Note: Descriptions are shown in the official language in which they were submitted.
CA 02474128 2004-08-10
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TTIZE OF THE INVENTION
"Interconnecting Disengageable Flooring System."
FIELD OF THE INVENTION
The present invention relates to flooring surfaces, preferably decorative
flooring
surfaces. In addition, the present invention relates to a system for
constructing a flooring
surface, e.g., a decorative flooring urface. 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
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.
A number of the known proposed systems are discussed to provide a background
for the
present invention.
U.S. Patent No. 3,~ 10,9I9 titled "Portable Floor," discloses a floor
comprising a.
plurality of like panels having straight sides, coupling elements at said
sides for coupling
arrangement with cooperating coupling elements on adjacent panels, and means
operatively
I
7
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associated with said coupling elements for releasably locking adjacent panels
in a side-by-side
contiguous relationship. As illustrated in Figure 2, the panels are 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. The
floor tiles arc:
formed with a plurality of identical, laterally projecting tongues and, in
their underside, with al
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
said 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 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
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tongue and a groove respectively projecting an opening outwardly angularly
towards the
second plane. The tongue and 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 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 tl';~e
heretofore known practice of driving nails or screws in the: panel edges to
fix the panels to tlhe
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 ofthe connector member 14 is
coplanar with the top
planar surfaces 16 and 18 of panels 10 and I2" 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
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 tap surFace and a pair of side surfaces
integral with the top
surface and the bottom surface. The side surfaces are joined with the top
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
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CA 02474128 2004-08-10
parallel to each other and 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 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 in 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 1 and 4, the upper wear surface of the slats ale spaced
apart to provide a
gap to facilitate the object of the invention, i.e., for 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. Patent No. 4,46I,I3I 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 channel located
beyond the edge of
the associated panel. Adjacent fittings-»~and adjacent panels are secured
together by elongated
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connector strips which have parallel elongated lugs received in the channels
of the adjacent
fittings. As shown in Figure 3, strips 40 form a portion of the top wear
surface and are thus,
visibly distinct from the upper surface I O 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 boaz-d 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.
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 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 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 Ioc;k member. A separate
unlocking
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a
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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 flange 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 formed therein to
receive the locking
members, and bonds tile 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 members may be
miter cut to a
desired length and the corners fastened together by a comer fastener
U.S. Patent No. 5,179,812 titled "Flooring Product," discloses a flooring
product
comprising a wood panel having an I,-shaped surround the base of which is
located 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,
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ff
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
ofthe 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
interlocking rib and groove, a groove connector secured to another outer edge
by an
interlocking lib 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. 5,735,227 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 intermediate 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 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 layer has a
multiplicity of closely
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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 Tiles 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 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 i:o
define a polygonal configuration and each of the members 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 cm
opposite sides of its frame members.
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 tile
principal plane of the panels. In each joint, the patent states that there is
provided a strip which
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x
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 goove in the rear side of the other joint edge to form a
second
mechanical connection locking the panels in a second direction parallel to the
principal plane ~~f
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 an 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 1, i.e.,
it should not be
mounted on the strip panel in connection with laying."
U.S. Patent No. 5,86,266 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 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
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a
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 mechanically locked together in a first direction also; and (c)
displacing one of the new
panels in its longitudinal direction relative to 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 tree
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 arid
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 strip material can be used, such
as sheets of other
metals, as well as aluminum or plastic sectians. 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."
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 o$; 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
of.~ and groove
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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 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 door
plate. The foaming resin is foamed and hardened. The hardened foaming resin
expands into
the 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
protrusion is formed on
one side of the base material while an engaging concave portion to which the
above engagimg
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 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.
Patentschlift 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.
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Patentschrift No. 1 534 278 discloses in Figures 1-3 to assemble two adjacent
structures wherein the first structure includes a groove and a notch for
receipt of a
con:esponding 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 counterprofile. 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 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.
Offenlegungsschrift DE 304178IA1 discloses the inner connection of two panels
wherein the panels include a tongue on one edge and a groove in another edge
~o provide
interlocking connections between two panels used especially for constructing a
skating rink or
skittle alley The patent discIases 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
patent 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.
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CA 02474128 2004-08-10
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O~enlegungsschrift DE 35 44 845 A1 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 ffan:ks 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 flanks
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.
Patenttihakemus-Patentansokan 843067 (PCT/SE 83100423) 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. 2 697 275 discloses the formation of a surface from
rectangular shaped slabs placed on a flat horizontal surface. 'T"he
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 which
are shaped so that
they slide into a matching groove in the adjacent slab. Figure 2 appears to
disclose a member
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CA 02474128 2004-08-10
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 form 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 res'ln compound either containing reinforcing elements or 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 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 gl-oove 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 contiguous with
the side of
another such block. The method is stated to also comprise the use of
connecting members
having flanges adopted to engage beneath the overhanging flanges of two
adjacent blocks
where a change in direction of laying is required.
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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 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 2
a
specific tongue and groovelnotch and tooth joint structure for interconnecting
plastic and 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 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 N'o. 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 predetermined
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.
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Utlengningsskrift No. 157871 discloses in the figures the connection of two
adjoining
members utilizing a tongue and groove joint at the edges and which includes
recesses formed 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 part of the
top wear surface. The application further discloses a U-shaped member for
insertion on the
backside of the panels to bold the two panels together at the joint where the
joint block exists.
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 "ADevice 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 ofthe joining floor boards. The Legs are shaped at a 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.
P:\Post\Wilson.~rt\W72127USlspec 16
CA 02474128 2004-08-10
s
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 layer being provided with
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 modulus of elasticity
in tension not
exceeding 5000 kg/cm2.
Offenlegungsscti~ 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 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.
P:lPostlWilsanartlW72127US1sgec 17
3
CA 02474128 2004-08-10
Utlaggningsskrift No. 8206934-5 discloses the joining of two panels wherein a
tongue
and groove arrangement is utilised. The drawings further disclose a U-shaped
clip for insertion
into the panels on either side of the joint for holding the two panels
together at said joint.
WO 97147834 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
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.
There still exists a need for a system, including methods and. components,
which
provides an eflscient and easy means far the assembly and disassembly of thin
floating
decorative laminate floor surfaces wherein a level uniform seam is formed
between adjacent
panels and the visible flooring surface consists of only the decorative
surface.
SLTw>MARY OF THE INVE'NTLON
According to one embodiment, the present invention comprises a disengageable
interconnecting floor system for use in forming temporary or permanent
flooring surfaces
on top of a support structure from individual flooring panels. 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,
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
P:\PosdWilsonart\W72127US\spec , I g
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CA 02474128 2004-08-10
recesses extend substantially the entire length of the panel edges. The
preferred connector
comprises a base and a projection extending vertically from the base, spaced
from the base
and substantially parallel thereto. The projection is shaped to be received in
a
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 a projection that is shaped to be received
in a
disengageable horizontal connected fashion into at least one groove or recess
of tht:
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 projection.
According to yet another embodiment of the present invention, a projection of
the
connector according to the present invention has a groove or other recess
formed 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 projection.
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 projection,
preferably tongue-
shaped, of the connector is less than the distance from the bottom surface to
the top wear
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
P:~PosHW ilsonardW72127US1spec 19
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CA 02474128 2004-08-10
a
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
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 have four edges with identical grooves formed
therein,
preferably in all edges, for receipt of a vertically extending projection of
the track. The
panels also have notches or other recesses, e.g. channels, formed in their
bottom surfaces
shaped for receipt of nodes 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 projection 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 projection extends the entire length of
the
connector. The base of the connector further has two nodes or two other
protrusions
extending vertically from either side of the base spaced from the single
projection. The
protrusions. 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 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 ofthe panels.
According to another embodiment of the present invention, a vertical and
horizontal
interconnecting flooring system for use in forming a flooring surface on tog
of a support
P:lPostiW ilsonart1W72127L)S~spec
CA 02474128 2004-08-10
surface is provided. The system comprises two or more individual flooring
panels, preferably
laminated floor panels, having a thickness, and at Least ane connecting track.
The flooring
panels have a top wear surface and a bottom surface for contact with a support
surface. Tlhe
panels have at least three edges wherein all edges have first identical
recesses formed therein.
The first recesses are shaped to receive a first connection projection 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
from the track. The track, according to this embodiment, has a base, a first
connection
projection, and a second connection projection. The first connection
projection is connected to
and extends vertically a,distance from the base and is shaped to be received
in the first recesses
of the panels to form a vel*ical connection between the panels. The second
connection
projection connected to and extending vertically a distance from the base,
preferably a distance
less than the first projection, and shaped to be received in the second
recesses of the panels to
form a horizontal connection between the panels. According to this embodiment,
the distance
from the base ofthe track to an uppermost vertical portion ofthe first
projection is less than the
distance between the top wear surface and 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 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
P:\PostlWilsonart\W?2127USlspec Z 1
CA 02474128 2004-08-10
identical receiver located in said edges, i.e., each edge of each panel
comprises the samE
configuration. The connectors, preferably camprise 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 ai'~
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
substantiall~~
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 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 extending vertically therefrom in a direction away from the support
structure. Th.e
projection has top and bottom portions consisting of identical right and left
halves, each half
preferably comprising a tongue-like extension extending a distance
substantially parallel to anal
spaced above said base. Optionally, according to a particularly preferred
embodiment, the base
includes two additional protrusions extending vertically therefrom. These
protrusions are
spaced apart and located on either side of said projection.
P:\Post\W ilsonart\W 72127LIS\spec 2 2
CA 02474128 2004-08-10
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 extend substantially the entire length of the edges.
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
traditional fastening means
are not needed, e.g., nails, screws, adhesives, tacks, staples, ez'c. 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 substrate
material is needed
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 ~f the invention:
P:\Post\W ilsonart\W72127US~spec
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CA 02474128 2004-08-10
BRIEF DESCRIPTION OF TF~ DRAWINGS
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;
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 13 illustrates one embodiment of the connector of the present
invention;
Figure 14 illustrates a particularly preferred embodiment of the connector of
t:he
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 16 illustrates one embodiment of the connector of the present
invention;
Figure 17 illustrates one embodiment of the connector of the present
invention; and
Figure 18 illustrates a preferred embodiment of the connector of the present
invention
and a preferred embodiment of the panels of the present invention.
P:\Post\Wilsonarc\W72127US1spec 24
CA 02474128 2004-08-10
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 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 nurrlber 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 a.s containing a number of laminae that are
consolidated to
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, tile
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 andlor an overlay,impregnated with melamine resin. The
core or base
member functions to impart rigidity to the laminate and usually comprises a
solid substrate
which may or may not be formed prior_ to the initial laminating step. Prior to
stacking, the
P:lPostlW ilsonart\W72127LJS1spec 2$
CA 02474128 2004-08-10
r
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 or core member include: (I) a
plurality of
sheets of 90 to 1S0 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, v;~oodwaste, 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; 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 SO to 12S 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 comprise a decorative design
or pattern,
or a photo reproduction of natural materials, such as, wood, marble, leather,
etc. !1s
stated above, the decorative sheet and/or an overlay sheet may be impregnated
with
melamine resin. _..
PaPostlWilsonart\W72127USVspec 26
CA 02474128 2004-08-10
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
the laminate stack to temperatures ranging from about 150° F to about
500° 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 afrer consolidation. Finally, the
decorative laminates
are further processed and are generally bonded to a reinforcing substrate,
such as medium
to high density fiber board, wood/plastic compositions, woods, - plywood,
hardboard,
asbestos board, particleboard, ceramics, filled and unfilled plastics, closed-
cell rigid foams,
or the like. If a cushioning ef~'ect 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 t>e
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 I50 F to about 500° F and pressures ranging below
about 800 ito
about 1600 psi far 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
P:lPostlWilsonardW72127USLepec
CA 02474128 2004-08-10
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 maybe prepared from any suitable extnldable thermoplastic, so long
as it has 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 mast
0.001 inch.
Preferably, 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/6utadiene/styrene) (hereafter referred to
as ABS)
resins such as flame retardant ABS resins and glass filled ABS resins;
polycarbonate; hi~;h
impact polystyrene ~S), polystyrene, polyphenylene oxide (PPO), and polyvinyl
chloride (PVC). Preferably, the reinforcing substrate is prepared from 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 bf high
molecular weight, including glass micrgspheres, glass fibers, asbestos, boron
fibers, carbon
P:lPost\Wilsonart\W72127US\spec
CA 02474128 2004-08-10
and graphite fibers, whiskers, quartz and silica fibers, alurnina fibers,
fused fiber materials
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 the total
weight of the
reinforcing substrate member, preferably in a range from about 1 to about 25
weight
percent of the total weight ofthe 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 repellant and most preferably substantially waterproof. As with
conventional
flooring panels, the present panels include a decorative Iayer, 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, the backing layer includes, from bottom up, a hydrophobic
waterproof layer
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
TM ~
layer may be a DYLARKelike compound. DYLAR,K is a styrene-malefic anhydride
TM
copolymer manufactured by NOVA Chemicals, Inc. DYLA'RK exhibits outstanding
bonding characteristics with the phenolic resin impregnated kraft paper. The
excellent
P:~r~cvw;~o"~cvwnm~rs~ 29
CA 02474128 2004-08-10
bonding characteristics are thought to be a result of the carboxyl groups
found on the
malefic anhydride of the I)YLARK copolymer. The carboxyl groups bind with the
phenolic resin to produce a very stable laminate. Although I7YLA.RK is
disclosed as the
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 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 tile substantially flat configuration of the flooring
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
flooring panel to warp in an undesirable manner. A.s such, it should be
appreciated by
those of ordinary skill in the art that the phenolic layers may be varied to
maintaiin a
balanced relation between the backing and the decorative layers.
As stated, the substrate is preferably poly(acrylonitrile-c-butadiene-c-
styrene)
(ABS) foam. The construction oz" the backing layer and the substrate results
in a
P:lPostlWiLwnart1W72127US~pex
CA 02474128 2004-08-10
a ; '
waterproof flooring panel which is not susceptible to the harrnful
environmental conditiions
commonly found in certain environments. Specifically, the ABS substrate and
styrene-
malefic anhydride copolymer layer create a 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 Ieast two edges have
recesses formed
therein during manufacture of the panel and thus; reduce the amount of
material needed to
manufacture the panel. In ac'dition, the panel of the present invention,
according to one
embodiment, may be manufactured utilizing injection molding techniques wherein
all edges are
formed.
The connector of the present invention includes a number of embodiments. A few
of
the embodiments are graphically set forth in Figures 1-18. Referring now to
Figures 1-18,
wherein the same numerals are used to identify the components of a connector
of the present
invention, as follows: "2" identifies the base of connector l, "3" identifies
a support extending
vertically from base 2; "4" identifies a part of a projection extending
vertically from base 2 via
support 3, "5" identifies another part of a projection extending vertically
from base 2 via
support 3, "6" identifies a protrusion extending vertically from base 2 of
connector 1, "7"
identifies another protrusion extending from base 2 of connector 1, "8"
identifies a recess in
one side of base 2 of connector 1, "9" identifies a recess on another side of
base 2 of connector
1, "10" and "1I" identify second projections extending from parts 4 and 5
ofthe first projection
which ars extending vertically from base 2 via support 3, "12" identifies a
recess in between
second projections 10 and 11, and "13" and "14" identify recesses located
underneath the top
P:~PoatlWilsonari1W72127C3Slspec , 31
CA 02474128 2004-08-10
a r
portion of the projection (collectively 3, 4, and 5). Preferably, the system
of the present
invention comprises a connector having the projection (collectively 3, 4, and
5) and protrusions
6 and 7, and the panels have 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 1-18 are not meant to limit the scope of
the
invention but are provided to give example embodiment, including the preferred
embodiment,
of various components of the novel connector of the present invention. Indeed,
various
combinations of different embodiments of various individual components of the
connector can
be utilized, i.e., various base 2 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
projection, e,g., but not
limited to Figures 1, 2, ~, 5, 6, I6, 17, I8, 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
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 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 afthe top wear surface, i.e.; preferably, a decorative layer. The
connector projections
P:lPostlWilsonart1W72127USlspoc 3 2
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CA 02474128 2004-08-10
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 (vertic:ally)
relative to each other and thus, provide a level 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.
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
ir?vention. It being understood that the panels can be configured to provide
an exact fit with
the connectors or a non-exact fit; as long as the advantages of the present
invention are
achieved. For example, inhere 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
P:lPostlWilsonart\W72127US~Spec 33
CA 02474128 2004-08-10
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:
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.
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 fop wear 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 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, thc: 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 tlvvckness from about .240 inches to about .320
inches. According to
another embodiment, the panels are less than an inch think.
P:lPostlWilsonart\W72127L)Slspec 3 4
CA 02474128 2004-08-10
y ; a
The system of the present invention also provides panels which utilize
substantially all
of the manufactured laminate top wear surface and thus, provides an economic
advantage over
many prior art systems. 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
adjacent panel. Ta form the tongue, the top wear surface has to be machined
o$' 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,
and/or replacement. Consequently, the cost and time of manufacture increases.
Utilizing the
system of the present iilvention; 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 all 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
panE:ls
at the factory and thus, no adhesive or other fastening means is required to
be applied - again,
reducing material casts, labor costs, and time to manufacture. Tn a preferred
embodiment, the
panels are manufactured having all of the necessary recesses formed therein
utilizing injection
molding techniques. ~Jn another preferred embodiment, wherein the middle
reinforcing
substrate of the panel is extruded, only two edges have to be 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
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CA 02474128 2004-08-10
material used is reduced, i.e., never produced. In prior art systems, the
reinforcing substrate
material is manufactured and then, a portion is machined away to form a
groove.
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 tonl;ues
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
diff cult, if not impossible, to damage a recess 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 easy
to repair and/or change. For example, many prior art systems, for example, the
systems in U. S.
Patent Nos. 5,706,621 and 5,860,266 require holding the 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 the fifth panel in a sequence of 20 panels needs to be
replaced, e.g., due to
damage, panels 6 through 20 have to be removed in reverse order to reach panel
5. Utiliizing
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CA 02474128 2004-08-10
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the system of the present invention, which does not require the angling down
of each new
panel underneath a portion of an existing panel, panels 1 to 4 of the sequence
can be removed
and panel 5 replaced. Thus, the present inventive system substantially reduces
the time and
aggravation of removing and replacing panels. In addition, due to the fact
that the panels of the
present inventive system do not require a single directional laying sequence,
more than ane
person can construct different portions of a single flooring surface
simultaneously for
interconnection later. 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 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.
Typically, when constructing a flooring surface using prior art systems with
handed 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 cut length or uridth wise to
fit. In prior art systems
utilizing handed panels, once a panel is~cut there is a substantial
possibility that the remaining
P:lPost~Wilsonart1W7212'7US15pec
CA 02474128 2004-08-10
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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 are formed with one long edge of each either being a tongue or a
groove. At trie
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. However, with the panels of the present invention, i.e., each panel is
constructed with
grooves on all edges, 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.
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 base Z, projection (collectively 3, 4 and 5), and
protrusions ~i
and 7 spaced apart from and on either side of the projection (collectively 3,
4 and 5)
projecting vertically from base 2. Protrusions 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 toward the end of said base. Thus, the portion of the
protrusions
closest to the center~of the base and projection (3, 4 and 5) extend the
greatest distance
vertically. A particularly preferred embodiment of the connector of the
present inventive
system is shown in Figure 14. The scale of Figure 14 is 9 times actual size,
i.e., 1.00
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CA 02474128 2004-08-10
~ ~.; m
equals 1:00 inch. 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.e.,
wherein the connector is fully encompassed by the two connecting panels.
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