Note: Descriptions are shown in the official language in which they were submitted.
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VERTICAL JOINT SYSTEM AND ASSOCIATED SURFACE COVERING SYSTEM
Field of the Invention
The present invention relates to a vertical joint system for substrates
enabling the
substrates to be jointed together side by side. Non-limiting examples of such
substrates
include wooden boards or panels which may be used as floor, wall or ceiling
covering. The
present invention also relates to a surface covering system utilising
substrates which
incorporate the joint system.
Background Art
"Click" type floor coverings comprise a plurality of substrates, each provided
with
like joint systems to facilitate coupling of adjacent substrates. These joint
systems often
comprise first and second joints running along two opposite sides of the
substrate. The joints
are configured so that the first joint on one substrate is able to engage the
second joint on
an adjacent substrate. The joints rely on specific configurations of tongues,
grooves,
protrusions, recesses and barbs to effect interlocking engagement.
Joint systems for flooring may be generally categorised as horizontal (or "lay
down")
joint systems or vertical joint systems. Horizontal joint systems require
motion in a plane
substantially parallel to a plane containing a major surface of the flooring
substrate (i.e. a
horizontal plane) in order to effect the engagement of joints on adjacent
substrates. Vertical
joint systems on the other hand require motion and/or force in a plane
perpendicular to a
major surface of the substrates to effect engagement of the joints. Thus it
should be
understood that the expression "vertical" in the context of the present type
of joint system,
and as used in this specification, does not mean absolutely vertical but
rather perpendicular
to a major surface of a substrate. When the substrate is laid on a horizontal
surface then
"vertical" in this context is also absolute vertical. But as those skilled in
the art will
understand substrates can be laid on surfaces of other dispositions for
example on vertical
surfaces such as a vertical wall; or, inclined surfaces such as on a pitched
ceiling. In such
situations the vertical joint system holds it's meaning as a joint system that
operates/engages by way of motion and/or force in a plane perpendicular to a
major surface
of the substrates
There are also "quasi" vertical joint systems which, while their manufacturer
may
claim to be a vertical system, initially require engagement of joints of
adjacent panels by a
lateral insertion of one joint into another followed by a rotation of one
panel relative to
another so that their respective major surfaces are coplanar.
The above references to the background art do not constitute an admission that
the
art forms a part of the common general knowledge of a person of ordinary skill
in the art.
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The above references are also not intended to limit the application of the
joint system as
disclosed herein.
Summary of the Invention
Aspects of the present invention provide vertical joint systems for
substrates. The
vertical joint systems facilitate the provision of surface covering system
that allow for very
easy installation and more particularly repair. To this end repair can be
achieved by vertical
lifting of damaged panels without the need to pull up excess flooring from the
closest wall to
the damaged panels.
Other aspects of the present invention a provide vertical joint systems for
substrates wherein engaged substrates can rotate or pivot relative to each
other in either
positive or negative (i.e. clockwise or anticlockwise) while maintain
engagement
In one aspect there is provided vertical joint system for a substrate having
an
opposed major first and second surfaces, the joint system comprising:
first and second non-symmetrical joints extending along opposite sides of the
substrate, the first and second joints configured to enable two substrates
with
like joint systems to engage each other in response to a force applied in an
engagement direction which is perpendicular to the major surfaces;
the first and second joints each provided with two laterally spaced
transversely
extending surfaces configured to enable the first joint of one substrate to
engage the second joint of a second substrate with the two transversely
extending surfaces of the first joint located relative to the two transversely
extending surfaces of the second joint to form respective first and second
locking planes on an innermost and an outermost side of each joint, each
locking plane lying parallel to the engagement direction and wherein the
transversely extending surfaces associated with each locking plane extend
laterally toward each other from opposite sides of the locking plane with the
transversely extending surfaces of the second joint overhanging the
transversely extending surfaces of the first joint to inhibit separation if
the
engaged joints, wherein in at least one of the transversely extending surfaces
associated with each locking plane has a curved profile.
In one embodiment the transversely extending surfaces are configured to enable
relative rotation of two engaged substrates by up to 3 while maintaining
engagement of the
two substrates.
In one embodiment the transversely extending surfaces are configured to enable
relative rotation of one of the engaged substrates relative to the other by an
angle of
between 7 to 10 in a direction into a surface of which the substrates are
laid while
maintaining engagement of the two substrates.
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In one embodiment a void is created on at least one side of each locking plane
by
virtue of the non-symmetrical configuration of the first and second joints.
In one embodiment at least one of the transversely extending surfaces
associated
with at least one of the locking planes has a profile of a continuous convex
curve.
In one embodiment at least one of the locking planes one of the transversely
extending surface has a profile of a continuous convex curve and the other has
a profile
comprising one or more straight lines.
In one embodiment each of the transversely extending surfaces has a profile of
a
continuous convex curve.
In one embodiment two or more of the transversely extending surfaces have
profiles of different continuous convex curves.
In one embodiment each joint comprises a protrusion extending in the
engagement
direction and an adjacent recess formed along a respective side of the
substrate; and the
transversely extending surfaces are formed on an outermost surface of each
protrusion and
an inner most surface of each recess.
In one embodiment the protrusion of the first joint has a bulbous profile with
a neck
of reduced width wherein a portion of the transversely extending surface on
the protrusion of
the first joint is adjacent an outermost side of the neck.
In one embodiment the recess of the second joint has a bulbous profile with a
neck
of reduced width wherein a portion of the transversely extending surface on
the recess of the
second joint is adjacent an outermost side of the neck.
In one embodiment a plane containing a line of shortest distance across the or
each
neck of is inclined relative to the major surfaces.
In one embodiment a plane containing a line of shortest distance across the or
each
neck lies in a plane inclined relative to the major surfaces.
In one embodiment the respective lines of shortest distance across each neck
are
parallel to each other.
In one embodiment the lines of shortest distance across each neck are
collinear.
In one embodiment each transversely extending surface constitutes a portion of
a
respective inflexion surface.
In one embodiment each of the first and second joints is formed with a third
transversely extending surface located between the two transversely extending
surfaces of
that joint, the third transversely extending surfaces relatively located to
form a third locking
plane disposed intermediate the first and second locking planes and wherein
the third
transversely extending surfaces associated with the third locking plane extend
laterally
toward each other from opposites of the third locking plane with the third
transversely
extending surface of the second joint in alignment with or overhanging the
third transversely
extending surface of the first joint.
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In one embodiment the first and second joints are relatively configured to
engage
each other about a third locking plane inhibiting separation of the engaged
joints in a
direction parallel to the engagement direction, the third locking plane being
disposed parallel
to and between the first and second locking planes.
In one embodiment each of the first and second joints comprise a third
transversely
extending surface wherein the third transversely extending surfaces extend to
opposite sides
of the third locking plane when in the engaged joint.
In a second aspect there is provided vertical joint system for a substrate
having an
opposed major first and second surfaces, the joint system comprising:
io first and second non-symmetrical joints extending along opposite sides
of the
substrate, the first and second joints configured to enable two substrates
with like joint
systems to engage each other in response to a force applied in an engagement
direction
which is perpendicular to the major surfaces;
the first and second joints each provided with two laterally spaced inflexion
surfaces
configured to enable the first joint of one substrate to engage the second
joint of a second
substrate with the two inflexion surfaces of the first joint engaging the two
inflexion surfaces
of the second joint on inner most and outer most sides of each joint to form
respective first
and second locking planes each of which independently inhibit separation of
the engaged
joints in a direction parallel to the engagement direction each locking plane
lying parallel to
the engagement direction and wherein the inflexion surfaces associated with
each locking
plane lie on both sides of that locking plane and wherein at least one the
inflexion surfaces
associated with each locking plane has a profile of a continuous curve.
In one embodiment the inflexion surfaces are configured to enable relative
rotation
of two engaged substrates by up to 3 while maintaining engagement of the two
substrates.
In one embodiment the inflexion surfaces are configured to enable relative
rotation
of one of the engaged substrates relative to the other by an angle of between
7 to 100 in a
direction into a surface of which the substrates are laid while maintaining
engagement of the
two substrates.
In one embodiment each joint comprises a third inflexion surface and the
respective
third inflexion surfaces are relatively configured to engage each other to
form a third locking
plane disposed between the first and second locking planes.
In one embodiment a void is created on at least one side of each locking plane
by
virtue of the non-symmetrical configuration of the first and second joints.
In one embodiment one inflexion surface associated with one locking plane has
a
profile of a continuous curve and the other inflexion of that locking plane
has a profile ,
comprising one or more straight lines.
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In one embodiment each of the inflexion surfaces has a profile of a continuous
curve.
In one embodiment each joint comprises a protrusion extending in the
engagement
direction and an adjacent recess formed along a respective side of the
substrate; and the
inflexion surfaces associated with the first and second locking planes are
formed on an
outermost surface of each protrusion and an inner most surface of each recess.
In one embodiment the protrusion of the first joint has a bulbous profile
having a
neck of reduced width wherein a portion of the inflexion surface on the
protrusion of the first
joint is formed along an outermost side of the neck.
In one embodiment the recess of the second joint has a bulbous profile having
a
neck of reduced width wherein a portion of the inflexion surface on the recess
of the second
joint is formed along an outermost side of the neck.
In one embodiment a plane containing a line of shortest distance across the or
each
neck of is inclined relative to the major surfaces.
In one embodiment a plane contain a line of shortest distance across the or
each
neck lies in a plane inclined relative to the major surfaces.
In one embodiment the respective lines of shortest distance across each neck
are
parallel to each other.
In one embodiment the lines of shortest distance across each neck are
collinear.
In a third aspect there is provided a vertical joint system for a substrate
having an
opposed major first and second surfaces, the joint system comprising:
non-symmetrical male and female joints extending along opposite sides of the
substrate, the male and female joints configured to enable two substrates with
like joint
systems to engage each other in response to a force applied in an engagement
direction
which is perpendicular to the major surfaces;
the male joint comprising a male protrusion extending generally perpendicular
from
the first major surface toward the second major surface and a male recess
formed inboard of
the male protrusion; the female joint comprising a female protrusion extending
generally
perpendicular from the second major surface toward the first major surface and
a female
recess formed inboard of the female protrusion; the male joint having a first
male locking
surface formed on a side of its male protrusion most distant from its female
recess, a second
male locking surface formed on a side of its female recess most distant from
its male
protrusion and a third male locking surface being a surface common to the male
protrusion
and male recess; the female joint having a first female locking surface formed
on a side of its
female recess most distant from its male protrusion, a second female locking
surface formed
on a side of its male protrusion most distant from its female recess, and a
third female
locking surface being a surface common to the female protrusion and female
recess; the
locking surfaces being configured so that when a male and female joint of two
substrates are
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engaged, the first male and first female locking surfaces engage to form a
first
locking plane, the second male and second female locking surfaces engage to
form a
second locking plane, and the third male and third female locking surfaces
engage to form a
third locking plane located between the first and second locking planes each
locking plane
inhibiting separation of the engaged joints in a direction parallel to the
engagement direction,
and wherein at leait one of the first male locking surface and the first
female locking surface
is provided with a smoothly curved transversely extending portion; and at
least one of the
second male locking surface and the second female locking surface is provided
with a
smoothly curved transversely extending portion.
io In one embodiment the locking surfaces are configured to enable relative
rotation of
two engaged substrates by up to 3 while maintaining engagement of the two
substrates.
In one embodiment the locking surfaces are configured to enable relative
rotation of
one of the engaged substrates relative to the other by an angle of between 7
to 10 in a
direction into a surface of which the substrates are laid while maintaining
engagement of the
'15 two substrates.
In one embodiment the other of the first male locking surface and the first
female
locking surface is provided with a transversely extending portion comprising
at least one
planar surface.
In one embodiment the other of the second male locking surface and the second
20 female locking surface is provided with a transversely extending portion
comprising at least
one planar surface.
In one embodiment each of first and second male and female locking suifaces
comprises a smoothly curved transversely extending portion.
In one embodiment each of the first male locking surface, first female locking
25 surface, second male locking surface and second female locking surface
is formed with an
inflexion; wherein the inflexions engage each other about the first and second
locking
planes.
In one embodiment at least one of the third male locking surface and the third
female locking surface is formed with an inflexion.
30 In a fourth aspect there is provided a vertical joint system for a
substrate having an
opposed major first -and second surfaces, the joint system comprising:
first and second non-symmetrical joints extending along opposite sides of the
substrate, the first and second joints configured to enable two or more
substrates with like joint systems to engage each other in response to a force
= surfaces and to enable engaged substrates to be disengaged by lifting a
first
substrate in a direction opposite the engagement direction to facilitate
rotation
of adjacent engaged substrates along opposite sides of the first substrate to
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lie in planes declined from the first substrate and subsequently applying a
force in the engagement direction to the second joints of the engaged
substrates.
In one embodiment the first and second joints are each provided with two
laterally
spaced transversely extending surface portions configured to enable the first
joint of one
substrate to engage the second joint of a second substrate with the two
transversely
extending surfaces of the first joint located relative to the two transversely
extending
surfaces of the second joint to form respective first and second locking
planes on an
innermost and an outermost side of each joint, each locking plane lying
parallel to the
engagement direction and wherein the transversely extending portions
associated with each
locking plane extend laterally toward each other from opposites of the locking
plane with the
transversely extending portions of the second joint overhanging the
transversely extending
portions of the first joint.
In one embodiment at least one of the transversely extending surfaces
associated
with at least one of the locking planes has a profile of a continuous convex
curve.
In one embodiment the first and second joints are each provided with two
laterally
spaced inflexion surfaces configured to enable the first joint of one
substrate to engage the
second joint of a second substrate with the two inflexion surfaces of the
first joint engaging
the two inflexion surfaces of the second joint on inner and outer most sides
of each joint to
form respective first and second locking planes each of which independently
inhibit
separation of the engaged joints in a direction parallel to the engagement
direction each
locking plane lying parallel to the engagement direction and wherein the
inflexion surfaces
associated with each locking plane lie on both sides of that locking plane.
In one embodiment the first joint is a male joint and the second joint is a
female
joint, the male joint comprising a male protrusion extending generally
perpendicular from the
first major surface toward the second major surface and a male recess formed
inboard of the
male protrusion; the female joint comprising a female protrusion extending
generally
perpendicular from the second major surface toward the first major surface and
a female
recess formed inboard of the female protrusion; the male joint having a first
male locking
surface formed on a side of its male protrusion most distant from its female
recess, a second
male locking surface formed on a side of its female recess most distant from
its male
protrusion and a third male locking surface being a surface common to the male
protrusion
and male recess; the female joint having a first female locking surface formed
on a side of its
female recess most distant from its male protrusion, a second female locking
surface formed
on a side of its male protrusion most distant from its female recess, and a
third female
locking surface being a surface common to the female protrusion and female
recess; the
locking surfaces being configured so that when a male and female joint of two
substrates are
engaged, the first male and first female locking surfaces engage to form a
first locking plane,
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the second male and second female locking surfaces engage to form a second
locking
plane, and the third male and third female locking surfaces engage to form a
third locking
plane located between the first and second locking planes each locking plane
inhibiting
separation of the engaged joints in a direction parallel to the engagement
direction.
In one embodiment the first and second joints are configured to create three
locking
planes when mutually engaged, each locking plane lying parallel to the
engagement
direction and inhibiting separation of engaged joints in a direction opposite
the engagement
direction.
In one embodiment when the substrate is in the configuration of a planar
rectangular or square substrate having four sides, the first joint extends for
two adjacent
sides and the second joint extends for the remaining two adjacent sides.
In a fifth aspect there is provided a surface covering system comprising a
plurality
of substrates where in each substrate is provided with a vertical joint system
in accordance
with any one of the first to fourth and tenth aspects.
In a sixth aspect there is provided a semi-floating surface covering system
comprising:
a plurality of substrates each substrate having a vertical joint system in
accordance
with any one of the first to fourth and tenth aspects;
a quantity of re-stickable adhesive bonded to the first major surface; and,
one or more release strips covering the re-stickable adhesive.
In one embodiment the quantity of re-stickable adhesive is applied it two or
more
spaced apart lines extending in a longitudinal direction of the substrate.
In one embodiment the quantity of re-stickable adhesive is applied as a
continuous
strip or bead in at least one of the spaced apart lines.
In one embodiment the re-stickable adhesive is applied in a plurality of lines
which
are evenly spaced from each other and symmetrically disposed about a
longitudinal centre
line of the substrate.
In one embodiment the re-stickable adhesive has a thickness measured
perpendicular to the first major surface of between 1 ¨ 6nnnn.
In one embodiment the re-stickable glue has a thickness of between 2 ¨ 4nnnn.
In one embodiment the quantity of adhesive comprises a quantity of joint
adhesive
bonded to the substrate and covered with a release strip, the joint adhesive
located in a
position wherein when the joint system of one substrate is coupled to the
joint system of
another substrate with the cover strip removed, the joint adhesive on the one
substrate
adheres to the joint of the other substrate.
In one embodiment the substrate is made from a material selected from the
group
consisting of; solid timber, engineered timber, laminate, Bamboo, plastics,
and vinyl.
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In a seventh aspect there is provided a method of manufacturing a semi-
floating
surface covering substrate comprising:
providing a surface covering system in accordance with the fifth aspect;
bonding a quantity of a re-stickable adhesive to the first major surface; and,
covering the adhesive with a release strip.
In one embodiment bonding the adhesive comprises applying the adhesive in two
or more spaced apart lines extending in a longitudinal direction of the
substrate.
In one embodiment the bonding comprises applying the adhesive as a continuous
strip or bead in at least one of the spaced apart lines onto the first major
surface.
In one embodiment the method comprises applying the adhesive with a uniform
thickness of between 1 - 6 mm measured in a direction perpendicular to the
major surfaces.
In one embodiment the method comprises applying the adhesive with uniform
thickness of between 2 - 4 mm.
In one embodiment the method comprises bonding a quantity of re-stickable
adhesive to at least a portion of the joint and covering the adhesive in the
joints with a
release strip, the re-stickable adhesive being applied at a location on a
first substrate
wherein when the vertical joint systems of the first and a second substrate
are coupled
together with a release strip covering the adhesive in the joint of the first
substrate being
removed, the adhesive adheres to the joint of the second substrate.
In an eighth aspect there is provided a surface covering system comprising a
plurality of substrates, each substrate having: opposite first and second
major surfaces
wherein the first major surface is arranged to face an underlying support to
be covered by
the system; and a vertical joint system, the vertical joint system comprising:
first and second non-symmetrical joints extending along opposite sides of a
substrate, the first and second joints configured to enable two or more
substrates to engage each other in response to a force applied in an
engagement direction which is perpendicular to the major surfaces and to
enable engaged substrates to be disengaged by: (a) lifting a first substrate
in
a direction opposite to the engagement direction to facilitate rotation of
adjacent engaged substrates along opposite sides of the first substrate to lie
in planes declined from the first substrate; and (b) subsequently applying a
force in the engagement direction to the second joints of the engaged
substrates.
In one embodiment the surface covering system comprises at least one a jack
dennountably attachable to the first substrate the jack comprising a shaft
arranged to pass
through a hole formed in the first substrate to bear on the underlying
support, the jack being
operable to extend the shaft through the hole to thereby lift the first
substrate form the
underlying support.
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In one embodiment of the surface covering system the vertical joint system is
in
accordance with any one of the first to fourth and tenth aspects.
In one embodiment the surface covering system comprises a quantity of re-
stickable adhesive bonded to the first major surface; and, one or more release
strips
covering the re-stickable adhesive.
In one embodiment the surface covering system comprises a quantity of re-
stickable adhesive bonded to one or both of the first and second joints and
respective
release strips overlying the re-stickable adhesive bonded on the joints.
In one embodiment the vertical joint system comprises a quantity of re-
stickable
adhesive bonded to one or both of the first and second joints and respective
release strips
overlying the re-stickable adhesive bonded on the joints.
In a ninth aspect there is provided a substrate for a surface covering system,
the
substrate comprising a vertical joint system according to any one of of the
first to fourth and
tenth aspects.
In one embodiment the substrate comprises a quantity of re-stickable adhesive
bonded to one or both of the first and second joints and respective release
strips overlying
the re-stickable adhesive bonded on the joints.
In one embodiment of the substrate each joint provided with the bonded re-
stickable adhesive is provide with a recess for seating the bonded re-
stickable adhesive.
In one embodiment the substrate comprises a quantity of re-stickable adhesive
bonded to the first major surface; and, one or more release strips covering
the re-stickable
adhesive on the first major surface.
In one embodiment the vertical joint system comprises a layer of wax being
provide
on surfaces of the joint which when engaged with a like joint engage to form
the first and
second locking planes.
In one embodiment of vertical joint system each recess of one substrate is
provided
with the joint system is configured to elastically open to enable a
corresponding protrusion of
a second substrate with a like joint system to like to enter and engage the
recess.
In a tenth aspect there is provided a vertical joint system for a substrate
having an
opposed major first and second surfaces, the joint system comprising:
first and second non-symmetrical joints extending along opposite sides of the
substrate, the first and second joints configured to enable two substrates
with
like joint systems to engage each other in response to a force applied in an
engagement direction which is perpendicular to the major surfaces;
the first and second joints being configured to enable relative rotation of
two
engaged substrates by up to 3 while maintaining engagement of the two
substrates.
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In one embodiment of the tenth aspect the first and second joints are each
provided
with two laterally spaced generally convex surfaces configured to enable the
first joint of one
substrate to engage the second joint of a second substrate with the two
generally convex
surfaces of the first joint located relative to the two generally convex
surfaces of the second
joint to form respective first and second locking planes on an innermost and
an outermost
side of each joint, each locking plane lying parallel to the engagement
direction and wherein
the generally convex surfaces associated with each locking plane extend
laterally toward
each other from opposite sides of the locking plane with the generally convex
surfaces of the
second joint overhanging the generally convex surfaces of the first joint to
inhibit separation
if the engaged joints, wherein in at least one of the generally convex
associated with each
locking plane has a curved profile.
In one embodiment of the tenth aspect each joint comprises a protrusion
extending
in the engagement direction and an adjacent recess formed along a respective
side of the
substrate; and the transversely extending surfaces are formed on an outermost
surface of
each protrusion and an inner most surface of each recess.
In one embodiment of the tenth aspect each recess configured to elastically
open to
enable a protrusion of a substrate with a like joint system to like to enter
and engage the
recess.
In one embodiment of the tenth aspect the first and second joints are
configured to
form a third locking plane intermediate the first and second locking planes.
In an eleventh aspect there is provided a vertical surface covering system
comprising a plurality of panels, each panel having an upper major surface and
a
lower major surface and a plurality of sides disposed between the upper and
lower
major surfaces, each panel further provided with a joint system configured to
enable:
(a) a first panel to be engaged on each of its sides with respective other
panels to
form at least a portion of a surface covering; and (b) the first panel to be
disengaged
from the other panels by initially lifting the first panel in a direction
perpendicular to a =
plane containing the upper major surface of the first panel surface covering
thereby
rotating each of two panels engaged on opposite side of the first panel to lie
in
respective planes declined from the first panel.
In a twelfth aspect there is provided a vertical surface covering system
comprising a
plurality of panels, each panel having an upper major surface and a lower
major surface and
a plurality of sides disposed between the upper and lower major surfaces, each
panel further
. provided with a joint system configured to enable a first panel, which is
engaged on each of
its sides with respective other panels by engagement of respective joint
systems on the
panels, to be disengaged from the other panels by lifting the first panel in a
direction
perpendicular to a plane containing the upper major surface of the first panel
thereby
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rotating each of two panels engaged on opposite side of the first panel to lie
in
respective planes declined from the first panel.
In a thirteenth aspect there is provided a vertical surface covering system
covering system comprising a plurality of panels, each panel having an upper
major
surface and a lower major surface and a plurality of sides disposed between
the
upper and lower major surfaces, each panel further provided with a joint
system
configured to enable a first panel to be (a) laid in a space between a
plurality of
previously laid and engaged panels by application of a force in an engagement
direction being perpendicular to the major surfaces wherein the joint system
of the
io first panel engages with like joint systems of the previously laid
panels adjacent the
space; and (b) removed from the previously laid panels by lifting the first
panel in a
direction opposite the engagement direction.
= In a fourteenth aspect there is provided A joint system for a panel of a
vertical
surface covering system the panel having an upper major surface and a lower
major
surface and a plurality of sides disposed between the upper and lower major
surfaces, the joint system extending along each side of the panel and
configured to
enable a first panel, which is engaged on each of its sides with respective
other
panels by engagement of respective joint systems on the panels, to be
disengaged
from the other panels by lifting the first panel in a direction perpendicular
to a plane
zo containing the upper major surface of the first panel thereby rotating
each of two
panels engaged on opposite side of the first panel to lie in respective planes
declined from the first panel.
In a fifteenth aspect there is provided a method of removing a first floor
panel
from a floor covering formed from a plurality of floor panels which are joined
together
by joint systems provided on each floor panels, the first floor panel being
joined on
all sides with the first floor panel by engaged other panels, the method
comprising:
vertically lifting the first floor panel from the floor covering in manner
wherein the first
floor panel remains substantially parallel to the floor covering to effect
rotation of two
of the other panels one of each on opposite sides of the first panel and a
partial
disengagement of the two other panels.
Brief Description of the Drawings
Notwithstanding any of forms which may fall within the scope of the joint
system as
set forth in the Summary, specific embodiments will now be described, by way
of example
only, with reference to the accompanying drawings in which:
Figure la is a section view of a panel incorporating an embodiment of the
vertical
joint system;
AMENDED SHEET
TEA/AU
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Received 09/07/2012
- 11b -
Figure lb is a cross section view of a portion of two panels incorporating the
vertical
joint system in an engaged state;
Figure 2 is an isometric view of a portion of two panels incorporating the
vertical
joint system when in a disengaged state;
Figure 3a illustrates the ability of engaged panels incorporating the vertical
joint
system to rotate in a first direction relative to each other;
Figure 3b illustrates the ability of engaged panels incorporating the vertical
joint
system to rotate in a second opposite direction relative to each;
Figure 4a illustrates the effect of lateral bowing of a substrate overlying a
depression or hollow in a supporting surface;
Figure 4b is an enlarged view of detail A marked on Figure= 4a;
AMENDED SHEET
1PEA/AU
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Figure 4c illustrates the effect of lateral bowing of a panel when overlying a
hump or
rise in an underlying surface;
Figure 4d is an enlarged view of detail B marked on Figure 4c;
Figure 4e is a schematic representation providing a comparison in the ability
to
accommodate surface a hump or rise between prior art joint systems and
vertical joint
systems in accordance with embodiments of the present invention;
Figure 4f is an enlarged view of detail C marked on Figure 4e;
Figure 4g is a schematic representation providing a comparison in the ability
to
accommodate surface a hollow or dip between prior art joint systems and
vertical joint
systems in accordance with embodiments of the present invention;
Figure 4h is an enlarged view of detail D marked on Figure 4g;
Figure 5a is a representation of the relative juxtaposition of panels
incorporating the
present vertical joint system being ready for engagement;
Figures 5b ¨ 5e depict sequentially the engagement of panels incorporating
embodiments of the vertical joint system from a point of initial contact in
Figure 5b to
complete engagement in Figure 5e;
Figures 5f ¨ 5k depict in sequence a self aligning feature of embodiments of
the
vertical joint system;
Figures 51¨ 5u provides a schematic comparison between the effect of the self
aligning feature enabled by embodiments of the present invention and the prior
art;
Figure 6a is an elevation view of an area covered by substrates joined
together with
embodiments of the present vertical joint system and identifying a panel to be
removed;
Figure 6b is a view of section A-A from Figure 6a;
Figure 6c is a top elevation of a panel fitted with jacks enabling the removal
of the
panel;
Figure 6d ¨ 6s depict in sequence steps for the removal and replacement of the
highlighted panel in Figure 6a;
Figure 7a is a side elevation of the jack depicted in Figure 6c;
Figure 7b is a top elevation of the jack shown in Figure 6c;
Figure 8a is a side elevation of a wedge used in conjunction with the jack for
extracting an engaged panel;
Figure 8b is an elevation view of the wedge shown in Figure 8a;
Figures 9a ¨ 9f depict in sequence the disengagement of joined panels from an
initial fully engaged state depicted in Figure 9a to a fully disengaged state
shown in Figure
9f;
Figure 10a depicts a panel incorporating a second embodiment of the vertical
joint
system;
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Figure 10b illustrates the engagement of two panels incorporating the second
embodiment of the vertical joint system;
Figure lla depicts a panel incorporating a third embodiment of the vertical
joint
system;
Figure llb illustrates the engagement of two panels incorporating the third
embodiment of the vertical joint system;
Figure 11c illustrates the ability of engaged panels incorporating the joint
system of
the third embodiment to rotate in a first direction relative to each other;
Figure 11d illustrates the ability of engaged panels incorporating the joint
system of
the third embodiment to rotate in a second opposite direction relative to
each;
Figure 12a depicts a panel incorporating a fourth embodiment of the vertical
joint
system;
Figure 12b illustrates the engagement of two panels incorporating the fourth
embodiment of the vertical joint system;
Figure 13a depicts a panel incorporating a fifth embodiment of the vertical
joint
system;
Figure 13b illustrates the engagement of two panels incorporating the fifth
embodiment of the vertical joint system;
Figure 14a depicts a panel incorporating a sixth embodiment of the vertical
joint
system;
Figure 14b illustrates the engagement of two panels incorporating the sixth
embodiment of the vertical joint system;
Figure 15a depicts a panel incorporating a seventh embodiment of the vertical
joint
system;
Figure 15b illustrates the engagement of two panels incorporating the seventh
embodiment of the vertical joint system;
Figure 16a depicts a panel incorporating a eighth embodiment of the vertical
joint
system;
Figure 16b illustrates the engagement of two panels incorporating the eighth
embodiment of the vertical joint system;
Figure 17a depicts a panel incorporating a ninth embodiment of the vertical
joint
system;
Figure 17b illustrates the engagement of two panels incorporating the ninth
embodiment of the vertical joint system;
Figure 17c schematically illustrates panels of different thickness
incorporating the
ninth embodiment of the vertical joint system;
Figure 17d illustrates the engagement of two panels shown in Figure 17c;
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Figure 17e provides a series of representations of illustrating the engagement
of
separate pair of panels of varying thickness the incorporating the ninth
embodiment of the
vertical joint system
Figure 18a depicts a panel incorporating a tenth embodiment of the vertical
joint
system;
Figure 18b illustrates the engagement of two panels incorporating the tenth
embodiment of the vertical joint system;
Figure 19a depicts a panel incorporating a eleventh embodiment of the joint
system;
Figure 19b illustrates the engagement of two panels incorporating the eleventh
embodiment of the vertical joint system;
Figure 20a depicts a panel incorporating a twelfth embodiment of the vertical
joint
system;
Figure 20b illustrates the engagement of two panels incorporating the twelfth
embodiment of the vertical joint system;
Figure 21a depicts a panel incorporating a thirteenth embodiment of the
vertical
joint system;
Figure 21b illustrates the engagement of two panels incorporating the
thirteenth
embodiment of the vertical joint system;
Figure 22 illustrates the engagement of two panels incorporating a fifteenth
embodiment of the vertical joint system;
Figure 23a depicts a panel incorporating a fourteenth embodiment of the
vertical
joint system;
Figure 23b illustrates the engagement of two panels incorporating the
fourteenth
embodiment of the vertical joint system;
Figures 23c - 23i depict in sequence the engagement and disengagement of the
fourteenth embodiment of the vertical joint system when incorporating a re-
stickable
adhesive.
Figure 24a depicts a panel provided with incorporating any embodiment of the
vertical joint system with the addition of a re-stickable adhesive laid as
strips;
Figure 24b is a view of section AA of the panel shown in Figure 24a;
Figure 24c shows the panel of Figures 24a and 24b when adhered to an
underlying
supporting surface;
Figure 25a depicts a panel provided with any embodiment of the vertical joint
system with the addition of a re-stickable adhesive laid as beads;
Figure 25b shows the panel of Figure 25a when adhered to an underlying
supporting surface;
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Figures 26a-26e depict in sequence the removal of a panel of the type shown in
Figures 25a and 25b which is adhered to an underlying supporting;
and,
Figures 27a and 27b depicts a method of laying a floor using jointed panels.
Detailed Description of Specific Embodiments
Figures la - 2 illustrate a first embodiment of a vertical joint system 10
(hereinafter
referred to as "joint system 10") for a substrate. The substrate is shown in
cross section
view and in this embodiment is in the form of an elongated rectangular panel
12. The
substrate or panel 12 has opposed major first and second surfaces 14 and 16
respectively.
Each of the surfaces 14 and 16 are planar surfaces and lie parallel to each
other. In one
orientation the surface 14 is an exposed surface of the panel 12 while the
surface 16 bears
against a support surface or structure such as but not limited to a concrete,
timber, tile or
vinyl floor or timber battens. Joint system 10 comprises a first joint Jnn and
a non-
symmetrical second joint Jf. The first joint Jnn can be notionally considered
to be a male
joint while the second joint Jf can be notionally considered to be a female
joint. This
designation of the joints will be explained shortly.
Assuming the substrate to be in the shape of a quadrilateral the joint Jnn
extends
along two adjacent sides and Jf extend along the remaining two adjacent sides.
For
example when the substrate is an elongated rectangular floor board as shown in
Figures lb
and lc the joint Jnn extends along one longitudinal side and an adjacent
transverse side,
while the joint Jf extends along the other (i.e. opposite) longitudinal side
and the other (i.e.
opposite) adjacent transverse side.
Figure lb illustrates a first joint Jm of a first panel 12a engaged with a
second joint
Jf of a second panel 12b having an identical joint system 10. For ease of
description the
panels 12a and 12b will be referred to in general as "panels 12".
As will be explained in greater detail shortly, the first and second joints
Jnn and Jf
are configured to enable two panels 12 (i.e. panels 12a and 12b) to engage
each other in
response to a pressure or force F (see Figure 5) applied in an engagement
direction D which
is perpendicular to the major surfaces 14 and 16. When the panels 12 are floor
panels the
direction D lies in the vertical plane and more particularly is directed
downwardly toward a
surface on which the panels are laid. This is equivalent to the joints Jnn and
Jf engaging by
virtue of motion of one joint (or substrate) relative to another in a
direction perpendicular to a
plane containing the major surfaces.
The joint Jnn comprises a male protrusion Pm and a male recess Rm, while the
joint
Jf comprises a female protrusion Pf and a female recess Rf. The first joint
Jnn is notionally
designated as the male joint by virtue of its protrusion Pm depending from the
upper surface
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14. The second joint Jf is notionally designated as the female joint by virtue
of its recess Rf
being configured to receive the protrusion Pm.
When describing features or characteristic common to all protrusions the
protrusions will be referred to in general in this specification in the
singular as "protrusion P",
and in the plural as "protrusions P". When describing features or
characteristic common to
all recesses the recesses will be referred to in general in this specification
in the singular as
"recess R", and in the plural as "recesses R". When describing features or
characteristic
common to all joints the joints will be referred to in general in this
specification in the singular
as "joint J", and in the plural as "joints J".
The male joint Jnn has first, second and third male locking surfaces ML1, ML2
and
ML3 respectively (referred to in general as "male locking surfaces ML"). Each
of the male
locking surfaces ML extends continuously in the general direction
perpendicular to the major
surfaces. Similarly the female joint Jf has first, second and third female
locking surfaces
FL1, FL2 and FL3 respectively, (referred to in general as "female locking
surfaces FL").
The male and female locking surfaces collectively and generally are referred
to locking
surfaces L.
Each of the locking surfaces L extends continuously in the general direction
perpendicular to the major surfaces. The expression "extend continuously in
the general
direction perpendicular to the major surfaces" in the context of the male and
female locking
surfaces is intended to denote that the surfaces extend generally between the
opposite
major surfaces but continuously so that it extends in one direction only, i.e.
always in the
direction of the surface 14 to the surface 16 or vice versa and thus does not
return upon
itself as would be the case for example if the surface included a barb or hook
like structure.
The male locking surface ML1 extends from an edge of the major surface 14
adjacent the protrusion Pm and down the adjacent side of the protrusion Pm to
appoint prior
to the surface of the protrusion Pm turning through greater than 45 from the
perpendicular
to the major surface 14. It will be noted that the locking surface ML1 extends
continuously in
the general direction perpendicular to the major surface 14, without returning
upon itself.
Thus every point on the surface ML1 lies on a different horizontal plane. In
contrast, in the
event that a hook or barb like structure were provided then the corresponding
surface would
turn upon itself and a plane parallel to the major surface 14 would insect the
surface at three
different locations.
The male locking surface ML2 extends from the second major surface 16 up along
an adjacent side of the recess Rnn to a point prior to the deepest portion of
the recess Rnn
turning through more than 45 toward the protrusion Pm. Finally, the third
male surface ML3
extends along a shared or common surface between a protrusion Pm and Rnn and
denoted
by end points prior to the surface turning through more than 45 to the
perpendicular at the
deepest portion of the recess Rm, or the most distant portion of the
protrusion Pm.
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As will be explained shortly, the first and second male and female locking
surfaces
engage about respective locking planes inhibiting vertical separation of
engaged joints Jnn
and Jf. The third male and female locking planes ML3 and FL3 may also be
configured to
form a third locking plane. Also, the locking surfaces L in various
embodiments comprise
inflexion surfaces which in turn may comprise transverse outward extending
surfaces which
may take the form of convex or cam surfaces, or bulges. The relationship
between the
locking surfaces L, inflexion surfaces and transverse outward extending
surfaces will be
apparent in the following description.
Looking at the configuration of the first and second joints Jnn and Jf
(referred to in
general as "joints J") more closely, it will be seen that each of these joints
is provided with
two laterally spaced apart transversely outward extending surfaces or bulges.
The
transversely extending surfaces bulges may also be considered and termed as
"cam
surfaces" as they move across and in contact with each other and at times
often with a
rolling or pivoting action. The transversely extending surfaces are designated
as Cnn1 and
Cnn2 on the first joint Jnn and Cf1 and Cf2 on the joint Jf. In many
embodiments transversely
extending surfaces are smoothly curved convex surfaces. However as will be
apparent from
the following description is some embodiments the transversely extending
surfaces are of
other configurations. For example a transversely extending surface may be
generally
convex in that the surface is not continuously or smoothly curved for its
entire length but is
composed of one or more straight/planar surfaces. For ease of reference the
transversely
extending surfaces on the male joint Jnn will be referred to "surface Cnni"
where i = 1,2,3 and
similarly the transversely extending surfaces on the female joint Jf will be
referred to
"surface Cfi" where i = 1,2,3.
The surface Cnn1 is formed on a protrusion Pm of a first joint Jnn while the
surface
Cnn2 is formed in a recess Rnn of joint Jnn. Similarly the surface Cf2 is
formed on a
protrusion Pf on the joint Jf while the surface Cf1 is formed in a recess Rf
of the second joint
Jf. (For ease of description the surfaces Cnn2 and Cnn1 will be referred to in
general as"
surface Cm"; surfaces Cf1 and Cf2 will be referred to in general as "surface
Cf"; and
collectively the surfaces Cnn2, Cnn1, Cf1 and Cf2 will be referred to in
general as " surfaces
C").
Figure lb depicts the joints J in an engaged state. As is evident when the
joints J
are engaged their respective transversely extending surfaces are located
relative to each
other to form respective first and second locking planes 18 and 20 which
inhibit the
separation of the engaged joints in a direction opposite the engagement
direction D.
Each locking plane 18, 20 lies parallel to the engagement direction D. The
transversely extending surfaces Cnn1, Cf1, Cm2, Cf2 associated with each
locking plane
extend laterally toward each other from opposite sides of the locking plane
with the
transversely extending surfaces of the second or female joint (i.e. Cf1 and
Cf2) overhanging
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the transversely extending surfaces of the first or male joint (i.e. Cm1 and
Cm2). This
inhibits separation of the engaged joints Jm and Jf. It will also be noted
that at least one of
the transversely extending surfaces associated with each locking plane has a
curved profile.
In this instance the surface Cf1 associated with locking plane 18, and both
surfaces Cf2 and
Cnn2 associated with locking plane 20 have curved profiles.
During the engagement of the joints Jm and Jf the surfaces Cnn1 and Cnn2 pass
and snap over the surfaces Cf1 and Cf2. This action is enabled by one or both
of resilient
compression of the protrusions Pm and Pf and resilient tension in the recesses
Rnn and Rf
as the surfaces Cm pass the surfaces Cf in response to application of the
force F. Whether
there is one or both of resilient compression of the protrusions Pm and Pf and
resilient
tension in the recesses Rnn and Rf is dependent on the material from which the
panel 12 is
made. For example in the case of a panel made from a very stiff or hard
material such as
strand bamboo there would be very little compression of the protrusions P but
tension in the
recess R which results in its opening or widening would allow for the
engagement. The
ability for the protrusions P to enter the recesses R is assisted by the
provision of a lubricant
such as wax on the joints Jm and Jf. The provision of the lubricant and in
particular wax
also substantially eliminates joint noise and aids in the ability of adjacent
engaged joints J to
rotate relative to each other. This rotation motion is describe later in the
specification.
Horizontal separation between engaged joints Jm and Jf is inhibited by the
seating
of the protrusions P in the respective recesses R. The joints Jm and Jf are
also provided
with respective planar abutment surfaces 24 and 26. The surfaces 24 and 26
extend from
opposite edges of and perpendicular to the major surface 14. The respective
surfaces Cm
and Cf are configured to create lateral compression forces between the
surfaces 24 and 26
maintaining them in contact thus preventing the creation of a gap between
joined panels 12a
and 12b.
Accordingly as described above, the surfaces Cm and Cf co-operate to provide
both vertical and horizontal arrestment of panels 12a and 12b when the
respective joints Jnn
and Jf are engaged. However in addition to this the surfaces Cm and Cf enable
limited
relative rotation between panels 12a and 12b while maintaining engagement of
the panels
12. This is depicted in Figures 3a and 3b.
Figure 3a shows the panel 12a being rotated by +3 (3 in an anticlockwise
direction) relative to the panel 12b. The rotation is facilitated by pivoting
at an upper corner
of surface 24 on surface 26. This rotates the protrusion Pm within recess Rf
and causes the
surface cam Cnn2 to ride or roll up, but not past the apex of, the surface
Cf2. The projection
Pf is now effectively pinched between the surfaces Cnn2 and Cnn3. In this
configuration
vertical separation between the substrates 12a and 12b is inhibited by this
pinching effect as
well as due to the surface Cnn1 remaining below surface Cf1. Horizontal
arrestnnent is
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maintained by virtue of the projections Pm and Pf remaining within respective
recesses Rnn
and Rf.
With reference to Figure 3b, the panel 12a is rotated by -3 (3 in a
clockwise
direction) relative to panel 12b. This is facilitated by the surface Cnn2
rolling down and acting
as a pivot or fulcrum point against the side of Joint Jf containing the
surface Cnn2. This
causes separation of the surfaces 24 and 26 creating a gap at the upper major
surfaces 14.
Nevertheless the panels 12a and 12b remain vertically and horizontally
engaged. Vertical
arrestnnent between the substrates is maintained by engagement of the surfaces
Cnn2 and
Cf2; and surfaces Cm1 and Cf1. Horizontal arrestnnent is provided by the
projections Pm
and Pf being maintained in their recess Rf and Rm.
The relative rotation between the panel 12a and 12b is of great assistance in
the
installation of the substrates particularly on uneven surfaces such as an
undulating concrete
floor. This is of great importance to the "do-it-yourself" user although
benefits also flow
through to the professional layer. Consider for example an uneven undulating
surface on
which it is desired to lay a click type floor covering having say a prior art
joint system where
the tongue is inserted laterally or at an inclined angle into a groove or
recess. The
undulation may be in the form of a concave recess or shallow in a portion of
the surface
having a width several times greater than the width of the panels. Depending
on the degree
or slope of the concavity it may be extremely difficult if not impossible to
insert a tongue of a
"to be" installed panel into the groove of a previously laid panel. This
arises because the two
panels do not and will not lie in the same plane, but rather are angled
relative to each other
due to the concavity.
Additionally, when installing floor boards of a length of about lm or longer
on an
uneven surface, banana-ing or lateral bowing occurs of the previously
installed floor board
by virtue of an installer kneeling on it when trying to lay the next floor
board. The kneeled on
board will bow under the weight of the installer due to the uneven underlying
surface. This
effect is depicted in Figures 4a to 4d. Figures 4a and 4b show lateral bowing
of a panel 12x
outwardly when the uneven surface is a fall or hollow. Figures 4c and 4d show
lateral
inward bowing of a panel 12x when the uneven surface is a hump. It will be
appreciated that
this bowing makes it very difficult to get full longitudinal engagement with
an adjacent panel
without gapping. In these circumstances, even professional installers have
difficulty in laying
the floor and will need to rely on substantial physical exertion and
experience. The do-it-
yourself installer will often give up and either returns the flooring to the
retailer on the basis
that it does not "click" together or end up paying for a profession installer.
To provide perspective of the effect of the relative rotation capabilities of
the joint
system 10 in comparison to the prior art reference made to Figures 4e to 4h.
Conventional
flooring systems are able to accommodate a concavity or a hump in an
underlying substrate
for example a concrete floor of 3 ¨ 5nnnn over a length of lm, being the
industry standard.
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Undulations greater than this either prohibit the use of many prior art
systems or at least
make them very difficult to install. Assuming that they can be installed the
undulation can
subsequently cause prior art joint systems to disengage horizontally and thus
gap
excessively. Specifically in the event that the undulation is in the form of a
hump or
undulation there is the possibility of either total horizontal separation
between the adjacent
panels and/or splitting or shearing of the joints. In the event that the
undulation is a
concavity prior art joints are liable to shear or break due to excessive
tensile force being
applied to the joints.
In Figures 4e to 4h (which are schematic only and not drawn to scale) the 3 ¨
5nnnn
surface undulation which can be accommodated by the prior art system is shown
as shaded
area 30. Figures 4e and 4f represent an undulation in the form of a rise or
hump of 3-5mm,
whereas Figures 4g and 4h represent an undulation in the form of a fall or
hollow of 3-5mm.
In comparison the + or¨ 3 rotation available by embodiments of the joint
system 10 over a
lm length provide a total possible displacement of 52nnnn. The +3 rotation is
illustrated in
Figures 4e and 4f, while the ¨ 3 rotation is illustrated in Figures 4g and
4h.This enables
substrates utilising embodiments of the joint system 10 to be successfully
laid on floors
without horizontal disengagement or separation where the floor may have for
example a
concave undulation which over a distance of one metre drops by 52nnnn below
adjacent
planar surface portion of the floor. Maintaining horizontal engagement
maintains the
structural integrity of the floor. This is beneficial in terms of the
appearance of the floor which
in turn can add value to an associated house.
It will be recognised by those skilled in the art that this enables the laying
of a
flooring system incorporating the embodiments of the current joint system on
substrates that
fall outside of 3 ¨ 5nnnn undulation over a length of lm dictated by the world
industry
standards. This has significant practical and commercial benefits. The
practical benefits are
that the flooring will be able to be successfully and easily laid by do-it
¨yourself installers and
professional installer on substrates that hitherto were unsuitable for
conventional click type
flooring. The commercial benefit is that because the flooring systems can be
laid they are
not returned to the point of sale by disgruntled and frustrated installers
requesting a refund
for a system that, in their eye, does not work. The conventional systems will
work if the
substrate is within the narrow band prescribed as the world industry standard.
But the
installer is usually unaware of the standard and in any event has not idea as
to whether or
not their substrate complies. This is not an issue with embodiments of the
present invention
as it is able to be installed without separation on substrates that fall
outside of the world
industry standards.
Returning to Figures 1 and 2, it can be seen that the surfaces Cm and Cf
constitute
portions of respective inflexion surfaces, which in turn form portions of
respective locking
surfaces L. Specifically, the surface Cnn1 constitutes a part of an inflexion
surface Im1
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(indicated by a phantom line) which in turn forms part of first male locking
surface ML1
(indicated by broken dot line) of the protrusion Pm. The inflexion surface
Innl extends
generally in the direction D from the abutment surface 24.
Similarly surface Cm2 constitutes a portion of inflexion surface Im2
(indicated by a
phantom line) which in turn forms part of second male locking surface ML2
(indicated by
broken dot line). Surface ML2 is formed on the surface of recess Rnn and
depends generally
in the direction D from near a root 32 of the recess Rm.
The surface Cf2 constitutes part of an inflexion surface If2 (indicated by a
phantom
line) which in turn forms part of second female locking surface FL2 (indicated
by broken dot
line) formed on an outer most side of the projection Pf and extending
generally in the
direction parallel to the direction D.
The surface Cfl constitutes part of the inflexion surface Ifl (indicated by a
phantom
line) which in turn forms part of first female locking surface FL1 (indicated
by broken dot
line). Surface FL1 depends from abutment surface 26 and in a direction
generally parallel to
direction D and toward a root 34 of the recess Rf.
Looking at Figure lb, it will be seen that the surfaces Cm1,Innl and ML1
engage
the surfaces Cfl, Ifl and FL1 respectively; and the surfaces Cm2, Im2 and ML2
engage the
surfaces Cf2, If2 and FL2 when the joints Jm and Jf are engaged. The
engagement of these
surfaces forms or create the first and second locking planes 18, 20. Different
portions of the
locking L, inflexion I and transversely extending surfaces C operate as
arresting and rolling
surfaces during various stages of engaging and disengaging of the joints Jnn
and Jf.
To provide the rolling action between adjacent engaged substrates at least one
of
the surfaces C and indeed one of inflexion surfaces I in each pair of engaged
or related
surfaces is formed with a profile of a continuous or smooth curve. For example
consider the
surfaces Cml and Cfl and corresponding inflexion surfaces Innl and Ifl. When
the joints
Jnn and Jf are engaged, surfaces Cml and Cfl are located about or adjacent the
first locking
plane 18; as are corresponding inflexion surfaces Iml and Ifl. In this
instance the surface
Cfl and the corresponding inflexion surface Ifl has a profile of a continuous
or smooth
curve. However the surface Cml and corresponding inflexion surface Innl has a
profile
which comprises a straight line 36. The straight line is relatively short and
forms a small
ridge or peak 38 on the surface Cml and inflexion surfaces Innl. The ridge 38
presents a
relatively small contact area against the inflexion surface Ifl minimising the
friction between
the surfaces and the possibility of sticking during relative rotational
motion.
In contrast, the surfaces Cm2 and Cf2; and corresponding inflexion surfaces
Im2
and If2 which are located about and form the second locking plane 20 each have
a profile of
a continuous curve. However other embodiments will be described later in which
one of the
surfaces Cm2/1m2 or Cf2/1f2 has a profile comprising one or more straight
lines.
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The first and second male locking surfaces ML1 and ML2, and indeed the
associated surfaces Cnn1 and Cnn2 and corresponding inflexion surfaces Inn1
and Im2
constitute the extreme (i.e. inner most and outer most) transversely extending
and inflexion
surfaces of the first (male) joint Jnn. The first and second female locking
surfaces FL1 and
FL2, and indeed the associated surfaces Cf1 and Cf2 and inflexion surfaces If1
and If2
constitute the extreme transversely extending and inflexion surfaces of the
second (female)
joint Jf. These extreme transversely extending and inflexion surfaces form
respective
surface pairs which create the extreme (i.e. inner most and outer most)
locking planes 18
and 20 in mutually engaged joints Jm and Jf. This is clearly evident from
Figure lb.
Specifically the surface pairs are in this embodiment: Inn1 and If1, or Cnn1
and Cf1; and, Im2
and If2, or Cm2 and Cf2. The above described relative rotation between panels
incorporating embodiments of the joint system 10 is facilitated by forming one
surface in
each of the surface pairs as a smoothly or continuously curved surface.
The surfaces Cnn1 and Inn1 form part of an outer peripheral surface 40 of the
protrusion Pm. The protrusion Pm has a generally ball like or bulbous profile
which depends
in the direction D from major surface 14. The outer surface 40 after the
inflexion surface Inn1
curves toward the recess Rm. The surface 40 is provided with a recess 42 at a
location
most distant the major surface 14. As shown in Figure lb, when the joints Jnn
and Jf are
engaged the recess 42 forms a reservoir 44 against a lower most portion of
surface 46 of the
recess Rf. Save for the recess 42 the end of the protrusion Pm facing the
bottom of recess
Rf1 is rounded or curved. The first male locking surface ML1 comprises the
combination of
surface 24 and the inflexion surface Inn1.
The recess 42 and corresponding reservoir 44 may be used for various different
purposes. These include but are not limited to receiving adhesive and/or
sealing compound;
acting as a reservoir for debris which may have fallen into the recess Rf
during installation,
or both.. In this regard the recess 42 faces a lowest part of the surface 46
in the recess Rf.
It is expected that most debris falling into the recess Rf will collect at the
lowest point on the
surface 46. As the joints Jnn and Jf are engaged by a vertical motion a
substantial
proportion of any debris is likely to be captured in the subsequently created
reservoir 44. In
the absence of such a feature, it may be necessary to clean the recess Rf for
example by
blowing with compressed air, use of a vacuum or a broom to remove debris which
may
otherwise interfere with the engagement process. The recess 42/reservoir 44
can also
accommodate expansion and contraction in the joints J.
The surface 40 after the recess 42 curves around to the recess Rm and
incorporates a further inflexion surface Im3. The inflexion surface Im3 is a
"shared" surface
between the protrusion Pm and recess Rm and includes a surface Cnn3. The
surface Cnn3
transitions the surface 40 from a generally horizontal disposition to a
generally vertical
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disposition. The third male locking surface ML3 is substantially co-extensive
with the
inflexion surface Im3.
It will be noted that the protrusion Pm is formed with a neck 48 having a
reduced
width in comparison to other portions of the protrusion Pm. It will be seen
that the surface
Cnn1 is adjacent an outer most side of the neck 48. Moreover, a portion of the
inflexion
surface Im1 adjacent the abutment surface 24 forms the outer most side of the
neck 48.
Further, a portion of the inflexion surface Im3 forms the opposite side of
neck 48. In this
embodiment a line 50 of shortest distance across the neck 48 is inclined
relative to the major
surface 14.
The inflexion surface Im3 leads to surface 52 formed in the root 32 of the
recess
Rm. The surface 52 curves around to meet with and join inflexion surface Im2.
The surface
Im2 extends generally in the direction D leading to a surface 54 which extends
perpendicular
to the major surfaces 14 and 16 and subsequently to a bevelled surface 56
which leads to
the major surface 16. The second male locking surface extends from above the
inflexion
surface Im2 and along the bevelled surface 56 to the major surface 16.
Looking at the configuration of the joint Jf on an opposite side of panel 12,
it can be
seen that the surface Cf1 and corresponding inflexion surface If1 extend
generally in the
direction D from the abutment surface 26. The first female locking surface FL1
comprises
the combination of surfaces 26 and If1. The inflexion surface If1 leads to the
surface 46 at
the root 34 of recess Rf. The surface 46 forms a vertical arrestnnent surface
for the
protrusion Pm. Moreover the surface 46 includes a centrally located
substantially horizontal
land 58 which faces the recess 42 when the joint Jim is inserted in the joint
Jf. The land 58
lies substantially parallel to the major surfaces 14 and 16. Moving in a
direction toward the
protrusion Pf, the surface 46 leads to and incorporates a further inflexion
surface If3 and
corresponding co-extensive third female locking surface FL3. The surfaces If3
and FL3 are
shared surfaces between recess Rf and protrusion Pf and extends in a direction
generally
opposite the direction D.
The inflexion surface If3 leads to an upper arcuate surface portion 60 of the
projection Pf which in turn leads to the surface Cf2 and inflexion surface
If2. The inflexion
surface If2 leads to the planar surface 62 that extends perpendicular to the
major surfaces
14 and 16. This surface in turn leads to inclined surface 64 in turn leads to
the major
surface 16. The second female locking surface comprises the combination of
surfaces If2,
62 and 64.
The recess Rf is configured to receive the protrusion Pm. Moreover, the recess
Rf
is formed with a neck 66. The neck forms a restricted opening into the recess
Rf. A line 68
of shortest distance across the neck 66 is in this embodiment inclined
relative to the major
surfaces 14 and 16. More particularly, the line 66 is inclined at
substantially the same angle
as the line 50.
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The protrusion Pf like protrusion Pm is of a ball like or bulbous
configuration.
Further, similar to the protrusion Pm, the protrusion Pf is formed with a neck
70 of reduced
width. A line 72 of shortest distance across the neck 70 is inclined to the
major surfaces 14
and 16. However in this embodiment the line 70 is inclined at a different
angle to the lines
50 and 68.
With reference again to Figure lb, it is also seen that the shared locking and
inflexion surfaces ML3 and FL3; and Im3 and If3 respectively, and indeed their
corresponding surfaces Cnn3 and Cf3 are located relative to each other to form
a third
locking plane 74 along which separation of the engaged joints J is inhibited.
The third
locking plane 74 is parallel with and between the inner and outer most locking
planes 18 and
20.
The joints Jm and Jf are based in part on anatomical joints of the human body
and
in particular the hip joint and shoulder joint. These joints Jm and Jf are
designed to provide
horizontal and vertical strength and allow relative rotational motion to a
limited extent without
disengagement. In effect the joints Jm and Jf can be considered as ball and
socket type
joints. The comparison with anatomical joints is enhanced in some embodiments
described
hereinafter which include a re-stickable flexible, elastic and non curing or
non-solidifying
adhesive acting between the joints Jm and JF. In such embodiments the adhesive
acts in a
manner akin to both a tendon allowing relative motion but maintaining
connection, and as
cartilage providing a cushioning effect. Also when wax is provided on the
joints can act as a
fluid in the joint providing lubrication.
It is further evident from Figure lb that due to their non-symmetrical nature
the
joints Jm and Jf are relatively configured so that when they are engaged
several spaces or
gaps are formed between the engaged joints. A space 76 is formed immediately
below the
abutment surfaces 24 and 26 and opposite the surface Cf1. The space 76 may
also be
described as being a space formed between respective upper portions of the
inflexion
surfaces Inn1 and If1. Space 78 is formed between lower parts of inflexion
surfaces Inn1 and
If1. A generally vertically extending space 80 is formed between the shared
inflexion
surfaces Im3 and If3; and a generally horizontal space 82 is formed between
the root 32 of
recess Rnn and arcuate surface portion 60 of the projection Pf. The spaces
allow thermal
expansion and contraction of the panels 12 without dislocation or fracturing
of the joints Jm
and Jf as well as assisting in the relative rotation of the panels 12.
The engagement and disengagement of the joints Jm and Jf will now be described
in detail with reference to Figures 5a ¨ 9f.
Figure 5a depicts a first panel 12a which has already been laid and a second
panel
12b which is in the process of being laid. The panels 12a and 12b are
supported on an
underlying horizontal surface 90. Panel 12a has a joint Jf which is open and
ready for
connection with the joint Jm of panel 12b. Panel 12b is laid adjacent panel
12a with the joint
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Jnn resting on the joint Jf. The edge of panel 12b provided with the joint Jf
is simply resting
on the surface 90 so that there is a small angle of approximately 1 -3
between the panels
12a and 12b.
From Figure 5b it will be seen that in this position surfaces Cnn1 and Cnn3
rest on
the surfaces Cf1 and Cf3 respectively while the surfaces Cnn2 and Cf2 are
vertically
separated. In this configuration upper portions of the surfaces Cf1 and Cf3
may be
considered as cam arresters in that they prohibit the entry of the projection
Pm into the
recess Rf.
In order to commence engagement of the surfaces Jnn and Jf a downward pressure
or force F is applied in the direction perpendicular to the major surfaces 14
and directed
toward the underlying surface 90. This pressure or force applies compression
to the
protrusion Pm and tension the recess Rf which depending on the material from
which the
panels 12 are made will result in one or both of the protrusion Pm compressing
and the
recess Rf opening or widening so that the surfaces Cnn1 and Cnn3 can slide
past the
surfaces Cf1 and Cf3. Again the provision of wax on the joints Jm and Jf
assist this sliding
action. This results in the protrusion Pm sliding through the neck 66 into
recess Rf. The
opening the recesses Rm and Rf generates stress in the joints shown by lines T
in Figure
5c. This stress is about the curvature at opposite ends of the root of each
recess Rf and
Rm. The stress is released as the protrusions Pm and Pf pass through the necks
of the
recesses Rf and Rm providing a spring action closing the recesses onto the
protrusions and
drawing the protrusions into the recesses. Thus the recesses are able to
elastically open
and subsequently self close. This action occurs with the other embodiments of
the joint
system described later in the specification.
The joints in this embodiment are configured so that the respective surfaces
Cm
and Cf which pass each other do so at slightly different times. In this
particular embodiment
the surface Cnn1 passes the surface Cf1 marginally before the surface Cnn3
passes the
surface Cf3. Once the surfaces Cnn1, Cnn3 pass surfaces Cf1, Cf3 the remainder
of
protrusion Pm is drawn into the recess Rf by an over centre or snap action.
This is due to
the relative configuration of the inflexion surfaces and the release of
compression in the
protrusion Pm after the surfaces Cnn1 and Cnn3 pass through the surfaces Cf1
and Cf3. In
effect the respective necks 48 and 66 lay one within the other.
Simultaneously with this action occurring, a similar action is occurring in
relation to
the protrusion Pf and the recess Rm. The surface Cnn2 passes the surface Cf2
marginally
after passing of the surfaces Cnn3 and Cf3. This is depicted in Figure 5c. As
the recess Rm
is pushed onto the protrusion Pf, by action of the downward pressure or force
F, the
protrusion Pf is compressed between the surfaces Cf3 and Cf2. After these
surfaces pass
the surfaces Cnn3 and Cnn2 the recess Rf is drawn onto the protrusion Pf by an
over centre
or snap action.
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While the joints J are engage by application of pressure or force in a
vertical
direction (i.e. perpendicular the major surfaces 14, 16) the relative motion
between the joints
J is not solely vertical. Rather there is a combined vertical motion with
lateral displacement.
With reference to Figures 5b-5e and the joint Jnn, this lateral motion is
motion of the joint Jnn
is to the left and is highlighted by the closing in the horizontal gap or
separation G of the
surface 24 and 26 during the engagement process. The horizontal gap G reduces
from a
maximum gap G1 in Figure 5b to progressively smaller gaps G2 and G3 and
finally to a zero
gap G4 in figure 5e in which case there is face to face contact between
surfaces 24 and 26,
when the joints Jnn and Jf are fully engaged. Which of the joints Jnn and Jf
laterally move is
1(:) just dependant on which one is least constrained from lateral motion.
Indeed both could
move laterally toward each other to equal or different degree. This lateral
motion is
symptomatic of the vertical stability of the engaged joint system
Figure 5d illustrates the joints Jnn and Jf marginally before full engagement.
Here it
can be seen that there is a small gap between the bottom of projection Pm and
the recess
Rf and that the major surface 14 of panel 12b is marginally raised relative to
the major
surface 14 on the panel 12a. The relative downward motion of the panel 12b is
halted and
the joint fully engaged when the projection Pm hits the arrestnnent surface 58
on the recess
Rf, as shown in Figure 5e. In this configuration the reservoir 46 is formed
between the
recess 42 and the arrestnnent surface 58. In this configuration the surfaces
Cm1, Cnn2, Cnn3
on the male joint Jnn lay underneath the corresponding surfaces Cf1, Cf2, Cf3
on the female
joint.
The aforementioned mentioned ability for the joints Jnn and Jf to enable both
positive and negative relative rotation without disengagement is able to
accommodate for
uneven surfaces. Additionally the joints Jnn and Jf facilitate self alignment
of adjacent panels
12. These features substantially simplify the installation to the extent that
a very average
home handyperson can easily install panel incorporating embodiments of the
joint system
10.
The self aligning aspect of the system 10 arises from the shape and
configuration of
the joints Jf and Jnn and is explained with reference to Figures 5b, and 5f ¨
5k.
Figure 5f shows a panel 12b being roughly positioned for subsequent engagement
with panel 12a and prior to the application of any downward force or pressure
to engage the
panels. The panels 12a and 12b are skewed relative to each other. At one end
85 the
protrusion Pm sits on top of recess Rf. The corresponding view in cross
section is as shown
in Figures 5b and 5j with the joint Jnn of panel 12b lying on top of the
recess Rf of panel 12a.
At the opposite end 87 the joints are laterally spaced apart. In between, the
degree of
separation between joints Jnn and Jf varies linearly. So at location AA joints
Jm and Jf are in
contact but protrusion Pm partially rests on protrusion Pf and partially
overlies recess Rf and
the panels separated by a distance X1 shown in Figure Si. While at a further
location BB
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along the panels the protrusion Pm lies directly above and on protrusion Pf
and the panels
are separated by a larger distance X2 shown in Figure 5h.
Now a downward pressure or force F is applied at a location between locations
85
and BB to commence engaging the joints and panels. This force is transmitted
between the
Consequently the force F when transmitted to the contacting surfaces of joints
Jnn
and Jf will initially resolve into components which include a lateral
(transverse) component
acting to urge the joint Jf into the recess and thus the panel 12b toward the
panel 12a.
Accordingly the distance between the panels at end 87 closes. As the location
of the
application of the force is advanced along the panel 12b toward end 87 the
this closing effect
It should also be understood that floors are often under dynamic tensile and
compressive load due to variations in temperature and humidity. They are also
under static
load from furniture or other household items. Should the tensile load exceed
the load
carrying capacity of the joints one or both of the protrusions Pm and Pf may
fracture or
Once this tension has been released it can be extremely difficult if not
virtually
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The release in tension, subsequent movement of panels and self re-tensioning
is
described in greater detail in Figures 51¨ 5u. Figure 51 illustrates a floor
composed of
plurality of panels 12. Two of the panels 12a and 12b are being removed and
replaced.
Assume that there is tension between the panels 12 as described in the
preceding
paragraph. Once the two panels 12a and 12b are removed leaving a gap 31 there
is
naturally a release of tension in the floor in the area of the gap 31.
Consequently, panels 12
adjacent the gap will shift away from each other as shown by the arrows 33 in
Figure 5m.
The effect of this is to produce a widening of the gap 31. This widening is
illustrated in
Figure 5n, and in enlarged view in Figure 5o, and occurs as an additional
longitudinal band
35 along a line of abutment which previously existed between panels 12a and
12b prior to
their removal. This widening does not only occur within the gap 31.There will
also be a
separation or at least an increase in tension between remaining adjacent
panels along a
continuation of the band 35 as there are now fewer panels to accommodate the
tension.
Figure 5p and corresponding enlarged view of Figure 5q illustrate the effect
of replacing the
panels with panels having conventional lay down or horizontal locking systems.
New panels
12a1 and 12b1 are inserted into the gap 31 and engaged with adjacent panels on
either
side. However due to the widening of the gap 31, the new installed panels 12a1
and 12b1
cannot be fully engaged with each other. The widening may only be in the order
of 0.5 to
2nnnn but this is sufficient to be easily visible on a floor.
Ordinarily, in the case for example of a tongue and groove type locking
system, the
tongue will have been sawn off so that there is no mechanical joining between
the panels
12a1 and 12b1. A filler will be used to fill the band 35 between the panels
12a1 and 12b1.
Significantly the filler is unable to transfer tension across the panels 12a1
and 12b1.
Consequently, it is not possible to reinstate the tension within the floor as
a whole. Now
tension within the floor will act on opposite sides of the filler and the band
35. In time this is
likely to lead to the fracturing of the filler and the creation of a new gap
37 shown in Figure 5r
and corresponding enlarged view Figure 5s between the panels 12a1 and 12b1.
Figure 5t and enlarged view Figure 5u shows the result in using panels or
substrates incorporating joint systems in accordance with embodiments of the
present
invention. That is assume all of the panels 12 in Figs 51-5s are provided with
say joint
system 10. When panels 12a and 12b are removed there is still a widening of
gap 31 by
creation of band 35. New panel 12a1 is installed and engaged with panels 12c
and 12d.
Now panel 12b1 is inserted with say its female joint Jf beneath the male joint
Jnn of panel
12a1 and the male joint Jnn of panel 12b1 lying on top of the female joint Jf
of adjacent
panels 12e and 12f.
Applying downward pressure on the male joint of panel 12a1 where it overlies
joint
Jf of panel 12b1. This results in these joints and corresponding panels
engaging. This will
cause a slight motion of the panel 12b1 away from panels 12e and 12f. However
this motion
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does not cause a separation greater than the distance X2 shown in Figure 5h.
By now
applying downward pressure on the male joint Jnn of panel 12b1, the panels
12b1 and 12e
and 12f are pulled toward each other. Moreover the panels on either side of an
interface 39
between panels 12a1 and 12b1 are pulled inwardly toward each other as shown by
the
arrows 33 in Figures 5f and 5u. Further the joints Jnn and Jf of panels 12b1;
and, 12e and
12f are engaged and the entirety of the floor thus re-tensioned and structural
integrity re-
instated. .
The above describes the situation where the floor is under tension. But
equally
problems arise in prior art systems when a floor in under compression in which
case there
can be a closing in the gap 31. With the prior art systems one must cut the
panels to reduce
their width to fit in the closed gap. Consequently there will be no full
mechanical joint
between the newly installed panels and the existing panels. The structural
integrity is lost.
Embodiments of the present invention can operate in essentially the same
manner as
described above with reference to Figures 5I-5u but in "reverse" to push the
gap open and
mechanically engage all adjacent panels 12 to reinstate full structural
integrity. Again this
will be effective for gap of up to about the lateral extend of surface Cf1
which may range to
about 2nnnn.
The above self aligning and "zipper" effects also apply when a panel is warped
or
twisted about its length. . Embodiments of the joint system enable a warped
panel to be
aligned and pulled in having the effect of flattening the warp or twist in the
panel provided
the panel to which it is being engaged is flat and not itself warped or
twisted.
When engaging the joints Jnn and Jf downward pressure can be applied by a
person of a weight of about 70 kilograms or more traversing the joints Jnn a
small hopping or
one legged jumping or small stomping motion. In this way joining of adjacent
panels 12 can
be achieved without the need to constantly kneel and stand as is required with
prior art
systems. The engagement of joint Jnn into joint Jf may also be aided by light
tapping with a
rubber mallet M. The ease of installation not only widely expands the range of
do-it-yourself
installers by reducing the skill and strength level required it also has
significant benefits to all
installer including professionals by way of minimising physical stress and
exertion. For an
employer or installation company this reduces injury and sick leave to
workers.
Consequently workers are able to work longer and have increased income and
insurance
premiums for and compensation claims against the employer can be reduced.
When panels12 with the joint system 10 are used in large area such as for
example
in commercial premises a modified compactor can be used to apply the force or
pressure to
engage the joints Jnn and Jf. The compactor is envisaged as being in the form
similar to
those used for compacting sand prior to laying pavers, but having a soft
smooth non scratch
base lining. The lining may comprise but is not limited to a rubber, foam,
felt, or cardboard
sheet.
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The process of removal of a damaged panel will now be described with
particular
reference to Figures 6a ¨ 9f. As will become evident from the following
description the
removal process of a damaged panel relies on the relative rotation enabled
between the
joined panels by virtue of the configuration of the joint system 10. Figures
6a ¨ 6s depict in
sequence various steps in the removal and replacement of a damaged panel. The
removal
and replacement is facilitated by use of an extraction system which comprises
in
combination a jack 92 shown in Figures 7a and 7b and a wedge tool 94 shown in
Figures 8a
and 8b.
The jack 92 is a simple hand screw jack which is applied to a panel being
removed.
The screw jack 92 is provided with an elongated threaded shaft 96 provided at
one end with
a cross bar handle 98. The thread of the shank 96 is engaged within a threaded
boss 100
formed on a clamp plate 102. The plate 102 is of a square shape with the boss
100 located
centrally in the plate 102. The boss 100 overlies a through hole in the plate
102 through
which the shaft 96 can extend. Distributed about the plate 102 are four
through holes 104
for receiving respective fastening screws 106.
The wedge tool 94 comprises a wedging block 108 coupled at one end to a handle
110. The wedging block 108 is formed with a base surface 112 which in use will
bear
against a surface on which the panels 12 are installed, and an opposite
surface 114 which
lies beneath and contacts a major surface 16 of the panel 12 adjacent the
panel being
removed. The surface 114 includes the relatively inclined portion 116 and a
parallel land
118. The inclined portion 116 extends from a leading edge 120 of the wedge
block 108
toward the handle 110. The surface 116 is inclined relative to the surface
112, while land
118 lies parallel to the surface 112 and is formed contiguously with the
surface 116. The
handle 110 is bent so that a free end 122 of the handle 110 lies parallel with
but laterally
displaced from a distal end 124 which is connected with the wedge block108.
Figure 6a depicts an area of flooring including a damaged panel 12b which is
connected along each side with adjacent panels 12. For the purpose of
describing the
method of replacing the damaged panel 12b reference will be made only to two
of the
connected panels 12a and 12c which engage along opposite longitudinal sides of
the panel
12b. The three side by side interlocked panels 12a, 12b and 12c are each
provided with an
embodiment of the joint system 10 and cover a surface 90 as shown in Figure
6b. The
central panel 12b has a major surface 14 which is damaged by virtue of a
scratch, gash or
water damage 126. It should also be understood that unless one of panels 12a
or 12c is
immediately adjacent a wall then other panels 12 will be interlocked with each
of panels 12a
and 12c.
In order to replace the damaged panel 12b, a drill 130 (see Figure 6d) is used
to
drill a hole 128 through the panel 12b for each jack 92 used in the extraction
process. The
hole 128 is formed of a diameter sufficient to enable the passage of shank 96.
The length of
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the panel 12b being removed dictates the number of jacks 92 that may be
required. Thus in
some instances, extraction can be effected by the use of one jack 92 whereas
others may
require two or more jacks. In this particular instance two jacks 92 are used
as shown in
Figure 6c, but for ease of description the extraction process refers to only
one of the jacks
92.
Upon completion of the hole 128, the clamp plate 102 is placed on the panel
12b
with its boss 100 overlying the hole 128hole as shown in Figure 6e. The plate
102 is fixed to
the panel 12b by way of the four self tapping screws 106 that pass through
corresponding
holes 104. This is illustrated in Figure 6f. The screws may be screwed in by a
DIY battery
operated screw driver or using a manual screwdriver.
The next stage in the removal process is shown in Figures 6g and 6h involves
engaging the shank 96 with the threaded boss 100 and then screwing down the
shaft 96 by
use of the handle 98 to lift the panel 12b above the surface 90. It should be
immediately
recognised that this action requires the relative rotation of the joints Jrn
and Jf of panel 12b
while maintaining their engagement with the joints of adjacent panels 12a and
12c. This
rotation is a relative negative rotation as will be explained shortly. However
simultaneously
there is also a positive rotation of the joints between the panels engaged on
either side of
panels 12a and 12c opposite the panel 12b.
The jack 92 is operated to lift the damaged panel 12b vertically upward by a
distance sufficient to effect a negative rotation between the damaged panel
12b and the
adjacent adjoining panels 12a and 12c. The negative rotation is in the order
of 7 ¨ 100
.
This is explained with particular reference to Figure 6h which shows an angle
01 between
the major surfaces 14 of panels 12a and 12b; and an angle 02 between major
surfaces 14 of
panels 12b and 12c. Prior to lifting of the panel 12d, it should be understood
that the angles
01 and 02 will be 180 assuming that the surface 90 is flat. Formation of a
negative angle
between adjoined panels 12 is indicative of the angle 01 exceeding 180 . The
amount by
which the angles 01 and 02 exceed 180 during the disengagement is equated to
the
negative rotation of the panels during this process. For example if angle 01
is say 187 then
the relative negative rotation between panels 12a and 12b is 7 .
It will be understood by those skilled in the art that vertically raising of
any prior art
system having a lateral projection (e.g. a tongue) that seats in a groove or
recess of an
adjacent panel is virtually impossible without breaking the tongue or
fracturing the panel with
the groove. Thus this action if attempted with a prior art system is very
likely to result in the
damaging of one more panels which were not previously damaged or in need of
replacement.
The ability for the panels incorporating embodiments of the present joint
system to
be removed by vertical lifting is a direct result and consequence of the joint
system. This
provides a lay¨down disengagement process of panels being directly opposite to
the prior
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art which requires a lay-up disengagement process. As a consequence of the
joint system
and the ability to disengage without damaging adjacent panels by vertical
lifting, repair of a
floor can be achieved in a world's best practice manner fully reinstating the
integrity of the
floor without the need to peel back the entire floor from one wall to the
damaged area,
and/or engaging a professional installer.
The jack 92 mechanically lifts and self supports the panel 12b, panels 12a,
12c and
panels adjacent to panels 12a and 12c. Thus the installer does not need to
rely on their own
strength to lift and hold the panels. In contrast some prior art systems use
suction cups for
example as used by glaziers to hold glass sheets to grip a panel to be
removed. The
installer must then use their strength to lift the panel. While this is
difficult enough it
becomes impossible if the panel is also glued to the surface 90. The jack 92
which provides
a mechanical advantage is able to operate in these circumstances. In addition
as the jack
self supports the panels 12 the installer is free to use both hands in the
repair process and
indeed is free to walk away from the immediate vicinity of the pane112b.
The jack 92 is operated to lift the panel 12b vertically upwards to a location
where
the negative rotation between the panel 12b and adjacent panels 12a and 12c is
in the order
of 7 to 10 . This is the position shown in Figure 6h and 9d. In this
position, there is partial
dislocation of the joints Jnn and Jf between panels 12a and 12b. This partial
dislocation
arises from the surface Cnn1 rolling over surface Cf1 with the surface 38
snapping past the
apex of surface Cf1 and is denoted by an audible "clunk". Notwithstanding this
dislocation
the panels remain engaged due to the pinching of protrusion Pf between
surfaces Cnn2 and
Cnn3.
The jack 92 can be provided with a scale to give an installer an indication of
the
when the negative rotation is in the order of 7 to 10 . The scale could
comprise for example
a coloured band on the shank 96 which becomes visible above the boss 100 when
shank
has been screwed down to lift the panel sufficiently to create the above
mentioned negative
rotation. Several bands could be provided on the shank for panels of different
thickness.
In order disengage panel 12b one must first disengage whichever of the panels
12a
or 12c has its female joint Jf engaged with panel 12b. In this instance this
is panel 12a.
Working above the panels 12 an installer will not immediately know that it is
panel 12a. But
this can be easily determined by either: lightly tapping on both panels 12a
and 12c; or,
applying light hand pressure and feeling for joint movement. Due to the
orientation of the
joints this tapping will result in panel 12a fully disengaging in the vicinity
of the tapping.
Thereafter as shown in Figure 6i, applying a downward force or pressure on the
panel 12a at
other locations along its length will result in a total disengagement of
joints Jnn and Jf on the
panels 12a and 12b.
The interaction between the respective surfaces on the joints Jnn and Jf on
the
panels 12a and 12b from the position where the panels are fully engaged and
lie on the
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same plane as shown in Figure 6f to the point of disengagement shown in Figure
6h will be
described in more detail with reference to Figures 9a ¨ 9e.
Figure 9a illustrates the panels 12a and 12b prior to operation of the jack
92. This
equates the relative juxtaposition of the panels shown in Figures 6a, 6b, and
6d-6g. As the
jack 92 is operated to progressively lift the panel 12b from the surface 90,
there is a gradual
rotation between the respective joints Jm and Jf. Figure 9b illustrates the
joint Jnn of panel
12b and joint Jf of panel 12a at relative rotation of approximately -2 . Here
the abutment
surfaces 24 and 26 commence to separate with the surface Cnn1 and in
particular the ridge
38 commencing to ride up the surface Cf1. Simultaneously the surface 40 of
projection Pm
commences to lift from the surface 46 of recess Rf. There is also now a slight
increase in
the separation between upper portions of inflexion surfaces and Im3 and If3.
Finally, the
surface Cnn2 rides down the surface Cf2.
Figure 9c shows the effect of continued lifting of the panel 9b to a position
where
the relative negative rotation between the panels 12a and 12b is about 5 .
Here the
separation between abutment surfaces 24 and 26 is more pronounced and the
surface Cm1
and in particular ridge 38 reside higher on the surface Cf1 but not yet
disengaged from the
surface Cf1. There is an increase in the separation between the surfaces 40
and 46 and the
surface Cnn2 is now seated firmly in a deepest portion of the concavity in
inflexion surface
If2. This is increasing pressure /force exerted by: surface Cnn2 on the neck
of protrusion Pt
and, surface Cnn1 on surface Cf1.
Continued operation of the jack 92 further increases the angle between the
panels
12a and 12b to approximately -7 as shown in Figure 9d. At this point, the
surface Cnn1 and
ridge 38 have now moved past the surface Cf1 and lie outside of the neck 66 of
recess Rf.
This would ordinarily be indicated to the installer by an audible "clunk".
However the surface
Cnn3 is engaged by and below the surface Cf3; and the surface Cnn2 resides
below the
surface Cf2. More particularly, the protrusion Pf is now being compressed or
pinched on
opposite sides by the surfaces Cnn3 and Cnn2. Thus while at this -7
disposition, the joints
Jnn and Jf are still partially engaged and in the absence of any external
force, maintain
vertical and horizontal locking of the panels 12a and 12b. Further, during the
rotation of the
joints Jnn and Jf up to the -7 rotation the surface Cm2 operates as a fulcrum
lifting the
projection Pm from the recess Rf.
The application of a downward pressure or force on the panel 12a results in
one or
both of: compressing the projection Pf; or, opening the neck of recess Rm
formed by the
surfaces Cnn3 and Cnn2, to enable the projection Pf to escape the recess Rm.
Wax in the
joint will reduce friction and now assist in the disengagement of the joints.
Now the panel
12a is free to fall back to the surface 90 as shown in Figure 9f and Figure
6i. Thus at this
point in time the panels 12a and 12b are fully disengaged.
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However removal of the panel 12b also requires disengagement of the joint Jf
of
panel 12b from the joint Jnn of panel 12c. This process is shown in Figures 6j
to 61.
Immediately after disengagement of panels 12a and 12b, the panel 12b is held
above surface 90 by the jack 92. To continue the replacement process the panel
12b is
lowered back to the surface 90 by unscrewing shaft 96 from the boss 100 of the
clamp plate
102. An installer next grips and lifts the joint Jnn of panel 12b to insert
the wedge tool 94
between the disengaged joints of the panels 12a and 12b and push it to a
position where the
land 118 of surface 114 is in contact with the major surface 16 of panel 12c
and inside of the
joints Jnn and Jf. This is shown in Figure 6j. Disengagement of the panel 12b
from the
panel 12c is now effected by initially rotating the panel 12b by about -7 to -
10 to effect a
disengagement of the surface Cnn1 of panel 12c from the surface Cf1 in the
joint Jf of panel
12b. The wedge tool 94 is configured to assists the installer in achieving
this rotation. This
is also depicted in Figure 6j. Moreover when the wedge block 108 is under the
under panel
12c slightly inboard of its joint Jnn, and the panel 12b is rotated in the
anti-clockwise direction
toward the handle 110, the panel 12b will rotate or pivot by 7 to 10 prior
to or by the time it
abuts the handle 110. The reaching of this position is ordinarily denoted by
an audible
"clunk" as the surface Cm1 passes from below to above surface Cf1. This
juxtaposition of
the joints Jnn and Jf is as shown in Figure 9d.
Subsequent application of downward pressure or force for example by way of
rubber mallet M as shown in Figure 6k will result in total disengagement of
the joints Jf and
Jnn of panels 12b and 12c respectively as shown in Figure 61. Now the damaged
panel 12b
is totally disengaged from both adjacent panels 12a and 12c and can be
removed.
To replace the damaged panel 12b with a new panel 12b1 an installer now
removes
the wedge tool 94, lifts the edge of panel 12c by hand and slides a new panel
12b1 beneath
the raised panel 12c so that the joint Jnn lies above the joint Jf. The
opposite side of panel
12b1 rests on panel 12a. This sequence of events is shown in Figures 6m-6p.
The installer now lowers the panel 12c onto the panel 12b1. When this occurs,
the
male joint Jnn of panel 12c rests on the neck 48 of female joint Jf of panel
12bi; and the joint
Jnn of panel 12b1 will rest on the neck 48 of the joint Jf of previously laid
panel 12a. This is
shown in Figure 6q.
To fully engage the panel 12b1 downward force or pressure is applied on the
male
joints Jnn of panels 12c and 12b1. This can be done in either order, i.e.
panel 12c then
panel 12b1 or panel 12b1 then panel 12c. Figure 6q shows the configuration
when joint Jnn
of panel 12c is first engaged with joint Jf of panel 12b1. Figure 6r depicts
the joint Jnn of
panel 12b1 now engaged with joint Jf of panel 12a, reinstating the floor as
shown in Figure
6s. The self aligning properties of the joint system as described above with
reference to
Figures 5f-5k will operate during this process if the panels are initially
misaligned.
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The ability to easily remove and replace only the panels 12 which are damaged
instead of peeling back the entire floor has enormous practical, commercial
and
environmental benefits. These are summarised as follows:
The panels can be easily replaced by handypersons of limited skill and with
very
rudimentary and low cost equipment. This avoid the need for hiring
professional installers
The repair is also relatively clean as there is no need to chisel or cut out
panels or
parts thereof.
As only the damaged panels need be replaced there is no need to move furniture
which in itself is often difficult and inconvenient
From the view point of the retailer there is initial benefit in that the
retailer should
encourage the purchaser to purchase slightly more panels that required to
cover a given
area to provide spare panels in the event of damage. For example the retailer
would explain
the benefits in purchasing say an additional one to three square meters of
panels. This is
much the same as when say a new house in build and the builder leave extra
floor and roof
tiles or paint for the purposes of repair. A major issue with repair of
damaged flooring it the
difficultly is sourcing identical panels several years after installation. If
identical panel cannot
be sourced it may be that an entire level of flooring will need to be replaced
when only a
small number (e.g. two or three) panels are damaged. For example say the
ground floor of
a house has three bed rooms a hallway, kitchen and family room all cover by
wooden floor
panels of the same appearance forming a continuous floor. The entire housing
furniture
selection and decor is often selected to match with the floor. In such
instances when
matching replacement panels are not available the entire ground level floors
may need to be
replaced. Indeed this occurred on a large scale flooring a freak storm in
Perth, Western
Australia in March 2010. A much more common trigger for this is the spilling
overtime of
water from refrigerators with water dispensers. Having a small supply of
replacement panel
at hand avoids the need for full scale floor replacement. A new and growing
market for
wooden flooring is that uses a relative cheap and plentiful material for the
panel and using a
bubble jet printer to print a pattern for example the wood grain of exotic
trees on the upper
major surface 12. It will be appreciated that these patterns can be very
complex and trying
to rectify a scratch by use of an ink pen is virtually impossible. Again a
small supply of
additional panels made with the initial purchase of the flooring can
potentially save
thousands of dollars. A similar situation applies with wooden flooring is that
use a relative
cheap and plentiful material and are stained on their major surface to mimic
the appearance
of a more exotic and expensive timber.
The commercial consequence of full floor replacements as described above
should
not be underestimated. Often this is at the expense of insurance companies.
This naturally
has a knock effect with insurance premiums increasing and shareholder
dividends reducing.
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Also there are timing issue where insurance companies may not be able to have
damage
assessed and therefore rectified for months.
Now consider the environmental aspects. Typically wooden floor panel are
coated
with polyurethane or other sealants. Also they may bear adhesives and glues.
This often
prevents destruction of the damaged boards by incineration due to generation
of toxic
gases. Consequently they must go to land fill.
The joint 10 depicted in Figures 1-9f is representative of one of a large
number of
possible embodiments. A small selection of other possible embodiments will now
be
described. In describing these embodiments the same referencing system will be
used as for
the joint 10 however each specific embodiment of a joint will be demarcated by
the addition
of the alphabetical suffix e.g. "a, b, c, ...".
Figures 10a and 10b depict a second embodiment of a joint system 10a
incorporated into a substrate 12. The joint system 10a comprises a male joint
Jm and
female joint Jf along opposite sides. It can be seen that the joint system 10a
is of the same
general configuration as the joint system 10 shown in Figures 1 and 2. In
particular the male
joint Jnn comprises male locking surfaces ML1, ML2, ML3; inflexion surfaces
Im1, Im2, and
Im3; as well as surfaces Cnn1, Cnn2, and Cm3. Likewise the female joint Jf is
provided with
female locking surfaces FL1, FL2, FL3; inflexion surfaces If1, If2, If3 and
surfaces Cf1, Cf2
and Cf3. The relative locations of the locking surfaces, inflexion surfaces
and surfaces for
the joint system 10a are generally the same as for the joint system 10.
However, there are
subtle differences in the specific shape and depth of the surfaces. In
particular the surface
Cnn 1 in the joint 10a is continuously curved rather than being provided with
the ridge 38 of
the joint system 10. In addition the mating inflexion surfaces Inn1 and If1
are shallower so
that the spaces 76 and 78 about the locking plane 18 are smaller than that for
the joint
system 10. This can be seen by comparison between Figures 10b and Figure lb.
Further,
there is a lessening in the depth of the inflexion surfaces Im3 and If3 to the
extent that there
is no space equivalent to the space 80 of the joint system 10. It can also be
seen that the
inflexion surfaces Im2 and If2 in the joint system 10a are shallower than the
corresponding
surfaces in the joint system 10 resulting in a smaller overlap in the surfaces
Cf2 and Cnn2
when the joints Jnn and Jf of adjacent panels 12 are engaged.
The joint system 10a may be used in the same circumstances and with the same
materials with the system 10. However due to the slightly shallower depth of
the inflexion
surfaces I, the joint system 10a is suited to more rigid substrates such as
but not limited to
bamboo where the compressibility of the projections Pm and Pf2 when passing
through the
necks of the corresponding recesses Rm and Rf may be limited.
Figures 11 a to 11d depict a further embodiment of the joint system 10b
provided on
opposite sides of the substrate 12. The substantive differences between the
joint systems
10b and 10 lie in: (a) the configuration of the immediate inflexion surfaces
Im3 and If3; and,
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(b) the removal of the concave recess 42 from the projection Pm and the
formation of a
similar recess 42f on the surface 58 of recess Rf.
In general, the inflexion surfaces Im3 and If3 are "angularised" in that they
are not
smoothly or continuously curved for their entire length. Specifically the
surface Cnn3 (which
is part of the inflexion surface Im3) is provided with a narrow ridge 140
similar to the ridge 38
depicted on the protrusion Pm of joint system 10. In addition the inflexion
surface Im3 is
provided with a "V" shaped gear tooth 142 extending toward the root 52 of the
recess R. On
the female joint Jf the surface Cf3 is sharpened to form a narrow ridge 144.
As depicted in
Figure 11 b, the apex 145 of gear tooth 142 bears against surface Cf3 below
the ridge 144
when joints Jnn and Jf are engaged.
The purpose and effect of the variation in configuration of the inflexion
surfaces Im3
and If3, and in particular the provision of the gear 142 and variations in the
configuration of
the surfaces Cf3 and Cnn3 is to allow greater relative rotation of up to 5 to
10'or more of
between joined while maintaining engagement to assist in installation on
undulating
surfaces. This is shown in Figures 11 c and 11d. The ability to increase the
degree of
rotation is most pronounced in the positive or upward direction of the male
jointed panel 12b
relative to panel 12a. This is facilitated by the surface Cnn3 bearing against
the surface of
protrusion Pf in the recess Rf after the apex 145 of gear tooth 142 has passed
over the ridge
144. As a consequence the protrusion Pf remains pinched between the surfaces
Cm3 and
Cnn2 thus maintaining horizontal and vertical engagement. The joint system 10b
enables a
panel to ramp up relative to an adjacent horizontal panel to say a raised
cross-over or floor
trim piece.
Figures 12a and 12b depict a further embodiment of joint system 10c
incorporated
in a substrate 12. The joint systems 10c and 10 differ in substance in
relation to their aspect
ratios. Joint system 10c may be used for substrates of smaller thickness than
for joint
system 10. As there is less thickness or depth in the substrate 12 the male
and female
joints Jnn and Jf of joint system 10c are shallower but broader. This is most
notable by a
visual comparison between the protrusion Pm and recess Rf of the joint systems
10c and
10. In joint 10c the protrusion Pm is broader and provided with a flatter
bottom surface 42 as
is the recess Rf. The broadening of the protrusion Pm also is the effect of
sharpening the
profile of the Cnn3. However, the method of operation and effect of the joint
system 10c is
the same as for joint system 10. In particular the remains three vertical
locking planes 18,
20 and 74 and respective substrates 12 are able to rotate by up to 3 degrees
in opposite
directions relative to each other.
Figures 13a and 13b depict a further embodiment of the joint system 10d
applied to
a substrate 12. The substantive differences between the joint system 10d and
10 lies in the
depth and relative disposition of the intermediate inflexion surfaces Im3 and
If3; and the
width of the protrusions P and recesses R. In the joint system 10d, the
inflexion surfaces Im3
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and If3 are shallower and are inclined more towards the horizontal i.e. toward
a plane
containing major surfaces 14 and 16. As a consequence, when the male and
female joints
Jnn and Jf are engaged only inner and outer locking planes 18 and 20 are
created; the third
locking plane 74 which arises with the earlier embodiments of the joint system
being absent.
In the joint system 10d, there is no point on the inflexion surface Im3 which
is vertically
below and laterally inside of a point on the inflexion surface If3. Also the
protrusions P and
recesses R are broader in the joint system 10d. This provides greater
horizontal shear
strength along shear planes S1 and S2 which pass through the protrusions Pm
and Pf
parallel to the major surfaces 14 and 16. This is beneficial with panels of
smaller thickness
(e.g. say 7mm-3mm) which are otherwise susceptible to shearing along planes S1
and S2.
Notwithstanding this, the joint system 10d operates in substantially the same
manner as the
joint systems 10-10c in that it is a vertical system and adjoining substrates
12 can to rotate
by 3 degrees relative to each other without disengagement.
Figures 14a and 14b illustrate a further embodiment of the joint system 10e
applied
to a substrate 12. The joint system 10e embodies the same basic concepts as
the joint
system 10 and in particular has extreme (or inner and outermost) locking,
inflexion and
transversely extending surfaces which form respective locking planes 18 and 20
and enable
relative rotation between the male and female joints Jf and Jm of joined
substrates 12. Also
as with all of the embodiments the joint system 10e is a vertical system where
joints are
engaged by the application of a force or pressure in a direction perpendicular
to the major
surfaces 14 and 16. However as it is readily apparent from a comparison
between the joint
system 10e and the joint system 10 there are numerous differences in the
specific
configuration of the projections P and recesses R on the male or female joints
Jf and Jr.
Starting with the male joint Jnn, in the system 10e, there is a bevelled
surface 146
between the major surface 14 and the side surface 24. In addition, between the
side surface
24 and the inflexion Inn1 the joint system 10e comprises a right angle rebate
148. The
protrusion Pm is more symmetrical than in joint system 10 and is provided with
a central slot
150 which extends in a direction perpendicular to the major surfaces 14 and
16. Additionally
surface 40 of the protrusion Pm is flat rather than arcuate. The slot 150
provides the
protrusion Pm with a degree of resilience. This resilience is not in order to
effect
engagement of the protrusion Pm with recess Rf but rather provides resilience
to assist in
the rotation of the protrusion Pm within the recess Rf.
The protrusion Pf is more rounded than the corresponding protrusion Pf in
system
10 and is also provided with a central slot 152 which extends parallel to the
slot 150. Slot
152 also provides resilience to the protrusion Pf to assist in its rotation
within the socket Rm.
Surface 58 at the root 34 of recess Rf is flat and lies parallel with the
major surfaces 14 and
16 and also parallel with the surface 40. A square shoulder 154 is formed
between the
inflexion surface If1 and side surface 26 on the female joint Jf. Shoulder 154
engages the
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rebate 148 when the joints Jf and Jm are engaged as shown in Figure 14b. A
further
difference in the configuration of joint system 10e is the provision of an
inclined surface 156
between the inflexion surface Im2 and the bevelled surface 56 at the joint Jm.
It will be seen from Figure 14b that the joint system 10e has three vertical
locking
planes 18, 20 and 74 as in the joint system 10. A space 158 is created between
the
surfaces 40 and 58 when the male joint Jm is engaged with a female joint Jf.
This space
may be used in the same manner as the void 44 shown in Figure lb for the
collection of
debris.
Figures 15a and 15b depict a further embodiment of a joint system 10f
incorporated
on a substrate 12. In the joint system 10f, the male and female joints Jm and
Jf are
shallower and squarer than that in the system 10. Male joint Jm comprises an
inflexion
surface If1 and corresponding surface Cnn1 on an outermost surface and an
inflexion
surface Im2 and corresponding surface Cnn2 on an innermost surface. There is
also an
intermediate surface Cnn3 but no intermediate inflexion surface Im3. The
female joint Jf is
formed with: surfaces Cf1 and Cf2 on inner and outermost surfaces of the joint
respectively;
and, an inflexion surfaces If2. However, the joint system 10f does not include
an
intermediate inflexion surface If3 nor an inflexion surface If2 on the
outermost surface of the
female joint.
Projections P and recesses R in the joint system 10f are squatter than those
in the
joint system 10. This provides improved shear strength as in the joint system
10d. When
substrates 12 incorporated in the joint system 10f are engaged with each other
two locking
planes 18 and 20 are created by the surface Cf1 and Cnn1; and Cf2 and Cnn2
respectively.
A "quasi" intermediate locking plane is formed by the provision of planar
surfaces 25 and 27
on protrusions Pm and Pf respectively. The surfaces 25 and 27 are
perpendicular to the
major surface 14. When the joints Jm and Jf are engaged the surfaces 25 and 27
abut each
other. This provides frictional locking against relative motion between the
joints Jm and Jf in
the vertical plane. This provides an effect similar to but to less degree than
the locking plane
74 in the joint system 10f. Vertical arrestnnent between the joined substrates
12 is created
by the abutment of the surface 40 of projection Pm with the surface 58 in the
recess Rf.
A further difference in the configuration between the joint systems 10f and 10
is the
omission in the joint system 10f of bevelled surfaces 56 and 64 which lead
from the surfaces
50 and 62 respectively to the major surface 16. Thus, in the joint system 10f,
the surfaces
54 and 66 extend directly from the respective surfaces Cnn2 and Cf2 to the
major surface 16.
Figures 16a and 16b depict a further joint system 10g which is suited to
panels
made of plastics materials such a vinyl or other relatively soft/flexible
materials. In the joint
system lOg various inflexion surfaces or transversely extending surfaces are
formed
comprising one or more planar surfaces. However, on each of the extreme
locking planes
18 and 20, there remains at least one arcuate transversely outward extending
surface to
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facilitate a rolling motion enabling rotation between the joint panels 12.
More specifically it
can be seen that the projection Pm in the joint system 10f comprises a first
locking surface
ML1 and having abutment surface 24 and contiguous inflexion surface Im1. The
inflexion
surface Im1 includes a planar and inwardly sloping surface 160 depending from
the surface
24, and an additional planar surface 162 which extends parallel to the surface
24 and is
contiguous with the surface 160. Thereafter, the inflexion surface Inn1
incorporates an
arcuate or a smoothly curved surface Cnn1. The surface Cnn1 leads to a planar
bottom
surface 40 of the projection Pm which lies in a plane parallel to the major
surfaces 14 and
16. The surface 40 is contiguous with an intermediate and smoothly curved
surface Cnn3.
However the concave recess 42 of earlier embodiments has been replaced with a
slot 163
which lies perpendicular to the major surface 14. The slot 163 provides the
projection Pm
with an increased ability to compress within recess Rm to facilitate rotation
during within the
recess Rm.
Extending from the surface Cnn3 is an inclined planar surface 164 which leads
to a
planar surface 52 of the recess Rm. The surface 52 lies parallel to the major
surfaces 14.
The planar surface 164 and the surface Cnn3 together form intermediate
inflexion surface
Im3 and third male locking surface ML3. This is provided with a sharp corner
where the
surface 164 meets the surface Cnn3. The innermost surface ML2 of the male
joint Jnn
includes an angular inflexion surface Im2 and planar surface 56. The inflexion
surface Im2
comprises contiguous planar surfaces 166 and 168 which are inclined relative
to each other
to form a generally concave but angular or sharp corner in the recess Rm. The
inflexion
surface Im2 further comprises another planar surface 170 which extends
perpendicular to
the major surfaces 14 and 16. This surface then joins bevelled surface 56
leading to the
major surface 16.
The female joint Jf has first female locking surface FL1 comprising abutment
surface 26 which extends perpendicular to major surface 14 and contiguous
inflexion
surface If1. Inflexion surface If1 is composed of planar surface172 which
slopes toward the
recess Rf, planar surface 174 which is parallel to surface 26 and a smoothly
curved concave
surface 176 which leads to the surface 58 at the root of recess Rf. The
surfaces 172, 174
and upper portion of surface 176 together form a transversely extending
surface in the form
of a generally convex cam Cf1. Surface 58 at the root 34 of recess Rf is
planar and parallel
to the major surface 14. Thereafter, the female joint Jf comprises an
intermediate surface
If3 which may be considered to be in inverted form of the inflexion surface
Im3. To this end
the inflexion surface If3 comprises a planar surface 180 which is inclined in
a direction
toward major surface 14, and a contiguous smoothly curved surface Cf3. The
surface Cf3
joins with a planar surface 60 parallel to the major surface 14. The outermost
side of the
female joint Jf in system 10f is formed with a second female locking surface
FL2 having
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smoothly curved surface Cf2 which leads to a planar surface 62 and
subsequently to
inwardly bevelled surface 64 leading to the major surface 16.
The joints Jnn and Jf are engaged by application of a force or pressure in a
direction
perpendicular to the major surfaces 14 and 16. As is evident from Figure 16d,
that joint
system 10f results in the provision of three locking planes 18, 20 and 74 as a
result of the
relative juxtaposition of the surfaces Cf1 and Cm1; Cnn1 and Cnn2; and Cnn3
and Cf3.
Further, in the engaged joint, the surfaces Cnn1 and Cnn3 reside in the
angular corners of the
recess Rf while smoothly curved surfaces Cf2 and Cf3 reside in the angular
corners formed
in the recess Rm. In this embodiment it will be noted that there remains on
each of the inner
and outermost locking planes, an arcuate or smoothly curved surfaces C.
Specifically, on
locking plane 18, the smoothly curved surface Cnn1 is able to roll against the
surface of the
joint Jf while on the locking plane 20, the arcuate surface Cf2 is able to
roll on the surface of
the male joint Jnn. Also due to the non-symmetrical configuration of the
joints Jnn and Jf
voids or spaces are created between the engaged surface to further assist in
the relative
rotation between joints and allow for expansion.
Figures 17a and 17b depict a further joint system 10h which is based on and
very
similar to the joint system 10f. In particular, the system 10h is of the same
general shape
and configuration of the system lOg with the substantive differences being the
omission of
the slot 163 and a reduced length in the bevelled surfaces 56 and 64. This
reduced length is
a function of the thickness of the substrate 12h which is less than that of
the substrate 12g.
In a non limiting example, the substrate 12g incorporating the joint system
lOg may have a
thickness in the order of 5.2mm, while the substrate 12h incorporating the
joint system 10h
may have a thickness in the order of 3.5nnnn.
In all other respects, the joint system 10h is the same in configuration and
function
as the joint system 10g.
Figures 17c to 17e illustrate a further feature of embodiments of the joint
system
relating to the ability to manufacture the system and panels of varying
thickness using a
single set of tools. Figure 17a and 17b illustrate the joint system 10h formed
in panels 12 of
a nominal thickness of say 3nnnn. In Figure 17c and 17d the nominal thickness
of 3nnnn is
marked as the innermost horizontal lines 14a and 16a. These lines indicate the
major
surfaces 14 and 16 of a panel 12. The next adjacent pair of lines 14b and 16b
illustrates the
major surfaces of the panel 12 if it were made to a thickness of 3.5nnnn.
Continuing in an
outward direction line pairs 14c and 16c; 14d and 16d; 14e and 16e; and 14f
and 16f;
illustrate the major surfaces 14 and 16 for panels 12 made to thicknesses of
4nnnn, 5nnnn,
6nnnn and 7nnnn respectively. Figure 17e provides perspective for panels 12
made to these
different thicknesses. As explained in greater detail hereinafter the ability
to manufacture
joint systems on panels of varying thickness with a single set of cutting
tools provides
benefits over the prior art. A further feature of this is that notwithstanding
the variation in
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thickness of the panels 12 it will be seen that the physical size of the
joints Jm and Jf and
the interlocking surfaces remains constant. Thus the strength of the
engagement between
panels is not compromised by a variation in the thickness of the panels.
Figures 18a and 18b depict a further embodiment of the joint system 10i. The
joint
system 10i may be viewed as a hybrid combining various features of earlier
described joint
systems. Both the male and female joints Jf and Jm comprise ball or bulbous
like
protrusions P, and recesses R having smoothly or continuously curved surfaces.
The
respective surfaces C of the male and female joints Jf and Jm are arranged to
provide three
locking planes 18, 20 and 74 when mutually engaged as depicted in Figure 18b.
The male
and female joints comprise complimentary planar stepped surfaces 148 and 154
which lie
parallel to the major surface 14 similar to the joint system 10e. Indeed the
joint system 10i
may be viewed as a modification of the joint system 10e but with the following
differences:
broadening of the respective protrusions P and recesses R; a marginal
inclining of the
surfaces 24 and 26 from the perpendicular of major surface 14; a flattening of
a portion of
the inflexion surface If1 between an upper end of surface Cf1 and surface 154;
and
extension of the bevelled surface 56 so as to extend directly from the Cnn2 to
the major
surface 16. It will be further noted from a comparison between Figures 18b and
14b that a
space 82 now exists between the planar surfaces 40 and 52, and there is a
space between
the surfaces 154 and 148 in the engaged joints Jm and Jf. The joint system 10i
operates in
the same way as the previously described joint systems in terms of engagement
and
disengagement and the rolling action between the joints.
Figures 19a and 19b depict a further embodiment of the joint system 10j. The
protrusions Pm and Pf are each provided with respective slots 163 and 152
similar to that of
the joint system 10e. In the joint system 10j the surfaces Cnn1, Cnn2, Cnn3,
Cf1 and Cf3 are
each smoothly curved. However the surface Cf2 on the female joint Jf is
angular, being
composed of a plurality of contiguous planar surfaces. Nevertheless, as shown
in Figure
19b, when the joints Jm and Jf are engaged the locking surfaces ML1 and FL1;
ML2 and
FL2; and ML3 and FL3 create three locking planes 18, 20 and 74 as herein
before
described. In each of the outermost locking planes 18 and 20, one of the two
respective
engaged surfaces is continuously curved. Specifically in locking planes 18 and
20 surfaces
Cnn1 and Cnn2 are continuously curved. This maintains the ability of the
joints to roll
provided the positive and negative relative rotation and the ability to
disengage and thus
move and replace a damaged substrate in an identical manner as described in
relation to
the earlier embodiments. The joint system 10j further includes surfaces 146
and 154 similar
to the subsystem 10e but in this instance these surfaces are inclined at an
acute internal
angle relative to the major surface 14. Further the projection Pm and recess
Rf are relatively
configured to form a relatively large void or space 190 between surfaces 40
and 58. The
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slots 152, 163 provide an internal suspension system enabling compression of
the
protrusions Pm and Pf to assist in the rolling motion.
Figures 20a and 20b depict a further embodiment of the joint system 10k. The
protrusion Pm is formed with continuously curved surfaces Cnn1, Cnn2 and Cnn3.
On the
female side the protrusion Pf is formed with angular surfaces Cf2 and Cf3,
surface Cf1
comprises contiguous planar surfaces 191, 192 and 193. Surface Cf3 comprises
contiguous
planar surfaces 194, 195 and 196. The surfaces 191 and 194 each lead to the
surface 60 of
protrusion Pf which lies parallel with major surface 14. Both surfaces 192 and
195 extend
perpendicular to the major surface 14 while surfaces 193 and 196 are inclined
toward each
other surface 193 leads to an oppositely inclined surface 162 which in turn
leads to bevelled
surface 64 which is cut inwardly but substantially parallel to surface 193.
The surface 64
leads to the major surface 16. The route 34 of the recess Rf is formed with
planar surface
46 which lies parallel to major surface 14, and to oppositely and outwardly
inclined surfaces
197 and 198. Surface 198 leads to an inwardly inclined surface 199 which in
turn is formed
contiguously with planar surface 200. Surface 200 lies perpendicular to the
major surface
14 and joins with surface 154. The combination of surfaces 196 and 197; and
surfaces 198
and 199 form respective concave recesses for seating the surfaces Cnn1 and Cm3
as shown
clearly in Figure 20b.
Looking at the male joint Jnn, it will be seen that opposite ends of the
surface 52 in
the recess Rnn lead to contiguous outwardly inclined surfaces 201 and 202.
Surface 201
then leads to a planar surface 203 which leads to the surface Cnn2. On the
opposite side
the surface 202 is formed contiguously with a further planar surface 204 which
then leads to
the surface Cnn3. Surfaces 203 and 204 lie perpendicular to the major surface
14. In
combination the surfaces 201, 203 and part of the surfaces Cnn2 form a concave
recess for
the surface Cf2. Similarly, the combination of the surfaces 202, 204 and part
of the surface
Cnn3 forms a further concave recess for seating the surface Cf3.
The protrusion Pm is also formed with a planar surface 205 that lies
perpendicular
to the major surface 14 and extends between the surface Cnn1 and the surface
148. When
the joints Jnn and Jf are engaged, the surfaces 205 and 204 are spaced apart
while the
respective surfaces 148 and 154; and 26 and 24 are in abutment.
Figures 21a and 21b depict a further embodiment of the joint system 101. The
protrusion Pm has a male locking surface ML1 which, starting from the major
surface 14 is
initially provided with a small bevelled surface 146 similar to that shown in
the joints 10e and
10i and extends downwardly ending in a smoothly curved surface Cnn1. The first
male
locking surface ML1 also comprises an inflexion surface Inn1 which includes a
planar portion
220 and extends from the bevelled surface 146 toward the surface Cnn1.
Protrusion Pm also includes a slot 158 similar to that of the joint system
10e. The
protrusion Pm is formed with a curved distal surface 40 and is of a generally
symmetrical
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configuration about a centreline passing through the slot 158. To this end the
line of
shortest distance 50 across the neck 48 of the protrusion Pm lies on a plane
parallel to the
major surface 14. The slot 158 in the protrusion Pm is outwardly flared near
the surface 40
so as to create in effect two prongs or a bifurcation with generally rounded
or curved
extremities 221.
The third inflexion surface 1m3 and corresponding third male locking plane ML3
on
a side of protrusion Pm opposite the inflexion surface IM1 is smoothly curved
and leads to a
planar surface 52 in the root 32 of recess Rm. The surface 52 lies parallel to
the major
surface 14. On an opposite side of the recess Rnn the joint Jnn is formed with
a second male
locking surface ML2 which comprises a smoothly curved inflexion surface 1M2
which
subsequently leads to bevelled surface 56.
The first female locking surface FL1 in the joint Jf comprises a short
bevelled
surface 155 commencing from the major surface 14 followed by a planar surface
portion 222
which extends perpendicular to the major surface 14. Surface 222 leads to
inflexion surface
If1 which is smoothly curved and extends toward a root 34 of recess Rf. The
root 34 is
provided with a planar surface 46 that extends parallel to the major surface
14. The surface
46 in turn leads to third inflexion surface 1f3 which is smoothly curved and
corresponds with
the third female locking surface FL3. Distal surface 60 of female protrusion
Pf extends
between the second and third female locking surfaces FL2 and FL3 and lies in a
plane
parallel to major surface 14. The second female locking surface FL2 extends
continuously
toward the major surface 16 beyond the inflection surface 1F2 in a smoothly
curved manner
and subsequently leads to bevelled surface 64.
It will be seen from Figure 21b that each of the respective male and female
locking
surfaces and the corresponding inflexion surfaces engage about respective
locking planes
18, 20 and 74.
In a further variation of the joint system 101 embodiment a bead B (shown in
phantom line) of adhesive of the type described in detail shortly can be
accommodated in
the mouth of the slot 158. This provides additional vertical locking between
engaged panels
as well as cushioning.
Figure 22 depicts a further embodiment of the joint system 10nn with joints Jf
and
Jnn depicted on separate but engaged panels 12a and 12b. The joint system 10nn
is similar
to the joint system 10 depicted in Figures la ¨ 2 with the main differences
residing in the
configuration of the surfaces Cnn3 and 1f3 on the male protrusion Pf. In the
joint system lOnn
the surface Cf3 extends further in the transverse outward direction so as to
hook under the
surface Cf3 when the joints Jnn and Jf are engaged. This provides greater
resistance to
vertical separation along the intermediate plane 74 in comparison to that of
the joint system
10. Further, the surface Cf3 is provided with small ridge or peak 38 similar
in configuration
and effect to the peak 38 on the surface Cnn1. Due to the configuration of the
surface Cf3
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there is an increased grab or pinching of the protrusion Pf between the
surfaces Cnn3 and
Cnn2 during the rotation of the joint Jnn in a negative sense relative to the
joint Jf. The joint
Jnn is particularly well, but not exclusively, suited for use with panels or
substrates made of
softer material.
Figure 23a and 23b depict a further embodiment of the joint system 10n. The
joint
system 10m differs from the joint system 10 depicted in Figures 1 ¨ 3b by the
provision of
additional of three concave recesses, namely concave recesses 42b, which is
formed in the
root of the recess Rf; concave recess 42c which is formed in the root of the
recess Rnn; and
concave recess 42d formed in the protrusion Pf. The recess 42d is located so
that when
1(:) joints Jnn and Jf are engaged the recesses 42 and 42b face each other
to form a
substantially cylindrical or elliptical void 230. Similarly, the concave
recesses 42c and 42d
are located to face each other when the joints Jnn and Jf are engaged to form
a further
substantially cylindrical void 232. The void 230 may be used as a dam or void
to collect dirt
and other debris generated during the laying of substrates 12 provided with
the joint system
Jm.
Alternately, one of the recesses 42 and 42b may be provided with a pre-laid re-
stickable flexible adhesive and configured to extend into the other of the
recess 42 and 42b.
The expression "re-stickable adhesive" throughout the specification and claims
is intended to
mean adhesive which is capable of being able to be removed and re-adhered,
does not set
or cure to a solid rigid mass and maintains long term (e.g. many years)
characteristics of
flexibility, elasticity and stickiness. The characteristic of being re-
stickable is intended to
mean that the adhesive when applied to a second surface can be subsequently
removed by
application of a pulling or shearing force and can subsequently be reapplied
(for example up
to ten times) without substantive reduction in the strength of the subsequent
adhesive bond.
Thus the adhesive provides a removable or non-permanent fixing. The
characteristics of
flexibility and elasticity require that the adhesive does not solidify, harden
or cure but rather
maintains a degree of flexibility, resilience and elasticity. Such adhesives
are generally
known as fugitive or "booger" glues and pressure sensitive hot melt glues.
Examples of
commercially available adhesives which may be incorporated in embodiments of
the present
invention includes, but are not limited to: SCOTCH-WELDT" Low Melt Gummy Glue;
and
GLUE DOTST" from Glue Dots International of Wisconsin.
It is noted that manufacturers of re-stickable glue/adhesive may advise that
the
adhesive is not suitable for particular materials for example wood. However
when the joint
system is incorporated in wooden or wood based panels this is does not
preclude the use of
such adhesives. This is because wooden or wood based panels are usually, and
if not can
be, coated with a polymer sealant or other coating. Thus provided the adhesive
is
recommended for use with polymer surfaces can be used on polymer coated wooded
or
wood based panels.
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Alternately, both recesses 42 and 42b may be provided with the re-stickable
adhesive so as to engage each other when the joints Jm and Jf are engaged.
In a similar manner, one or both of the concave recesses 42c and 42d may be
provided with a bead of re-stickable adhesive of the type described
hereinafter. When only
Provision of the adhesive material has multiple effects. Firstly, it acts to
assist in
20 One further feature of the joint system 10n is that the locking surfaces
ML3 and FL3
are each provided with planar surfaces 210 and 212 which lie parallel to the
locking plane
74. There surfaces are pressed together when the joints Jm and Jf are engaged.
Provided
no wax is placed on these surfaces they will in effect provide a frictional
intermediate locking
plane 74. Such frictional intermediate locking planes can be incorporated in
other of the
In one embodiment as shown in Figures 23c-23i adhesive is applied to both of
the
recesses in the male joint Jm only and not in the female joint Jf. In such an
embodiment,
due to the nature of the re-stickable adhesive, when a substrate 12 is removed
from
adjacent adjoining substrates, the adhesive remains in the recesses 42 and 42c
of the
Figure 23c shown joints Jm and Jf prior to engagement. Recesses 42 and 42c are
each provided with respective beads B1 and B2 of re-stickable adhesive 300
covered with
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Figure 23d shows the joints Jnn and Jf fully engaged with the release strips
R1 and
R2 removed so that the re-stickable adhesive 300 in beads B1 and B2 adhere to
the surface
of the recesses 42b and 42d.
Figures 23e -23i show the typical disengagement process of joints Jnn and Jf
in
embodiments of any joints system with initially the joint Jm being rotated in
a negative
(clockwise) direction relative to joint Jf to release protrusion Pm from
recess Rf, and the
subsequent application of downward pressure on the female joint Jf. The re-
stickable
adhesive is able to flex and move during the separation process to allow the
rotation and
subsequently is pulled from the recesses 42b and 42d to remain in recesses 42
and 42c.
The adhesive beads B bonded to a joint J may also act to absorb debris that
lies in
a recess into which the bead B is to be adhered. For example a bead B bonded
in recess
42 can absorb debris in the recess 42b into which the bead B is adhered. The
debris will
initially adhere to the outside surface of the bead B. As the panels 12 move
in normal use
there will also be some movement and rolling of the bead B. It is believed
that this will have
the effect of drawing the debris into the adhesive so that the adhesive
envelops the debris
and provides a fresh adhesive surface to stick to the recess 42b.
One or more adhesive beads can be provided in each of the previously described
embodiments to provide added vertical and horizontal locking strength while
still allowing the
full operation and benefits of the embodiments. This may be achieved for
example by the
provision of one or more recesses 42 in one of the joints Jnn or Jf to seat a
bead of the re-
stickable adhesive. Depending on the thickness of the bead a receiving recess
may or may
not be required on the other joints Jnn and Jf. The provision of the re-
stickable adhesive can
be seen as providing an additional locking plane to the joint system.
Typically, as in the above example, the adhesive is laid in only one of two
mutually
facing recesses 42. The bond when the adhesive is initially placed in that
recess is stronger
than the bond when that adhesive contacts a surface of the opposed recess in
another
substrate. Thus when a substrate is removed, the adhesive originally applied
to that
substrate remains with that substrate.
In all of the above described the embodiments of the joint system 10, it will
be noted
that the protrusions Pm and Pf are not of the same configuration, i.e. cannot
be transposed
over each other. Similarly the recesses Rnn and Rf are not of the same
configuration, i.e.
cannot be transposed over each other. More particularly the respective
engaging
protrusions and recesses are not of a complementary configuration. Thus the
protrusions
Pm and Pt the recesses Rnn and Rf; and joints Jnn and Jf are asymmetrical. As
a
consequence when a protrusion P is engaged in a recess R gaps or spaces are
created
between the male and female locking surfaces ML1, FL1 and ML2, FL2 at the
inner and
outer locking planes 18 and 20. This assists in providing the ability of
embodiments of the
joint system to roll or rotate in opposite directions by up to 3 by providing
space into which
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the protrusion can roll without disengaging. In turn this aids in the ability
of the joint system
to be used easily and with success on undulating floors. This will be
recognised by those in
the art as filling a need particularly in the do it yourself market for
flooring system which
hitherto has endured systems that require high quality underlying surfaces for
successful
installation.
As a result of the specific configuration of the joint systems in accordance
with
embodiments of the present invention, and in particular as they are true
vertical systems it is
possible for manufacturers to manufacture panels with a wide range of
thickness with a
single set of cutting tools. For example for manufactured or natural wood
substrates a single
set of cutting tool can produce joint systems on panel ranging from 20mm to
8nnnn with the
only adjustment required being a simple one of cutting depth. Similarly with
plastics panels
such LVT a single set of cutting tool can produce joint systems on panel
ranging from 7mm
to 3nnnn as shown and previously described with reference to Figures 17c-17e.
This is of
significant commercial benefit giving rise to reduced production costs which
can be passed
on to the consumer.
The range in cost for set of cutting tools for cutting a joint system is
typically
between US$30,000 to US$50,000. Usually a set of cutting tools used for prior
art joints can
be used for two different thicknesses. For example one set is used for joints
on panels of
thickness of 7nnnn-6nnnn; and a second set for thickness of 5nnnn-4nnnn. It
also takes about 3
hours to replace a set of cutting tools then several additional hours to set
up the cutting
machine with the new set of tool. Subsequently several test runs are made and
products
evaluated to fine tune the tool and machine setting before full scale
production can
recommence. If the only adjustment required is to change the depth of cut then
there is no
cost for new cutting tools and the downtime is reduced to a total of about 1
hour. A further
benefit of this is that relative small manufactures and able to afford to
produce relative small
production runs of at low coast and thus compete with larger manufactures.
This may
increase competition and thus in turn benefit the consumer.
With reference to Figures 24a-26e a semi floating/semi direct stick surface
covering
system may be provided by a plurality of substrates 12 incorporating any one
of the joints
systems 10 as hereinbefore described and further incorporating a quantity of
the re-stickable
adhesive 300 bonded to the first major surface 16. The re-stickable adhesive
300 is used in
conjunction with a sealant or sealing membrane (not shown) which is applied to
an
underlying surface onto which the adhesive 300 is to be bonded. Many sealants
are
commercially available which may perform this function. Such sealants may
include for
example BONDCRETETm or, CROMMELINTm concrete sealer. The type of sealant used
is
simply dependent on the type of surface onto which the semi-floating surface
covering
system is to be used. The purpose is to prevent the generation of dust which
may otherwise
interfere with the bonding strength of the blue adhesive 300.
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Others have in the past used glues to adhere substrates to floors. In
particular
adhesives have been used to glue wooden floor boards to an underlying surface.
However
to the best of the inventor's knowledge, all such systems use glues which are
specifically
designed to set or cure to a solid unyielding bonded layer. In the art of
timber or wooden
flooring, this is known as "direct stick" flooring. Some have proposed to
utilize adhesives
which take up to an hour or two to set or cure to enable installers to move
the flooring panels
during installation to ensure correct alignment. Indeed others propose using
adhesives
which may take up to 28 days to fully cure or harden.
Some consumers prefer direct stick flooring to floating flooring as it
provides a
harder more solid feel and significantly does not provide bounce when being
walked on and
does not generate noise such as creaking or squeaking. A disadvantage however
of the
direct stick flooring is that it is very messy to apply, and once the adhesive
has cured, which
it is specifically designed to do, removal and/or repair of one or more
damaged panels is
problematic. The removal of a direct stick panel generally requires the use of
power tools to
initially cut through a section of the panel, and then much hard labour in
scraping the
remainder of the plank and adhesive from the underlying subsurface. This
generates
substantial dust and noise and of course usually comes at substantial expense
due to the
associated time required.
Use of the re-stickable adhesive as described hereinabove with substrates 12
incorporating the joint system 10 provides a semi-floating surface covering
system having
the benefits of both traditional floating surface coverings and direct stick
coverings but
without the substantial disadvantages of direct stick surface coverings.
Specifically, the use
of the re-stickable adhesive 300 eliminates bounce and noise often found with
conventional
floating flooring, but still provides a degree of cushioning due to the
flexible and elastic
characteristics of the adhesive which does not set or cure. Further the
characteristics of the
adhesive also enable movement of substrates/panels 12 due to changes in
environmental
condition such as temperature and humidity. This is not possible with direct
stick flooring.
Indeed recently, the world market has been having problems with direct
sticking of
compressed bamboo substrates due to the completely rigid and inflexible bond
created by
the traditional adhesives. Accordingly, should the compressed bamboo need to
move or
expand due to variations in environmental conditions it is restricted from
doing so by the
direct stick adhesive. Consequently it has been suggested by multiple flooring
associations
around the world that compressed bamboo should not be direct stuck to
substrates but
limited to application in floating floor systems which enable it to move in
response to
dynamic seasonal changes.
The provision of the re-stickable adhesive also enables for the take up of
undulations or variations in the underlying surface to which it is applied.
This is facilitated by
providing the adhesive 300 in beads or strips of a thickness measured
perpendicular to the
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major surfaces 14, 16 of between 1 ¨ 6mm and more particularly 2 ¨ 4nnnn. In
addition to
taking up variations in the underlying surface, the adhesive as mentioned
above also
provides acoustic benefits in: (a) eliminating noise and squeak which may
otherwise arise
from the bounce or deflection in traditional floating floors; (b) dampening
vibrations (i.e.
noise) transmission between adjacent panels; and (c) dampening vibrations
(i.e. noise)
transmission in multi-storey buildings from an upper level to an immediately
adjacent lower
level. This again is to be contrast with direct stick glues which due to their
curing into a rigid
bond, do not in any way dampen vibration or noise transmission.
The benefits and advantages of the use of re-stickable adhesive as herein
before
described in their own right give rise to a floor covering systems comprising
substrates which
may be tessellated and on which the adhesive is applied. Such systems do not
necessarily
require vertical joints systems of the type described hereinabove and may also
be used with
other types of joints systems. Indeed in certain circumstances, it is believed
that the re-
stickable adhesive concept gives rise to a surface covering system with joint-
less substrates.
Thus in one embodiment there would be provided a semi-floating surface
covering system
which comprises a plurality of substrates each substrate having first and
second opposite
major surfaces, the first major surface arranged to lie parallel to and face a
surface to be
covered; a quantity of re-stickable adhesive as herein before described bonded
to the first
major surface; and one or more release strips covering the removal adhesive.
It is envisaged in one embodiment that the adhesive 300 will be applied at the
time
of manufacture of the substrate 12. Thus in this embodiment a commercial
product would
comprise for example boxes of substrates 12 provided with one or more lines of
adhesive
material 300 covered with release strips 302. Installers are then able to
simply install a
surface covering by applying, if it does not already exist, a sealing coat or
membrane to the
surface 304, removing the release strip 302 and pressing the substrate 12 onto
an
underlying surface 304. In the event that the substrate also includes a joint
system such as,
but not limited to, the joint systems 10 et al as described herein above, then
the installer
would engage joints of adjacent panels during the installation process
In one example it is envisaged that the adhesive material 302 may be applied
by
rolling a strip or bead of hot melt pressure sensitive adhesive onto the major
surface 16.
Figures 24a-24c illustrate the adhesive 300 applied as strips of adhesive,
while Figures 25a
and 25b illustrate the adhesive 300 applied as beads B of adhesive. In
embodiments where
the re-stickable adhesive is provided by say GLUE DOTSTm adhesive dots, the
dots can be
applied by nnachine16.
In the present embodiments the quantity of re-stickable adhesive 300 is
applied in
three spaced apart lines extending in a longitudinal direction L of a panel
12. However as
will be explained in greater detail below, the adhesive material 300 may be
applied in
different configurations. The re-stickable adhesive material 300 is covered by
one or more
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release strips 302. In the depicted embodiment a separate release strip 302 is
applied
individually to each individual line of adhesive material 300. However in an
alternate
embodiment, a single release strip having dimensions substantially the same as
dimensions
of the major surface 16 may be applied to the quantity of re-stickable
adhesive 300. In that
instance, when using the substrate 12, an installer need peel off only one
release strip 302
rather than a number of separate release strips.
Figures 24c and 25b depict the use of the adhesive based surface covering
systems on an underlying surface 304 which may, for example, be a concrete
pad. In order
to apply the panel 12 the release strips 302 are removed and the panel 12 is
applied with
surface 16 directed toward or facing the surface 304. By contacting the
adhesive material
300 to the surface 304 and applying downward pressure, the panel 12 is adhered
to the
surface 304. Additional panel 12 can be likewise adhered to a surface 304 and
tessellated
to form a surface covering. The adhesive material 300 is sufficiently tacky
and strong to
adhere to the surface 304 with sufficient force to prevent lifting or
separation between the
panel 12 and surface 304 under normal use conditions. It is believed that
providing the
adhesive in the form of beads B (Figures 25a and 25b) may provide greater
horizontal
movement which typically occurs with changes in environmental conditions (e.g.
temperature and humidity). This stems from the rounded nature of the beads B
which may
facilitate an easier rolling or shear rolling effect than the strips of
adhesive.
Removal of a damaged panel (either with no joint system or with joint system
of a
type described herein above, i.e. a vertical joint system) can be performed in
the same
manner as described herein above in relation to Figures 6a-6s. That is, a
damaged panel is
removed vertically by use of one or more jacks 92. Figures 26a ¨ 26e depict in
part the
removal of a damaged panel 12b of a semi-floating surface covering system
which includes
adjoined panels 12a and 12c. Each of the panels in the semi-floating floor
system is formed
with a joint system 10 which may be in accordance with any one of the
embodiments of the
joint system described above. In addition beads B of adhesive material 300
adhere the
panels 12 to the underlying surface 90. In this particular embodiment there
are no beads of
adhesive material in between the joints Jnn and Jf of the joint system 10.
However in
alternate embodiments such adhesive material may be provided. In terms of the
process for
removal of the panel 12b the provision of additional adhesive between the
joints Jnn and Jf is
of no consequence. That is, the removal process remains the same as
irrespective of
whether or not adhesive material exists between the joints Jnn and Jf.
Figures 26b ¨ 26e show sequentially the steps of attaching a jack 92 to the
damaged board 12b and subsequently operating the jack to lift the panel 12b
from the
surface 90. The sequence of steps and the method of their performance are
identical to that
described herein above in relation to Figures 6d ¨ 6h. However in this
instance due to the
provision of the beads B of adhesive 300 the operation of the jack 92 to
vertically lift the
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panel 12b also has the effect of initially flexing and stretching the beads B
and subsequently
causing the beads B to detach and lift from the underlying surface 90. This
will occur
generally in sequence as a jack is operated to lift the panel 12b from a
region in the vicinity
of the jack 92 outwardly to lower lying regions. Thus the first beads B to
detach form surface
90 will be those on either side of or otherwise closest to the shaft 96 of the
jack 92. As the
jack 92 progressively lifts the panel 12b the beads B of adhesive 300 nearest
the most
recently detached beads will now lift off the surface 90 and so on.
Generally, the entirety of the bead B will lift from the surface 90 and thus
remain
bonded to the substrate 12. In some instances, very small portions of the
adhesive 300 may
remain on the underlying surface 90. Once the jack 92 has been operated to the
extent to
lift the panel 12b so that all of the adhesive beads B have been detached, the
remainder of
the normal removal process as described in relation to Figures 6g ¨ 6i; and
indeed the
entirety of the replacement processes shown and described in relation to
Figures 6j ¨ 6o is
be employed to reinsert a fresh undamaged panel.
It will be noted that some of the beads B of adhesive 300 have separated from
the
adjacent panels 12a and 12c. During the reinstatement process, these beads
which remain
on the panels 12a and 12c will re-adhere to the underlying surface 90. In
addition, of course
when a fresh panel is joined to the panels 12a and 12c, the adhesive 300 on
that fresh panel
will now also adhesively bond to the surface 90.
As will be understood by those skilled in the art, this represents a huge
advantage
over direct stick flooring systems in terms of the ability to properly repair
a damaged floor.
The accepted industry standard for optimal repair of a damaged floor is to
peel back all of
the panels from the closest wall to the damaged panel or panels. With direct
stick systems,
this is such a difficult task, that generally repairers take shortcuts and
simply attempt to
remove and replace only the damaged panels. This makes it impossible to
reconnect
mechanical joints between panels. In the event of any dimensional variation in
the panels
either due to environmental expansion or contraction, or simply due to the
inability to source
dimensionally equivalent fresh panels, installation will generally also
require the use of fillers
to make good any gap between the existing panels and the newly instated panel.
A further feature of substrates incorporating having embodiments of the joint
system 10 is the ability to reverse lay. Reverse laying has two meanings in
the art. One
meaning refers to the ability to lay form both sided of a panel. For example
consider a first
panel approximately midway between parallel walls in a room. The ability to
reverse lay
enables two installers (or two teams of installers) to lie in opposite
directions away from the
first panel. This naturally greatly reduces the installation time. This is
used with direct stick
panels and has the benefit of enabling run out to be amortised between
opposing walls of a
room to provide a superior visual appeal. Reverse laying with direct stick is
possible
because a layer can fix with glue a first panel in an optimum position in or
near the middle of
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the room to minimise run out near the walls. Additional panels can be stuck
down form
opposite side of the first panel. This cannot be done with floating floors
because a first panel
placed in an optimum position is not fixed, it floats, and thus cannot be used
as a base to lay
in opposite directions.
The other meaning of reverse lay refers to the ability to engage panels 12
which
extend perpendicular (or some orientation other than parallel) to each other.
This enables
for example the ability to lay in say a herring bone pattern.
Current prior art, even with direct stick, makes it reasonably difficult to
reverse lay
flooring because traditionally one must lay from the female joint away. This
is because in
the prior art lay down process the male joint is traditionally 50+% shorter
than the female
joint thus creating a less extreme angle needed or not needed to engage the
male portion
into the female portion into a locked horizontal plane. As the present joint
system 10 is
vertical, there is no lay down process. Rather the vertical nature of the
joint system 10
makes it exceptionally easy to engage panels from either side, either placing
a male joint on
an exposed female joint, in order to lay in one direction, or sliding the
female joint under a
male joint of a previously laid panel in order to lay in the reverse
direction.
Figures 27a and 27b illustrate the above aspects or meaning of reverse laying
pictorially. Figure 27a shows a floor plan 400 of a building in which a floor
comprising a
plurality of panels 12 is laid. Figure 27b illustrates in enlarged view detail
A of Figure 27a
encompassing a portion of a passageway of the building. Consider the laying a
traditional
floating floor in the building. The layer would choose a wall for example wall
402 in a room
403 as a starting wall against which a first panel 12a is laid. It is well
known that walls in
buildings are never perfectly parallel or square to each other and may be out
of alignment by
up to 100nnnn or more. In the current floor plan, wall 404 runs generally but
not exactly
parallel to a wall 402 and may be out of alignment by a length of say 100nnnn
between
opposite ends of the walls 402 and 404. Thus as the layer lays additional
panels 12b, 12c,
etc up to panel 12p the misalignment or divergence between the walls 404 and
402
becomes apparent as the edge of panel 12p does not abut the wall 404. Rather,
there is a
divergence between the edge of panel 12p and wall 404 requiring the provision
of obliquely
cut panels 12q laid end to end to make up the gap between the panels 12p and
wall 404. (It
should be explained that it would be unusual for a single panel to be of a
length sufficient to
extend for the full length of the room 403. Thus reference to panels 12a, 12b
etc is made
solely for the purposes of ease of description. Ordinarily for example panels
12a, 12b etc
shown in room 403 would comprise a plurality of panels joined end to end.)
The substantial misalignment between the walls 402 and 404 is highlighted by
the
obliquely cut panel 12q. It will be also seen in Figure 27a that there are
openings 406 and
408 for example as doorways in wall 404 into room 410 and hallway 412. The
panels laid in
room 410 and 412 follow the same direction and alignment with the panels 12 in
the room
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403. This then continues on the degree of misalignment between the panels and
the walls
of the house.
It will also be seen however that in other areas for example rooms 414, 416,
and
hallway 418 the panels 12 are laid generally perpendicular to the panels laid
in the other
rooms. This is provided as an illustration of the second form or type of
reverse laying.
With the use of the semi-floating semi-direct stick floor system as described
above
in relation to Figures 24a ¨ 25b, a layer can now utilise a centre line 420 of
say room 401 as
a starting point for the laying of the first panel and then reverse lay in
opposite directions. By
doing so the misalignment between the walls 402 and 404 from a visual
perspective can be
minimised by amortising the run out in the panels 12 immediately adjacent the
walls 402 and
404. This can be seen by the center line 420 passing obliquely through the
panels 12i and
12j which are shown in positions provided by traditional laying practice for
floating floors.
Now that embodiments of the vertical joint system and surface covering system
have been described in detail it will be apparent to those skilled in the art
that numerous
modifications and variations can be made without departing from the basic
inventive
concepts. For example embodiments are decided in relation to wooden flooring
panels.
However the systems are applicable to many different materials and may also be
applied to
surfaces or structures other than floors. For example panels incorporating the
joint system
may be made from plastics material to treat the LVT ("luxury vinyl tile")
market or may be
provided on base substrates made of plastics materials to which are attached
face panels of
other material such as carpet or ceramic tiles. In this embodiment the
resultant panel has a
laminate type structure where the base includes embodiments of the joint
system and the
face panel is provides a consumer with the desired finish. It will also be
apparent many of
the features of different embodiments are interchangeable or can be
additionally applied.
For example the recess 42 can be applied to each and every embodiment of the
joint
system. As can: an opposing recess of the type shown as recess 42b in Figure
22a; or
indeed additional recesses 42b, 42c and 42d. Further the re-stickable adhesive
300 may be
applied to such recesses. Also the jack 92 is described as a screw jack.
However other
types of jacks or lifting system can be used such as lever jack or pneumatic
or hydraulic
operated systems. Further the joint systems 10 are largely described in
application to
elongated rectangular panels. However they can be applied to panels of any
shape that can
tessellate. For example the joint system may be applied to square, hexagonal
or triangular
panels. Also there is no need for the panels to be of identical shape and/or
size.
All such modifications and variations together with others that would be
obvious to persons
of ordinary skill in the art are deemed to be within the scope of the present
invention the
nature of which is to be determined form the above description and the
appended claims.
