U.S. patent application number 14/905340 was filed with the patent office on 2016-12-22 for floor panel kit and method of forming the same.
The applicant listed for this patent is ARMSTRONG WORLD INDUSTRIES, INC.. Invention is credited to YON E. HINKLE, PAMELA A. NYESMITH, BRENT L. STOLL.
Application Number | 20160368701 14/905340 |
Document ID | / |
Family ID | 51303126 |
Filed Date | 2016-12-22 |
United States Patent
Application |
20160368701 |
Kind Code |
A1 |
STOLL; BRENT L. ; et
al. |
December 22, 2016 |
FLOOR PANEL KIT AND METHOD OF FORMING THE SAME
Abstract
A kit of floor panels and a method of forming the same. In one
aspect, the kit can be a kit of floor panels comprising: a
container having an inner cavity containing a stacked assembly of
floor panels; the stacked assembly of floor panels comprising: one
or more layers of first floor panels having a first width and a
first length; one or more layers of second floor panels having a
second width and a second length; one or more layers of a third
floor panel having a third width and a third length; and wherein
the third width is different than the first and second widths and
wherein the first length is different than the second and third
lengths.
Inventors: |
STOLL; BRENT L.; (Lititz,
PA) ; NYESMITH; PAMELA A.; (Elizabethtown, PA)
; HINKLE; YON E.; (Millersville, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ARMSTRONG WORLD INDUSTRIES, INC. |
Lancaster |
PA |
US |
|
|
Family ID: |
51303126 |
Appl. No.: |
14/905340 |
Filed: |
July 29, 2014 |
PCT Filed: |
July 29, 2014 |
PCT NO: |
PCT/US2014/048636 |
371 Date: |
January 15, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61859669 |
Jul 29, 2013 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04F 15/02 20130101;
B65B 5/10 20130101; B65D 85/62 20130101; B65B 61/20 20130101; E04F
15/107 20130101; B65B 5/02 20130101; B65B 11/004 20130101 |
International
Class: |
B65D 85/62 20060101
B65D085/62; B65B 5/02 20060101 B65B005/02; B65B 5/10 20060101
B65B005/10; E04F 15/02 20060101 E04F015/02; E04F 15/10 20060101
E04F015/10 |
Claims
1. A kit of floor panels comprising: a container having an inner
cavity containing a stacked assembly of floor panels; the stacked
assembly of floor panels comprising: a first amount of one or more
layers of first floor panels, each of the first floor panels having
a first width and a first length; a second amount of one or more
layers of second floor panels, each of the second floor panels
having a second width and a second length; a third amount of one or
more layers of a third floor panel, each of the third floor panels
having a third width and a third length; and wherein the third
width is different than the first and second widths and wherein the
first length is different than the second and third lengths; and
wherein the first amount is not equal to the second amount and the
first amount is not equal to the third amount.
2. The kit according to claim 1 wherein the first amount comprises
two layers of the first floor panels, the second amount comprises
four layers of the second floor panels, and the third amount
comprises eight layers of the third floor panels contained within
the inner cavity of the container.
3. The kit according to claim 1 wherein each layer of the first
floor panels includes four of the first floor panels, each layer of
the second floor panels includes two of the second floor panels,
and each layer of the third floor panels includes one of the third
floor panels, and wherein each layer of the first, second and third
floor panels has the same overall width and length.
4. The kit according to claim 1 wherein the first and second widths
are the same.
5. The kit according to claim 1 wherein the second and third
lengths are the same.
6. The kit according to claim 1 wherein the floor panels are
positioned within the package in an upside-down stacked arrangement
such that the one or more layers of the third floor panel are at a
bottom of the package, the one or more layers of the second floor
panels are stacked atop of a top layer of the one or more layers of
third floor panels, and the one or more layers of the first floor
panel are stacked atop of a top layer of the one or more layers of
second floor panels.
7. The kit according to claim 1 wherein the first width and the
first length are each about 200 mm, wherein the second width is
about 200 mm and the second length is about 400 mm, and wherein the
third width and the third length are each about 400 mm.
8. The kit according to claim 1 wherein each layer of the first
floor panels comprises four of the first floor panels, wherein each
layer of the second floor panels comprises two of the second floor
panels, and wherein each layer of the third floor panels comprises
one of the first floor panels, and wherein each of the layers of
the first, second and third floor panels has substantially the same
overall width and length.
9. The kit according to claim 1 wherein the first floor panels, the
second floor panels and the third floor panels are arranged on a
floor in an opus pattern.
10. The kit according to claim 1 further comprising an instruction
sheet positioned within the container, the instruction sheet
containing instructions for positioning the first, second and third
floor panels on the floor in an opus pattern.
11. A kit comprising: a container containing: a plurality of floor
panels that can be arranged in an opus pattern; the plurality of
floor panels comprising: a first set of floor panels having a first
width and a first length; a second set of floor panels having a
second width and a second length; and a third set of floor panels
having a third width and a third length; and wherein the first,
second and third sets of floor panels are positioned in the package
in a stacked arrangement.
12. The kit according to claim 11 wherein the container is a carton
or box.
13. The kit according to claim 11 wherein the first set of floor
panels comprises two layers having four floor panels in each layer,
wherein the second set of floor panels comprises four layers having
two floor panels in each layer, and wherein the third set of floor
panels comprises eight layers having one floor panel in each
layer.
14. The kit according to claim 11 wherein the first and second
widths are the same and the third width is different than the first
and second widths, and wherein the second and third lengths are the
same and the first length is different than the second and third
lengths.
15. The kit according to claim 14 wherein the first width is about
200 mm and the first length is about 200 mm, wherein the second
width is about 200 mm and the second length is about 400 mm, and
wherein the third width is about 400 mm and the third length is
about 400 mm.
16. A method of packaging a plurality of floor panels comprising:
a) providing an unfolded container; b) positioning one or more
layers of first floor panels on the unfolded container, wherein
each of the one or more layers of the first floor panels comprises
four of the first floor panels each having a first width and a
first length; c) positioning one or more layers of second floor
panels atop a top layer of the first floor panels, wherein each of
the one or more layers of the second floor panels comprises two of
the second floor panels each having a second width and a second
length; d) positioning one or more layers of a third floor panel
atop a top layer of the second floor panels, wherein each of the
one or more layers of the third floor panel comprises one of the
third floor panels having a third width and a third length; e)
folding the container around the layers of the first, second and
third floor panels; and f) flipping the carton so that the first,
second and third floor panels are upside-down in the container.
17. The method according to claim 16 wherein the first and second
widths are the same, the third width being different than the first
and second widths, and wherein the second and third lengths are the
same, the first length being different than the second and third
lengths.
18. The method according to claim 17 wherein the first length is
the same as the second width and wherein the second length is the
same as the third width.
19. The method according to claim 18 wherein the first width, the
first length and the second width are approximately 200 mm, and
wherein the second length, the third width and the third length are
approximately 400 mm.
20. The method according to claim 16 wherein step b) comprises
positioning two layers of the first floor panels on the unfolded
container, wherein step c) comprises positioning four layers of the
second floor panels atop the top layer of the first floor panels;
and wherein step d) comprises positioning eight layers of the third
floor panel atop the top layer of the second floor panels so that
eight of each of the first, second and third floor panels are
positioned within the container.
21.-25. (canceled)
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] The present application claims the benefit of U.S.
Provisional Patent Application Ser. No. 61/859,669, filed Jul. 29,
2013, the entirety of which is incorporated herein by
reference.
FIELD
[0002] The present invention relates generally to a kit containing
a plurality of floor panels, and particularly to a kit containing a
plurality of floor panels having different dimensions.
BACKGROUND
[0003] When laying floor panels or tiles on a floor, it can be
desirable to use floor panels having different dimensions to create
a desired pattern with the floor panels. Typically, this requires a
consumer purchasing multiple boxes of floor panels, each box having
floor panels with the same width and length dimensions. However,
purchasing floor panels in this manner results in the consumer
having excess floor panels of one size and not enough floor panels
of another size.
[0004] Thus, a need exists for a floor panel kit that includes
floor panels of different sizes.
SUMMARY
[0005] The present disclosure is directed to a kit of floor panels
and a method of forming the same. In some embodiments the kit
includes a container and a plurality of different layers of floor
panels, the layers having floor panels with differing
dimensions.
[0006] In one embodiment, the kit can be a kit of floor panels
comprising: a container having an inner cavity containing a stacked
assembly of floor panels; the stacked assembly of floor panels
comprising: one or more layers of first floor panels having a first
width and a first length; one or more layers of second floor panels
having a second width and a second length; one or more layers of a
third floor panel having a third width and a third length; and
wherein the third width is different than the first and second
widths and wherein the first length is different than the second
and third lengths.
[0007] In another embodiment, the kit can be a kit comprising: a
package containing a plurality of floor panels that can be arranged
on a floor in an opus pattern; the plurality of floor panels
comprising: a first set of floor panels having a first width and a
first length; a second set of floor panels having a second width
and a second length; and a third set of floor panels having a third
width and a third length; and wherein the first, second and third
sets of floor panels are positioned in the package in a stacked
arrangement.
[0008] In a further embodiment, a method of packaging a plurality
of floor panels comprises: a) providing an unfolded container; b)
positioning one or more layers of first floor panels on the
unfolded container, wherein each of the one or more layers of the
first floor panels comprises four of the first floor panels each
having a first width and a first length; c) positioning one or more
layers of second floor panels atop a top layer of the first floor
panels, wherein each of the one or more layers of the second floor
panels comprises two of the second floor panels each having a
second width and a second lengths; d) positioning one or more
layers of a third floor panel atop a top layer of the second floor
panels, wherein each of the one or more layers of the third floor
panel comprises one of the third floor panels having a third width
and a third length; e) folding the container around the layers of
the first, second and third floor panels; and f) flipping the
carton so that the first, second and third floor panels are
upside-down in the container.
[0009] In yet another embodiment, the kit can be a kit of floor
panels comprising: a container having an inner cavity containing a
stacked assembly of floor panels; the stacked assembly of floor
panels comprising: at least one first layer comprising four first
floor panels, each of the first floor panels having a first width,
a first length and a first area; at least one second layer
comprising two second floor panels, each of the second floor panels
having a second width, a second length and a second area; at least
one third layer comprising a third floor panel, the third floor
panel having a third width, a third length and a third area; and
wherein each of the first, second and third areas are
different.
[0010] Further areas of applicability of the present invention will
become apparent from the detailed description provided hereinafter.
It should be understood that the detailed description and specific
examples, while indicating the preferred embodiment of the
invention, are intended for purposes of illustration only and are
not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention will become more fully understood from
the detailed description and the accompanying drawings,
wherein:
[0012] FIG. 1 is a stacked and individual view of floor panels of a
kit in one embodiment;
[0013] FIG. 2 is a cross-sectional schematic of the floor panels of
FIG. 1 positioned within a container to form the kit; and
[0014] FIG. 3 is a cross-sectional schematic of the floor panels of
FIG. 1 showing additional details thereof.
[0015] All drawings are schematic and not necessarily to scale.
DETAILED DESCRIPTION
[0016] The following description of the preferred embodiment(s) is
merely exemplary in nature and is in no way intended to limit the
invention, its application, or uses. The description of
illustrative embodiments according to principles of the present
invention is intended to be read in connection with the
accompanying drawings, which are to be considered part of the
entire written description. Moreover, the features and benefits of
the invention are illustrated by reference to the exemplified
embodiments. Accordingly, the invention expressly should not be
limited to such exemplary embodiments, which illustrate some
possible non-limiting combinations of features that may exist alone
or in other combinations of features; the scope of the invention
being defined by the claims appended hereto.
[0017] In the description of embodiments disclosed herein, any
reference to direction or orientation is merely intended for
convenience of description and is not intended in any way to limit
the scope of the present invention. Relative terms such as "lower,"
"upper," "horizontal," "vertical,", "above," "below," "up," "down,"
"top" and "bottom" as well as derivative thereof (e.g.,
"horizontally," "downwardly," "upwardly," etc.) should be construed
to refer to the orientation as then described or as shown in the
drawing under discussion. These relative terms are for convenience
of description only and do not require that the apparatus be
constructed or operated in a particular orientation. Terms such as
"attached," "affixed," "connected," "coupled," "interconnected,"
and similar refer to a relationship wherein structures are secured
or attached to one another either directly or indirectly through
intervening structures, as well as both movable or rigid
attachments or relationships, unless expressly described
otherwise.
[0018] Referring first to FIG. 1, various floor panels that can be
included in the inventive kit will be described. In certain
embodiments, the various floor panels can be used to form an opus
pattern when the floor panels are adhered to a floor in a
consumer's home. However, the invention is not to be so limited and
the floor panels can be intended to form other patterns including
without limitation straight, diagonal, running bond, checkerboard,
diagonal with dots, pinwheel, basketweave, modular, Versailles,
herringbone, windmill or the like. All of the various floor panels,
regardless of their size, shape and dimensions, can be provided
within a single package or container in a stacked arrangement while
preventing or reducing the likelihood of breaking any of the floor
panels. Thus, all of the different sized floor panels necessary to
create an opus pattern (or other desired pattern) can be packaged
and sold in a single container.
[0019] The floor panels include first floor panels 250, second
floor panels 350 and third floor panels 450. Four of the first
floor panels 250 are arranged together to form a collective first
panel layer 200, two of the second floor panels 350 are arranged
together to form a collective second panel layer 300, and each one
of the third floor panels 450 forms a collective third panel layer
400 on its own.
[0020] The first floor panels 250 have a first width W.sub.1 and a
first length L.sub.1 and a first area, the first area being equal
to the first width W.sub.1 multiplied by the first length L.sub.1.
Furthermore, the collective first panel layer 200, which is formed
from four of the first floor panels 250 being arranged in an
adjacent and abutting manner, has an overall width W.sub.0 and an
overall length L.sub.0. In certain embodiments, the first width
W.sub.1 can be eight inches (203.2 mm) and the first length L.sub.1
can be eight inches (203.2 mm) such that each of the first floor
panels 250 are eight inch (203.2 mm) by eight inch (203.2 mm)
square floor panels or tiles. Furthermore, in certain embodiments
the overall width W.sub.0 can be sixteen inches (406.4 mm) and the
overall length L.sub.0 can be sixteen inches (406.4 mm) such that
the first panel layer is a sixteen inch (406.4 mm) by sixteen inch
(406.4 mm) square layer formed from four of the first floor panels
250. Of course, the invention is not to be so limited and various
modifications in the first width W.sub.1 and the first length
L.sub.1 of the first floor panels 250 and the overall width W.sub.0
and length L.sub.0 of the first panel layer 200 can be made so that
the dimensions of the first floor panels 250 and of the first panel
layers 200 can be other than that noted above. For example, the
first floor panels 250 can be two inch (50.8 mm) by two inch (50.8
mm) squares, four inch (101.6 mm) by four inch (101.6 mm) squares,
two inch (50.8 mm) by four inch (101.6 mm) rectangles or any other
dimension in other embodiments. Furthermore, the first panel layer
200 can be eight inch (203.2 mm) by eight inch (203.2 mm) squares,
twenty inch (508 mm) by twenty inch (508 mm) squares, sixteen inch
(406.4 mm) by twenty inch (508 mm) rectangles or any other
dimension in other embodiments.
[0021] The second floor panels 350 have a second width W.sub.2 and
a second length L.sub.2 and a second area, the second area being
equal to the second width W.sub.2 multiplied by the second length
L.sub.2. Furthermore, the collective second panel layer 300, which
is formed from two of the second floor panels 350 being arranged in
an adjacent and abutting manner, has the same overall width W.sub.0
and the same overall length L.sub.0 as the first panel layers 200.
In certain embodiments, the second width W.sub.2 can be eight
inches (203.2 mm) and the second length L.sub.2 can be sixteen
inches (406.4 mm). Of course, the invention is not to be so limited
and various modifications in the second width W.sub.2 and the
second length L.sub.2 of the second floor panels 350 can be made.
For example, the second floor panels 350 can be two inch (50.8 mm)
by two inch (50.8 mm) squares, four inch (101.6 mm) by four inch
(101.6 mm) squares, two inch (50.8 mm) by four inch (101.6 mm)
rectangles or any other dimension in other embodiments.
[0022] The third floor panels 450 have a third width W.sub.3 and a
third length L.sub.3 and a third area, the third area being equal
to the third width W.sub.3 multiplied by the third length L.sub.3.
In the exemplified embodiment, the third panel layer 400 is formed
from a single third floor panel 450, and thus the third width
W.sub.3 and the third length L.sub.3 are the same as the overall
width W.sub.o and the overall length L.sub.0. Thus, in the
exemplified embodiment the third width W.sub.3 and the third length
L.sub.3 are approximately sixteen inches (406.4 mm) such that the
third floor panel 450 is a sixteen inch (406.4 mm) by sixteen inch
(406.4 mm) square floor panel. Of course, the invention is not to
be limited by the specific dimensions of the third floor panel 450
in all embodiments, and the third width W.sub.3 and the third
length L.sub.3 can be other than that noted above, such that the
third floor panel 450 can be an eight inch (203.2 mm) by eight inch
(203.2 mm) square, a twenty inch (508 mm) by twenty inch (508 mm)
square, or the like.
[0023] In certain embodiments, due to the various width and length
dimensions of the first, second and third floor panels 250, 350,
450 discussed above, each of the first, second and third areas are
different. In certain embodiments the third area is greater than
the first and second areas and the second area is greater than the
first area. Thus, the first floor panels 250 are the smallest in
terms of overall surface area and the third floor panels 450 are
the largest in terms of overall surface area, the second floor
panels 350 having an overall surface area in between the first and
third floor panels 250, 450. In certain embodiments the area of the
first floor panels 250 can be approximately 64 square inches
(approximately 1600 mm.sup.2), the area of the second floor panels
350 can be approximately 128 square inches (approximately 3250
mm.sup.2), and the area of the third floor panels 450 can be
approximately 256 square inches (approximately 6500 mm.sup.2).
[0024] Although specific examples of the dimensions of the first,
second and third panel layers 250, 350, 450 are provided above, the
invention is not to be particularly limited thereby. However, in
certain embodiments the first width W.sub.1 of the first floor
panel 250 is the same as the second width W.sub.2 of the second
floor panel 350 while the third width W.sub.3 of the third floor
panel 350 is different than the first and second widths W.sub.1,
W.sub.2. Furthermore, in the exemplified embodiment the second
length L.sub.2 of the second floor panel 350 is the same as the
third length L.sub.3 of the third floor panel 450, but the first
length L.sub.1 of the first floor panel 250 is different than each
of the second and third lengths L.sub.2, L.sub.3. Furthermore, in
the exemplified embodiment each of the first, second and third
panel layers 200, 300, 400 has the same overall dimensions (i.e.,
the width W.sub.0 and the length L.sub.o), but the invention is not
to be so limited in all embodiments.
[0025] Referring to FIGS. 1 and 2 concurrently, a kit 1000 of the
floor panels 250, 350, 450 will be further described. To form the
kit, the first, second and third floor panels 250, 350, 450 are
arranged in a stacked assembly and positioned within a container
500. The container 500 can be a box, a carton, a crate or any other
type of packaging structure. In some embodiments, the container 500
is a carton or box formed of a cardboard material. The container
may be a corrugated container 500 in some embodiments. However, the
invention is not to be so limited in all embodiments and the
container 500 can be formed of other materials. Furthermore, in
some embodiments the container 500 may include indicia thereon such
as instructions for forming a particular pattern, such as an opus
pattern, using the floor panels 250, 350, 450 of the kit 1000,
manufacturer information, product installation information or the
like. In some embodiments the instructions for forming a particular
pattern may be in the form of a website link that provides the
instructions to the consumer. Furthermore, in some embodiments
instructions may not be provided on the box itself, but rather in a
pamphlet, sheet, booklet or the like that is positioned within the
container 500 as discussed in more detail below.
[0026] The floor panels 250, 350, 450 are positioned within an
inner cavity 501 of the container 500 in the form of the panel
layers 200, 300, 400. As noted above, each of the panel layers 200
comprises four of the floor panels 250 that are arranged in an
abutting and adjacent manner, each of the panel layers 300
comprises two of the floor panels 350 that are arranged in an
abutting and adjacent manner, and each of the panel layers 400
comprises one of the floor panels 450. In the exemplified
embodiment, each of the panel layers 200, 300, 400 has the same
length and width dimensions. However, the invention is not to be so
limited in all embodiments unless so specified in the claims.
[0027] The kit 1000 comprises a first and a second 201, 202 of the
first panel layers 200, a first, a second, a third and a fourth
301, 302, 303, 304 of the second panel layers 300 and a first, a
second, a third, a fourth, a fifth, a sixth, a seventh and an
eighth 401, 402, 403, 404, 405, 406, 407, 408 of the third panel
layers 400 arranged in a stacked assembly. The first 201 of the
first panel layers 200 is positioned within the package 500 first,
and then the second 202 of the first panel layers 200 is positioned
atop the first 201 of the first panel layers 200. The first 301 of
the second panel layers 300 is positioned atop the second 202 of
the first panel layers 200, and then the second, third and fourth
302, 303, 304 of the second panel layers 300 are positioned, in
order, atop of the first 301 of the second panel layers 300.
Finally, the first 401 of the third panel layers 400 is positioned
atop the fourth 304 of the second panel layers 300, and then the
second, third, fourth, fifth, sixth, seventh and eighth 402, 403,
404, 405, 406, 407, 408 of the third panel layers 400 are
positioned, in order, atop the first 401 of the third panel layers
400.
[0028] The first panel layer 200 includes four of the first floor
panels 250 and there are two of the first panel layers 200 in the
container 500, and thus the kit 1000 includes eight of the first
floor panels 250 therein. The second panel layer 300 includes two
of the second floor panels 350 and there are four of the second
panel layers 300 in the container 500, and thus the kit 1000
includes eight of the second floor panels 350 therein. The third
panel layer 400 includes one of the third floor panels 450 and
there are eight of the third panel layers 400 in the container 500,
and thus the kit 1000 includes eight of the third floor panels 450
therein. Thus, in the exemplified embodiment the kit 1000 includes
eight of each of the first, second and third floor panels 250, 350,
450. However, the invention is not to be so limited and various
numbers of the different floor panels can be positioned within the
container 500 and form a part of the kit 1000 in various other
embodiments.
[0029] Still referring to FIGS. 1 and 2 concurrently, a method of
forming the kit 1000 will now be described. First, the container
500 is provided in an unfolded state so that a top surface 502 of
the container 500 is face down. Then, the first panel layers 200
(i.e., layers 201 and 202) are positioned within the inner cavity
501 of the container 500 so as to be positioned on a roof 503 of
the inner cavity 501, the roof 503 of the inner cavity 501 sharing
a flap of material with the top surface 502. Next, the second panel
layers 300 (i.e., layers 301, 302, 303 and 304) are positioned
within the inner cavity 501 of the container 500 so as to be
positioned atop of the first panel layers 200, and more
specifically atop of the second 202 of the first panel layers 200.
Next, the third panel layers 400 (i.e., layers 401, 402, 403, 404,
405, 406, 407 and 408) are positioned within the inner cavity 501
of the container 500 so as to be positioned atop of the second
panel layers 300, and more specifically atop of the fourth 304 of
the second panel layers 300.
[0030] Finally, in certain embodiments, an instruction sheet 600
can be provided in the container 500. The instruction sheet 600 can
be a piece of paper, a packet of papers, a booklet, a compact disc
(CD) or any other medium that can provide the consumer with
information regarding the product, including information regarding
how to assemble the floor panels 250, 350, 450 into a desired
pattern, such as for example without limitation an opus pattern. Of
course, the instruction sheet 600 need not form a part of the kit
1000 and can be omitted in other embodiments.
[0031] In the exemplified embodiment, the instruction sheet 600 is
positioned atop of the eighth 408 of the third panel layers 400.
However, the invention is not to be so limited and the instruction
sheet 600 can be positioned at any location in the container 500,
including in between any of the adjacent panel layers 200, 300,
400, between the panel layers 200, 300, 400 and a sidewall of the
container 500, or taped or otherwise adhered to an outer surface of
the container 500. Furthermore, in still other embodiments the
instruction sheet 600 can be altogether omitted. In such
embodiments the kit 1000 may not include any instructions, or the
instructions may be provided directly onto the container 500 as
discussed above, or through a website on the Internet. Furthermore,
the instruction sheet 600 is illustrated as being smaller (at least
in one of the length or width dimensions) than the floor panels
250, 350, 450. However, in other embodiments the instruction sheet
600 may have the same or similar dimensions as the dimensions of
the floor panels 250, 350, 450.
[0032] After all of the panel layers are positioned within the
container 500 and the instruction sheet 600 is positioned within
the container 500 in embodiments that include the instruction sheet
600, the container 500 is folded around the panel layers and sealed
shut, such as by using tape, glue, other adhesives, fasteners or
the like. Finally, after sealing the container 500, the container
500 is flipped or rotated so that the top surface 502 of the
container 500 is exposed. Flipping of the container 500 is achieved
by rotating the container 500 180.degree. about an axis extending
through the sidewalls of the container 500 (as opposed to an axis
extending through the bottom and top surfaces of the container
500). Upon flipping or rotating the container 500 as noted above,
the floor panels 250, 350, 450 will be upside-down in the container
500 such that the top surfaces of the floor panels 250, 350, 450
will be facing the floor, pallet or other structure upon which the
container 500 is placed and the top surface 502 of the container
500 will be positioned away from the floor, pallet or other
structure upon which the container 500 is placed and will be
exposed for consumer viewing.
[0033] When the container 500 is flipped and shut, the largest
floor panels (i.e. the third floor panels 450) are positioned on
the bottom of the stacked assembly and the smallest floor panels
(i.e., the first floor panels 250) are positioned on the top of the
stacked assembly, with the second floor panels 350 being positioned
in between the first and third floor panels 250, 450. Such an
arrangement can be beneficial to prevent damage of the floor panels
250, 350, 450 during shipping. Specifically, because the largest
third floor panels 450 are on the bottom of the container 500
during shipping, the kit 1000 is sturdy. To the contrary, if the
smaller first floor panels 250 were on the bottom of the container
500 during shipping, it is possible that movement of the first
floor panels 250 relative to one another could cause the larger
floor panels 350, 450 positioned above them to crack during
shipping. Thus, the arrangement of the stacked assembly of floor
panels disclosed herein and exemplified in FIG. 2 prior to flipping
of the container 500 (thus FIG. 2 illustrates the stacked assembly
opposite to the arrangement during shipping because after the
container 500 is closed the entire container 500 is flipped so that
the top surface 502 is exposed).
[0034] Referring now to FIG. 3, the structural details of the floor
panels 250, 350, 450 will be described. Each of the floor panels
250, 350, 450 can have the same structural components as discussed
below. In the exemplified embodiment, the floor panel 250, 350, 450
is a laminate structure comprising a top layer 180 having a top
surface 10 and a bottom layer 181 having a bottom surface 11. Each
of the top layer 180 and the bottom layer 181 may comprises a
plurality of layers. In one such embodiment, the top layer 180 may
comprise a mix layer, a wear layer and a top coat layer. Moreover,
in other embodiments, the floor panel 250, 350, 450 can comprise
layers in addition to the top and bottom layers 180, 181, such as
an intermediate fiberglass or polyester scrim layer. Additional
layers may also include one or more of an antimicrobial layer, a
sound deadening layer, a cushioning layer, a slide resistant layer,
a stiffening layer, a channeling layer, a mechanically embossed
texture, or a chemical texture.
[0035] The top layer 180 comprises the top surface of the body 110.
In one embodiment, the top layer 180 comprises a flexible sheet
material comprising plastic, vinyl, polyvinyl chloride, polyester,
or combinations thereof. The bottom layer 180, in certain
embodiments, may comprise a flexible sheet material comprising
plastic, vinyl, polyvinyl chloride, polyester, polyolefin, nylon,
or combinations thereof. Thus, in certain embodiments the floor
panels 250, 350, 450 have a degree of flexibility in that they are
not completely rigid like a stone or ceramic tile, but are capable
of being slightly bent or flexed. In that regard, the floor panel
250, 350, 450, in one embodiment, is designed so as to have a
Young's modulus in a range of 240 MPA to 620 MPA. In another
embodiment, the floor panel 250, 350, 450 is designed so as to have
a Young's modulus in a range of 320 MPA to 540 MPA
[0036] In one embodiment, the body 110 of the floor panel 250, 350,
450 has a thickness in the range of 2 mm to 12 mm. In another
embodiment, the body 110 of the floor panel 250, 350, 450 has a
thickness in the range of 2 mm to 5 mm. In one specific embodiment,
the body 110 of the floor panel 250, 350, 450 has a thickness in
the range of 3 mm to 4 mm.
[0037] In the illustrated embodiment, the top layer 180 comprises a
clear film/wear layer positioned atop a top mix layer. The top mix
layer may be formed, for example, from a substantially flexible
sheet material, such as plastic, vinyl, polyvinyl chloride,
polyester, or combinations thereof. A visible decorative pattern
163 may be applied to the top surface of the top layer 180, such as
beneath the clear film/wear layer. The clear film/wear layer, in
certain embodiments, may have a thickness of about 4-40 mils (about
0.1-1.0 millimeters), preferably about 6-20 mils (about 0.15-0.5
millimeters), and more preferably about 12-20 mils (about 0.3-0.5
millimeters).
[0038] The top layer 180, in certain embodiments, may have a
thickness of about 34-110 mils (about 0.8-2.8 millimeters),
preferably about 37-250, 350, 450 mils (about 0.9-2.5 millimeters),
and more preferably about 38-250, 350, 450 mils (about 1.0-2.5
millimeters).
[0039] The bottom layer 181, in the illustrated embodiment,
comprises only a bottom mix layer. The bottom mix layer may be
formed, for example, from a flexible sheet of material comprising
plastic, vinyl, polyvinyl chloride, polyester, polyolefin, nylon,
or combinations thereof. The bottom layer 181 may also, in other
embodiments, include recycled material, such as post-industrial or
post-consumer scrap.
[0040] The bottom layer 181, in certain embodiments, may have a
thickness of about 34-110 mils (about 0.8-2.8 millimeters),
preferably about 37-250, 350, 450 mils (about 0.9-2.5 millimeters),
and more preferably about 38-250, 350, 450 mils (about 1.0-2.5
millimeters).
[0041] In certain embodiments, the bottom surface of the top layer
180 is laminated to the top surface of the bottom layer 181 by an
adhesive. The adhesive may be, for example, any suitable adhesive,
such as a hot melt adhesive, a pressure sensitive adhesive, or a
structural and/or reactive adhesive. The adhesive may have, for
example, a bond strength of at least 25 force-pounds, and more
preferably about 25-30 force-pounds after having been heat aged for
about 24 hours at 145 degrees Fahrenheit. In the illustrated
embodiment, the adhesive is provided on substantially an entirety
of the top surface of the bottom layer 181. The adhesive may be
applied to have a thickness, for example, of about 1-2 mils (about
0.0254-0.0508 millimeters). It will be appreciated by those skilled
in the art, however, that the thickness of the adhesive may vary
depending on the texture of the bottom surface of the top layer 180
and the texture of the top surface of the bottom layer 181 in that
a substantially smooth surface would require less of the adhesive
due to better adhesion and bond strength.
[0042] The top and bottom mix layers may be made from plasticizer,
filler, and binder, and may be made in the following percentages
for certain embodiments: [0043] Average % Plasticizer of Bottom Mix
layer and the Top Mix layer (without the clear film): Range of 6.4%
to 8.1% [0044] Average % Filler of Bottom Mix layer and the Top Mix
layer (without the clear film): Range of 65.9% to 78.7% [0045]
Average % Binder of Bottom Mix layer and the Top Mix layer (without
the clear film): Range of 21.3% to 34.1%
[0046] By altering the percentages, the wear, flexibility and other
performance characteristics of the floor panel 250, 350, 450 can be
varied.
[0047] In certain embodiments, the floor panels 250, 350, 450
described herein are groutable floor panels or tiles meaning that
the floor panels 250, 350, 450 are coupled together when being
placed on the floor by using grout in joints between tiles. The
floor panels 250, 350, 450 can be adhered to the floor using a
thinset mortar, an epoxy, a mastic or any other type of adhesive
material commonly used when tiling a floor. After adhering the
floor panels 250, 350, 450 to the floor, grout can be used to fill
in the gaps or spaces between the adjacent floor panels 250, 350,
450 to create a finished installed flooring product.
[0048] The exemplified embodiment is disclosed whereby three
different floor panel sizes are positioned within a container and
sold as a kit. However, the invention is not to be so limited and
in other embodiments the kit may only include two different floor
panel sizes, or the kit may include four, five or more different
floor panel sizes.
[0049] As used throughout, ranges are used as shorthand for
describing each and every value that is within the range. Any value
within the range can be selected as the terminus of the range. In
addition, all references cited herein are hereby incorporated by
referenced in their entireties. In the event of a conflict in a
definition in the present disclosure and that of a cited reference,
the present disclosure controls.
[0050] While the invention has been described with respect to
specific examples including presently preferred modes of carrying
out the invention, those skilled in the art will appreciate that
there are numerous variations and permutations of the above
described systems and techniques. It is to be understood that other
embodiments may be utilized and structural and functional
modifications may be made without departing from the scope of the
present invention. Thus, the spirit and scope of the invention
should be construed broadly as set forth in the appended
claims.
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