5,283,102; 5,295,341; 5,437,934; 5,618,602; 5,694,730;
5,736,227; and 4,426,820 and U.S. Published Patent Application Nos.
20020031646 and 20010021431 and U.S. patent application Ser. No.
09/460,928, and all are incorporated in their entirety by reference
herein.
[0100] Thus, in at least one embodiment, the present invention
encompasses any type of joint or connecting system that adjoins
edges of floor planks together in some fashion with the use of
straight edges, grooves, channels, tongues, splines, and other
connecting systems for at least two edges. Optionally, the planks
can be joined together wherein at least a portion of the planks are
joined together at least in part by an adhesive. An example of such
a system is described in U.S. patent application Ser. No.
10/205,408, which is incorporated herein in its entirety.
[0101] The surface-covering system of the present teachings can be
used in a variety of applications including, but not limited to,
wall planks, ceiling planks, flooring surfaces, decks, patios,
furniture surfaces, shelves, deck planks, fascia, partition planks,
horizontal surfaces, table tops, chest tops, counter tops, and
other surface-coverings or parts thereof.
[0102] Applicants specifically incorporate the entire contents of
all cited references in this disclosure. Further, when an amount,
concentration, or other value or parameter is given as either a
range, preferred range, or a list of upper preferable values and
lower preferable values, this is to be understood as specifically
disclosing all ranges formed from any pair of any upper range limit
or preferred value and any lower range limit or preferred value,
regardless of whether ranges are separately disclosed. Where a
range of numerical values is recited herein, unless otherwise
stated, the range is intended to include the endpoints thereof, and
all integers and fractions within the range. It is not intended
that the scope of the invention be limited to the specific values
recited when defining a range. In some embodiments, dimensions
provided herein for various structural features are for
illustrative purposes only, and are in no way intended to limit the
scope of the present invention.
[0103] Other embodiments of the present teachings will be apparent
to those skilled in the art from consideration of the specification
and practice of the present teachings disclosed herein. It is
intended that the specification and examples be considered as
exemplary only, with the true scope and spirit of the present
invention being indicated by the following claims and equivalents
thereof.
* * * * *