Note: Descriptions are shown in the official language in which they were submitted.
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TITLE: FLOORING SYSTEM
FIELD
[0001] The following specification relates to a flooring system for covering
an underlying surface that can provide moisture protection to a finished floor
material mounted thereon.
BACKGROUND
[0002] WO/19982/003099 (Bergsland) discloses a protective sheet, in
particular for a foundation wall or a floor on the ground, said sheet being
made of
a relatively stiff plastics material. A large number of spaced knobs protrude
from
one side of the sheet, whereby the other side obtains a corresponding number
of
recesses. The knobs have a centrally disposed crater-like portion, the
narrowest
end of which is flush with the other side of the sheet. Between adjacent
recesses
there is arranged an open channel provided through forming such that on the
said one side of the sheet there appears a corresponding ridge between the
knobs. Externally of the other side of the sheet there may be arranged a
filtrating
canvas co-acting with said channels.
[0003] Canadian Patent No. 2,315,462 (Smith) discloses a floor panel for
use in a sub-floor application. The floor panel has an upper member and a
lower
member. The upper member is made from a sheet floor material and the lower
member is made from a waterproof sheet material. The lower member has a
series of projections extending away from the floor panel and located adjacent
to
an underlying surface when the panel is in use. The projections allow moisture
to
drain between the floor panels and the underlying surface and also permit air
circulation.
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SUMMARY
[0004] This summary is intended to introduce the reader to the more
detailed description that follows and not to limit or define any claimed or as
yet
unclaimed invention. One or more inventions may reside in any combination or
sub-combination of the elements or process steps disclosed in any part of this
document including its claims and figures.
[0005] ' In one aspect, a flooring system comprises: a) a plurality of
moisture impermeable base panels cooperating to cover an underlying surface,
each base panel having opposing upper and lower surfaces and comprising a
plurality of projections extending from the lower surface for contacting and
supporting the lower surface of the base panel above the underlying surface;
b) a
plurality of base panel connection elements attaching together adjacent ones
of
the base panels to inhibit relative horizontal movement therebetween and to
form
a continuous, moisture impermeable base surface; c) a plurality of upper
panels
made of a subfloor material, the upper panels being supported by the base
panels; and d) a plurality of upper panel connection elements attaching
together
adjacent ones of the upper panels to inhibit relative vertical movement
therebetween and to form a generally continuous upper subfloor surface.
[0006] In some examples, the plurality of upper panels are unconnected to
the base panels allowing relative horizontal movement between the upper panels
and the base panels to accommodate differing rates of expansion between the
base panels and the upper panels.
[0007] In some examples, the base panel connection elements comprise
overlapping margins of adjacent base panels. The plurality of projections can
comprise marginal projections positioned in the overlapping margins, and the
base panel connection elements can comprise first ones of the marginal
projections of a first margin of a first base panel and second ones of the
marginal
projections of a second margin of a second base panel, the first margin
overlapping the second margin. The flooring system can include recesses
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formed by a generally concave interior of the second ones of the marginal
projections, wherein the first ones of the marginal projections nest within
respective ones of the recesses. The first ones of the marginal projections
can
be arranged in a first pattern in the first margin, and the second ones of the
marginal projections can be arranged in a second pattern in the second margin,
the first pattern being in registration with the second pattern. The base
panel
connection elements can comprise a seam formed between an outer edge of the
first margin of the first base panel and an inner edge of the second margin of
the
second base panel, each seam being sealed to provide a moisture impermeable
connection between the first and second base panels. Each seam of the
plurality
of seams can be sealed with a moisture impermeable tape. A snap-fit
connection can be provided between the first ones of the marginal projections
and the respective ones of the recesses. The snap-fit connection can comprise
a
catch protruding radially outwardly from an outer surface of the first ones of
the
marginal projections and a corresponding detent extending radially inwardly of
an
inner surface of the respective ones of the recesses.
[0008] In some examples, the upper panel connection elements can
comprise tongue and groove connections. Each upper panel comprises at least
one groove and at least one tongue, one tongue of a first upper panel engaging
one groove of an adjacent second upper panel, and one groove of the first
upper
panel engaging one tongue of an adjacent third upper panel. The subfloor
material can comprise wood. The subfloor material can comprise oriented strand
board.
[0009] In some examples, each base panel can be formed from a single,
uninterrupted plastic sheet. The plurality of projections can be frusto-
conical
projections having a root portion proximate the lower surface and a peak
portion
spaced apart from the root portion.
[0010] According to another aspect, a method of providing a flooring
system for covering an underlying surface comprises the steps of: a) providing
a
plurality of moisture impermeable base panels, each base panel having opposing
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upper and lower surfaces and comprising a plurality of discrete projections
extending from the lower surface for contacting and supporting the lower
surface
of the base panel above the underlying surface; b) arranging the plurality of
base
panels to cover the underlying surface; c) connecting together adjacent base
panels to prevent relative horizontal movement therebetween and to form a
moisture impermeable base surface; d) providing a plurality of upper panels
and
layering them on top of the base panels to generally cover the base surface;
and
e) connecting adjacent ones of the plurality of upper panels together to
inhibit
relative vertical movement therebetween and to form an upper subfloor surface
resting above the base surface.
[0011] In some examples, the upper panels remain free of connection to
the base surface, wherein the upper subfloor surface is free to move
horizontally
relative to the base surface to accommodate differing rates of expansion
between the upper panels and the base panels.
[0012] In some examples, step (c) can comprise overlapping a first margin
of a first base panel over a second margin of an adjacent second base panel.
The plurality of projections of the first base panel can comprise a plurality
of first
marginal projections in the first margin and the second margin can comprise a
plurality of recesses for receiving the first marginal projections, and step
(c) can
comprise nesting each of the first plurality of marginal projections in a
respective
one of the recesses. The plurality of projections of the second base panel can
comprise a plurality of second marginal projections arranged in the second
margin and the recesses can be defined by generally concave interiors of
respective ones of the second marginal projections.
[0013] The first marginal projections can be arranged in a first pattern and
the second marginal projections are arranged in a complimentary second
pattern,
and step (c) can comprise registering the first pattern with the second
pattern.
Step (c) can comprise snapping each of the first marginal projections into the
respective ones of the recesses to form a snap-fit connection therebetween.
The
snap-fit connection can include a catch protruding radially outwardly from an
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outer surface of the first ones of the marginal projections and a
corresponding
detent extending radially outwardly of an inner surface of the respective ones
of
the recesses, and step (c) can include urging the catch to seat within the
corresponding detent.
[0014] A seam can be defined between an outer edge of the first margin of
the first base panel and an inner edge of the second margin of the second base
panel and step (c) can include sealing the seam to provide the moisture
impermeable base surface. Sealing the seam can comprise applying a moisture
impermeable tape along an extent of the seam.
[0015] Step (e) can comprise connecting adjacent upper panels using a
tongue and groove connection.
BRIEF DESCRIPTION OF DRAWINGS
[0016] For a better understanding of the flooring system described herein
and to show more clearly how they may be carried into effect, reference will
now
be made, by way of example only, to the accompanying drawings which show at
least one exemplary embodiment, and in which:
[0017] Figure 1 is a perspective view of an example of a flooring system
covering an underlying surface;
[0018] Figure 2 is top view of a base panel;
[0019] Figure 3 is a side view of the base panel of Figure 2;
[0020] Figure 4 is bottom view of the base panel of Figure 2;
[0021] Figure 5 is a perspective view of an upper panel;
[0022] Figure 6a is a perspective view of a connection between adjacent
base panels;
[0023] Figure 6b is a partial exploded view of the connection between
adjacent base panels of Figure 6a; and
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[0024] Figure 7 is a perspective view of an alternate example of a
connection between adjacent base panels.
DETAILED DESCRIPTION
[0025] Various apparatuses or processes will be described below to
provide an example of an embodiment of each claimed invention. No
embodiment described below limits any claimed invention and any claimed
invention may cover processes or apparatuses that are not described below. The
claimed inventions are not limited to apparatuses or processes having all of
the
features of any one apparatus or process described below or to features
common to multiple or all of the apparatuses described below. It is possible
that
an apparatus or process described below is not an embodiment of any claimed
invention. Any invention disclosed in an apparatus or process described below
that is not claimed in this document may be the subject matter of another
protective instrument, for example, a continuing patent application, and the
applicants, inventors or owners do not intend to abandon, disclaim or dedicate
to
the public any such invention by its disclosure in this document.
[0026] Referring to Figure 1, an example of a flooring system 100 for
covering an underlying surface 102 is illustrated. The underlying surface 102
may be a basement floor or any other surface that a user wishes to cover with
flooring.
[0027] The accumulation of moisture on the underlying surface 102 may
damage some types of finished flooring material (not shown) that a user (for
example a home owner) may wish to install over the underlying surface 102.
Examples of finished flooring materials include carpet, hardwood, linoleum
flooring, vinyl flooring and laminate flooring. Even if the finished flooring
material
is not visibly damaged by the moisture, exposure to moisture may lead to the
growth of mold and mildew, and may cause rotting or other damage to some
finished flooring materials or to subfloor materials underneath the finished
flooring. The flooring system 100, as described herein, may provide a moisture
impermeable support structure over which a finished flooring material can be
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installed. The flooring system 100 may inhibit moisture from the underlying
surface 102 from contacting or penetrating the selected finished flooring
material.
[0028] Referring to Figure 1, the flooring system 100 includes a plurality of
moisture impermeable base panels 104 that cooperate to cover the underlying
surface 102 and to define a moisture impermeable base surface 106. The
flooring system 100 also includes plurality of upper panels 108 provided above
the base panels 104 and arranged to form an upper subfloor surface 110 that
overlies the base surface 106. The base surface 106 functions as a moisture
and vapour barrier, inhibiting the transmission of moisture from the
underlying
surface 102 to the upper panels 108. Arranged above the moisture impermeable
base surface 106, the upper subfloor surface 110 can provide a surface for
supporting a finished flooring material.
[0029] In the illustrated example, each base panel 104 is formed from a
single, uninterrupted sheet of moisture impermeable plastic. The material of
the
base panel 104 can provide a desired degree of moisture impermeability and
strength to support a floor. Examples of suitable materials can include
polyvinylchioride, polyethylene, polypropylene or other plastics. In other
examples the base panels 104 may be formed from any other suitable, moisture
impermeable material, including metal, rubber, polymers, fiberglass, composite
materials and foams. The base panels 104 may be formed into the desired
shape, explained in greater detail below, using any manufacturing process that
is
appropriate for the material selected, including stamping, molding, machining
and
casting.
[0030] Each base panel 104 has opposing first (upper) and second (lower)
surfaces 112, 114 and comprises a plurality of discrete projections 116
extending
from the second (lower) surface 114. In the example illustrated, the
projections
116 extend away from the second surface 114 and contact the underlying
surface 102 and support the base panel 104 above the underlying surface 102.
In this configuration the lower surface 114 of the base panel 104 is supported
above (i.e. spaced apart from) the underlying surface 102 which may enable air
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or liquid (e.g. water) to flow between the lower surface 114 and the
underlying
surface 102. Enabling air to circulate between the base panels 104 and the
underlying surface 102 may reduce the accumulation of condensate between the
base panels 104 and the underlying surface 102. The separation of the lower
surface 114 from the underlying surface 102 may also allow any liquid that
accumulates on the underlying surface 102 to flow to a predetermined location
on the underlying surface 102, such as a floor drain or sump (not shown),
which
may reduce the likelihood of moisture accumulating in an undesired location or
being retained between a base panel 104 and the underlying surface 102.
[0031] Referring to Figure 3, the distance or spacing between the lower
surface 114 of each base panel 104 and the underlying surface 102 is
determined by a projection height 118. The projection height 118 is the
distance
between the root portion 120 and an opposing peak portion 122 of each
projection 116. The projection height 118 may be between 2mm and 25mm, and
in the illustrated example is approximately 5mm. The root portions 120 of the
projections 116 are proximate the second surface 114 and the peak portions 122
are spaced apart from the second surface 114 by the projection height 118. In
the illustrated example, the projections 116 have equal projection heights
118. In
other examples the projections 116 may be of differing projection heights 118.
[0032] Referring to Figure 3, each base panel 104 also has a base panel
thickness 119 that defines the distance between the opposing upper and lower
surfaces 112, 114. In some examples the base panel thickness 119 may be
between 0.05mm and 10mm, and in the illustrated examples is approximately
0.5mm. The selected thickness of the base panel 104 in any given example may
be based on multiple factors, including the material of the base panel 104,
the
number and configuration of projections 116 and the expected load to be
carried
by the base panel 104.
[0033] The projections 116 may be integral with the base panels 104 such
that the downward extending projections 116 form corresponding dimples or
recesses 124 in the upper surface 112 of the base panels 104 defined by the
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generally concave interior 126 of the projections 116. The interior 126 of
each
projection 116 may have generally the same size and configuration as the outer
surface of the projections 116.
[0034] The plurality of projections 116 on each base panel 104 may be
configured in any suitable pattern or configuration. In the illustrated
example, the
projections 116 are in a pattern comprising grid-like rows 132 of projections
and
in which each projection 116 is equally spaced from adjacent projections 116
by
a projection spacing distance 117 (measured as a centre-to-centre distance
between adjacent projections 116). In some examples the projection spacing
distance 117 is between 15mm and 50mm, and in the illustrated example is
approximately 27mm. In other examples, projections 116 may be arranged in
any suitable pattern that provides the desired support for the base panels 104
and enables the attachment of adjacent base panels 104 as described below.
[0035] In the illustrated example, the projections 116 are frusto-conical
and have concave recesses 124 defined by the interiors 126 of the projections,
which have corresponding, generally concave frusto-conical shapes. In other
examples, the projections 116 may have a different shape, such as, for example
semi-spherical, cylindrical, cubic and pyramidal. The recesses 124 defined by
the interiors 126 of the projections 116 may be of a different, generally
concave
shape that corresponds to the shape of the projections 116 (i.e. semi-
spherical
projections may have corresponding semi-spherical interiors that define
generally
concave, semi-spherical recesses).
[0036] In the example illustrated, the base panels 104 are installed in a
first configuration in which the base panel first surfaces 112 are facing the
upper
panels 108 and the base panel second surfaces 114 are facing down, toward the
underlying surface 102, so that the tips 122 of the projections bear against
the
underlying surface 102. In other examples, the base panels 104 may be
installed
in an opposite, second configuration in which the base panel first surfaces
112
face and bear against the underlying surface 102 and the projections 116
extend
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upward, such that the tips 122 are disposed above the roots 120 and the upper
panels 108 bear against the tips 122 of the projections 116.
[0037] Optionally, some or all of the projections 116 may not be integral
with the base panels 104 and may be formed from separate, discrete members
that are connected to the base panels 104. In such examples, the projections
116 may be the same material as the base panels or a different material, and
the
recesses 124 may independent from the projections 116. Such independent
recesses 124 may be depressions formed in the upper surfaces 112 of the base
panels 104 or other features that are suitable for receiving a projection 116
(as
explained below), such as slits or apertures extending between the upper and
lower surfaces 112, 114 of the base panels 104. If the recesses 124 comprise
apertures or through holes the sealing between adjacent base panels 104,
described in detail below, may be adapted to seal the apertures so as to
maintain
desired levels of moisture impermeability of the base surface 106.
[0038] Referring to Figure 2, each base panel 104 has a width 136 and
length 140. In the illustrated example base panels 104 are square and have a
width 136 of 4 feet (4ft.) and a length of 4ft. (i.e. a 4ft. x 4ft. square).
In some
examples, the width 136 and length 138 may be between 0.5ft. and 8ft. In other
examples, base panels 104 may be provided in shapes other than square, such
as rectangular, hexagonal, triangular and polygonal. In such examples the
width
136 may be different than the height 138 (i.e. a rectangular base panel 104
may
be 4ft. x 8ft. or 2ft. x 4ft., for example). Base panels 104 can also be
provided in
a roll that is, for example, 4ft. wide and has a length of 25ft., 50ft. or
longer. A
user can install a rolled base panel 104 in the manner described herein and
cut
the rolled base panel 104 to a desired length and/or the user can cut the
rolled
base panel 104 into two or more smaller base panels 104 prior to installation.
[0039] When arranged over the underlying surface 102, adjacent base
panels 104 are connected together by a plurality of base panel connection
elements 128 to form the base surface 106. The base panel connection
elements 128 connect adjacent base panels 104 together such that relative
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horizontal movement between adjacent base panels 104 is inhibited. Preventing
relative horizontal movement between adjacent base panels 104 inhibits the
relative shifting or sliding of the base panels 104 when the flooring system
100 is
being installed or when in use and may reduce the formation of gaps or leaks
between adjacent base panels 104. The presence of gaps or leaks in the base
surface 106 may allow moisture from the underlying surface 102 to reach the
upper panels 108. In the illustrated example, the base panel connection
elements 128 comprise overlapping margins 134 of adjacent base panels 104
that are sealed to provide a moisture impermeable joint or interface between
adjacent base panels 104. The margin 134 of each base panel 104 is the region
extending around the periphery of the base panel 104 that engages an adjacent
base panel 104. Projections 116 positioned within a margin 134 of a base panel
104 may be referred to as marginal projections 135.
[0040] In the illustrated example the marginal projections 135 are the
same as the rest of the projections 116 extending from the lower surface 114.
In
other examples, the marginal projections 135 may have a different shape or
configuration than the projections 116 outside the margins 134. In the
illustrated
example, the base panel connection elements 128 comprise marginal projections
135 in the margins 134 of each base panel 104 that are arranged in rows 132,
forming part of the grid-like pattern of projections 116.
[0041] Referring to Figures 6a and 6b, a first base panel 104a is
connected to a second, adjacent base panel 104b by overlapping a first margin
134a over a second margin 134b. The first margin 134a comprises first marginal
projections 135a and the second margin 134b comprises second marginal
projections 135b. The first and second marginal projections 135a, 135b are
arranged in complimentary first and second patterns, for example rows 132a,
132b respectively, so that when the first margin 134a overlaps the second
margin
134b the first marginal projections 135a are in registration with respective
second
marginal projections 135b. When overlapped, the first marginal projections
135a
nest within corresponding recesses 124 defined by the generally concave
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interiors 126 of the second marginal projections 135b. In this example the
base
panel connection elements 128 comprise marginal projections 135a forming two
rows 132a in the first margin 134a and second marginal projections 135b
forming
two complimentary rows 132b in the second margin 134b. While shown as
parallel rows 132a and 132b extending along the first and second margins 134a,
134b, it is understood that in other examples the marginal projections 135a,
135b
may be provided in other complimentary patterns.
[0042] In another example, as shown in Figure 7, the base panel
connection elements 128 for connecting first and second base panels 104a, 104b
include overlapping margins 134a, 134b that comprise marginal projections
135a, 135b respectively that are arranged into single rows 132a, 132b, as
opposed to the pairs of rows 132a, 132b shown in Figures 6a-6b. In other
examples (not shown), the base panel connection elements 128 may include
margins 134 that comprise more than two rows 132 or other patterns of
complimentary, nesting marginal projections 135a, 135b.
[0043] In some examples, the marginal projections 135a on the first base
panel 104a may nest completely within the recesses 124 of the marginal
projections 135b of second base panel 104b so that the overlapping portion 142
of the lower surface 114 of the first base panel 104a abuts and is flush with
the
upper surface 112 of the second base panel 104b. In other examples (not
shown), the marginal projections 135a on the first base panel 104a may be only
partially nested within the recesses 124 of the marginal projections 135b of
second base panel 104b when the base panels 104a, 104b are connected, so
that a gap or clearance is formed between the overlapping portion 142 of the
lower surface 114 of the first base panel 104a and the upper surface 112 of
the
second base panel 104b.
[0044] When in the nested configuration, as shown in Figures 6a and 7,
the base panel connection elements 128 also comprise a seam 140 that is
formed at the interface between the overlapping portion 142 of the lower
surface
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114 of the first base panel 104a and the upper surface 112 of the adjacent
second base panel 104b.
[0045] In the example illustrated, the seam 140 is formed between an
outer edge 137 of the first margin 134a and an inner edge 139 of the second
margin 134b. Seams 140 between adjacent base panels 104 can be sealed to
provide a desired moisture impermeable connection between adjacent base
panels 104, to facilitate providing a moisture impermeable base layer 106.
[0046] The seams 140 may be sealed using any suitable sealing
technique that provides the desired level of moisture impermeability,
including,
for example, glue, adhesives, gaskets, welding and/or by applying moisture
impermeable tape 144 along the extent of the seam 140. In the illustrated
example, the seams 140 extend generally along the entire width 136 or length
138 of the base panel 104. In other examples, the seams 140 may extend along
only a portion of the width 136 or length 138 of the base panel 104.
[0047] In some examples, the seams 140 may be sealed using separate
sealing members, such as, for example, gaskets and/or moisture impermeable
tape 144. In other examples, the base panels 104 may comprise integral sealing
features that cooperate to effectively seal the seams 140 formed between
adjacent base panels 104, without the use of separate sealing members. In some
examples, the marginal projections 135a of the first base panel 104a may be
pressed into the recesses 124 of the second base panel 104b to create a snap-
fit
connection between the first and second base panels 104a, 104b. The snap-fit
connection may comprise a slight interference fit so that air flow and
moisture
flow between the first and second base panels 104a, 104b is inhibited. The
snap-fit connection between the base panels 104a, 104b may exert a sufficient
pressure on the interface between the abutting surfaces that define the seam
140
(the overlapping portion of the lower surface 142 of the first base panel 104a
and
the upper surface 112 of the second base panel 104b) that the surfaces 112,
142
bear against each other sufficiently tightly to inhibit air flow or moisture
passage
between the surfaces 112, 142 as well as between the snap-fit projections 135a
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and recesses 124. In such a configuration, the snap-fit connection between the
first marginal projections 135a and the recesses 124 can effectively seal the
entire extent of the seam 140. In addition to, or in alternative to, the snap-
fit
connection between first marginal projections 135a and recesses 124, the first
and second base panels 104a, 104b may include additional snap-fit fasteners
(not shown) arranged in registration, within the overlapping margins 134.
Examples of such snap-fit fasteners include clips, tongue and groove
connections, mating ridges and grooves and other complimentary fasteners.
[0048] In the illustrated example, the snap-fit connection includes a catch
protruding radially outwardly from an outer surface of the first ones of the
marginal projections and a corresponding detent extending radially outwardly
of
an inner surface of the respective ones of the recesses.
[0049] In further examples, the interface between opposing, abutting
surfaces 112, 114 of adjacent base panels 104 may be effectively self-sealing
due to the material properties of the base panels 104. For example overlapping
margins 134 and abutting surfaces 112, 142 on rubber or polychioroprene base
panels 104 may provide an effectively self-sealing seam 140 due to the
inherent
properties of the materials selected.
[0050] While described using adjacent first and second base panels 104a,
104b, it is understood that the connection elements described above are used
to
connect a given base panel 104 to a plurality of adjacent base panels 104 so
as
to inter-connect the plurality of base panels 104 together to form the base
surface 106.
[0051] Referring again to Figure 1, an upper subfloor surface 110 is
formed above the base surface 106 by inter-connecting the plurality of upper
panels 108. The upper panels 108 are made of a subfloor material that is
selected to provide a suitable surface for supporting the user-selected
finished
floor material. Examples of possible subfloor materials include wood, plywood,
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particle board, MDF, oriented strand board, plastic and foam. In the
illustrated
example the upper panels 108 are formed from oriented strand board.
[0052] Referring to Figure 5, each upper panel 108 has a width 146 and a
length 148. In the illustrated example, the upper panels 108 are generally
square
shaped, having a width 146 is the same as the length 148. In other examples,
as
described above in relation to the base panels 104, the upper panels 108 may
have a different shape, such as a rectangle, a triangle, a hexagon or other
polygonal shape. In the illustrated example, the upper panels 108 are smaller
than the supporting base panels 104, and have a width 146 of 2 ft. and a
length
148 of 2ft. Accordingly, a single base panel 104 may support a plurality of
upper
panels 108. In other examples, the upper panels 108 may be the same size as,
or larger than the base panels 104. Optionally, the upper panels 108 may be a
different shape than the base panels 104. For example, the base panels 104
may be Oft. x 4ft. squares and the upper panels 108 may be 2ft. x 4ft.
rectangles
or 2ft.x 2ft. squares. In some examples a mixture of differently sized and/or
shaped base panels 104 may be used to form the base layer 106 (i.e. a
plurality
of square base panels 104 mixed with a plurality of rectangular base panels),
and
a mixture of differently sized and/or shaped upper panels 108 may be used to
form the upper subfloor surface 110.
[0053] To form the upper subfloor surface 110, adjacent upper panels 108
can be attached together using a plurality of upper panel connection elements
150 to inhibit relative vertical movement between upper panels 108.
Optionally,
the upper panel connection elements 150 may also inhibit relative horizontal
movement between adjacent upper panels 108. In the illustrated example, the
upper panel connection elements 150 are separate from the base panel
connection elements 128.
[0054] Referring to Figure 5, one example of the upper panel connection
elements 150 includes connecting or engaging margins 152 of adjacent upper
panels 108. In the illustrated example, as shown in Figures 1 and 5, the upper
panel connection elements 150 comprise upper panel 108 margins 152 that form
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tongue and groove connections 154. Each tongue and groove connection 154
comprising a tongue 156, defined in the margin 152 of a first upper panel 108,
and a corresponding groove 158, defined in the margin 152 of a second,
adjacent upper panel 108. To enable the inter-connection of multiple upper
panels 108, any given upper panel 108 may comprise at least one groove 158 for
engaging a respective tongue 156 of an adjacent second upper panel 108, and at
least one tongue 156 for engaging a respective groove 158 of an adjacent,
third
upper panel 108.
[0055] In other examples, the upper panel connection elements 150 may
include any suitable connection features, including complimentary nesting
projections, fasteners (including nails and screws), adhesives, and lap
joints.
[0056] In the illustrated example, the plurality of upper panels 108 are
unconnected to the base panels 104. Accordingly, the upper subfloor surface
110 rests upon, but is not connected or attached to the base surface 106. In
this
configuration, the upper subfloor surface 110 may be described as a floating
floor
surface. Arranging the upper panels 108, and the upper subfloor surface 110,
in
such a floating configuration allows relative horizontal movement between the
upper panels 108 and the base panels 104 to accommodate differing rates of
expansion between the base panels 104 and the upper panels 108.
[0057] In examples where the base panels 104 are formed from a different
material than the upper panels 108 (e.g. plastic base panels 104 supporting
oriented strand board upper panels 108), there may be a difference in the rate
and amount of expansion between the base panels 104 and the upper panels
108 when both panels 104, 108 are subjected to environmental changes.
[0058] For example, an increase in the temperature of the flooring system
100 may cause the base panels 104 to expand (or contract) faster, and by a
larger extent, than the upper panels 108. If the upper panels 108 were
fastened
or attached to the base panels 104 the different relative expansion (or
contraction) of the panels 104, 108 may introduce stress into the flooring
system
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100 and may lead to warping, cracking, gap formation or other unwanted
outcomes. In another example, an upper panel 108 formed from oriented strand
board may expand faster and by a larger extent than a plastic base panel 104
when the panels 104, 108 are exposed to increased humidity. Configuring the
upper panels 108 to form a floating upper subfloor surface 110 enables the
upper
panels 108 to expand as necessary, without affecting the underlying base
panels
104.
[0059] One example of a method of providing the flooring system 100 for
covering the underlying surface 102, as illustrated in Figure 1, begins with
the
step of providing a plurality of moisture impermeable base panels 104. As
described above, each base panel 104 has opposing upper and lower surfaces
112, 114 and comprises a plurality of discrete projections 116 extending from
the
lower surface 114. The projections 116 are placed in contact with and support
the lower surface 114 of the base panel 104 above the underlying surface 102.
[0060] The base panels 104 are then arranged to cover some or all of the
underlying surface 102. Once the base panels 104 are arranged over the
desired portion of the underlying surface 102 the user can connect together
adjacent base panels 104 to prevent relative horizontal movement therebetween.
Once adjacent base panels 104 are connected the user can seal the seams
between adjacent base panels 104 to help provide a generally moisture
impermeable base surface 106.
[0061] In some examples, the step of connecting adjacent base panels
106 includes overlapping a portion of lower surface 114 of a first base panel
104a (for example a first margin 134a) over a portion of the upper surface 112
of
an adjacent second base panel 104b (for example a second margin 134b as
shown in Figures 6a-7). The process of overlapping the first and second base
panels 104a, 104b can include nesting first marginal projections 135a arranged
in one or two (or more) rows 132a on the first base panel 104a into
complimentary recesses 124 of the second marginal projections 135b, arranged
in corresponding rows 132b on the second base panel 104b.
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[0062] Having overlapped adjacent base panels 106 in the appropriate
manner, the user can then seal the seam 140 formed between panels 104a,
104b using a suitable method, for example by applying moisture impermeable
tape over the seam.
[0063] Having formed the base surface 106, the next step is to provide a
plurality of upper panels 108 and to lay them on top of the base panels 104 to
generally cover the base surface 106, or at least a desired portion thereof.
Adjacent upper panels can be connected together to inhibit relative vertical
movement therebetween and to form the upper subfloor surface 110 that rests
above the base surface 106. By not attaching the upper subfloor floor surface
110 to the base surface 106, the upper subfloor surface 110 may remain free to
move horizontally relative to the base surface 106, which can, for example,
accommodate differing rates of expansion between the upper panels 108 and the
base panels 104.
[0064] In the illustrated example, the user connects respective margins
152 of adjacent upper panels 108 using upper panel connection elements 150
that comprise complimentary tongue and groove connections 154.
[0065] What has been described above has been intended to be
illustrative of the invention and non-limiting and it will be understood by
persons
skilled in the art that other variants and modifications may be made without
departing from the scope of the invention as defined in the claims appended
hereto.
