U.S. patent application number 12/587422 was filed with the patent office on 2010-04-08 for flooring panel with first and second decorative surfaces.
Invention is credited to Milton W. Goodwin.
Application Number | 20100083603 12/587422 |
Document ID | / |
Family ID | 42074667 |
Filed Date | 2010-04-08 |
United States Patent
Application |
20100083603 |
Kind Code |
A1 |
Goodwin; Milton W. |
April 8, 2010 |
Flooring panel with first and second decorative surfaces
Abstract
A flooring panel for a flooring system comprises a core
interposed between a first decorative surface and a second
decorative surface. The core has opposing first and second side
surfaces extending substantially perpendicular to the first and
second decorative surfaces. The first and second decorative
surfaces have different visible designs, and at least the first
side surface is provided with at least a portion of a locking
member.
Inventors: |
Goodwin; Milton W.;
(Lancaster, PA) |
Correspondence
Address: |
ARMSTRONG WORLD INDUSTRIES, INC.;LEGAL DEPARTMENT
P. O. BOX 3001
LANCASTER
PA
17604-3001
US
|
Family ID: |
42074667 |
Appl. No.: |
12/587422 |
Filed: |
October 7, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61103642 |
Oct 8, 2008 |
|
|
|
Current U.S.
Class: |
52/589.1 ;
52/792.11 |
Current CPC
Class: |
E04F 2201/0523 20130101;
E04F 2201/0107 20130101; E04F 2201/0146 20130101; F16B 2001/0028
20130101; E04F 2201/0115 20130101; E04F 2201/08 20130101; F16B
5/0056 20130101; F16B 5/002 20130101; E04F 15/02 20130101; F16B
11/006 20130101; E04F 2201/023 20130101; F16B 5/0012 20130101 |
Class at
Publication: |
52/589.1 ;
52/792.11 |
International
Class: |
E04B 2/08 20060101
E04B002/08; E04C 2/34 20060101 E04C002/34 |
Claims
1. A flooring panel for a flooring system, comprising: a core
interposed between a first decorative surface and a second
decorative surface, the core having opposing first and second side
surfaces extending substantially perpendicular to the first and
second decorative surfaces, the first and second decorative
surfaces being impregnated cellulosic layers having different
visible designs; and at least the first side surface being provided
with at least a portion of a locking member.
2. The reversible flooring panel of claim 1, wherein the flooring
panel is symmetrical about a central axis extending substantially
parallel to the first and second decorative surfaces and
substantially perpendicular to the first and second side
surfaces.
3. The reversible flooring panel of claim 1, wherein the second
side surface has at least a portion of a locking member, the
locking member of the first side surface corresponding to the
locking member of the second side surface.
4. The reversible flooring panel of claim 1, wherein the core is a
high density fiberboard or medium density fiberboard.
5. The reversible flooring panel of claim 4, wherein the locking
member on the first side surface is a tongue and the locking member
on the second side surface is a groove.
6. The reversible flooring panel of claim 4, wherein the locking
member on the first side surface is a substantially L-shaped first
locking extension and the locking member on the second side surface
is a substantially L-shaped second locking extension.
7. The reversible flooring panel of claim 4, wherein the locking
member includes a flexible securing member separate from the
flooring panel.
8. A flooring system, comprising: at least a first and second
flooring panel, the first and second flooring panels each having a
core interposed between a first decorative surface and a second
decorative surface, the core having opposing first and second side
surfaces extending substantially perpendicular to the first and
second decorative surfaces, the first side surface of the first
flooring panel being positioned adjacent to the second side surface
of the second flooring panel, the first and second decorative
surfaces being impregnated cellulosic layers having different
visible designs; and a locking member extending between the first
side surface of the first flooring panel and the second side
surface of the second flooring panel that locks the first flooring
panel to the second flooring panel.
9. The flooring system of claim 8, wherein the first and second
flooring panels are symmetrical about a central axis extending
substantially parallel to the first and second decorative surfaces
and substantially perpendicular to the first and second side
surfaces.
10. The flooring system of claim 8, wherein the first decorative
surface of the first flooring panel is in the same plane as the
first decorative surface of the second flooring panel.
11. The flooring system of claim 8, wherein the first decorative
surface of the first flooring panel is in the same plane as the
second decorative surface of the second flooring panel.
12. The flooring system of claim 8, wherein the core is a high
density fiberboard or medium density fiberboard.
13. The flooring system of claim 8, wherein the first and second
flooring panels are mounted on a sub-floor, the first and second
flooring panels being reversible such that the first decorative
surfaces or the second decorative surfaces of the first and second
flooring panels can be mounted adjacent to the sub-floor.
14. The flooring system of claim 13, wherein the first decorative
surface of the first flooring panel is mounted adjacent to the
sub-floor and the second decorative surface of the second flooring
panel is mounted adjacent to the sub-floor.
15. The flooring system of claim 14, wherein the locking member
prevents the first and second flooring panels from moving in a
direction substantially perpendicular to the first and second side
surfaces and in a direction substantially perpendicular to the
first and second decorative surfaces.
16. The flooring system of claim 8, wherein the first and second
flooring panels are identical.
17. The flooring system of claim 8, wherein the locking member
includes a tongue and a groove.
18. The flooring system of claim 17, wherein the tongue has
opposing lateral surfaces provided with indentations corresponding
to projections provided on opposing lateral surfaces of the
groove.
19. The flooring system of claim 17, wherein the tongue is provided
with a hook material corresponding to a loop material provided on
the groove.
20. The flooring system of claim 17, wherein at least the groove is
provided with an adhesive.
21. The flooring system of claim 17, wherein the tongue has
opposing lateral surfaces provided with roughened surfaces
corresponding to roughened surfaces provided on opposing lateral
surfaces of the groove.
22. The flooring system of claim 17, wherein the tongue has at
least one indentation corresponding to at least one projection
provided on the groove.
23. The flooring system of claim 17, wherein the tongue has
opposing lateral surfaces provided with curved profiles
corresponding to curved profiles provided on opposing lateral
surfaces of the groove.
24. The flooring system of claim 8, wherein the locking member
includes substantially L-shaped first locking extension extending
from the first side surface and a substantially L-shaped second
locking extension extending from the second side surface.
25. The flooring system of claim 24, wherein the first and second
locking extensions each have a mating projection and a mating
recess.
26. The flooring system of claim 25, wherein the mating projections
have opposing lateral surfaces provided with indentations
corresponding to projections provided on opposing lateral surfaces
of the mating recesses.
27. The flooring system of claim 25, wherein the mating projections
are provided with a loop material corresponding to hook material
provided on the mating recesses.
28. The flooring system of claim 25, wherein at least the mating
recesses are provided with an adhesive.
29. The flooring system of claim 25, wherein the mating projections
have opposing lateral surfaces provided with roughened surfaces
corresponding to roughened surfaces provided on opposing lateral
surfaces of the mating recesses.
30. The flooring system of claim 25, wherein the mating projections
are provided with at least one indentation corresponding to at
least one projection provided on the mating recesses.
31. The flooring system of claim 25, wherein the mating projections
have opposing lateral surfaces provided with curved profiles
corresponding to curved profiles provided on opposing lateral
surfaces of the mating recesses.
32. The flooring system of claim 8, wherein the locking member
includes a flexible securing member separate from the first and
second flooring panels.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Patent
Application Ser. No. 61/103,642, filed Oct. 8, 2008, which is
hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a flooring panel for a
flooring system wherein the flooring panel has a core provided with
at least a portion of a locking member, and the core is interposed
between opposing first and second decorative surfaces.
BACKGROUND OF THE INVENTION
[0003] Flooring panels, such as laminate flooring panels, include a
core and a top decorative surface with a visible design. Each of
the flooring panels therefore has only a single visible design.
Since most flooring applications require a large number of flooring
panels, it is therefore necessary for manufacturers, distributors
and sellers to inventory a large number of flooring panels for each
type of visible design. Additionally, it is difficult to mix
multiple visible designs in a single flooring application, because
separate flooring panels, which may or may not be compatible for
installation, need to be purchased.
[0004] It is therefore desirable to provide a flooring panel with
more than one decorative surface wherein each of the decorative
surfaces has a different visible design so that the amount of
inventory can be reduced for each type of visible design. It is
further desirable to develop a flooring panel with more than one
decorative surface wherein each of the decorative surfaces has a
different visible design so that multiple visible designs can
easily be mixed to achieve a desired floor design. It is still
further desirable to develop a locking member for the
aforementioned flooring panel so that the flooring panel can easily
be installed with either decorative surface being visible.
BRIEF SUMMARY OF THE INVENTION
[0005] The invention relates to a flooring panel for a flooring
system comprising a core interposed between a first decorative
surface and a second decorative surface. The core has opposing
first and second side surfaces extending substantially
perpendicular to the first and second decorative surfaces. The
first and second decorative surfaces have different visible
designs, and at least the first side surface is provided with at
least a portion of a locking member.
[0006] The invention further relates to a flooring system
comprising at least a first and second flooring panel. The first
and second flooring panels each have a core interposed between a
first decorative surface and a second decorative surface. The core
has opposing first and second side surfaces extending substantially
perpendicular to the first and second decorative surfaces. The
first side surface of the first flooring panel is positioned
adjacent to the second side surface of the second flooring panel.
The first and second decorative surfaces have different visible
designs. A locking member extends between the first side surface of
the first flooring panel and the second side surface of the second
flooring panel and locks the first flooring panel to the second
flooring panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a partial cross sectional view of a first example
of a flooring system including flooring panels according to a first
embodiment of the invention.
[0008] FIG. 2 is partial cross sectional view of a second example
of a flooring system including the flooring panels according to the
first embodiment of the invention.
[0009] FIG. 3 is a cross sectional view of a first alternate
embodiment of a locking member of the flooring panels according to
the first embodiment of the invention.
[0010] FIG. 4 is a cross sectional view of a second alternate
embodiment of the locking member of the flooring panels according
to the first embodiment of the invention.
[0011] FIG. 5 is a cross sectional view of a third alternate
embodiment of the locking member of the flooring panels according
to the first embodiment of the invention.
[0012] FIG. 6 is a cross sectional view of a fourth alternate
embodiment of the locking member of the flooring panels according
to the first embodiment of the invention.
[0013] FIG. 7 is a cross sectional view of a fifth alternate
embodiment of the locking member of the flooring panels according
to the first embodiment of the invention.
[0014] FIG. 8 is a cross sectional view of a sixth alternate
embodiment of the locking member of the flooring panels according
to the first embodiment of the invention.
[0015] FIG. 9 is a cross sectional view of a seventh alternate
embodiment of the locking member of the flooring panels according
to the first embodiment of the invention.
[0016] FIG. 10 is a cross sectional view of the seventh alternate
embodiment of the locking member of the flooring panels according
to the first embodiment of the invention shown in a mated
position.
[0017] FIG. 11 is a perspective view of a flexible securing member
of the seventh alternate embodiment of the locking member of the
flooring panels according to the first embodiment of the
invention.
[0018] FIG. 12 is a cross sectional view of an eighth alternate
embodiment of the locking member of the flooring panels according
to the first embodiment of the invention.
[0019] FIG. 13 is a cross sectional view of the eighth alternate
embodiment of the locking member of the flooring panels according
to the first embodiment of the invention shown in a mated
position.
[0020] FIG. 14 is a perspective view of a flexible securing member
of the eighth alternate embodiment of the locking member of the
flooring panels according to the first embodiment of the
invention.
[0021] FIG. 15 is a partial cross sectional view of a flooring
system including flooring panels according to a second embodiment
of the invention.
[0022] FIG. 16 is a cross sectional view of a first alternate
embodiment of a locking member of the flooring panels according to
the second embodiment of the invention.
[0023] FIG. 17 is a cross sectional view of a second alternate
embodiment of the locking member of the flooring panels according
to the second embodiment of the invention.
[0024] FIG. 18 is a cross sectional view of a third alternate
embodiment of the locking member of the flooring panels according
to the second embodiment of the invention.
[0025] FIG. 19 is a cross sectional view of a fourth alternate
embodiment of the locking member of the flooring panels according
to the second embodiment of the invention.
[0026] FIG. 20 is a cross sectional view of a fifth alternate
embodiment of the locking member of the flooring panels according
to the second embodiment of the invention.
[0027] FIG. 21 is a cross sectional view of a sixth alternate
embodiment of the locking member of the flooring panels according
to the second embodiment of the invention.
[0028] FIG. 22 is a cross sectional view of a seventh alternate
embodiment of the locking member of the flooring panels according
to the second embodiment of the invention shown in a partially
mated position.
[0029] FIG. 23 is a cross sectional view of the seventh alternate
embodiment of the locking member of the flooring panels according
to the second embodiment of the invention shown in a mated
position.
[0030] FIG. 24 is a cross sectional view of an eighth alternate
embodiment of the locking member of the flooring panels according
to the second embodiment of the invention shown in a partially
mated position.
[0031] FIG. 25 is a cross sectional view of the eighth alternate
embodiment of the locking member of the flooring panels according
to the second embodiment of the invention shown in a mated
position.
[0032] FIG. 26 is a partial cross sectional view of a flooring
system including flooring panels according to a third embodiment of
the invention shown in a pre-mated position.
[0033] FIG. 27 is a cross sectional view of the flooring panels
according to the third embodiment of the invention shown in a
partially-mated position.
[0034] FIG. 28 is a cross-sectional view of the flooring panels
according to the third embodiment of the invention shown in a mated
position.
DETAILED DESCRIPTION OF THE EMBODIMENT(S)
[0035] FIG. 1 shows a flooring system 1 including first and second
flooring panels 2, 3 according to a first embodiment of the
invention. As shown in FIG. 1, the flooring system 1 consists of at
least two of the first and second flooring panels 2, 3 mounted on a
sub-floor 4. In the illustrated embodiment, the first and second
flooring panels 2, 3 are identical and each consists of a core 5, a
first decorative surface 6, a second decorative surface 7, and a
locking member 10. The core 5 is interposed between the first and
second decorative surfaces 6, 7. The core 5 may be, for example, a
wood laminate core consisting of one or more layers of high density
fiberboard or medium density fiberboard. The core 5 has opposing
first and second side surfaces 8, 9 that extend substantially
perpendicular to the first and second decorative surfaces 6, 7. The
first decorative surface 6 opposes the second decorative surface 7
and extends substantially parallel thereto. The first and second
decorative surfaces 6, 7 may consist, for example, of a printed and
impregnated cellulosic layer having a desired visible design. The
visible design of the first decorative surface 6 is different from
the visible design of the second decorative surface 7. It will be
appreciated by those skilled in the art, however, that the visible
design of the first decorative surface 6 and the visible design of
the second decorative surface 7 may be the same. Each of the first
and second flooring panels 2, 3 are symmetrical about a central
axis 15 extending substantially parallel to the first and second
decorative surfaces 6, 7 and substantially perpendicular to the
first and second side surfaces 8, 9. The flooring panels 1, 2 can
be of various shape, for example, rectangular, square, or any other
shape.
[0036] The locking member 10 is formed on the first and second side
surfaces 8, 9 of the core 5. The locking member 10 consists of a
tongue 11 and a groove 12. The tongue 11 extends from the first
side surface 8 of the core 5 substantially from a center thereof.
The tongue 11 may be materially formed in one piece with the core
5. The tongue 11 has opposing lateral surfaces provided with
indentations 13. The tongue 11 has a mating surface 16 extending
substantially perpendicular to the first and second decorative
surfaces 6, 7. The mating surface 16 may be beveled to facilitate
insertion of the tongue 11 into the groove 12. The groove 12 is
formed in the second side surface 9 of the core 5 in a substantial
center thereof. The groove 12 has a size and configuration
corresponding to the size and configuration of the tongue 11. The
groove 12 has an abutment surface 17 extending substantially
perpendicular to the first and second decorative surfaces 6, 7. The
groove 12 has opposing lateral surfaces provided with projections
14 corresponding to the indentations 13 of the tongue 11. The
projections 14 may be materially formed in one piece with the core
5. The tongue 11 and the groove 12 are formed such that when the
first side surface 8 of the first flooring panel 2 opposes the
second side surface 9 of the second flooring panel 3, the tongue 11
is capable of mating with the groove 12 and locking therewith.
Although the tongue 11 is shown and described herein as having the
indentations 13 and the groove 12 is shown and described herein as
having the projections 14, it will be appreciated by those skilled
in the art that alternatively the tongue 11 may be formed to have
the projections 14 and the groove 12 may be formed to have the
indentations 13. Further, it is not necessary that the number of
the projections 14 and the number of the indentations 13 be the
same or be limited to two, the number of the projections 14 and the
number of the indentations 13 may be varied to achieve a desired
result.
[0037] As shown in FIG. 1, when the first and second flooring
panels 2, 3 are mounted on the sub-floor 4, the first and second
flooring panels 2, 3 are arranged such that the second decorative
surfaces 7 of both of the first and second flooring panels 2, 3 are
arranged adjacent to the sub-floor 4. The first side surface 8 of
the first flooring panel 2 opposes the second side surface 9 of the
second flooring panel 3. The tongue 11 of the first flooring panel
2 is inserted into the groove 12 of the second flooring panel 3 so
that the projections 14 engage with the indentations 13 to lock the
first flooring panel 2 to the second flooring panel 3. When the
first flooring panel 2 is locked to the second flooring panel 3,
the first and second flooring panels 2, 3 are prevented from moving
in a direction substantially perpendicular to the first and second
decorative surfaces 6, 7 and in a direction substantially
perpendicular to the first and second side surfaces 8, 9. It will
be appreciated by those skilled in the art, however, that the first
and second flooring panels 2, 3 may also be arranged such that the
first decorative surfaces 6 of both of the first and second
flooring panels 2, 3 are arranged adjacent to the sub-floor 4.
Thus, because the first and second flooring panels 2, 3 are
reversible, the visible design of the first decorative surface 6 or
the visible design of the second decorative surface 7 may be made
visible depending on the desired floor design.
[0038] FIG. 2 shows a second example of the flooring system 1
including the first and second flooring panels 2, 3 according to
the first embodiment of the invention. As shown in FIG. 2, when the
first and second flooring panels 2, 3 are mounted on the sub-floor
4, the first and second flooring panels 2, 3 are arranged such that
the first decorative surface 6 of the first flooring panel 2 and
the second decorative surface 7 of the second flooring panel 3 are
arranged adjacent to the sub-floor 4. The first side surface 8 of
the first flooring panel 2 opposes the second side surface 9 of the
second flooring panel 3. The tongue 11 of the first flooring panel
2 is inserted into the groove 12 of the second flooring panel 3 so
that the projections 14 engage with the indentations 13 to lock the
first flooring panel 2 to the second flooring panel 3. When the
first flooring panel 2 is locked to the second flooring panel 3,
the first and second flooring panels 2, 3 are prevented from moving
in a direction substantially perpendicular to the first and second
decorative surfaces 6, 7 and in a direction substantially
perpendicular to the first and second side surfaces 8, 9. Thus,
because the first and second flooring panels 2, 3 are not only
reversible, but also the locking member 10 is configured to be
reversible, the visible design of the first decorative surface 6
and the visible design of the second decorative surface 7 may be
caused to alternate depending on the desired floor design.
[0039] FIG. 3 shows a first alternate embodiment of the locking
member 10 of the first and second flooring panels 2, 3 according to
the first embodiment of the invention. As shown in FIG. 3, the
locking member 10 consists of the tongue 11 and the groove 12. The
mating surface 16 of the tongue 11 is provided with a hook material
20. The abutment surface 17 of the groove 12 is provided with a
loop material 21. The tongue 11 of the first flooring panel 2 is
inserted into the groove 12 of the second flooring panel 3 so that
the hook material 20 engages with the loop material 21 to lock the
first flooring panel 2 to the second flooring panel 3. Although the
tongue 11 is shown and described herein as having the hook material
20 and the groove 12 is shown and described herein as having the
loop material 21, it will be appreciated by those skilled in the
art that alternatively the tongue 11 may be formed to have the loop
material 21 and the groove 12 may be formed to have the hook
material 20.
[0040] FIG. 4 shows a second alternate embodiment of the locking
member 10 of the first and second flooring panels 2, 3 according to
the first embodiment of the invention. As shown in FIG. 4, the
locking member 10 consists of the tongue 11 and the groove 12. The
abutment surface 17 of the groove 12 is provided with an adhesive
22. The adhesive 22 may be, for example, a pressure sensitive
adhesive or a microsphere encapsulated adhesive. The tongue 11 of
the first flooring panel 2 is inserted into the groove 12 of the
second flooring panel 3 so that the mating surface 16 engages the
adhesive 22 to lock the first flooring panel 2 to the second
flooring panel 3. Although the abutment surface 17 of the groove 12
is shown and described herein as being provided with the adhesive
22, it will be appreciated by those skilled in the art that
alternatively the mating surface 16 of the tongue 11 may be
provided with the adhesive 22. Additionally, the adhesive 22 may be
a two part adhesive wherein a first part of the adhesive is applied
to the mating surface 16 and a second part of the adhesive is
applied to the abutment surface 17 or vice versa.
[0041] FIG. 5 shows a third alternate embodiment of the locking
member 10 of the first and second flooring panels 2, 3 according to
the first embodiment of the invention. As shown in FIG. 5, the
locking member 10 consists of the tongue 11 and the groove 12. The
opposing lateral surfaces of the tongue 11 and the opposing lateral
surfaces of the groove 12 are provided with roughened surfaces at
23, 24, respectively. The tongue 11 of the first flooring panel 2
is inserted into the groove 12 of the second flooring panel 3 so
that the roughened surfaces 23, 24 engage to frictionally lock the
first flooring panel 2 to the second flooring panel 3.
[0042] FIG. 6 shows a fourth alternate embodiment of the locking
member 10 of the first and second flooring panels 2, 3 according to
the first embodiment of the invention. As shown in FIG. 6, the
locking member 10 consists of the tongue 11 and the groove 12. The
opposing lateral surfaces of the tongue 11 and the groove 12 have
corresponding curved profiles 25, 26, respectively. Each of the
curved profiles 25, 26 is substantially S-shaped. The tongue 11 of
the first flooring panel 2 is inserted into the groove 12 of the
second flooring panel 3 so that the curved profiles 25 of the
tongue 11 engage with the curved profiles 26 of the groove 12 to
lock the first flooring panel 2 to the second flooring panel 3.
[0043] FIG. 7 shows a fifth alternate embodiment of the locking
member 10 of the first and second flooring panels 2, 3 according to
the first embodiment of the invention. As shown in FIG. 7, the
locking member 10 consists of the tongue 11 and the groove 12. The
mating surface 16 is provided with an indentation 27 formed in a
substantial center thereof. The indentation 27 has a substantially
rectangular cross-section. The abutment surface 17 is provided with
a projection 28 extending from a substantial center thereof. The
projection 28 may be materially formed in one piece with the core
5. The projection 28 is configured substantially in the shape of an
arrow in that the projection 28 consists of a shaft with a distal
end having opposing inclined surfaces that converge at a central
point. The tongue 11, of the first flooring panel 2 is inserted
into the groove 12 of the second flooring panel 3 so that the
projection 28 engages with the indentation 27 to lock the first
flooring panel 2 to the second flooring panel 3. Although the
tongue 11 is shown and described herein as having the indentation
27 and the groove 12 is shown and described herein as having the
projection 28, it will be appreciated by those skilled in the art
that alternatively the tongue 11 may be formed to have the
projection 28 and the groove 12 may be formed to have the
indentation 27.
[0044] FIG. 8 shows a sixth alternate embodiment of the locking
member 10 of the first and second flooring panels 2, 3 according to
the first embodiment of the invention. As shown in FIG. 8, the
locking member 10 consists of the tongue 11 and the groove 12. The
mating surface 16 is provided with an indentation 29 formed in a
substantial center thereof. The indentation 29 has a distal portion
having a smaller cross-section than a proximal portion thereof. The
abutment surface 17 is provided with a projection 30 extending from
a substantial center thereof. The projection 28 may be materially
formed in one piece with the core 5. The projection 30 is
configured substantially in the shape of a wedge and has a distal
portion having a greater cross-section than a proximal portion
thereof. The tongue 11 of the first flooring panel 2 is inserted
into the groove 12 of the second flooring panel 3 so that the
projection 30 engages with the indentation 29 to lock the first
flooring panel 2 to the second flooring panel 3. Although the
tongue 11 is shown and described herein as having the indentation
29 and the groove 12 is shown and described herein as having the
projection 30, it will be appreciated by those skilled in the art
that alternatively the tongue 11 may be formed to have the
projection 30 and the groove 12 may be formed to have the
indentation 29.
[0045] FIGS. 9-10 show a seventh alternate embodiment of the
locking member 10 of the first and second flooring panels 2, 3
according to the first embodiment of the invention. As shown in
FIG. 9, the locking member 10 consists of the tongue 11, the groove
12, and a flexible securing member 33. One of the opposing lateral
surfaces of the tongue 11 is provided with an indentation 31 having
a substantially rectangular cross section and an inclined bottom
surface. The opposing lateral surfaces of the groove 12 are
provided with securing member receiving indentations 32
corresponding to the indentation 31 of the tongue 11. A flexible
securing member 33 is arranged in at least one of the securing
member receiving indentations 32. As shown in FIG. 11, the flexible
securing member 33 is separate from the first and second flooring
panels 2, 3 and is a substantially elongated strip having an end
section with a protrusion 34. The protrusion 34 of the flexible
securing member 33 is configured to project from the securing
member receiving indentation 32 when the flexible securing member
33 is received in the securing member receiving indentation 32. The
flexible securing member 33 may be made, for example, by molding,
preferably injection molding, any type of polymer material, such as
nylon, polyethylene terphthlate, polyethylene, or
polypropylene.
[0046] As shown in FIG. 9, as the tongue 11 of the first flooring
panel 2 is inserted into the groove 12 of the second flooring panel
3, the tongue 11 engages the protrusion 34 of the flexible securing
member 33 and pushes the protrusion 34 into the securing member
receiving indentation 32 in one of the opposing lateral surfaces of
the groove 12. As shown in FIG. 10, when the tongue 11 is fully
received in the groove 12, the protrusion 34 of the flexible
securing member 33 is caused to project into the indentation 31 in
the tongue 3 to lock the first flooring panel 2 to the second
flooring panel 3.
[0047] FIGS. 12-13 show an eighth alternate embodiment of the
locking member 10 of the first and second flooring panels 2, 3
according to the first embodiment of the invention. As shown in
FIG. 12, the locking member 10 consists of the tongue 11, the
groove 12, and a flexible securing member 37. The opposing lateral
surfaces of the tongue 11 are provided with indentations 35 having
a substantially rectangular cross section and an inclined bottom
surface. The opposing lateral surfaces of the groove 12 are
provided with securing member receiving indentations 36
corresponding to the indentations 35 of the tongue 11. A flexible
securing member 37 is arranged in each of the securing member
receiving indentations 36. As shown in FIG. 14, the flexible
securing member 37 is separate from the first and second flooring
panels 2, 3 and is a substantially elongated strip having a
substantial V-shape and an end section with a protrusion 38. The
protrusion 38 of the flexible securing member 37 is configured to
project from the securing member receiving indentation 36 when the
flexible securing member 37 is received in the securing member
receiving indentation 36. The flexible securing member 37 may be
made, for example, by molding, preferably injection molding, any
type of polymer material, such as nylon, polyethylene terphthlate,
polyethylene, or polypropylene.
[0048] As shown in FIG. 12, as the tongue 11 of the first flooring
panel 2 is inserted into the groove 12 of the second flooring panel
3, the tongue 11 engages the protrusions 38 of the flexible
securing members 37 and pushes the protrusions 38 into the securing
member receiving indentations 36 in the opposing lateral surfaces
of the groove 12. As shown in FIG. 13, when the tongue 11 is fully
received in the groove 12, the protrusions 38 of the flexible
securing members 37 are caused to project into the indentations 35
in the tongue 3 to lock the first flooring panel 2 to the second
flooring panel 3.
[0049] FIG. 15 shows a flooring system 40 including first and
second flooring panels 41, 42 according to a second embodiment of
the invention. As shown in FIG. 15, the flooring system 40 consists
of at least two of the first and second flooring panels 41, 42
mounted on a sub-floor 43. In the illustrated embodiment, the first
and second flooring panels 41, 42 are identical and each consists
of a core 44, a first decorative surface 45, a second decorative
surface 46, and a locking member 50. The core 44 is interposed
between the first and second decorative surfaces 45, 46. The core
44 may be, for example, a wood laminate core consisting of one or
more layers of high density fiberboard or medium density
fiberboard. The core 44 has opposing first and second side surfaces
47, 48 that extend substantially perpendicular to the first and
second decorative surfaces 45, 46. The first decorative surface 45
opposes the second decorative surface 46 and extends substantially
parallel thereto. The first and second decorative surfaces 45, 46
may consist, for example, of a printed and impregnated cellulosic
layer having a desired visible design. The visible design of the
first decorative surface 45 is different from the visible design of
the second decorative surface 46. It will be appreciated by those
skilled in the art, however, that the visible design of the first
decorative surface 45 and the visible design of the second
decorative surface 46 may be the same. The flooring panels 41, 42
can be of various shape, for example, rectangular, square, or any
other shape.
[0050] The locking member 50 is formed on the first and second side
surfaces 47, 48 of the core 44. The locking member 50 consists of a
first locking extension 51 and a second locking extension 52. The
first locking extension 51 extends from the first side surface 47
of the core 44 on a side proximate the second decorative surface
46. The first locking extension 51 is substantially L-shaped and
includes a mating projection 53 and a mating recess 54. The mating
projection 53 has a mating surface 55 extending substantially
parallel to the first and second decorative surfaces 45, 46. The
mating projection 53 has opposing lateral surfaces provided with
indentations 77. The mating recess 54 has an abutment surface 56
extending substantially parallel to the first and second decorative
surfaces 45, 46. The mating recess 54 has opposing lateral surfaces
provided with projections 76. The projections 76 may be materially
formed in one piece with the first locking extension 51. The first
locking extension 51 may be materially formed in one piece with the
core 44.
[0051] The second locking extension 52 extends from the second side
surface 48 of the core 44 on a side proximate the first decorative
surface 45. The second locking extension 52 is substantially
L-shaped and includes a mating projection 57 and a mating recess
58. The mating projection 57 has a mating surface 59 extending
substantially parallel to the first and second decorative surfaces
45, 46. The mating projection 57 has opposing lateral surfaces
provided with indentations 77 corresponding to the projections 76
of the first locking extension 51. The mating recess 58 has an
abutment surface 60 extending substantially parallel to the first
and second decorative surfaces 45, 46. The mating recess 58 has
opposing lateral surfaces provided with projections 76
corresponding to the indentations 77 of the first locking extension
51. The projections 76 may be materially formed in one piece with
the second locking extension 52. The second locking extension 52
may be materially formed in one piece with the core 44. The second
locking extension 52 has a size and configuration corresponding to
the size and configuration of the first locking extension 51. The
first locking extension 51 and the second locking extension 52 are
formed such that when the first side surface 47 of the first
flooring panel 41 opposes the second side surface 48 of the second
flooring panel 42, the first locking extension 51 is capable of
mating with the second locking extension 52 and locking
therewith.
[0052] As shown in FIG. 15, when the first and second flooring
panels 41, 42 are mounted on the sub-floor 43, the first and second
flooring panels 41, 42 are arranged such that the second decorative
surfaces 46 of both of the first and second flooring panels 41, 42
are arranged adjacent to the sub-floor 43. The first side surface
47 of the first flooring panel 41 opposes the second side surface
48 of the second flooring panel 42. The first locking extension 51
of the first flooring panel 41 is mated with the second locking
extension 52 of the second flooring panel 42 so that the
projections 76 engage the indentations 77 to lock the first
flooring panel 41 to the second flooring panel 42. When the first
flooring panel 41 is locked to the second flooring panel 42, the
first and second flooring panels 41, 42 are prevented from moving
in a direction substantially perpendicular to the first and second
decorative surfaces 45, 46 and in a direction substantially
perpendicular to the first and second side surfaces 47, 48. It will
be appreciated by those skilled in the art, however, that the first
and second flooring panels 41, 42 may also be arranged such that
the first decorative surfaces 45 of both of the first and second
flooring panels 41, 42 are arranged adjacent to the sub-floor 43.
Thus, because the first and second flooring panels 41, 42 are
reversible, the visible design of the first decorative surface 45
or the visible design of the second decorative surface 46 may be
made visible depending on the desired floor design.
[0053] FIG. 16 shows a first alternate embodiment of the locking
member 50 of the first and second flooring panels 41, 42 according
to the second embodiment of the invention. As shown in FIG. 16, the
locking member 50 consists of the first locking extension 51 and
the second locking extension 52. The mating surfaces 55, 59 of each
of the mating projections 53, 57 of the first and second locking
extension 51, 52 are provided with a loop material 62. The abutment
surfaces 56, 60 of each of the mating recesses 54, 58 of the first
and second locking extension 51, 52 are provided with a hook
material 61. The mating projection 53 of the first flooring panel
41 is inserted into the mating recess 58 of the second flooring
panel 42 so that the hook material 61 engages with the loop
material 62, and the mating projection 57 of the second flooring
panel 42 is inserted into the mating recess 54 of the first
flooring panel 41 so that the hook material 61 engages with the
loop material 62 to lock the first flooring panel 41 to the second
flooring panel 42. Although the mating projections 53, 57 are shown
and described herein as having the loop material 62 and the mating
recesses 54, 58 are shown and described herein as having the hook
material 61, it will be appreciated by those skilled in the art
that alternatively the mating projections 53, 57 may be formed to
have the hook material 61 and the mating recesses 54, 58 may be
formed to have the loop material 62 or any other combination
thereof.
[0054] FIG. 17 shows a second alternate embodiment of the locking
member 50 of the first and second flooring panels 41, 42 according
to the second embodiment of the invention. As shown in FIG. 17, the
locking member 50 consists of the first locking extension 51 and
the second locking extension 52. The abutment surfaces 56, 60 of
the mating recesses 54, 58 are provided with an adhesive 63. The
adhesive 63 may be, for example, a pressure sensitive adhesive or a
microsphere encapsulated adhesive. The mating projection 53 of the
first flooring panel 41 is inserted into the mating recess 58 of
the second flooring panel 42 so that the mating surface 55 engages
the adhesive 63 and the mating projection 57 of the second flooring
panel 42 is inserted into the mating recess 54 of the first
flooring panel 41 so that the mating surface 59 engages the
adhesive 63 to lock the first flooring panel 41 to the second
flooring panel 42. Although the abutment surfaces 56, 60 of mating
recesses 54, 58 are shown and described herein as being provided
with the adhesive 63, it will be appreciated by those skilled in
the art that alternatively the mating surfaces 55, 59 of the mating
projections 53, 57 may be provided with the adhesive 63.
Additionally, the adhesive 63 may be a two part adhesive wherein a
first part of the adhesive is applied to the mating surfaces 55, 59
and a second part of the adhesive is applied to the abutment
surfaces 56, 60 or vice versa.
[0055] FIG. 18 shows a third alternate embodiment of the locking
member 50 of the first and second flooring panels 41, 42 according
to the second embodiment of the invention. As shown in FIG. 18, the
locking member 50 consists of the first locking extension 51 and
the second locking extension 52. Opposing lateral surfaces of the
mating projections 53, 57 and opposing lateral surfaces of the
mating recesses 54, 58 are provided with roughened surfaces at 64,
65, respectively. The mating projection 53 of the first flooring
panel 41 is inserted into the mating recess 58 of the second
flooring panel 42 and the mating projection 57 of the second
flooring panel 42 is inserted into the mating recess 54 of the
first flooring panel 41 so that the roughened surfaces 64, 65
engage to frictionally lock the first flooring panel 41 to the
second flooring panel 42.
[0056] FIG. 19 shows a fourth alternate embodiment of the locking
member 50 of the first and second flooring panels 41, 42 according
to the second embodiment of the invention. As shown in FIG. 19, the
locking member 50 consists of the first locking extension 51 and
the second locking extension 52. The opposing lateral surfaces of
the mating projections 53, 57 and the mating recesses 54, 58 have
corresponding curved profiles 66, 67, respectively. Each of the
curved profiles 66, 67 is substantially S-shaped. The mating
projection 53 of the first flooring panel 41 is inserted into the
mating recess 58 of the second flooring panel 42 and the mating
projection 57 of the second flooring panel 42 is inserted into the
mating recess 54 of the first flooring panel 41 so that the curved
profiles 66 of the mating projections 53, 57 engage with the curved
profiles 67 of the mating recesses 54, 58 to lock the first
flooring panel 41 to the second flooring panel 42.
[0057] FIG. 20 shows a fifth alternate embodiment of the locking
member 50 of the first and second flooring panels 41, 42 according
to the second embodiment of the invention. As shown in FIG. 20, the
locking member 50 consists of the first locking extension 51 and
the second locking extension 52. The mating surfaces 55, 59 are
provided with an indentation 68 formed in a substantial center
thereof. The indentation 68 has a substantially rectangular
cross-section. The abutment surfaces 56, 60 are provided with a
projection 69 extending from a substantial center thereof. The
projection 69 may be materially formed in one piece with the core
44. The projection 69 is configured substantially in the shape of
an arrow in that the projection 69 consists of a shaft with a
distal end having opposing inclined surfaces that converge at a
central point. The mating projection 53 of the first flooring panel
41 is inserted into the mating recess 58 of the second flooring
panel 42 and the mating projection 57 of the second flooring panel
42 is inserted into the mating recess 54 of the first flooring
panel 41 so that the projections 68 engage with the indentations 68
to lock the first flooring panel 41 to the second flooring panel
42. Although the mating projections 53, 57 are shown and described
herein as having the indentations 68 and the mating recesses 54, 58
are shown and described herein as having the projection 69, it will
be appreciated by those skilled in the art that alternatively the
mating recesses 54, 58 may be formed to have the projections 69 and
the mating projections 53, 57 may be formed to have the
indentations 68 or any other combination thereof.
[0058] FIG. 21 shows a sixth alternate embodiment of the locking
member 50 of the first and second flooring panels 41, 42 according
to the second embodiment of the invention. As shown in FIG. 21, the
locking member 50 consists of the first locking extension 51 and
the second locking extension 52. The mating surfaces 55, 59 are
each provided with an indentation 70 formed in a substantial center
thereof. The indentation 70 has a distal portion having a smaller
cross-section than a proximal portion thereof. The abutment
surfaces 56, 60 are each provided with a projection 71 extending
from a substantial center thereof. The projection 71 may be
materially formed in one piece with the core 44. The projection 71
is configured substantially in the shape of a wedge and has a
distal portion having a greater cross-section than a proximal
portion thereof. The mating projection 53 of the first flooring
panel 41 is inserted into the mating recess 58 of the second
flooring panel 42 and the mating projection 57 of the second
flooring panel 42 is inserted into the mating recess 54 of the
first flooring panel 41 so that the projections 71 engage with the
indentations 70 to lock the first flooring panel 41 to the second
flooring panel 42. Although the mating projections 53, 57 are shown
and described herein as having the projections 71 and the mating
recesses 54, 58 are shown and described herein as having the
indentations 70, it will be appreciated by those skilled in the art
that alternatively the mating recesses 54, 58 may be formed to have
the projections 69 and the mating projections 53, 57 may be formed
to have the indentations 68 or any other combination thereof.
[0059] FIGS. 22-23 show a seventh alternate embodiment of the
locking member 50 of the first and second flooring panels 41, 42
according to the second embodiment of the invention. As shown in
FIG. 22, the locking member 50 consists of the first locking
extension 51, the second locking extension 52, and the flexible
securing member 33. A distal lateral surface of each of the mating
projections 53, 57 is provided with an indentation 72 having a
substantially rectangular cross section and an inclined bottom
surface. The first side surface 47 of the first flooring panel 41
and the second side surface 48 of the second flooring panel 42 are
each provided with securing member receiving indentations 73
corresponding to the indentations 72 of the mating projections 53,
57. The flexible securing member 33 is arranged in each of the
securing member receiving indentations 73. As shown in FIG. 11 and
previously discussed herein, the flexible securing member 33 is a
substantially elongated strip having an end section with the
protrusion 34. The protrusion 34 of the flexible securing member 33
is configured to project from the securing member receiving
indentation 73 when the flexible securing member 33 is received in
the securing member receiving indentation 73.
[0060] As shown in FIG. 22, as the mating projection 53 of the
first flooring panel 41 is inserted into the mating recess 58 of
the second flooring panel 42 and the mating projection 57 of the
second flooring panel 42 is inserted into the mating recess 54 of
the first flooring panel 41, the mating projections 53, 57 engage
the protrusions 34 of the flexible securing members 33 and push the
protrusions 34 into the securing member receiving indentations 73.
As shown in FIG. 23, when the mating projections 53, 57 are fully
received in the mating recesses 54, 58, the protrusions 34 of the
flexible securing members 33 are caused to project into the
indentations 72 in the mating projections 53, 57 to lock the first
flooring panel 41 to the second flooring panel 42.
[0061] FIGS. 24-25 show an eighth alternate embodiment of the
locking member 50 of the first and second flooring panels 41, 42
according to the second embodiment of the invention. As shown in
FIG. 24, the locking member 50 consists of the first locking
extension 51, the second locking extension 52, and the flexible
securing member 37. A distal lateral surface of each of the mating
projections 53, 57 is provided with an indentation 75 having a
substantially rectangular cross section and an inclined bottom
surface. The first side surface 47 of the first flooring panel 41
and the second side surface 48 of the second flooring panel 42 are
each provided with securing member receiving indentations 75
corresponding to the indentations 74 of the mating projections 53,
57. The flexible securing member 37 is arranged in each of the
securing member receiving indentations 75. As shown in FIG. 14 and
previously discussed herein, the flexible securing member 37 is a
substantially elongated strip having a substantial V-shape and an
end section with a protrusion 38. The protrusion 38 of the flexible
securing member 37 is configured to project from the securing
member receiving indentation 75 when the flexible securing member
37 is received in the securing member receiving indentation 75.
[0062] As shown in FIG. 24, as the mating projection 53 of the
first flooring panel 41 is inserted into the mating recess 58 of
the second flooring panel 42 and the mating projection 57 of the
second flooring panel 42 is inserted into the mating recess 54 of
the first flooring panel 41, the mating projections 53, 57 engage
the protrusions 38 of the flexible securing members 37 and push the
protrusions 38 into the securing member receiving indentations 75.
As shown in FIG. 25, when the mating projections 53, 57 are fully
received in the mating recesses 54, 58, the protrusions 38 of the
flexible securing members 37 are caused to project into the
indentations 74 in the mating projections 53, 57 to lock the first
flooring panel 41 to the second flooring panel 42.
[0063] FIG. 26 shows a flooring system 80 including first and
second flooring panels 81, 82 according to a third embodiment of
the invention. As shown in FIG. 26, the flooring system 80 consists
of at least two of the first and second flooring panels 81, 82
mounted on a sub-floor 83. In the illustrated embodiment, the first
and second flooring panels 81, 82 are identical and each consists
of a core 84, a first decorative surface 85, a second decorative
surface 86, and a locking member 90. The core 84 is interposed
between the first and second decorative surfaces 85, 86. The core
84 may be, for example, a wood laminate core consisting of one or
more layers of high density fiberboard or medium density
fiberboard. The core 84 has opposing first and second side surfaces
87, 88 that extend substantially perpendicular to the first and
second decorative surfaces 85, 86. The first decorative surface 85
opposes the second decorative surface 86 and extends substantially
parallel thereto. The first and second decorative surfaces 85, 86
may consist, for example, of a printed and impregnated cellulosic
layer having a desired visible design. The visible design of the
first decorative surface 85 is different from the visible design of
the second decorative surface 86. It will be appreciated by those
skilled in the art, however, that the visible design of the first
decorative surface 85 and the visible design of the second
decorative surface 86 may be the same. Each of the first and second
flooring panels 81, 82 are symmetrical about a central axis 89
extending substantially parallel to the first and second decorative
surfaces 85, 86 and substantially perpendicular to the first and
second side surfaces 87, 88. The flooring panels 81, 82 can be of
various shape, for example, rectangular, square, or any other
shape.
[0064] The locking member 90 consists of a pair of opposing grooves
91, 92 and a flexible securing member 93. The grooves 91, 92 are
formed in the first and second side surfaces 87, 88, respectively,
in a substantial center thereof. The grooves 91, 92 have a size and
configuration corresponding to the size and configuration of the
flexible securing member 93. The grooves 91, 92 have opposing
lateral surfaces provided with projections 94. The projections 94
are arranged proximate an opening into the grooves 91, 92. The
projections 94 may be materially formed in one piece with the core
5. The flexible securing member 93 is separate from the first and
second flooring panels 81, 82 and is a substantially elongated
strip having a substantially C-shape and end sections with
protrusions 95. The flexible securing member 93 may be made, for
example, by molding, preferably injection molding, any type of
polymer material, such as nylon, polyethylene terphthlate,
polyethylene, or polypropylene.
[0065] As shown in FIG. 26, when the first and second flooring
panels 81, 82 are mounted on the sub-floor 83, the first and second
flooring panels 81, 82 are arranged such that the second decorative
surfaces 86 of both of the first and second flooring panels 81, 82
are arranged adjacent to the sub-floor 83. The first side surface
87 of the first flooring panel 81 opposes the second side surface
88 of the second flooring panel 82. The flexible securing member 93
is inserted into the groove 91 of the first flooring panel 81 until
the protrusion 95 rides over the projection 94 and locks behind the
projection 94. As shown in FIG. 27, the flexible securing member 93
is inserted into the groove 92 of the second flooring panel 82
until the protrusion 95 rides over the projection 94 and locks
behind the projection 94. The protrusions 95 therefore engage with
the projections 94 to lock the first flooring panel 81 to the
second flooring panel 82, as shown in FIG. 28. When the first
flooring panel 81 is locked to the second flooring panel 82, the
first and second flooring panels 81, 82 are prevented from moving
in a direction substantially perpendicular to the first and second
decorative surfaces 85, 86 and in a direction substantially
perpendicular to the first and second side surfaces 87, 88. It will
be appreciated by those skilled in the art, however, that the first
and second flooring panels 81, 82 may also be arranged such that
the first decorative surfaces 85 of both of the first and second
flooring panels 81, 82 are arranged adjacent to the sub-floor 83.
Thus, because the first and second flooring panels 81, 82 are
reversible, the visible design of the first decorative surface 85
or the visible design of the second decorative surface 86 may be
made visible depending on the desired floor design. Additionally,
because the locking member 10 is configured to be reversible, the
visible design of the first decorative surface 85 and the visible
design of the second decorative surface 86 may be caused to
alternate depending on the desired floor design.
[0066] The foregoing illustrates some of the possibilities for
practicing the invention. Many other embodiments are possible
within the scope and spirit of the invention. For example, the
locking member is not limited to the locking members 10, 50, 80
shown and described herein. It will be appreciated by those skilled
in the art that other locking members may be use to lock or
otherwise secure the first flooring panels 2, 41, 81 to the second
flooring panel 3, 42, 82 including but not limited to, other known
mechanical locking members that are formed integral with and/or
separate from the first and second flooring panels 2, 3, 41, 42,
81, 82 or adhesives. Additionally, although the first and second
flooring panels 2, 3, 41, 42, 81, 82 are shown and described herein
as being identical, it will be appreciated by those skilled in the
art that the first and second flooring panels 2, 3, 41, 42, 81, 82
may have other configurations and still be capable of locking
together and performing the functions shown and described herein.
It is, therefore, intended that the foregoing description be
regarded as illustrative rather than limiting, and that the scope
of the invention is given by the appended claims together with
their full range of equivalents.
* * * * *