Note: Descriptions are shown in the official language in which they were submitted.
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TITLE OF THE IIWENTION
"Multidirectional Panels"
CONTINUATION STATEMENT
This is a continuation-in-part of pending Application No.: 09/436,317, filed 8
November 1999.
FIELD OF THE INVENTION
The present invention relates to flooring surfaces, preferably decorative
flooring
to surfaces. In addition, the present invention relates to a system for
constructing a flooring
surface, e.g., a decorative flooring surface. More specifically, the present
invention
relates to thin laminate flooring surfaces comprising a top wear surface,
preferably
decorative in nature, a substrate reinforcing material or layer, and
optionally, a backing
material or layer. The present invention also relates to components, systems,
and methods
for ' constructing a disengageable decorative laminate flooring surface from
individual
flooring panels. In addition, the present invention relates to decorative
laminate flooring
products or components, e.g., panels and elements for connecting the panels.
BACKGROUND OF THE INVENTION
2o Various systems have been proposed in an attempt to provide a means for
easily
constructing a flooring surface; however, none to date have found overwhelming
acceptance in the market place, especially in relation to disengageable thin
laminate
"floating floor" surfaces.
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Typically; manufacturers of laminate flooring panels have produced a flooring
product that contain both a tongue and a groove profile within the same
flooring panel.
The tongue profile is machined into one side and one end of the panel with the
groove
being machined into the opposite side and end of the same panel. This type of
manufacturing creates a panel that has a directional orientation or
"handedness" (right or
left hand orientation).
In prior art systems, a panel is manufactured having a top wear surface. After
manufacture, the panel is machined at the edges to remove a portion of the top
wear
surface to form a tongue extension for insertion into a corresponding. groove
of an
to adjacent panel. To form the tongue, the top wear surface has to be machined
.off thus,
decreasing the amount of marketable square feet of flooring per panel. In
addition, the
removal of more top wear surface accelerates tool wear and thus, tools require
more
maintenance, andlor replacement. Consequently, the cost and time of
manufacture
increases. Likewise, in prior art systems, a reinforcing substrate material is
manufactured
and then, a portion is machined away to form the groove.
Typically, when constructing a flooring surface using prior art systems with
handed tongue/groove panels, the construction starts at one wall and proceeds
across the
space to the other wall. And, normally, a space to be floored is not of a
dimension which
is equally divisible by the size of a flooring panel, i.e., panels at an end
wall have to be
zo cut length or width wise to fit. In prior art systems utilizing handed
panels, once a panel
is cut there is a substantial possibility that the remaining portion is
unusable. For
example, in a prior art system utilizing rectangular panels with tongues and
grooves on
opposing intersecting edges respectively, when a panel is cut lengthwise two
panel pieces
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_ ° . Wilsonart No.: 1062F1
are formed with one long edge of each either being a tongue or a groove. At
the end wall;
a portion of a panel may be needed with a groove on the long edge and it is
inserted. As a
result, only a panel piece having a tongue on the long edge remains without a
long groove
edge.
Many prior art systems, for example, the systems in U.S. Patent Nos. 5,706,621
and 5,860,266, require holding a new panel to be joined at an angle relative
to a principal
plane of a first laid panel and angling down the new panel to become
mechanically
locked underneath a portion of the first panel. This is repeated until a floor
is
constructed. If panel number 5 in a sequence of 20 panels needs to be
replaced, e.g., due
to to damage, panels 6 through 20 have to be removed in reverse order to reach
panel
number 5. This is particularly disadvantageous in large floor systems 'subject
to
excessive wear in certain areas, e.g., in a retail space environment.
A number of the known proposed systems are discussed to provide a background
for the present invention.
U.S. Patent No. 3,310,919 titled "Portable Floor," discloses a floor
comprising a
plurality of like panels having straight sides, coupling elements at the sides
for coupling
arrangement with cooperating coupling elements on adjacent panels, and means
operatively associated with the coupling elements for releasably locking
adjacent panels
in a side-by-side contiguous relationship. As illustrated in Figure 2, the
panels are
2o coupled together using locking screws 19 and nails 15.
U.S. Patent No. 3,657,852 titled "Floor Tiles," discloses a floor or tile
consisting
either of a single piece composed of any one of a range of different materials
or a
plurality of superimposed laminations each composed of any one of a range
materials.
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The floor tiles are formed with a plurality of identical, laterally projecting
tongues and, in
their underside, with an equal number of identical pockets which open to the
periphery of
the tiles and alternate around the periphery with the tongues. The tongues and
pockets
being so shaped that any tongue of any one of the tiles is adapted to engage
and fit within
any pocket of any one of the other tiles and when so engaged, it is held
against endwise
withdrawal from the pocket so that, when the two tiles are located in a common
plane,
relative movement there between in the plane is prevented.
U.S. Patent No. 4,449,346 titled "Panel Assembly," discloses a panel assembly
including at least two panels and a connector member for mounting the panels
to a
to support surface, the panels being positioned edge-to-edge in coplanar
relationship with
the respective confronting edges thereof spaced apart, and the connector
member between
the confronting panel edges and interlocking the panels together by being
fixedly secured
to the support surface. Each panel has first and second surfaces in first and
second
parallel planes and each has on its respective edge a tongue and a groove. The
tongue and
groove extend along the panel edge in between the first and second planes, and
respectively project an opening outwardly angularly towards the first plane.
The
connector member comprises an elongated body filling the space between the
confronting
panel edges and having on each side thereof a tongue and a groove respectively
projecting an opening outwardly angularly towards the second plane. The tongue
and
2o groove on either side are complimentary to lockingly engage with the
respective groove
and tongue on the adjacent respective confronting edges of the panel. The
connector
member cooperates with the panels to urge the panels toward one another in a
tight
locking engagement as a result of a compressive force being exerted on the
member in
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the direction toward the support surface when the member is secured to the
support
surface. The patent states that the provision of such a connector member does
away with
the heretofore known practice of driving nails or screws in the panel edges to
fix the
panels to the support surface, while still providing a tight locking
engagement between
the panels. As shown in Figure 2, the connecting member is fixedly secured to
the
support surface using screw 86. In addition, "the top surface 56 of the
connector member
14 is coplanar with the top planar surfaces 16 and 18 of panels 10 and 12" and
therefore,
forms a part of the top wear surface -- which is readily visible.
U.S. Patent No. 4,135,339 titled "Slatted Floor System," discloses a slatted
floor
to system which is said to be easily assembled, provides firm footing and
comfort to
confined animals, resists corrosion, discourages accumulation of animal waste,
is easily
cleaned, and can be used to span significantly greater distances than prior
art slats. The
slatted floor system is stated to comprise a plurality of elongated, spaced,
generally
parallel slats. Each slat has a top, load-carrying surface with spaced apart,
opposite outer
edges. Each slat also has a bottom surface substantially parallel to the top
surface and a
pair of side surfaces integral with the top surface and the bottom surface.
The side
surfaces are joined with the tog surface along lines recessed from the outer
edges of the
top surface. The side surfaces are said to further taper toward each other in
first
positions, adjacent to the top surface, then extend substantially parallel to
each other and
2o vertically relative to the bottom surface in second portions. It is stated
that this forms
with the top and bottom surfaces a generally Y-shaped, enclosed main
compartment. The
patent discloses that each slat also includes a first pair of projection
receiving means
extending longitudinally along the tapered first portion of its side surfaces
and a second
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pair of projection receiving means extending longitudinally along the second
portion of
the side surfaces. Adjacent slats are said to be connected and locked in
spaced-apart
relationship iri a plurality of connectors. Each connector has a pair of
projections, with
each projection being receivable by one of the first pair of projection
receiving means on
each of two adjacent slats, and the second pair of projection receiving means
on each of
two adjacent slats. At least one , of the first and second pairs of
projections on the
connectors are adapted to interlock with its corresponding projection
receiving means on
adjacent slats. As stated above, and shown in Figures l and 4, the upper wear
surface of
the slats are spaced apart to provide a gap to facilitate the object of the
invention, i.e., for
1o discouraging the accumulation of animal waste. In addition, as shown in the
same
figures, the projections and connector means can only be assembled by sliding
the edges
of the slats and connector together when held in parallel coplanar
relationship to one
another. And as shown, the connector member does not extend the entire length
of the
slat members.
U.S. Paxent No. 4,461,131 titled "Panel Interconnection System," discloses an
assembly of panels of rectangular shape, as for example, a floor, in which the
panels
comprise upper and lower ridged sheets separated by a core, elongated fittings
extending
along adjacent edges of adjacent panels and having lateral extension receipt
means
between edge portions of the sheets of the panels. Each fitting has an
upwardly open
2o channel located beyond the edge of the associated panel. Adjacent fittings
and adjacent
panels are secured together by elongated connector strips which have parallel
elongated
lugs received in the channels of the adjacent fittings. As shown in Figure 3,
strips 40 form
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At~".ney Docket No. 068368.0131
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a portion of .the top wear surface and are thus, visibly distinct from the
upper surface 10
of flooring panels P.
U.S. Patent No. 4,796,402 titled "Step Silencing Parquet Floor," discloses a
step
silencing parquet board, in which the sound of steps which are perceivable
from one
room to another are silenced by using a surface-press non-homogeneous fiber
board in
the supporting construction layers provided underneath the wear surface layer
of the
parquet board. The patent discloses that the board has longitudinal sides and
ends formed
with a tongue and groove whereby said board will cooperate with adjacent
boards to form
a self silencing parquet floor
1o U.S. Patent No. 5,022,200 titled "Interlocking Sections for Portable Floors
and
the Like," discloses an alleged improved locking mechanism including first and
second
members which fit together for locking purposes. The second locking member has
pins
mounted therein for motion along defined paths between first and second
positions,
referred to in the patent as closed and open positions. The patent discloses
means for
t5 normally urging the pins to their closed positions. The first locking
member is stated to
have means for moving the pins to their open positions when the two lock
members are
moved together and for permitting the pins to return to their closed positions
after
engagement of the first and second lock members. The first lock member has
engagement surfaces which contact the pins when forces are applied to move the
first and
2o second lock members apart. The shape or slope of these engagement surfaces
relative to
the paths of the defined motion of the pins is such as to cause substantial
interference of
the first lock member with the pins which prevents movement of the pins to the
open
position and therefore, prevents removal of the lock member. A separate
unlocking
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mechanism is provided to move the pins to the open position and thereby permit
disengagement of the mechanism. According to a preferred embodiment disclosed
in the
patent, the first locking member includes a Mange and the second locking
member
includes means to define a recess to receive the flange. The pins are
positioned generally
within the receiving space, and the flange includes surfaces on its outer edge
for moving
the pins to the open position, and hook-like portions having engagement
surfaces which
engage the pins in a locked position. The patent also discloses an alleged
improved panel
construction wherein a panel is formed in a single molding process which
encapsulates a
core member in urethane; molds the edge tongue and groove portions . with
recesses
1o formed therein to receive the locking members, and bonds the decorative
endurable floor
surface.
U.S. Patent No. 5,157,890 titled "Floor," discloses a flooring system of
individual panel assemblies that may be cooperatively interengaged. The patent
discloses
that the periphery of each panel is bound by frame members having two spaced
generally .
parallel flanges and a generally perpendicular web extending therebetween. On
one side
of the web, between the upper and lower flanges, the frame members include a
track for
receiving a key block. The key block comprises a generally rectangular base
with a key
tongue extending therefrom. The base is slottably received in the track of one
frame
member and the tongue is received in the track of an adjacent frame member.
The frame
2o members may be miter cut to a desired length and the corners fastened
together by a
corner fastener:
U.S. Patent No. 5,179,812 titled "Flooring Product," discloses a flooring
product
comprising a wood panel having an L-shaped surround the base of which is
located
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below the wood panel. The patent discloses the use of a plurality of parallel
aluminum
battens which are connected to the base of the panel. These battens are said
to comprise a
groove. In practice, the patent discloses that two flooring products having
similar joint
arrangements are secured together by locating the base of the surround of each
product in
the groove and the elongated members of the other product. The connection
cannot be
disengaged unless one of the flooring panels is tilted relative to the other.
U.S. Patent No. 5,295,341 titled "Snap-Together Flooring System," discloses a
flooring system having a base member having a top side, an underside, and four
circumferentially spaced outer edges, a tongue connector secured to one outer
edge by an
to interlocking rib and groove, a groove connector secured to another outer
edge by an
interlocking rib and groove, a tongue connector having forwardly converging
compressible side walls terminating in rear transverse locking surfaces, the
groove
connector having a large inner opening and a small outer opening. The tongue
sidewalk
in a compressed position being smaller than said groove outer opening to pass
through
the outer opening but elastically expandable to be larger than said outer
opening to Lock a
tongue and a groove. The patent discloses that preferably the connectors are
attached to
the base members and recesses of the outer edges by additional tongues and
grooves and
that they are attached to the base members at the factory during manufacture.
U.S. Patent No. 5,736,227 titled "Laminated Wood Flooring Product and Wood
Floor," discloses a flooring product which includes a top decorative layer, an
intermediate layer bonded to the top layer, and a base layer bonded to the
intetznediate
layer. The top, intermediate, and base layers are bonded to define a laminated
elongated
wood flooring strip. A tongue and groove are formed on respective side edges
of the
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flooring strip. The tongue and groove extend along the length of the flooring
strip, and
lock adjacent flooring strips together side-to-side to form an assembled wood
floor. The
base Iayer has a multiplicity of closely spaced-apart scores cut transverse to
the length of
the flooring strip along substantially the entire length of the flooring
strip. The scores
relieve stress and increase flexibility in the wood strip for more closely
adhering to
irregularities of the sub floor.
U.S. Patent No. 3,694,983 titled "Pile or Plastic Tiies for Flooring and the
Like
Applications," discloses tiles adapted to constitute by juxtaposition a
continuous, plain or
diversified carpet or revetment of textile, plastic or other material. Each
tile is secured to
a backing of the same dimensions but having projections along two adjacent
edges of the
tile to form an embedded strip. Each strip is provided with means permitting
the mutual
engagement of fastening means provided in embedded condition under the edges
of two
sides of the adjacent tile. The fastening means have a thickness inferior to
that of said
backing so that in assembled condition no extra thickness is produced in
relation to the
t 5 normal backing thickness.
U.S. Patent No. 3,859,000 titled "Road Construction and Panel for Making
Same," discloses a road construction comprised of a plurality of identical
invertible
polygonal panels. Each panel comprises a plurality of single piece peripheral
frame
members fixed together to define a polygonal configuration and each of the
members
2o having a roughly L-shaped projection extending therefrom. The projection is
adapted to
be interlocked with an identical projection of an associated member. Each
panel also has
a pair of load carrying sheets fixed on opposite sides of its frame members.
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U.S. Patent No. 5,706,621 titled "System for Joining Building Boards,"
discloses
a system for laying and mechanically joining building panels, especially thin,
hard,
floating floors. The patent discloses that adjacent joint edges of two panels
engage each
other to provide a first mechanical connection locking the joint edges in a
first direction
perpendicular to the principal plane of the panels. In each joint, the patent
states that there
is provided a strip which is integrated with or integrally formed with one
joint edge and
which projects behind the other joint edge. The patent discloses that the
strip has
upwardly protruding locking elements engaging in a locking groove in the rear
side of the
other joint edge to form a second mechanical connection locking the panels in
a second
1o direction parallel to the principal plane of the panels and at right angles
to the joint. Both
the first and second mechanical connections allow mutual displacement of
joined panels
in the direction of the joint. The patent discloses that the strip is mounted
at the factory on
the underside of the panel and extends throughout the joint edge. The patent
discloses the
strip may be made of flexible, resilient aluminum, and can be affixed
mechanically, by
means of glue or any other suitable way. The patent discloses that
alternatively, the strip
may be integrally formed with the strip panel. According to the patent, "at
any rate, the
strip 6 should be integrated with the panel l, i.e., it should not be mounted
on the strip
panel in connection with laying."
U.S. Patent No. 5,860,266 titled "Method for Joining Building Boards,"
discloses
a method for laying and mechanically joining rectangular building panels in
parallel
rows. The patent discloses the following steps: (a) placing a new one of the
panels
adjacent to a Long edge of a previously laid first panel in a first row and to
a short edge of
a previously laid second panel in an adjacent second row, such that the new
panel is in
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the second row while holding the new panel at an angle relative to a principal
plane of the
first panel, such that the new panel is spaced from its final longitudinal
position relative
to the second panel and such that the long edge of the new panel is provided
with a
locking groove which is placed in contact with a locking strip at the adjacent
long edge of
the first panel; (b) subsequently angling down the new panel so as to
accommodate a
locking element of the strip of the first panel in a locking groove of the new
panel,
whereby the new panel and the first panel are mechanically connected with each
other in
a second direction with respect to the thus connected long edges, wherein the
long edges,
and the angled down position of the new panel, are engaged with each other and
thereby
to mechanically locked together in a first direction also; and (c) displacing
one of the new
panels in its longitudinal direction relative tv the first panel towards a
final longitudinal
position and to a locking element of one of the short edges of the new panel
and the
second panel snaps up into a locking groove of the other one of the short
edges, whereby
the new panel and the second panel are mechanically connected with each other
in both
the first and second directions with respect to the connected short edges. The
patent states
that the strip 6 projects horizontally from a panel and is mounted at the
factory on the
underside of the panel and extends the entire edge of the panel. The patent
discloses that
strip 6 may be made of flexible, resilient sheet aluminum, and can be affixed
mechanically, by means of glue or any other suitable way. The patent discloses
that other
2o strip material can be used, such as sheets of other metals, as well as
aluminum or plastic
sections. Alternatively, the patent teaches that the strip 6 may be integrally
formed with
the strip panel. The patent states that "at any rate, the strip 6 should be
integrated with a
strip panel, i.e., it should not be mounted on the strip panel in connection
with laying."
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Japanese Patent Application No. 56-5347 titled "A Method for Partially
Recovering Floor Plates," discloses floor plates laid on a floor bed with
tongue joints
engaged with groove joints. The patent teaches a saw is inserted into gap A
between both
the side floor plates of a floor plate to be replaced and the tongue joints
are cut off
thereby connection between the floor plates is cut and the floor plate to be
replaced is
removed. The patent teaches that the subsequently left tongue joints in the
groove joints
of the adjacent floor plates are removed. The portion where there were tongue
joints
before in the floor plates is cut off and groove joints are newly formed. The
patent states
that Figure 4 shows a new floor plate and that along both sides of the floor
plate are
to formed relatively shallow and wide slots in relatively deep concaved
portions. The
bottom of the concaved portion is dented so as to hold a foaming synthetic
resin. The new
floor plate is then inserted into the position where the removed floor plate
was located
and at a status wherein the new floor plate is level with the adjacent floor
plate. The
foaming resin is foamed and hardened. The hardened foaming resin expands into
the
t5 groove joints to form a tongue joint. It is also noted that the new floor
plate in contact
with the floor bed is secured by adhesive.
Japanese Patent Application No. 1-30691 titled "Floor Plates," discloses floor
plates to be laid on a ground floor characterized by having a thin wooden
decorative plate
laminated onto the surface layer of a base material in a sheet shape. An
engaging
20 protrusion is formed on one side of the base material while an engaging
concave portion
to which the above engaging protrusion may be engaged is formed on the other
end
thereof while an engaging concave portion to which the above engaging
protrusion may
be engaged is formed on the end of the other side thereof. The patent teaches
that the
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floor plates include a stopper protrusion formed on one side of the engaging
protrusion
and on one side of the engaging concave portion. And a stopper concave portion
to which
the stopper protrusion is engaged is formed on the other side of the engaging
protrusion
and on the other side of the engaging concave portion.
Patentschrift No. 200949 discloses in Figures 1 and 2 flooring panels having
four
edges wherein two edges include an upper groove for insertion thereunder of an
adjacent
panel, while the other two edges include an extension including a tooth formed
to be
inserted under the upper groove portion of an adjacent panel when assembled.
Patentschrift No. 1 534 278 discloses in Figures 1-3 to assemble two adjacent
1o structures wherein the first structure includes a groove and a notch for
receipt of a
corresponding tongue and tooth of an adjacent structure to be connected
thereto.
Offenlegungsschrift 25 02 992 discloses a flooring panel especially suitable
for
use in making a temporary floor, as for example, in a camping tent. The
flooring panel is
disclosed to have a flat thread surface bent back on at least two edges, one
of which is
given a distinct profile and the other having a fitting countetprofile. The
patent teaches
that these bent sections are preferably on two opposite sides, one being
roughly U-shaped
with its outer shank and the resultant slot-type opening facing upwards and
the
counterprofile consisting of a shank at right angles to the thread surface.
The patent
teaches that such profiles may be provided alternatively, on all four edges of
the panel. It
2o is disclosed that the panels may be of plastic, and formed in a single
piece, corrugated
projections underneath preferably of a softer material. As shown in Figure 3,
the panels
are assembled together using a tongue and groove arrangement.
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OffenIegungsschrift DE 3041781A1 discloses the inner connection of two panels
wherein the panels include a tongue on one edge and a groove in another edge
to provide
interlocking connections between two panels used especially for constructing a
skating
rink or skittle alley. The patent discloses at the root of the tongue there
are two parallel
sides with faced pieces aligned at right angles to the edge of equal
thickness. The patem
discloses that the groove has two initial parallel sidewalls against which the
tongue side
face pieces come to rest. It is disclosed that this part of the groove is
succeeded by a
semi-trapezoidal shaped recess or a fully trapezoidal shaped recess. The
patent discloses
that the tongue may be rounded on the side opposite to its acute-angled side
face.
to Offenlegungsschrift DE 35 44 845 Al discloses a board used for the
manufacture
of solid wood panels which consists of glued boards engaging complimentary
profiles.
Longitudinal edges of the boards have a joint profile which sections extend at
an angle to
the vertical board edge. The application discloses that the joint profile has
two parallel
straight sideward displaced upright flanks which are connected at their inner
ends via
straight transverse flanks. The inward upward flank encloses an acute angle
with the
board surface, while the other flank forms an obtuse angle with the associated
board
surface. Upright hanks and transverse flanks enclose acute angles.
European Patent Application No. 0248127 titled "A Table Top for a Motor
Lorry" discloses a motor lorry table top consisting of a plurality of planks
which are fixed
to at least two beams forming part of the motor lorry chassis. The planks
consist of
extruded aluminum and are fixed to the chassis by means of clips with the
planks
interlocking to secure the planks from relative movement therebetween.
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Patenttihakemus-Patentansokan 843067 (PCT/SE 83/00423) discloses a means
for interconnecting adjacent panels wherein the edges of panels to be
connected include
tongues and grooves. In addition, located to either side of the tongue and
groove joint of
two connected panels are recesses formed in said panels for receipt of a U-
shaped metal
clamp means for holding the two panels together at the tongue and groove
joint.
French Application No: 2 697 ?75 discloses the formation of a surface from
rectangular shaped slabs placed on a flat horizontal surface. The application
discloses that
the body of the slab has shaped sections on all four sides and that the slabs
can be
mechanically joined together via a number of ribs running lengthwise .along
the slab
1o which are shaped so that they slide into a matching groove in the adjacent
slab. Figure 2
appears to disclose a member 33 for connecting two adjacent slabs. As shown,
the top
surface of the member 33 forms a portion of the top wear surface of the
resulting floor.
This also can be seen in Figure 1 where members 5 and 6 fomn a portion of the
top wear
surface.
~ Japanese Application No. 54-65528 shows in Figures 1-3 a particular tongue
and
groove arrangement for interconnecting two adjacent panels.
French Application 2 568 295 discloses a prefabricated flooring system
consisting of a series of flat panels which are laid directly on the ground.
The panels are
made, for example, from a resin compound either containing reinforcing
elements or
2o incorporating granules of a durable material such as quartz or carborumdum.
The patent
discloses that the panels have interlocking joints on all their edges, made in
the form of
projections and recesses, and the under surface of each panel can be covered
with a layer
HO(.'03:7 I 1508.1 17
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of non-decomposing cellular and flexible material which is able to compensate
for
irregularities in the surface of the ground.
UK Patent Application No. 424,057 discloses a method of constructing a parquet
floor which comprises the use of reversible rectangular blocks each having
protruding
flanges forming sphenoidal grooves on each of its four sides, each groove
extending
across the whole of the side in which it is situated. The patent teaches the
grooves on two
co-terminus sides having their mouths facing upwards when the mouths of the
other two
grooves on the other two sides face downwards, whereby a plurality of such
blocks may
be built up into a floor covering in which each block is locked on each side
which lays
to contiguous with the side of another such block. The method is stated to
also comprise the
use of cDnnecting members having flanges adopted to engage beneath the
overhanging .
flanges of two adjacent blocks where a change in direction of laying is
required.
UK Patent No. 1,237,744 titled "Improved Building Structure," discloses that
it
relates to a building structure composed of panels joined at their edges by
first tongue and
t5 groove connections having elements located in the plane of the building
structure as well
as by second tongue and groove connections having elements located
perpendicular to
said plane.
UK Patent No. 1,430,423 titled "Joint Structure," discloses in Figures l and
'? a
specific tongue and groove/notch and tooth joint structure for interconnecting
plastic and
2o metal materials.
UK Patent Application No. 2 117 813A titled "Pivotal Assembly for Simulated
Wall Panels," discloses a joint assembly comprising a pair of strips secured
to the edges
of the respective panels by folding the outer skins of the panels and by a
dovetail joint in
~touos:~t tsos. t i8
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p ~" , ~ Wilsonart No.: 1062P1
the foam insulation material inside the panels. The application discloses the
connecting
strips provide a curved tongue and groove. The groove strip has a pivotal body
of part-
cylindrical shape so that one strip can be pivoted relative to the other for a
tongue to enter
the groove. The application discloses that a locking strip is provided to be
inserted into a
groove to lock the panels together.
UK Patent Application No. 2 256 023A titled "Joint," discloses a joint between
the joining side edges of two similar panels in which one panel has a channel-
section
recess open towards the front face and the other panel has a rib facing
towards the rear
face for reception in the recess to restrict separation of the panels . to
provide a
to predeternvned expansion gap between the adjacent side edges. The
application discloses
that the panels may be tongue and groove boards for construction of, for
example, a door.
The application discloses in the figures a particular tongue and groove/notch
and tooth
joint.
Utlengningsskrift No. 157871 discloses in the figures the connection of two
t5 adjoining members utilizing a tongue and groove joint at the edges and
which includes
recesses fomued in said panels spaced from the joint for receipt of a U-shaped
member
for holding the two panels together at the tonguelgroove joint.
Utlaggningsskrift No, 7114900-9 discloses in Figures 1-3 means for connecting
two adjacent members utilizing connection blocks 2, 5 and 9 wherein said
blocks form a
2o part of the top wear surface. The application further discloses a U-shaped
member for
insertion on the backside of the panels to hold the two panels together at the
joint where
the joint block exists.
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" o . Wilsonarc No.: 1062P1
WO 84/02155 titled "Device for Joining Together Building Boards, Such as
Floor Boards," discloses a device for joining together building boards, such
as floor
boards, edge surface to edge surface. The application discloses a system
wherein the
boards comprise a groove in the rear side of each board, the groove running
over the
entire length of the board parallel to its joining edge, and a substantially U-
shaped spring
device, the legs of which are each adapted to engage the groove of one board,
and which
is prestressed so that, upon engagement, the boards are tightly clamped
together edge
surface to edge surface.
Patentschrift 200949 discloses in Figures 1-6 panels for joinder one to
another
wherein the panels include on two intersecting edges extending tongue strips
and on the
other intersecting edges an extending groove strip.
WO 93/13280 titled "A Device for Joining Floor Boards," discloses a device for
joining floor boards comprising elongated, flat-shaped body with legs adapted
to engage
a longitudinal groove in each of the joining floor boards. The legs are shaped
at a
t5 distance from the ends of the plate-shaped body in such a manner that the
plate-shaped
body supports the boards on each side of the grooves.
U.S. Patent No. 3,538,665 titled "Parquet Flooring," discloses a floating
parquet
flooring comprising rectangular-shaped two-layer flooring units composed of a
parquet
layer and a backing layer. The bottom face of the backing Iayer being provided
with
2o marginal recesses along the four sides of the unit and a strip of backing
layer material
being inserted in the space formed by such marginal recesses for bridging the
joint
between adjacent units. The patent discloses that the backing layer material
has a
modules of elasticity in tension not exceeding 5000 kg/cm'.
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Offenlegungsscrift 26 16 077 A discloses a connection web with a flange for
connecting plates resting flat on a supporting substrate. The patent
application discloses
the arrangement is especially useful for connecting prefabricated parquet
floor elements.
The application discloses that a pliable connection arrangement is provided
which
replaces rigid connectors such as adhesives or nails. The application states
that the system
is advantageous because it accommodates expansion and shrinking stresses which
thus,
prevents cracking. It is stated that the connecting web prevents overlapping
of the plate
edges on uneven substrates and in use the connection web is loaded in tension
when the
plates expand. On contraction of the plates, the connection web pulls the
plates together
1o and prevents gap formation.
French Application No. 1 293 043 discloses in Figures 1-3 a tile having four
edges wherein one set of intersecting edges includes a tongue extending
therefrom and
the other two intersecting edges includes a groove open in the direction of
the bottom
side of the tile. Figures 4-6 disclose tiles having four edges wherein two
intersecting
edges include a notch and a groove open toward the top side of the panel and
the other
two intersecting edges have a notch and a groove open toward the bottom of the
panel.
Utlaggningsskrift No. 8206934-5 discloses the joining of two panels wherein a
tongue and groove arrangement is utilized. The drawings further disclose a U-
shaped
clip for insertion into the panels on either side of the joint for holding the
two panels
2o together at said joint.
WO 97/47834 titled "Floor Covering, Consisting of Hard Floor Panels and
Methods for Manufacturing Such Floor Panels," discloses a floor covering
consisting of
hard floor panels which, at least at the edges of two opposite sides, are
provided with
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coupling parts cooperating with each other. The coupling parts are
substantially in the
form of tongues and grooves characterized in that the parts are provided with
integrated
mechanical locking means. The locking means prevent the drifting apart of two
coupled
floor panels into a direction perpendicular to the related edges and parallel
to the
underside of the coupled floor panels.
In view of the prior art, there is a need for floor panels which do not have a
"handed" configuration.
SLJwIMARY OF THE INVENTION
to According to one embodiment, the present invention comprises a
disengageable
interconnecting floor system for use in forming temporary or permanent
flooring surfaces
from individual Mooring panels on top of a support structure. The system
preferably
comprises two or more flooring panels comprising a top wear surface and a
bottom
surface for contact with the support structure. The panels, according to this
embodiment.
t5 comprise at least three edges wherein all of the edges have identical
grooves or recesses
formed therein for receipt of a projection from a connector. Preferably, the
grooves or
recesses extend substantially the entire length of the panel edges. The
preferred connector
comprises a base and an extension extending vertically from the base, spaced
from the
base and substantially parallel thereto. The extension is shaped to be
received in a
2o disengageable vertical connected fashion into at least one recess of at
least one panel.
According to a preferred embodiment, the preferred connector of the system of
the present invention further includes an extension that is shaped to be
received in a
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disengageable horizontal connected fashion into at least one groove or recess
of the
panels.
According to another embodiment of the present invention, the base of the
novel
connecting element has grooves or other recesses formed therein, and at least
one panel
edge is shaped to be received in a disengageable horizontal connected fashion
into the
groove or recess of the base of the connecting element. The groove or recess
may be
formed in the base or in part of the above-described extension.
According to yet another embodiment of the present invention, an extension of
the connector according to the present invention has a groove or other recess
formed
1o therein, and at least one panel is shaped to be received in a disengageable
horizontal
connected fashion in the groove or other recess of the extension.
According to a further embodiment of the present invention, the distance from
the
base of the connector to the top or uppermost point of the extension,
preferably tongue--
shaped, of the connector is less than the distance from the bottom surface to
the top wear
t 5 surface of the panels.
According to another embodiment of the present invention, a disengageable
interconnecting flooring system is provided for use in forming temporary or
permanent
flooring surfaces on top of a support structure from individual flooring
panels. The
system comprises two or more flooring panels, preferably laminated, and at
least one
2o elongated connector, e.g., a track. The flooring panels preferably have a
top wear
surface, a middle reinforcing substrate material, and a bottom surface for
contact with a
support floor structure. The panels preferably have four edges with identical
grooves
formed therein; preferably in all edges, for receipt of a vertically extending
extension of
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the track. The panels also have notches or other recesses, e.g. channels,
formed in their
bottom surfaces shaped for receipt of nodes, ridges, or other protrusions from
the
connector. Preferably, the grooves and the channels extend substantially the
entire length
of the edges of the panels.
The connector, according to one embodiment of the present invention, has a
base
with preferably a single extension extending vertically therefrom shaped to be
received in
a disengageable vertical connected fashion into grooves or other recesses in
the edges of
the panels. Preferably, the connector is substantially, if not the same,
length as the panel
edges to be connected. Preferably, the extension extends the entire length of
the
1o connector. The base of the connector further has two nodes, ridges, or two
other
protrusions extending vertically from either side of the base spaced from the
single
extension. The protrusions or ridges are shaped to be received in a
disengageable
horizontal connected fashion into the notches or other recesses, e.g.,
channels, in the
bottom surface of the panels. Preferably, the protrusions or ridges extend
substantially
the entire length of the edges of the panels. When the panels are connected
using the
connector, the resultant visible flooring surface consists of only the top
wear surface of
the panels.
According to another embodiment of the present invention, a vertical and
horizontal interconnecting Mooring system for use in forming a Mooring surface
on top of
2o a support surface is provided. The system comprises two or more individual
flooring
panels, preferably laminated floor panels, having a thickness, and at least
one connecting
track. The flooring panels have a top wear surface and a bottom surface for
contact with
a support surface. The panels have at least three edges wherein all edges have
first
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identical recesses or grooves formed therein. The first recesses or grooves
are shaped to
receive a first connection projection or flange from the track. The panels
also have
second recesses, e.g., channels, located along the bottom surfaces of the
panels open in
the direction of the ground or support surface for receipt of a second
connection
projection or ridge from the track. The track, according to this embodiment,
has a base, a
first connection projection or flange, and a second connection projection or
ridge. The
first connection projection or flange is connected to and extends vertically a
distance
from the base and is shaped to be received in the first recesses or grooves of
the panels to
form a vertical connection between the panels. The second connection
projection or
1o ridge is connected to and extends vertically a distance from the base,
preferably a
distance less than the first projection, and shaped to be received in the
second recesses or
channels of the panels to form a horizontal connection between the panels.
According to
this embodiment, the distance from the base of the track to an uppermost
vertical portion
of the first projection or flange is less than the distance between the top
wear surface and
t5 the bottom surface of the panel in contact with the support surface such
that when two
panels are connected, said first and second connections form a flooring
surface consisting
of only the top wear surface of the panels.
According to a further embodiment of the present invention, a disengageable
decorative laminate flooring system for application to an existing floor
surface without
2o the use of adhesives or traditional fastening devices is provided. The
system comprises a
plurality of identical individual floor panels and connectors. The individual
floor panels
have a top decorative wear surface and comprise at least three edges each
having an
identical receiver located in said edges, i.e., each edge of each panel
comprises the same
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configuration. The connectors, preferably comprise rails, of substantially the
same length
as the edges of the panels. The rails have extending vertically therefrom a
first projection
and a second pair of projections. The first projection being shaped for
insertion into the
receivers for disengageable vertical interconnection of the individual
flooring panels at
their edges. The second pair of projections being shaped for insertion into
the receivers
for disengageable horizontal interconnection of the individual flooring panels
at their
edges. Preferably, the first projection and second pair of projections extend
substantially
the entire length of the rail. And when the panels are interconnected using
the connectors,
according to this embodiment, the visible resultant flooring surface only
.consists of the
to top decorative wear surface, i.e., no portion of the connector forms a part
of the visible
flooring surface.
According to one embodiment, the present invention is directed to a
disengageable connector for vertically and horizontally interconnecting
individual
flooring panels to form a laminate flooring surface on top of a support
structure. The
connector preferably comprises a base for contact with the support structure.
The base,
according to one embodiment, has a projection or extension extending
vertically
therefrom in a direction away from the support structure. The projection or
extension has
top and bottom portions consisting of identical right and left halves, each
half preferably
comprising a tongue-like extension or flange extending a distance
substantially parallel to
2o and spaced above said base. Optionally, according to a particularly
preferred
embodiment, the base includes two additional protrusions or ridges extending
vertically
therefrom. These protrusions or ridges are spaced apart and located on either
side of said
pro~ecrion or extension.
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.m " Wilsonart No.: 1062P1
According to yet another embodiment, the present invention is directed to
individual flooring panels for use in forming a flooring surface on a support
structure,
said flooring surface comprised of said panels disengageably interconnected
horizontally
and vertically. The panels; according to this embodiment, comprise a top
surface, a
bottom surface, and edges between the top and bottom surfaces. The top surface
comprises a decorative wear surface. The edges comprise identical grooves
and/or
recesses extending substantially the entire length of the edges. The bottom
surface
comprises identical channels formed therein and open toward the support
structure or
away from the top surface. These channels are parallel to, spaced from, ,and
preferably
to extend substantially the entire length of the edges.
According to one aspect of the invention, there is provided a mufti-
directional
laminate flooring panel for use in constructing a floor, the panel comprising:
a top
surface, a bottom surface and sides extending between the top and bottom
surfaces,
wherein the sides have identical grooved profiles.
° According to a further. aspect of the invention, there is provided a
multi-
directional laminate flooring system comprising: at least two panels, wherein
each panel
comprises a top surface, a bottom surface and sides extending between the top
and
bottom surfaces, wherein the sides have identical recessed profiles; and a
connector
separate from the at least two panels for connecting the at least two panels
together to
2o form a floor.
According to another aspect of the invention, there is provided a mufti-
directional
laminate flooring panel comprising: a top surface, a bottom surface and sides
extending
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between the top and bottom surfaces, wherein each side has a groove and the
bottom
surface has a channel extending parallel to each groove.
According to still another aspect of the invention, there is provided a method
for
constructing a flooring surface on a subfloor support, the method comprising:
placing a
first panel on the subfloor support, wherein the first panel has a top
surface, a bottom
surface and sides extending between the top and bottom surfaces, wherein each
side has a
groove; mating a connector with a groove of the first panel; placing a second
panel on the
subfloor support; wherein the second panel has a top surface, a bottom surface
and sides
extending between the top and bottom surfaces, wherein each side has , a
groove; and
to mating the connector with a groove of the second panel, wherein the mated
connector is
below the top surface of the first and second panels.
According to still a further aspect of the invention, there is provided a
method for
constructing a flooring surface, the method comprising: mating a connector
with a
groove of a first panel, wherein the first panel has a top surface, a bottom
surface and
sides extending between the top and bottom surfaces, wherein each side has a
groove:
positioning a second panel in the same plane as the first panel, wherein the
second panel
has a top surface, a bottom surface and sides extending between the top and
bottom
surfaces, wherein each side has a groove; and mating the connector with a
groove of the
second panel while the first and second panels are in the same plane, wherein
the mated
2o connector is below the top surfaces of the first and second panels.
The present invention is directed to a unique and novel system for easily
joining
and disjoining a flooring surface, preferably a thin (less than an inch thick)
laminate
flooring surface of the "floating" type. The system is designed such that
additional
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traditional fastening means are not needed, e.g., nails, screws, adhesives,
tacks, staples,
etc. are unnecessary. The present inventive system accomplishes this task
without the
need of special tools or floor laying experience. The present inventive system
accomplishes its advantages utilizing preferably identical joining panels with
preferably
identical novel edges making assembly easy and flexible, even for the novice.
Moreover,
the present inventive system provides a single connecting means for use in
relation to all
edges of the novel panels -- again, making assembly and disassembly easy. More
importantly, due to the fact that at least two edges of the panels have
recesses formed
therein during manufacture, either less reinforcing middle substrate material
is needed to
to manufacture the panels and thus, saving resources and/or less decorative
top surface
material is wasted, i. e., it is not necessary to remove as much of the top
wear surface
portions to provide for the interconnecting system of the invention.
A further advantage of the invention is that the panels may be oriented in any
direction (during installation) without the need to mechanically modify a
factory
is produced tongue or groove profile. These panels may be manufactured in a
cost-effective
manner (no tongue profile to machine). The amount of material (approximately
1/8 inch
in width) needed to mechanically create the tongue profile. does not have to
be machined
off. The result is a significant cost reduction due to the elimination of the
tooling needed
to produce the tongue profile. Also, this results in an additional 1/8 inch
net saleable
2o surface area. The material previously machined away to form a tongue
profile
(approximately 1/8 inch in width) is now machined into a groove profile. The
creation of
a groove, as opposed to a tongue, yields additional surface area. Crreater
surface area
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results in greater revenue because the surface area is available to be sold,
rather than
machined away and disposed.
The system of the present invention also eliminates "seam swell" or "peaking"
caused by the typical tongue and groove systems. When moisture (water)
penetrates the
seam from above the floor or reaches the seam from the underside of the
flooring panel
the seam profile swells. By way of explanation, the tongue profile will grow
in size and
the groove profle will shrink in size. This causes the entire panel thickness
to change
(grow in thickness) in the seam area. The result is "peaking" ~ directly above
the seam
area: Since the present invention uses a connector having flanges to make the
joint
to between two panels, the flange is no longer made of a material that absorbs
moisture.
Thus, there is no tongue which expands upon absorbing moisture so that
"peaking" is no
longer a problem when using the present inventive system:
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is better understood by reading the following
description of
non-limitative embodiments with reference to the attached drawings wherein
like pans in
each of the several figures are identified by the same reference characters,
and which are
briefly described as follows:
Figure 1 illustrates one embodiment of the connector of the present invention;
Figure 2 illustrates one embodiment of the connector of the present invention;
Figure 3 illustrates one embodiment of the connector of the present invention;
Figure 4 illustrates one embodiment of the connector of the present invention:
Figure 5 illustrates one embodiment of the connector of the present invention;
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Figure 6 illustrates a preferred embodiment of the connector of the present
invention;
Figure 7 illustrates one embodiment of the connector of the present invention;
Figure 8 illustrates one embodiment of the connector of the present invention;
Figure 9 illustrates one embodiment of the connector of the present invention;
Figure 10 illustrates one embodiment of the connector of the present
invention;
Figure 11 illustrates one embodiment of the connector of the present
invention;
Figure 12 illustrates one embodiment of the connector of the present
invention;
Figure i 3 illustrates one embodiment of the connector of the present
invention;
Figure 14 illustrates a particularly preferred embodiment of the connector of
the
present invention (Scale 9x; 1.00 = 1-inch);
Figure 15 illustrates a shaded view of a preferred embodiment of the connector
of
the present invention;
Figure I6 illustrates one embodiment of the connector of the present
invention;
Figure 17 illustrates one embodiment of the connector of the present
invention; a
Figure I8 illustrates a preferred embodiment of the connector of the present
invention and a preferred embodiment of the panels of the present invention;
Figure 19A is a top view of a panel having truncated grooves in the backing
layer;
Figure 19B is an end view of the panel of Figure I 9A;
Figure 20A is a top view of a connector having angled ends;
Figure 20B is an end view of the connector shown in Figure 20A;
Figure 20C is a side view of the connector shown in Figures 20A and 20B;
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Figure 21 is a top view of a partially assembled section of floor covering
comprising square panels and connectors with angled ends;
Figure 22 is a top view of a partially assembled section of floor covering
comprising square and triangular panels and connectors with angled ends;
Figure 23 is a top view of a partially assembled section of floor covering
comprising rectangular panels, transverse connectors and longitudinal
connectors;
Figure 24A is a top view of a transverse connector;
Figure 24B is an end view of the transverse connector shown in Figure 24A;
Figure 24C is a side view of the transverse connector shown in Figures 24A and
24B;
Figure 25 is a side view of a transverse connector assembled with two
longitudinal connectors, wherein end views of the longitudinal connectors are
shown:
Figure 26A is a top view of a rectangular panel having complete grooves;
Figure 26B is an end view of the panel shown in Figure 26A; and
Figure 27 is a top view of a partially assembled floor system having hexagon
and
triangle shaped panels.
It is to be noted, however, that the appended drawings illustrate only typical
embodiments of this invention and are therefore not to be considered limiting
of its
scope, as the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION OF THE INVENTION
In a preferred embodiment, the present inventive system is directed to
decorative
laminate flooring panels, squares, tiles, rectangles, etc. each having a top
wear surface, a
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° ° Attorney Docket No. 068368.0131
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middle substrate or reinforcing material below the top surface, and
optionally, a backing
layer surface attached to the middle substrate material for contact with the
supporting or
existing floor or ground surface.
The top wear surface of the panels of the present invention, preferably
comprises
decorative laminates or laminates prepared by heat and pressure consolidation.
These
panels have been produced commercially for a number of years, and have found
widespread acceptance in the building and furniture industry as counter and
table tops,
bathroom and kitchen work surfaces, wall paneling, partitions and doors. Such
decorative
laminates can be described as containing a number of laminae that are
consolidated to
1o form a composite or unitary structure carrying a surface decoration which
can range from
something as simple as a solid color to something as complex as an embossed
simulated
wood grain finish.
More specifically, a decorative laminate, useful in the present invention,
generally comprises a plurality of layers of synthetic resin impregnated paper
sheets
consolidated or bonded together into a unitary structure under heat and
pressure. In
normal practice, the decorative laminate assembly, from the bottom up,
consists of a core
of one or more sheets impregnated with phenolic resin, above which lies a
decorative
sheet impregnated with melamine resin and/or an overlay impregnated with
melamine
resin. The core or base member functions to impart rigidity to the laminate
and usually
2o comprises a solid substrate which may or may not be formed prior to the
initial
laminating step. Prior to stacking, the sheets of the core member are
impregnated with a
water alcohol solution of phenol and formaldehyde or a formaldehyde precursor,
dried
and partially cured in a hot air oven, and finally cut into sheets. Examples
of such a base
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or core member include: ( 1 ) a plurality of sheets of 90 to 150 pound ream
kraft paper
impregnated throughout and bonded with a substantially completely cured
phenolic resin
which has been converted to the thermoset state during the initial laminating
step; (2) a
precured plastic laminate such as glass fiber-reinforced thermoset polyester
resin
laminates or the like; (3) a wood product such as hardboard, fiberboard,
woodwaste.
particle boards, plywood or the like; (4) a mineral base board such as cement-
asbestos
board, sheet rock, plaster board or the like; (5) plastic impregnated boards:
(6)
plastic/wood compositions; (7) plastic compositions; (8) closed-cell
polyurethane foam.
e.g., RIM foam; (9) urethane impregnated boards; ( 10) a combination of these
substrates:
to or (11) any material suitable to perform the desired function of the base
or core member.
The decorative sheet, useful in the panels of the present invention, generally
functions to give an attractive appearance to the laminate, and also gives the
panel its
surface characteristics (i.e., resistance to chemical agents, to heat, to
light, to shock and to
abrasion). The decorative sheet typically is a high quality 50 to 125 ream
weight, pigment
filled, alpha cellulose paper that has been impregnated with a water-alcohol
solution of
melamine-formaldehyde resin, dried and partially cured, and finally cut into
sheets. The
decorative sheet may be of a solid color or may compt~ise~ a decorative design
or pattern,
or a photo reproduction of natural materials, such as, wood, marble, leather,
etc. As stated
above, the decorative sheet and/or an overlay sheet may be impregnated with
melamine
resin.
The decorative laminate useful in the manufacture of the panels of the present
invention, is generally obtained by, but not limited to, placing the resin
impregnated core
and decorative sheets between steel coated; steel, or stainless steel plates
and subjecting
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° Attorney Docket No. 068368.OI31
° ° ~ . Wilsonart No.: 1062P 1
the laminate stack to temperatures ranging from about 150° F to about
S00° F and
pressures ranging from about 800 to about 1600 psi for a time sufficient to
consolidate
the laminate and cure the resins {generally about 25 minutes to an hour). This
causes the
resin in the paper sheets to flow, cure, and consolidate the sheets into a
composite or
unitary laminated mass referred to in the art as a high pressure decorative
laminate
(HPDL). More than one laminate can be formed at one time by inserting a
plurality of
assembled sheets in a stack with each assembly being separated by a release
sheet which
allows the individual laminates to be separated after consolidation. Finally,
the decorative
laminates are further processed and are generally bonded to a reinforcing,
substrate, such
to as medium to high density fiber board, woodlplastic compositions, woods,
plywood,
hardboard, asbestos board, particleboard, ceramics, filled and unfilled
plastics, closed-cell
rigid foams, or the like. If a cushioning effect is desired, the reinforcing
substrate may be
comprised of open-cell foam.
The decorative laminate useful in the practice of the present invention may
also
be obtained by placing the resin impregnated core and decorative sheets
between steel
coated, steel, or stainless steel plates and subjecting the laminate stack to
temperatures
ranging between about 150 F to about 500° F and pressures ranging below
about 800 to
about 1600 psi for a sufficient time to consolidate the laminate and cure the
resins. This
causes the resin in the paper sheets to flow, cure, and consolidate the sheets
into a
zo composite or unitary laminated mass known in the art as a low pressure
decorative
laminate (LPDL).
In addition, according to one embodiment, the reinforcing substrate of the
present
invention may be prepared from any suitable extrudable thermoplastic, so long
as it has
HOC.'03:711508.1 35
CA 02354841 2001-08-09
~ Atwrney Docket No. 068368.0131
. ' . ° Wilsonart No.: 1062P1
the structural and mechanical properties necessary for the end use desired. In
particular, it
is preferred that the substrate have a compression set that is approximately
the same or
better than conventional medium or high density fiberboard or particle board
(wherein
compression set is measured in accordance with ASTM F970, as thickness
decreases as a
function of compressive stress). Preferably; this thickness decrease at 2000
psi is at most
0.01 inch, more preferably at most 0.005 inch, and most preferably at most
0.001 inch.
Possibly, the reinforcing substrate useful in the practice of the present
invention
comprises one or more members selected from the group consisting of rigid
urethanes
(e.g:, RIM foam), poly(acrylonitrile/butadiene/styrene) (hereafter referred to
as ABS)
to resins such as flame retardant ABS resins and glass filled ABS resins;
polycarbonate;
high impact polystyrene (HIPS), polystyrene, polyphenylene oxide (PPO), and
polyvinyl
chloride (PVC). Preferably, the reinforcing substrate is prepared fram a
commingled
resin system containing, but not limited to, one or more of the above listed
polymers.
Further, these polymers can be filled or unfilled, although from an impact
resistance and
physical property standpoint, the filled polymers are best. Preferred fillers
include
calcium carbonate, talc, silica, glass fibers, alumina and wollastonite, with
the more
preferred being calcium carbonate and wollastonite, and the most preferred
being calcium
carbonate. Non-limiting examples of reinforcing agents include inorganic or
organic
products of high molecular weight, including glass microspheres, glass fibers,
asbestos,
2o boron fibers, carbon and graphite fibers, whiskers, quartz and silica
fibers, alumina fibers,
fused fiber matet~ials and organic fibers. When such conventional ingredients
are utilized,
they will generally be present in a range from about 0.01 to about 50 weight
percent of
HOU03:7 t 1508.1 36
CA 02354841 2001-08-09
' , Alwrney Docket No. 068368.0131
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the total weight of the reinforcing substrate member, preferably in a range
from about 1
to about 25 weight percent of the total weight of the member.
Additional optional layers may be inserted between the core member and the
decorative surface member, on the back of the reinforcing substrate member, or
on the
decorative surface member. It should be understood that backing layers and/or
decorative
layers may be coextruded with the reinforcing substrate member, or may be
applied after
the extrusion step by any suitable' method.
The panels, according to one embodiment of the present invention, are
preferably
water repellent and most preferably substantially waterproof. As with
conventional
1o flooring panels, the present panels include a decorative layer, a
substrate, and a backing
layer. The decorative layer and the backing layer are respectively bound to
the substrate
in a conventional manner to form the present panel. In accordance with a
preferred
embodiment of the present invention wherein the reinforcing substrate material
is
fiberboard, thetbacking layer includes, from bottom up, a hydrophobic
waterproof layer
t5 and three layers of phenol formaldehyde resin impregnated kraft paper. As
with the
bottom resin impregnated layer of the decorative layer, the top resin
impregnated layer of
the backing layer is sanded for bonding with the substrate. The hydrophobic
waterproof
layer rnay be a DYLARK-like compound. DYLARK is a styrene-malefic anhydride
copolymer manufactured by NOVA Chemicals, Inc. DYLARK exhibits outstanding
2o bonding characteristics with the phenolic resin impregnated kraft paper.
The excellent
bonding characteristics are thought to be a result of the carboxyl groups
found on the
malefic anhydride of the DYLARK copolymer. The carboxyl groups bind with the
phenolic resin to produce a very stable laminate. Although DYI,ARK is
disclosed as the
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CA 02354841 2001-08-09
AtiBrney Dockei No. 068368.0131
Wilsonart No.: 1062P1
preferred material for the bottom layer of the backing, other functionally and
structurally
equivalent polymers may be used without departing from the spirit of the
present
invention. It is not only desirable to prevent moisture from penetrating the
backing layer
but also to maintain the original as-manufactured moisture content of the
panel to prevent
panel warpage.
In addition, although phenol formaldehyde resin impregnated kraft paper is
used
in accordance with a preferred embodiment of the present invention, other
resin
impregnated papers (or similar materials) may be used without departing from
the spirit
of the present invention. The resin impregnated layers are maintained in the
present
to backing layer to balance the resin impregnated layers commonly found in
decorative
layers which may be used in conjunction with the backing layer. That is, the
resin
impregnated layers in the decorative layer and the backing layer similarly
expand and
contract as a result of temperature to maintain the substantially flat
configuration of the
Mooring panel. If the resin impregnated layers in the backing layer were not
included, the
decorative panel would expand and contract at a different rate than the
backing layer.
This would cause the Mooring panel to warp in an undesirable manner. As such,
it should
be appreciated by those of ordinary skill in the art that the phenoiic layers
may be varied
to maintain a balanced relation between the backing and the decorative layers.
As stated according to one aspect of the invention, the substrate is
2o poly(acrylonitrile-c-butadiene-c-styrene) (ABS) foam. The construction of
the backing
layer and the substrate results in a waterproof flooring panel which is not
susceptible to
the harmful environmental conditions commonly found in certain environments.
Specifically, the ABS substrate and styrenemaleic anhydride copolymer layer
create a
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r A s Anurney Docket No. 068368.0131
' . Wilsonart No.: 1062P1
moisture barrier which protects the resin impregnated layers from the
undesirable effects
of moisture.
The above-described flooring panels are manufactured utilizing techniques
known in the art. During manufacturing, panels may be machined to form the
appropriate
recesses in the edges or preferably; may be manufactured wherein at least two
edges have
recesses formed therein during manufacture of the panel and thus, reduce the
amount of
material needed to manufacture the panel. In addition, the panel of the
present invention,
according to one embodiment, may be manufactured utilizing injection molding
techniques wherein all edges are formed.
1o The connector of the present invention includes a number of embodiments.
Referring now to Figures I-18, wherein the same numerals are used to identify
the
components of a connector of the present invention, end views of various
embodiments
of the connector 1 are shown. The connector 1 comprises a base 2 and an
extension I5.
The base 2 is a substantially flat portion for resting on the floor or surface
to be covered
by the assembled panels and connectors. The extension 15 is a projection
shaped like a
"T" having a vertical support 3 and two horizontal flanges 4 and 5. The
support 3 is the
vertical portion of the "T" and the flanges 4 and 5 are those portions that
extend
horizontally at the top of the "T". As shown in many of the exemplary
embodiments, the
connector I has ridges b and 7 which extend vertically from the base 2 near
the distal
2o extremities of the base 2 distant from the center where the support 3 is
attached to the
base 2. In further embodiments, the connector 1 has depressions 8 and 9 in the
upper
surface of the base 2 immediately adjacent opposite sides of the support 3. At
the distal
ends of the flanges 4 and 5 of the T-shaped extension 15, some embodiments of
the
Hovo3:~ t tsos. t 39
CA 02354841 2001-08-09
m ° Al,..mey Docket No. Q68368.0131
' ° f WiIsonart No.: 1062P 1
connector 1 have vertically extending projections 10 and 11. In some
embodiments, a
slot 12 is formed in the tap of the T-shaped extension I S between the
vertically extending
projections 10 and I 1. Embodiments of the connector 1 further comprise
notches I3 and
14 that are located in the underneath side of the proximal ends of the flanges
4 and 5
where they are connected to the support 3. Preferably, the system of the
present
invention comprises a connector 1 having a T-shaped extension and ridges 6 and
7, and
the panels having recesses and channels such that two panels can be
disengageably
interconnected using the connector in a horizontal and vertical fashion
without the use of
glue or other adhesives.
It is to be understood that Figures 1-I8 are not meant to limit the scope of
the
invention but are provided to ,,.give example embodiments, includiz~,g the
preferred
embodiment, of various components of the novel connector of the present
invention.
Indeed, various combinations of different embodiments of various individual
corrrponents
of the connector can be utilized, i.e., various base ? configurations
illustrated in, e.g.; but
not limited to, Figures 1, 2, 7, 8, 9, 10, 11, 12, etc. can be utilized with
various
embodiments of the extension, e.g., but not limited to Figures l, 2, 3, S, 6,
16, I7, 18,
etc., even though the exact combination configuration may not be graphically
shown in
the figures. Preferably, the connector is less than .240 inches in height.
The connector of the present invention may be manufactured from materials
2o selected from the group consisting of filled and unfilled plastics,
rubbers, wood
compositions, ceramics, metals, and combinations thereof. Preferably, in use
with the
preferred laminate flooring panels, the connector of the present invention is
manufactured
from metal or plastic. Depending upon the material and size, the connector may
be
HOt,'03:711508.1 40
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g y A~.,,mey Docket No. 068368.0131
' ' Wilsonart No.: 1062P 1
manufactured using techniques known in the art, e.g., the connector is
preferably
manufactured from aluminum.
The panels of the present invention include recesses formed therein shaped to
receive a connector such that when the panels are connected, the top visible
flooring
surface only consists of the top wear surface, i.e., preferably, a decorative
Layer. The
connector projections and panel recesses are formed such that when two panels
are joined
together using a connector of the present invention, the panels are vertically
connected
together, i. e., if two panels are connected at their edges, the edges of the
opposing panels
do not move up or down (vertically) relative to each other and thus, provide a
level
to uniform seam between the two. For example, in a preferred embodiment, once
connected
the panels are engaged against movement relative to each other in the
direction of a plane
extending vertically from the support surface and perpendicular thereto.
In a particularly preferred embodiment, in addition to vertical connection,
the
panels and connectors are so shaped to provide a horizontal connection between
adjacent
panels at their edges, i.e., if two panels are connected at their edges, the
edges cannot
move any from each other horizontally resulting in a gap between adjacent
panels. For
example, and according to one embodiment, once connected, the panels are
engaged
against movement relative to each other in a direction horizontal to the
support surface
and parallel thereto.
2o Various non-limiting embodiments of the connector of the present invention
have
been described and while not shown, the panels of the present invention are
necessarily
configured, for example; to correspond to these connectors to achieve the
advantages of
the present invention. It being understood that the panels can be configured
to provide an
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CA 02354841 2001-08-09
Attorney Docket No. 068368.0131
WiIsonart No.: 1062P 1
exact fit with the connectors or a non-exact fit, as long as the advantages of
the present
invention are achieved. For example, where a permanent structure is desired,
an
embodiment allowing space for glue to accumulate between the panels and the
connectors may be appropriate. In addition, when utilizing certain reinforcing
substrate
materials it might be undesirable for the panels and connectors to fit
together exactly,
especially when a temporary structure is desired. For example, some space
between
certain portions of the connector projections and the recesses of the panels
can be
tolerated as long as the advantages of the invention are achieved, especially
a resultant
floor having only the top wear surface visible with level uniform seams.
1o The panels are constructed such that they disengageably interconnect with
the
connectors of the present invention, i.e., while the connectors and panels are
securely
connected to perform the function of a flooring surface, the panels can, if
desired, be
removed by lifting a panel and pulling the panel away from the connector --
disengaging
the panel/connector interconnection.
t 5 The panels of the present invention, according to one embodiment, are
constructed such that when connected together utilizing a connector of the
present
invention, they always form a tight uniform level seam between the panels. The
panels>
according to a preferred embodiment; are constructed such that the depth of
the recess or
channel in the bottom surface of each panel is always a certain distance from
the top wear
2o surface. As stated above, these recesses or channels are shaped to receive
a protrusion
projecting from the base of a connector (preferably a track) to disengageably
interconnect
two panels together horizontally. Thus, at the interconnection point, both
panels rest on
the connector. Consequently, even when the support structure or ground floor
is uneven
HOL~03:71 t X08.1 42
CA 02354841 2001-08-09
E ~ Attorney Docket No. 068368.0131
' ' ' . Wilsonart No.: 1062P1
or not Level, the seam is always tight, uniform and Level. Thus, even if the
thickness of the
panels vary, a uniform level seam is provided when two panels are
interconnected
because the depth of the recesses or channels in the bottom surface of each
panel is
formed to be a certain distance from the top wear surface. Therefore, the top
wear
surfaces of two adjacent panels will always come to rest at the same level,
i.e., a certain
distance from the base protrusions of the connector. Preferably, the panels of
the present
inventive system, range in thickness from about .240 inches to about .320
inches.
According to another embodiment, the panels are less than an inch thick.
The system of the present invention also provides panels which utilize
to substantially all of the manufactured laminate top wear surface and thus,
provides an
economic advantage over many prior art systems. Utilizing the system of the
present
invention, the amount of top wear surface of the panels that needs to be
machined to
remove any part of the already manufactured and paid for decorative top wear
surface is
greatly reduced. Substantially alI of the manufactured decorative top wear
surface is sold
to the end user -- eliminating waste experienced in prior art systems. As a
result, the total
square footage of saleable flooring produced by a plant is increased and costs
are
reduced.
In addition, the connectors of the present invention are not fixed to the
panels at
the factory and thus, no adhesive or other fastening means is required to be
applied --
2o again, reducing material costs; labor casts, and time to manufacture. In a
preferred
embodiment, the panels are manufactured having all of the necessary recesses
formed
therein utilizing injection molding techniques. In another preferred
embodiment, wherein
the middle reinforcing substrate of the panel is extruded, only two edges have
to be
HOU03:711508.1 43
CA 02354841 2001-08-09
q ~ ~ o Attorney Docket No. 068368.0131
- Wilsonart No.: 1062P1
machined to form recesses therein -- the other two edges running in machine
direction are
formed during extrusion. Both of the above provide additional savings due to
the fact that
the amount of middle reinforcing substrate material used is reduced, i. e.,
never produced.
The system of the present invention also provides panels which are less
susceptible to damage than prior art tongue and groove systems. For example,
it is
known that the tongues of panels are susceptible to damage during shipping,
handling,
and even assembly and disassembly. If a tongue is broken off or substantially
deformed,
it will not be able to engage the groove of an adjacent panel and therefore,
is rendered
useless. The panels of the present invention do not include tongues -- they
only have
recesses or grooves formed therein. It is difficult, if not impossible, to
damage wrecess or
groove during shipping; handling, assembly and disassembly. Thus, the panels
of the
present invention are more durable than many prior art panels. This is a
significant
advantage in relation to the use of the panels for "floating floor" surfaces
and temporary
flooring constructions which will be removed and reassembled many times. The
system
of the present invention provides connectors (preferably made from metal)
which are
fairly tough, and easy and economical to replace, when compared to the cost of
a new
panel. The present inventive systems substantially reduce, if not eliminate,
the risk of
damaging a panel to the extent that it is inoperable.
The flooring system of the present invention provides a flooring surface which
is
2o easy to repair and/or change. The panels of the present inventive system do
not require a
single directional laying sequence, so that a damaged panel may be removed and
replaced
by first removing adjacent panels in any direction. Adjacent panels may be
removed in a
direction having the fewest number of panels, so as to simplify the removal
and
HOU03:711508. I 44
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Attorney Docket No. 068368.0131
Wilsonart No.: 1062P1
replacement process. The present inventive system substantially reduces the
time and
aggravation of removing and replacing panels. Further, since the floor may be
constructed in multiple directions, more than one person can construct
different portions
of a single flooring surface simultaneously. According to one processes for
assembly,
panels are laid in a central portion of the floor space and panels are added
outwardly from
the center. This is especially advantageous in relation to the installation of
large flooring
surfaces, e.g., retail spaces.
The panels of the present inventive system also provide substantially more
aesthetic flexibility than prior art panels. For example, since the panels are
not right or
to left handed, i.e., one or unidirectional, but instead are multidirectional
due to each edge
being identical, each individual panel can be placed into a flooring surface
being
constructed in the most eye-appealing manner. Moreover, the panels of the
present
inventive systems allow for flexibility in designing and constructing parquet-
type
flooring surfaces. For example, it is known that a panel is usually
manufactured wherein
the grain runs in the machine direction; however, since the panels of the
present invention
are multidirectional, the direction of the grain on the flooring surface can
be easily
alternated to form a parquet floor, or a floor of any grain design.
The panels of the present inventive system also reduce waste during floor
construction. With the panels of the present invention, i.e., each panel is
constructed with
2o grooves on ail edges so that any panel portion remaining after completing
the floor up to
a portion of the end wall is also possibly useable to complete another portion
of the floor
up to the end wall.
HOI:03:711508.1 45
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z ' , At~umey Docket No. 068368.0131
' . Wilsonart No.: 1 o62P 1
The panels of the present inventive system are constructed such that to
assemble
two panels together it is not necessary to hold one panel at an angle relative
to the other
panel and angle down the new panel into place. The fact that the panels can be
interconnected by forcing two together while they are lying in the same plane
is very
advantageous in relation to constructing certain portions of flooring surfaces
challenged
by various physical boundaries, e.g., the interface between a flooring surface
and a
fireplace.
Referring now to Figure 6, the preferred embodiment of connector 1 of the
present invention is comprised of a base 2, an extension I5, ridges 6 and 7
spaced apart
to from and on either side ofthe extension 15 and projecting vertically from
base 2. Ridges
6 and 7 are preferably rounded on the top portion as shown, and taper away,
i.e., decrease
in height as you move away from the center of the base 2 toward the end of
said base.
Thus, the portion of the ridges closest to the center of the base 2 and
extension 1 S extend
the greatest distance vertically
A particularly preferred embodiment of the connector 1 of the present
inventive
system is shown in Figure 14. The scale of Figure 14 is 9 times actual size.
It is also to
be understood however, while not shown that base 2 of connector 1 may be
constructed
such that it does not touch the support structure, i.~, wherein the connector
is fully
encompassed by the two connecting panels.
Referring to Figures 19A and 19B, top and end views, respectively, of a square
panel 20 are shown. The panel ~0 has a top wear surface 21, a middle substrate
22 and a
backing layer surface 23. In the embodiment shown, the panel 20 has four
grooves 24 in
the middle substrate 22 in each of the four sides of the panel 20. Further,
the panel 20
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CA 02354841 2001-08-09
' A«orney Docket No. 06$368.013I
° 7 Wilsonart No.: 1062P1
has four channels 25 in the backing layer surface 23 that run parallel to and
slightly
distanced from each of the four sides of the panel 20.
In an alternative embodiment (not shown), two or more channels 25 are formed
in
the backing layer surface 23 adjacent to each side of the panel 20. Of course,
in this
embodiment, the connector 1 has two or more con-esponding ridges {6 or 7) on
each side
of the connector.
A connector is shown in Figure 20A - 20C for joining panels as illustrated in
Figures I9A and 19B. Top, end and side views of the connector I are shown,
respectively. The connector 1 has a base 2 and an extension 15 as previously
described.
1o The base 2 has two ridges 6 and 7 on the upper surface. The extension 15
has a support 3
and two flanges 4 and 5. The extension 15 has a slot I2 in its top. The ends
of the
connector 1 are angled at 45 degrees (see Figure 20A) to create end faces 16.
Since the
end faces 16 on the same end are each cut at 45 degrees, a 90 degree angle
point is
formed in the middle of the connector 1 at each end.
As shown in Figure 21, an assemble section of floor comprises square panels 20
joined to each other by connectors I. The end faces 16 of two connectors I are
placed in
contact with each other wherein the connectors are secured to adjacent sides
of a single
panel 20. A benefit of this configuration is that the top wear surfaces of the
panels 20 are
completely supported by the connectors I, even at the corners where the
connectors 1
meet.
In an alternative embodiment, some of the panels 20 are manufactured in
triangular shapes. Triangle shapes increase the decorative possibilities for
the assembled
floor covering. One possible arrangement of an assembled portion of floor is
shown in
HOU03:71 ( 508. t 47
CA 02354841 2001-08-09
Auurney Docket No. 068368.0131
° , ~ Wilsonart No.: 1062P1
Figure 22. Of course, different connectors 1 are required to join the
triangular panels.
They must have end faces cut at 22.5 degrees is some cases and 45 degrees in
others.
In further embodiments, the panels have square, rectangle, triangle, pentagon,
hexagon and octagon geometries. According to the assembly systems of the
present
invention, it is possible to assemble panels having these geometries because
the panels
and connectors are assembled while the panels are laid Ilat on the subfloor
support. For
example in Figure 27, a top view of hexagon panels 20 in a partially assembled
floor
system are shown. While connectors 1 are used to make the connections between
the
panels 20, the connectors 1 are not shown for simplicity. The panel 20b is in
position for
to connection to panels 20f and 20g. Since panels 24f and 20g are already
assembled, they
are laying flat on the subfloor support. Panel 20b is connected by laying
panel 20b ilat
on the subfloor and sliding panel 20b toward panels 20f and 20g. Contact with
panels
20f and 20g is made simultaneously and the panel 20b is snapped into mating
connection
with the connectors (not shown) between the panels. Similarly, panel 20a is
shown in
position for connection to panels 20c, 20d and 20e. Panel 20a is placed on the
subfloor
adjacent the other panels so as to be in the same plane as the other panels.
Panel 20a is
then slid toward panels 20b, 20c and 20d until contact is made simultaneously
with the
panels.
Figure I S best illustrates a panel/connector assembly. The panels 20 become
2o attached to the connectors I by "snapping" a flange 4, 5 of a connector I
into a groove 24
of a panel 20. Initial contact is made be inserting flange 4, 5 into a groove
24. As the
panel 20 and connector 1 are further moved toward each other, the ridge 6, 7
slides across
the backing layer surface 23 of the panel. When the panel 20 and connector I
are
HOL'03 v71 1508. ( -~g
CA 02354841 2001-08-09
A~'.~ney Docket No. 068368.0131
a Witsonart No.: 1062P1
completely moved together, the flange 4, 5 completely extends into the groove
24 and the
ridge 6, 7 "snaps" into the channel 25. Throughout the entire process, the
base 2 of the
connector 1 and the panel 20 remain substantially in the same plane. Since the
connectors I and panels 20 remain in the same plane during assembly, it is
possible to
simultaneously connect a panel to multiple other panels. This single-plane,
"snap"
assembly process enables the use of panels of various geometries, as described
above.
Referring to Figure 23, another configuration is shown for a floor covering of
the
present invention comprises panels which are rectangularly shaped. In this
embodiment,
the panels 20 are joined by two separate types of connectors: longitudinal.
connectors 30
to and transverse connectors 31. In one embodiment of the invention, the
longitudinal
connectors 30 span several panels 20 and are therefore much longer than any
given panel
20 in the longitudinal direction. In another embodiment of the invention, the
longitudinal
connectors 30 are approximately the same length as panels 20 in the
longitudinal
direction. The transverse connectors 31 are approximately the same length as
the width
of the panels 20. The transverse connectors 31 extend at right angles between
two
adjacent, parallel, longitudinal connectors 30. In the configuration shown in
Figure 23,
each set of panels 20 extending end to end in the longitudinal direction are
offset from
each adjacent set of panels running end to end in the longitudinal direction.
Since the
panels end at different locations on either side of a particular longitudinal
connector, the
2o assembly is significantly stronger as the joints are more evenly dispersed
throughout the
assembly. If the ends of all panels were not offset from one row to the next,
weaknesses
in the floor at a "four corners" area would occur where the adjacent
transverse connectors
3 T attach to a single longitudinal connector 30. Also for similar reasons, in
some
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A._.,cney Docket No. 068368.0131
Wilsonart No.: 1062P1
embodiments of the invention, the ends of the longitudinal connectors 30 do
not coincide
with the longitudinal ends of the panels 20 so that the connectors span at
least two
consecutive panels 20.
Referring to Figures 24a through 24c, top, and side views, respectively, of a
transverse connector 3I are shown. Similar to the previously described
connectors, this
transverse connector 31 has a base 2 and an extension I5. The extension 15 is
comprised
of a support 3 and flanges 4 and 5. The transverse connector 31 further
comprises ridges
6 and 7 located ax opposite ends of the base 2. A significant feature of the
transverse
connector 3I is that the extension 15 is longer than the base 2. Thus, at both
ends, of the
1o extension IS extends beyond the base 2. As shown in Figure 24c, at both
ends of the
extension 15, there are cutouts 32 and 33. The shape and dimensions of the
cutouts 32
and 33 are negative images of the ridges 6 and 7.
A view of a transverse connector 31 assembled to two longitudinal connectors
30
is shown in Figure 25. Longitudinal connectors 30 are viewed from the end
while the
transverse connector 31 is viewed from the side. The longitudinal connectors
30 are in
parallel while the transverse connector 31 is positioned between and at right
angles to the
longitudinal connectors 30. A cutout 32 of the transverse connector 3I is
positioned
immediately over ridge 7 of the longitudinal connector on the right. As shown
in the
figure, the cutout 33 of the transverse connector 31 is immediately over ridge
6 of the
longitudinal connector 30 on the left: As previously discussed, the extension
15 of the
transverse connector 31 extends over portions of the bases 2 of the
longitudinal
connectors 30.
HOU03:7I 1508.1 50
CA 02354841 2001-08-09
Au"~ney Docket No. 068368.0131
" . ° Wilsonart No.: 1062P1
Referring to Figures 26a through 26b, top and end views of a rectangular panel
are shown. This panel 20 is particularly suited for assembly with the
longitudinal and
transverse connectors described in Figures 23 through 25. Similar to the
previously
described panels, this panel has a top wear surface 21, a middle substrate 22,
and a
backing layer surface 23. The panel 20 also has a groove 24 for mating with
the flanges
4 and S of the connectors 30 and 31. The groove 24 extends entirely around the
perimeter of the panel 20. The panel 20 also has four channels 25 running
parallel to
each of the four sides of the panel. The channels 25 are cut or formed in the
bottom or
backing layer surface 23 of the panel 20. The channels 25 extend entirely from
side to
to side of the panel. The channels 25 of the panel 20 are adapted to mate with
ridges 6 and
7 of the longitudinal and transverse connectors 30 and 31
While the particular embodiments for flooring systems and components thereof
as
herein shown and disclosed in detail are fully capable of obtaining the
objects and
advantages hereinbefore stated, it is to be understood that they are merely
illustrative of
the preferred embodiments of the invention and that no limitations are
intended by the
details of construction or design herein shown other than as described in the
appended
claims.
HOU03:711508.1 51
CA 02354841 2001-08-09
Wilsonart Case No. 1062P1
A object of the invention is a system wherein each recessed profile comprises
a groove.
Another object of the invention is a system wherein each recessed profile
extends to and
intersects with a recessed prof le of another side.
Another object of the invention is a system further comprising channels in the
bottom
surface of each panel that correspond to the sides of said panel.
Another object of the invention is a system wherein one channel in the bottom
surface of
each panel extends substantially the entire length of the corresponding side
Another object of the invention is a system wherein one channel in the bottom
surface of
each panel extends to and intersects with another channel.
Another object of the invention is a system wherein a connector is a
longitudinal
connector.
Another object of the invention is a system wherein a connector is a
transverse connector.
Another object of the invention is a system wherein each panel further
comprises a
middle substrate between said top and bottom surfaces, wherein the middle
substrate comprises a
material selected from the group of materials consisting of medium density
fiberboard, high
density fiberboard, wood/plastic compositions, woods, ceramics, unfilled
plastics, filled plastics>
closed-cell rigid foams, and combinations thereof.
Another object of the invention is a mufti-directional laminate flooring panel
comprising
a top surface, a bottom surface and sides extending between the top and bottom
surfaces, wherein
each side has a groove and the bottom surface has a channel extending parallel
to each groove.
S1A
CA 02354841 2001-08-09
Another object of the invention is a system wherein one channel in the bottom
surface of
each panel extends substantially the entire length of the corresponding side.
Another object of the invention is a system wherein one channel in the bottom
surface of
each panel extends to and intersects with another channel.
Another object of the invention is a system wherein a connector is a
longitudinal
connector.
Another object of the invention is a system wherein a connector is a
transverse connector.
Another object of the invention is a system wherein each panel further
comprises a
middle substrate between said top and bottom surfaces, wherein the middle
substrate comprises a
material selected from the group of materials consisting of medium density
fiberboard, high
density fiberboard, wood/plastic compositions, woods, ceramics, unfilled
plastics, filled plastics,
closed-cell rigid foams, and combinations thereof.
Another object of the invention is a mufti-directional laminate flooring panel
comprising
a top surface, a bottom surface and sides extending between the top and bottom
surfaces, wherein
each side has a groove and the bottom surface has a channel extending parallel
to each groove.
51B
