U.S. patent application number 12/678468 was filed with the patent office on 2010-08-19 for floor covering system.
Invention is credited to Gordon Anderson.
Application Number | 20100205889 12/678468 |
Document ID | / |
Family ID | 40467432 |
Filed Date | 2010-08-19 |
United States Patent
Application |
20100205889 |
Kind Code |
A1 |
Anderson; Gordon |
August 19, 2010 |
FLOOR COVERING SYSTEM
Abstract
A floor covering system (10) including a first layer (14) of
planar material and a second layer (12) of planar material. At
least a portion of the second layer (12) is adapted for laminating
engagement with the first layer (12) to define a floor covering.
The system further includes a locating means for locating two or
more of the second layers in a substantially aligned configuration,
wherein the second layer (12) is adapted to receive the locating
means.
Inventors: |
Anderson; Gordon; (New South
Wales, AU) |
Correspondence
Address: |
KNOBBE MARTENS OLSON & BEAR LLP
2040 MAIN STREET, FOURTEENTH FLOOR
IRVINE
CA
92614
US
|
Family ID: |
40467432 |
Appl. No.: |
12/678468 |
Filed: |
September 18, 2008 |
PCT Filed: |
September 18, 2008 |
PCT NO: |
PCT/AU2008/001387 |
371 Date: |
March 16, 2010 |
Current U.S.
Class: |
52/588.1 |
Current CPC
Class: |
E04F 2203/06 20130101;
E04F 2201/0511 20130101; E04F 15/02 20130101; E04F 15/182 20130101;
E04F 15/18 20130101 |
Class at
Publication: |
52/588.1 |
International
Class: |
E04B 5/00 20060101
E04B005/00 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 18, 2007 |
AU |
2007905089 |
Claims
1. A floor covering system including: a first layer of planar
material; a second layer of planar material, at least a portion of
said second layer being adapted for laminating engagement with said
first layer to define a floor covering; and a locating means for
locating two or more of said second layers in a substantially
aligned configuration, wherein said second layer is adapted to
receive said locating means.
2. A floor covering system according to claim 1, including one or
more locating protrusions extending from one surface of said first
layer.
3. A floor covering system according to claim 2, wherein said
second layer includes one or more locating apertures disposed on
one surface thereof, said apertures being adapted for complementary
engagement with said locating protrusions.
4. A floor covering system according to claim 3, wherein said
locating apertures extend from the top to the bottom surface of
said second layer.
5. A floor covering system according to any one of claims 2 to 4,
wherein said first layer includes four of said locating
protrusions.
6. A floor covering system according to any one of claims 3 to 5,
wherein said second layer includes four of said locating
apertures.
7. A floor covering system according to any one of claims 3 to 6,
wherein said locating apertures are cut from said second layer to
form two or more off-cut portions and wherein said off-cut portions
are bonded to one surface of said first layer to define said
locating protrusions.
8. A floor covering system according to any one of claims 2 to 7,
wherein said locating protrusions are symmetrically disposed about
said first layer.
9. A floor covering system according to any one of claims 2 to 7,
wherein said locating protrusions are asymmetrically disposed about
said first layer.
10. A floor covering system according to any one of claims 3 to 9,
wherein said locating apertures are symmetrically disposed about
said second layer.
11. A floor covering system according to any one of claims 3 to 9,
wherein said locating apertures are asymmetrically disposed about
said second layer.
12. A floor covering system according to any one of the preceding
claims, wherein said second layer includes a pair of interlocking
portions disposed at its longitudinally opposed edges.
13. A floor covering system according to claim 12, wherein said
interlocking portions are adapted to substantially laterally
restrain longitudinally adjacent pairs of said second layers upon
installation.
14. A floor covering system including: a first layer of planar
material; a second layer of planar material, said second layer
being in laminated engagement with said first layer to define a
modular floor tile; and a locating member engageable with at least
a portion of said modular floor tile for locating two or more of
said modular floor tiles in a substantially aligned
configuration.
15. A floor covering system according to claim 14, wherein said
modular floor tile includes one or more locating apertures disposed
on one surface thereof.
16. A floor covering system according to claim 15, wherein said
locating member includes one or more locating protrusions extending
from one surface thereof, said protrusions being adapted for
locating engagement with said locating apertures.
17. A floor covering system according to claim 14 or claim 15,
wherein said one or more apertures include one or more elongate
slots.
18. A floor covering system according to claim 16 or claim 17,
wherein said one more locating protrusions include one or more
elongate flanges.
19. A floor covering system according to any one of claims 14 to
18, wherein said locating member is in the form of an extruded
track substantially formed from a plastics material.
20. A floor covering system according to any one of claims 14 to
18, wherein said locating member is in the form of an extruded
track substantially formed from extruded aluminium.
21. A floor covering system according to any one of the preceding
claims wherein said first or second layers includes a design
pattern on its top surface.
22. A floor covering system according to claim 21, wherein said
design pattern substantially resembles a wood, marble, ceramic or a
slate surface.
23. A floor covering system according to claim 21 or claim 22,
wherein said design pattern is printed on a supplementary layer,
which is bonded to one surface of said first or second layer.
24. A floor covering system according to any one of the preceding
claims, wherein said second layer includes and adhesive means for
bonding said second layer to said first layer.
25. A floor covering system according to any one of the preceding
claims, wherein said first or second layer is sized to
substantially correspond to standard ceramic, slate, marble tile or
wood plank dimensions.
26. A floor covering system according to any one of the preceding
claims, wherein said first and second layers are substantially
formed from a resilient plastics material such as polyvinyl
chloride.
27. A floor covering system according to any one of the preceding
claims, wherein said first layer is a floor plank and said second
layer is an underlay.
28. A floor covering system according to any one of claims 14 to 27
including a secondary adhesive means for bonding said locating
member to one or more of said modular floor tiles.
29. A floor covering system according to claim 28, wherein said
secondary adhesive means is disposed on said locating member.
30. A floor covering system substantially as herein described with
reference to any one of the embodiments of the invention
illustrated in the accompanying drawings and/or examples.
31. A method for installing a floor covering system in accordance
with any one of the preceding claims, said method including the
steps of: i. laying two or more of said second layers on a
subfloor; and ii. laying said first layer over two or more of said
second layers such that said locating means locates said second
layers in an aligned configuration.
32. A method for installing a floor covering system substantially
as herein described with reference to any one of the embodiments of
the invention illustrated in the accompanying drawings and/or
examples.
33. A modular underlay tile for a floor system, said underlay tile
including: substantially planar upper and lower surfaces, said
underlay tile being adapted for substantial aligned engagement with
one or more other modular underlay tiles to form an underlay for
said floor system.
34. A modular underlay tile according to claim 33 including two or
more interlocking portions disposed on two or more corresponding
edges of said tile.
35. A modular underlay tile according to claim 34, wherein said
interlocking portions are adapted to substantially restrain at
least adjacent pairs of said underlay tiles, upon installation.
36. A modular underlay tile according to any one of claims 33 to
35, wherein said underlay tile is substantially formed from a
resilient plastics material such as polyvinyl chloride.
37. A modular underlay tile substantially as herein described with
reference to any one of the embodiments of the invention
illustrated in the accompanying drawings and/or examples.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to floor covering systems.
[0002] The invention has been developed primarily as a floating
floor covering system and will be described hereinafter with
reference to this application. However, it will be appreciated that
the invention is not limited to this particular field of use.
BACKGROUND OF THE INVENTION
[0003] The following discussion of the prior art is intended to
place the invention in an appropriate technical context and enable
the associated advantages to be fully understood. However, any
discussion of the prior art throughout the specification should not
be considered as an admission that such art is widely known or
forms part of the common general knowledge in the field.
[0004] Flooring systems, which have no part secured to the building
structure or "subfloor" are known. These types of flooring systems
are free to float above the subfloor and are often referred to as
"floating floors". Advantageously, floating floors are relatively
easy to install and are able expand and contract with changes in
humidity and temperature and as a result, are hard wearing and
develop minimal gaps during use.
[0005] Floating floor systems typically include an underlay formed
from a resilient and moisture repellent material, and a series of
floor planks, which are laid over the underlay and interconnect to
define the main floor surface. The floor planks normally consist of
a thin layer of softwood or hardwood bonded to a high-density
fibreboard substrate. They are also often pre-coated to enhance
their wearability (polyurethane is common), but it's possible to
coat after installation.
[0006] In an alternate type of floating floor system, the floor
planks are in the form of laminate tiles formed primarily from
polyvinyl chloride (PVC), which have a design pattern printed on
their upper surface to resemble a desired surface finish. This
alternate type of floating floor has the advantage of being harder
wearing than the above-mentioned wood type floating floor as well
as being quieter and softer to walk on and better adapted for
installation in wet areas. Such a flooring system is disclosed in
U.S. Pat. No. 7,155,871 in the name of Tru Woods Limited.
[0007] In this system, a laminate tile is formed from two layers of
flexible PVC material, with the lower layer performing the underlay
function and the top layer having the desired pattern on its upper
surface. The two layers are laminated together in an offset
arrangement to define two marginal portions along the long edges of
each tile. These marginal portions include an adhesive coating to
allow adjacent tiles to be joined in a lap joint formation thereby
to progressively build up the floating floor.
[0008] However, a problem with such a system is that a significant
amount of skill and care is required to align adjacent tiles during
installation. Furthermore, a slight misalignment during
installation may be magnified many times over upon completion of
the flooring installation. This misalignment may result in
unsightly gaps at the periphery of the completed floor.
[0009] It is an object of the present invention to overcome or
ameliorate at least one of the disadvantages of the prior art, or
to provide a useful alternative.
[0010] Moreover, it is an object a preferred form of the invention
to provide a floating flooring system that is relatively easy to
maintain alignment between components during installation.
DISCLOSURE OF THE INVENTION
[0011] According to a first aspect, the invention provides a floor
covering system including: [0012] a first layer of planar material;
[0013] a second layer of planar material, at least a portion of the
second layer being adapted for laminating engagement with the first
layer to define a floor covering; and [0014] a locating means for
locating two or more of the second layers in a substantially
aligned configuration, [0015] wherein the second layer is adapted
to receive the locating means.
[0016] In one embodiment, the floor covering system includes one or
more locating protrusions extending from one surface of the first
layer. Preferably, the second layer includes one or more locating
apertures disposed on one surface thereof, the apertures being
adapted for complementary engagement with the locating
protrusions.
[0017] Preferably, the locating apertures extend from the top to
the bottom surface of the second layer. More preferably, the first
layer includes four of the locating protrusions. Even more
preferably, the second layer includes four of the locating
apertures.
[0018] In one embodiment, the locating protrusions are
symmetrically disposed about the first layer.
[0019] In one embodiment, the locating protrusions are
asymmetrically disposed about the first layer.
[0020] In one embodiment, the locating apertures are symmetrically
disposed about the second layer.
[0021] In one embodiment, the locating apertures are asymmetrically
disposed about the second layer.
[0022] In one embodiment, the locating apertures are cut from the
second layer to form two or more off-cut portions and wherein the
off-cut portions are bonded to one surface of the first layer to
define the locating protrusions.
[0023] In one embodiment, the second layer includes a pair of
interlocking portions disposed at its longitudinally opposed edges.
The interlocking portions are preferably adapted to substantially
laterally restrain longitudinal adjacent pairs of the second layers
upon installation.
[0024] According to a second aspect, the invention provides a floor
covering system including: [0025] a first layer of planar material;
[0026] a second layer of planar material, the second layer being in
laminated engagement with the first layer to define a modular floor
tile; and [0027] a locating member engageable with at least a
portion of the modular floor tile for locating two or more of the
modular floor tiles in a substantially aligned configuration.
[0028] In one embodiment, the modular floor tile includes one or
more locating apertures disposed on one surface thereof. The one or
more apertures preferably include one or more elongate slots.
[0029] In one embodiment, the locating member includes one or more
locating protrusions extending from one surface thereof, the
protrusions being adapted for locating engagement with the locating
apertures. The one more locating protrusions preferably include one
or more elongate flanges.
[0030] In one embodiment, the locating member is in the form of an
extruded track substantially formed from a plastics material.
[0031] In one embodiment, the locating member is in the form of an
extruded track substantially formed from extruded aluminium.
[0032] In one embodiment, one of the first or second layers
includes a design pattern on its top surface. The design pattern
preferably resembles a wood, marble, ceramic or a slate
surface.
[0033] In one embodiment, the design pattern is printed on a
supplementary layer, which is bonded to one surface of the first or
second layer.
[0034] In one embodiment, the second layer includes an adhesive
means for bonding the second layer to the first layer.
[0035] In one embodiment, the first or second layer is sized to
correspond to standard ceramic, slate, marble tile or wood plank
dimensions.
[0036] In one embodiment, the first and second layers are
substantially formed from a resilient plastics material such as
polyvinyl chloride.
[0037] In one embodiment, the first layer is a floor plank and the
second layer is an underlay.
[0038] In one embodiment, the floor covering system includes a
secondary adhesive means for bonding the locating member to one or
more of the modular floor tiles. In this embodiment, the secondary
adhesive means is disposed on the locating member.
[0039] According to yet a further aspect, the invention provides a
method for installing a floor covering system in accordance with
the first aspect, the method including the steps of: [0040] laying
two or more of the second layers on a subfloor; and [0041] laying
the first layer over two or more of the second layers such that the
locating means locates the second layers in an aligned
configuration.
[0042] In accordance with a further aspect, the invention provides
a modular underlay tile for a floor system, the underlay tile
including: [0043] substantially planar upper and lower surfaces,
the underlay tile being adapted for substantial aligned engagement
with one or more other modular underlay tiles to form an underlay
for the floor system.
[0044] In one embodiment, the modular underlay tile including two
or more interlocking portions disposed on two or more corresponding
edges of the tile. The interlocking portions are preferably adapted
to substantially restrain at least adjacent pairs of the underlay
tiles, upon installation.
[0045] In one embodiment, the underlay tile is substantially formed
from a resilient plastics material such as polyvinyl chloride.
[0046] Reference throughout this specification to "one embodiment",
"some embodiments" or "an embodiment" means that a particular
feature, structure or characteristic described in connection with
the embodiment is included in at least one embodiment of the
present invention. Thus, appearances of the phrases "in one
embodiment", "in some embodiments" or "in an embodiment" in various
places throughout this specification are not necessarily all
referring to the same embodiment, but may. Furthermore, the
particular features, structures or characteristics may be combined
in any suitable manner, as would be apparent to one of ordinary
skill in the art from this disclosure, in one or more
embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] Preferred embodiments of the invention will now be
described, by way of example only, with reference to the
accompanying drawings in which:
[0048] FIG. 1a is a plan view of an underlay in accordance with a
first embodiment of the invention;
[0049] FIG. 1b is an elevation view of the underlay of FIG. 1a;
[0050] FIG. 1c is a perspective view of the underlay of FIG.
1a;
[0051] FIG. 2a is a plan view of a floor plank in accordance with a
first embodiment of the invention;
[0052] FIG. 2b is an elevation view of the floor plank of FIG.
2a;
[0053] FIG. 2c is an underside view of the floor plank of FIG.
2a;
[0054] FIG. 2d is a partly disassembled perspective view of the
floor plank of FIG. 2a;
[0055] FIG. 3a is a partly assembled view of a floor covering
system in accordance with a first embodiment of the invention;
[0056] FIG. 3b is an underside view of the floor covering system of
FIG. 3a;
[0057] FIG. 4a is a plan view of an underlay in accordance with a
second embodiment of the invention;
[0058] FIG. 4b is an elevation view of the underlay of FIG. 4a;
[0059] FIG. 4c is a perspective view of the underlay of FIG.
4a;
[0060] FIG. 5a is a plan view of a floor plank in accordance with a
second embodiment of the invention;
[0061] FIG. 5b is an elevation view of the floor plank of FIG.
5a;
[0062] FIG. 5c is an underside view of the floor plank of FIG.
5a;
[0063] FIG. 5d is a partly disassembled perspective view of the
floor plank of FIG. 5a;
[0064] FIG. 6a is a partly assembled view of a floor covering
system in accordance with a second embodiment of the invention;
[0065] FIG. 6b is an underside view of the floor covering system of
FIG. 6a;
[0066] FIG. 7a is a plan view of an underlay in accordance with a
third embodiment of the invention;
[0067] FIG. 7b is an elevation view of the underlay of FIG. 7a;
[0068] FIG. 7c is a perspective view of the underlay of FIG.
7a;
[0069] FIG. 8a is a plan view of floor plank in accordance with a
third embodiment of the invention;
[0070] FIG. 8b is an elevation view of the floor plank of FIG.
8a;
[0071] FIG. 8c is an underside view of the floor plank of FIG.
8a;
[0072] FIG. 8d is a partly disassembled perspective view of the
floor plank of FIG. 8a;
[0073] FIG. 9a is a partly assembled view of a floor covering
system in accordance with a third embodiment of the invention;
[0074] FIG. 9b is an underside view of the floor covering system of
FIG. 9a;
[0075] FIG. 10a is a plan view of an underlay in accordance with a
fourth embodiment of the invention;
[0076] FIG. 10b is an elevation view of the underlay of FIG.
10a;
[0077] FIG. 10c is a perspective view of the underlay of FIG.
10a;
[0078] FIG. 11a is a plan view of a floor plank in accordance with
a fourth embodiment of the invention;
[0079] FIG. 11b is an elevation view of the floor plank of FIG.
11a;
[0080] FIG. 11c is an underside view of the floor plank of FIG.
11a;
[0081] FIG. 11d is a partly disassembled perspective view of the
floor plank of FIG. 11a;
[0082] FIG. 12a is a partly assembled view of a floor covering
system in accordance with a fourth embodiment of the invention;
[0083] FIG. 12b is an underside view of the floor covering system
of FIG. 12a;
[0084] FIG. 13 is a further partly assembled view of the floor
covering system of FIG. 12a;
[0085] FIG. 14a is a plan view of an underlay in accordance with a
fifth embodiment of the invention;
[0086] FIG. 14b is an elevation view of the underlay of FIG.
14a;
[0087] FIG. 14c is a partly disassembled perspective view of the
underlay of FIG. 14a;
[0088] FIG. 15a is a plan view of a floor plank in accordance with
a fifth embodiment of the invention;
[0089] FIG. 15b is an elevation view of the floor plank of FIG.
15a;
[0090] FIG. 15c is an underside view of the floor plank of FIG.
15a;
[0091] FIG. 15d is a partly disassembled perspective view of the
floor plank of FIG. 15a;
[0092] FIG. 16a is a partly assembled view of a floor covering
system in accordance with a fifth embodiment of the invention;
[0093] FIG. 16b is an underside view of the floor covering system
of FIG. 16a;
[0094] FIG. 17 is further partly assembled view of the floor
covering system of FIG. 16a; and
[0095] FIG. 18 is a partly assembled view of a floor covering
system in accordance with a sixth embodiment of the invention.
PREFERRED EMBODIMENTS OF THE INVENTION
[0096] Referring initially to FIGS. 1 to 3, there is provided a
floor covering system 10 in accordance with a first embodiment of
the present invention. The system includes a plurality of planar
underlays 12 for contact with a subfloor, and a plurality of planar
floor planks 14 for overlaying engagement with the underlays.
[0097] Each underlay includes four locating apertures 16
symmetrically disposed about its surface 18. In the illustrated
embodiment, the apertures extend all the way through the underlay.
However, in other not shown embodiments the apertures may not
extend all the way through the underlay.
[0098] Upon overlaying engagement, these apertures engage with four
complementary locating protrusions 20 extending from the undersides
22 of the floor planks 14. In this respect, a locating means is
provided by the protrusions, which in turn, is received by the
underlays 12. The underlays further include an adhesive coating on
their upper side 14 so that upon the overlaying engagement, the
floor plank is securely bonded along its planar surface or
"laminated" with the underlays. Alternatively, the adhesive coating
may be applied to the underside of the floor planks.
[0099] The arrangement is such that the locating protrusions 20
engage with the locating apertures 16 to allow a single floor plank
to positively and accurately position two or more adjacently
located underlays 12 in a respectively aligned side-by-side and/or
end-to-end configuration. In this way, a floor covering is defined
and a complete floor can be built up progressively with each
underlay being accurately aligned with adjacent underlays.
[0100] As best shown in FIG. 2, each floor plank 14 includes a
design pattern 24 printed on its upper surface so as to resemble,
for example, a marble, ceramic or wood textured surface.
Alternatively, the design pattern may be printed on a supplementary
layer, which is laminated to the floor plank's upper surface. In
the embodiment shown in FIGS. 1 to 3, the underlays and floor
planks have a square shape and therefore would most likely be used
to resemble a marble, slate, ceramic or other type of square type
floor tile.
[0101] As is commonly known in the art, the underlays 12 and floor
planks 14 are predominantly formed from a flexible polyvinyl
chloride material, otherwise known as PVC or vinyl. The completed
floor is therefore hardwearing, easy to walk on and suitable for
wet areas. In addition, using a resilient polyvinyl chloride
material allows a degree of planar compliance to compensate for
floor surface irregularities when laid. Of course, it should be
understood that other materials could be used in combination with
the PVC such as for example, resins and/or polyurethane, without
departing from the scope of the invention.
[0102] As is best shown with reference to FIG. 2d, in a preferred
form of fabrication, the apertures 16 are cut from the underlay to
define cut portions 26, and the protrusions 20 are formed by
bonding the cut portions 26 to the underside 22 of the floor plank
using an appropriate adhesive, or any other fixing method as is
commonly known in the art. It should be noted that this process of
cutting and bonding would normally be performed during automated
manufacture and, as a result, the apertures and protrusions would
be accurately positioned within desired tolerances.
[0103] Referring now to FIG. 3, to assemble the floor covering
system 10, four underlays 12 are first laid onto a subfloor in an
adjacent formation, ideally starting from a wall 28 or other
aligning feature. It should be understood that at this stage, it is
only required to approximately align the underlays relative to each
other. Also, no fixing is required to secure the underlays to the
subfloor because the flooring system 10 is a "floating type" and
therefore, allows for contraction and expansion of the assembled
floor during use.
[0104] A single floor plank 14 is then placed down onto the
underlays 12 allowing the protrusions 20 to engage one aperture 16
from each underlay. Another two underlays 12 are then laid down in
an adjacent formation again only approximating an aligned
configuration with one edge or end of the already laid underlays.
Another floor plank can then be placed down so that the protrusions
20 engage one or more apertures 16 from each underlay. It will be
appreciated that as a result of the engagement between
corresponding protrusions and apertures, the laid underlays will
move into exact relative alignment. At the same time, the
corresponding floor planks 14 will be also accurately aligned with
respect to the underlays.
[0105] This process continues until the underlays 12 and floor
planks 14 cover the desired floor surface. Upon completion, what
gaps in the floor surface that remain are covered by half sized
floor planks, either cut on site or supplied in half sizes. In
addition, an edge trim (not shown) or moulding (not shown) may also
be provided to seal any smaller peripheral gaps, as in commonly
known in the art.
[0106] As mentioned earlier there is an adhesive coating disposed
on the upper side 14 of each underlay 12. It is proposed that this
coating will be exposed by the removal of a disposable cover strip
(not shown). The coating may also be of the type that reacts when
in contact with the floor plank such that the bond formed becomes
stronger over time. Advantageously, this feature will allow any
laying mistakes to be easily corrected.
[0107] Referring now to FIGS. 4 to 6, there is provided a second
embodiment of the floor covering system 10 of the present
invention. This embodiment is similar to the first embodiment
except that both of the underlays 12 and floor planks 14 now have a
rectangular shape of substantially identical dimensions so that the
completed assembly more readily resembles typical wood type
flooring.
[0108] As shown in FIG. 6, the assembly procedure for this
embodiment is essentially identical to that described above for the
first embodiment except that the underlays 12 are now laid such
that their longer edges 30 do not continue all the way to the
periphery 32 of the desired flooring surface. Instead, the
peripherally located floor planks 14a are overlaid so that their
longer edges 34 continue to the periphery 32. For this reason, only
two of the peripheral floor plank's protrusions 20 engage with the
peripheral underlay's apertures 16, with the remaining unengaged
protrusions 20 resting directly on the subfloor to support the
overhung portion of the floor planks 14a.
[0109] Of course, in this embodiment it can be seen that in order
to achieve a staggered laying pattern, some cutting of the floor
planks will be required. This situation is exemplified by reference
to floor plank 14b, which will be cut along line 15 so that it ends
generally flush with the wall 28. Alternatively a half floor plank
may be supplied.
[0110] Referring now to FIGS. 7 to 9, there is depicted a third
embodiment of the floor covering system of the present invention.
This embodiment discloses similar shaped underlays and floor planks
to the second embodiment except that the underlays 12 now include a
pair of complementary interlocking portions 36 disposed at their
longitudinally opposed ends. As can be seen in FIG. 9, the
respective interlocking portions 36 engage upon assembly to provide
an extra degree of lateral restraint between longitudinally
adjacent underlays upon installation.
[0111] Accordingly, the assembly procedure for this embodiment is
essentially identical to that described above for the second
embodiment except that a certain degree of trimming of the
interlocking portions 36 may be required proximate the wall 28. To
assist in any trimming, a cut or perforation line (not shown) may
be provided on the interlocking portions.
[0112] Referring now to FIGS. 10 to 13, there is provided a fourth
embodiment of the present invention. This embodiment is similar to
the second embodiment in that, the underlays 12 and the floor
planks 14 have a rectangular shape of substantially identical
dimensions. However, in this embodiment, the protrusions 20 are
asymmetrically disposed about each floor plank 14. For this reason,
a slight modification to the assembly procedure is now required. As
best shown in FIGS. 12 and 13, the short edges 38 of the peripheral
underlays are now also offset from the periphery of the desired
floor surface, and the short edges of the floor planks continue to
the periphery 32. Advantageously, this embodiment allows for a
floor plank 14 to always cover the region 40 where the short ends
of the underlays 12 join.
[0113] Referring now to FIGS. 14 to 17, there is provided a fifth
embodiment of a present invention. This embodiment is similar to
the fourth embodiment in that, the protrusions are asymmetrically
disposed about the floor plank. However, in this embodiment, the
apertures 16 are now also asymmetrically disposed about the
underlay 12. Notwithstanding this difference, installation of this
embodiment is substantially identical to that described for the
fourth embodiment. Advantageously, this embodiment provides even a
greater degree of covering of the end join region of the
underlay.
[0114] It should be noted that during installation of the fourth
and fifth embodiments, a certain degree of trimming of both the
underlays 12 and floor planks 14 may be required.
[0115] Whilst the above embodiments all stipulate that the
protrusions 20 extend from the underside of the floor plank 14 and
that the apertures 16 are disposed in the underlay 12, it should be
appreciated that this structural arrangement may be reversed
without departing from the scope of the invention. That is, in
other not shown embodiments, the apertures may be disposed in the
floor plank and the protrusions may extend from one side of the
underlay.
[0116] Referring now to FIG. 18, there is depicted a further
embodiment of the floor covering system 10 of the present
invention. In this embodiment, the floor plank 14 and underlay 12
are already in laminated engagement to define a modular floor tile
41. Alternatively, in another form of this embodiment, the modular
floor tile is integrally formed to include both underlay and floor
plank portions. It should be noted, that these modular floor tiles
are generally formed from the same materials as the floor planks
and underlays of the first five embodiments and include a design
pattern on the upper surface of the floor plank portion.
[0117] In this embodiment, there is provided a locating member in
the form of an aluminium or plastic extruded track 42. The track
includes flange portions 44 for engagement with corresponding slots
46 disposed near the lateral and longitudinal sides of the modular
floor tiles. Upon this engagement, either longitudinally or
laterally adjacent modular floor tiles are positioned in a
generally aligned configuration relative to each other.
[0118] An adhesive coating 44 is located on the upper side of the
track 42 to create a permanent bond between the track and the
adjacent modular floor tiles upon assembly. In this way, a floor
covering can be gradually built up by laying down more and more
tracks 42 in between adjacent pairs of the modular floor tiles
41.
[0119] It will be appreciated that the above six embodiments
demonstrate alternate structural forms of the present invention.
The disclosed embodiments advantageously teach a floating flooring
system that is relatively easy to install because exact alignment
between the adjacent components occurs automatically upon assembly.
Advantageously, the system is supplied in kit form, which includes
both the underlays and floor planks, or modular floor tiles and
extruded tracks, and assembly may only require a single tool, such
as a knife or scissors, to trim any edges. Consequently, the
flooring system of the present invention advantageously does not
necessarily require any skilled labour for assembly and is
therefore particularly suited to "do-it-yourself" home renovators
and/or builders.
[0120] Ideally the components are formed from standard materials,
which are well suited to high-speed automated manufacture and,
accordingly, are relatively inexpensive to manufacture.
[0121] Although the invention has been described with reference to
specific examples, it will be appreciated by those skilled in the
art that the invention may be embodied in many other forms. In
particular, it should be appreciated that the underlays, floor
planks, apertures and protrusions may take a variety of shapes and
configurations, other than those specifically illustrated.
[0122] Moreover, it should be understood that the underlays 12 may
be used in isolation without the corresponding floor planks 14. It
has been found that an assembly of these `modular` type underlays
may be used in normal floating floor applications such as an
underlay for floorboards and/or vinyl sheets. Under these
circumstances, the underlays would not require, and would not be
provided with, any locating apertures 16. However, they may include
the complementary interlocking portions 36 disposed at its
longitudinal or potentially lateral ends to provide relative
alignment between adjacent underlays.
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