EP0817898A1

EP0817898A1 - Method for laying a floor covering as well as floor panels to be used for such method

Info

Publication number: EP0817898A1
Application number: EP96904383A
Authority: EP
Inventors: Jacobus Cornelis Kan; Simon Boekel
Original assignee: Forbo Krommenie BV
Current assignee: Forbo Krommenie BV
Priority date: 1995-03-08
Filing date: 1996-03-06
Publication date: 1998-01-14
Also published as: NL194446B; NL194446C; WO1996027722A1; NL9500462A

Abstract

Method for laying a floor covering, according to which the floor (9) is first covered with base panels (14) placed with one surface on the floor and the sides butting against each other in such a way that (tight) laying joints are formed, whereupon the remaining panel surfaces (4a), which are provided with an adhesive coating (10), are covered with top panels (6). According to the invention, after the base panels (4) have been laid against each other, the top panels (9) are laid with the joints (7) staggered at comparatively large distances in relation to the joints (5) of the base panels (4), whereupon a virtually unbreakable bond between the base panels and the top panels is obtained by pressing down said top panels (9).

Description

Method for laying a floor covering as well as floor panels to be used for such method.

The invention concerns . Tiethod for laying a floor covering, according to which the floor is first covered with base panels placed with one face on the floor and the sides butting against each other in such a way that (tight) joints are formed, whereupon the other faces of the base panels, which are provided with an adhesive coating, are covered with top panels.

It is a well-known fact that elastic floor covering and, albeit to a lesser extent, fabric floor covering need to be glued or worked on subfloors which are level, dry and compression resistant, and which retain their form. The actual practice, however, shows that often these quality requirements cannot be fully met. When laying a floor covering, problems arise with bricky subfloors that are not sufficiently level, despite the fact that there are many so-called flattening methods. Most flattening methods for concrete floors are based on powder systems, in which the powder is mixed with water to obtain a liquid mass, which is spread over the floor with a hand spatula, or which possesses such specific outflow properties that a level surface is obtained ..

Subsequently the floor has to be left to dry, until the water has evaporated to a sufficient extent, whereupon the actual floor covering can be laid according to the manufacturer's instructions. Obviously, this method is time-consuming and costly. Another problem arises with wooden subfloors, where the floor board structure or the slab shape shows through, as it were, e.g. in elastic floor coverings. To prevent this, wooden floors are levelled with e.g. hardboard or chipboard, the (laying) joints of which need to be carefully scoured. However, since some play will develop between the joints anyway after a while, these joints will show in the surface, especially that of elastic floors, in spite of the careful preparation. With fabric floor coverings this problem is less easy to detect and less conspicuous.

It will be clear from the above that the waiting times, the high preparation costs with respect to obtaining a level subfloor or base, as well as the cutting to size and gluing of the floor covering present significant problems, especially with linoleum and other elastic floor coverings. The invention overcomes the aforementioned drawbacks by introducing a system based on panels of a specific shape and size, which is characterized by the fact that after the base panels have been laid butting against each other, the top panels are laid with their joints staggered at comparatively large distances in relation to the joints of the base panels, whereupon a virtually unbreakable bond between the base panels and the top panels is obtained by pressing down the top panels. This efficient and effective floor covering system yields a perfect floor in one comparatively quick labour run, thereby completely overcoming the aforementioned problems such as time-consuming drying times. The end result is a floor surface ready to be finished, with a floor covering displaying strong, solid and aesthetically sound properties. Another advantage is the relative ease with which the floor covering, in accordance with the invention, can be taken up, which is particularly useful in case of removals, when the occupants are faced with the requirement of having to leave the floor in its original (bare) state.

It should be noted that the French patent specification no. 2080 356 describes a method which also uses panels; here, however, the floor covering does not only consist of three different panels of equal thickness, but also these are laid in such a way that at two sides only small strips of glue remain to hold the adjacent panels. This familiar type of fixing is insufficiently durable in the long run and leads to floor unevenness.

Preference should be given to the form of construction of the system characterized by the fact that the laying joints of the top panels are staggered over approximately % to V_ distance in relation to the joints of the base panels. Thus, a stable and solid floor covering is obtained.

Favourable is the form of construction characterized by the fact that some distance is kept between the panels and the limitations of the room such as walls and doors, in order to accommodate expansions of the panels due to physical influences, such as atmospheric humidity. Subsequently, covering profiles can be placed in or over the gaps or openings that have been formed.

In the method according to the invention, base panels as well as top panels can have any polygonal shape. Preferably, one of the faces should have an adhesive coating.

A favourable feature is a sound-proofing layer or a suitable insulation layer on the base panel. In a preferred form of construction, the top panel is designed with a wear- resistant and decorative layer, made of elastic or fabric material.

The invention will now be explained referring to the drawing, thereby illustrating its advantages and other features.

Figure 1 shows the view from above for part of the floor covering system;

Figure 2 shows the cross-sectional view according to line 2-2 from Figure

1 .

The view from above according to Figure 1 shows a schematization of a room in which the floor covering is to be laid.

Starting point is corner 1 of this room, which is confined by walls 2 and 3. In this explanation it is chosen to use rectangular panels with straight sides. It is, however, also possible to use bevelled edges or edges which are cut otherwise, thus obtaining solid and tight joints. At some distance, approximately 5 mm, of the walls, the first base panels 4 are laid in a manner as indicated by the dotted lines in the figure, the sides butting against each other, to form (tight) joints 5. Base panels 4 are then covered with top panels 6, indicated by the full line, which are also laid butting against each other to form joints 7. Incidentally, there is no need for joints 5 or 7 to be in line with each other, as indicated in the figure, since these positions depend on the lay-out or shape of the floor. It is, however, of major importance that joints 7 of top panels 6 be placed at a comparatively great distance from joints 5 of base panels 4. In the figure, this feature has been indicated by placing top panels 6 at approximately V_ to ¹/_ joint distance from each other as compared to base panels 4. To that end, base panels 4 at walls 2, 3 in this example have been covered by V_ or V_ surface part of top panels 6. The panels are secured by means of the usual adhesives. In order to accommodate changes, e.g. resulting from the relative humidity, between panels 4 and 6, a space or gap 8 will be kept open between the panels and walls 2, 3 or doors, which space or gap can later be filled up or covered by covering profiles. Preference is given to the form of construction of the system in accordance with the invention which is characterized by the fact that subfloor 9 is first covered with a water vapour proof foil or impact sound insulating foam layer 1 3, which is subsequently covered by base panels 4. This effectively ensures that moisture from subfloor 9 or changes in the relative air humidity in the room itself have as little effect as possible on the floor covering as a whole. It is also possible to prevent vaporous moisture from penetrating between the layers by covering the joints e.g. with strips of aluminium when laying the panels.

Figure 2 shows the view according to line 2 - 2 from Figure 1 , in which base panels 4 have been laid in accordance with the diagram in Figure 1 , on floor 9 and at some distance, e.g. 5 mm, from wall 3. In this example, panels 4 have been placed on top of water vapour proof foil 1 3, which significantly reduces the influences of moisture from floor 9. A suitable adhesive 10 has been applied to upper surface 4a, which has subsequently been covered with top panels 6 in accordance with the specific joint pattern as shown above (Figure 1 ). Preferably, a suitable adhesive will have been applied to bottom surfaces 6a of top panels 6 as well, so that a virtually unbreakable bond is obtained by pressing down panels 4 and 6, possibly mechanically. Furthermore, the upper surfaces of panels 6 may be provided with a decorative and at the same time wear resistant layer 1 1 , e.g. consisting of an elastic or fabric material.

After the panels have settled, e.g. affected by the air humidity, space 8 between walls 2, 3 and panels 4, 6 is filled up further or covered with suitable profiles 1 2, in such a way that the floor covering can imperceptibly move somewhat freely. For doorways, U-profiles or H-prof iles may be used between composite panels 4, 6.

Another advantage is that the panels are made of chipboard or plywood, or of HDF (High Density Fibre) board or MDF (Medium Density Fibre) board, which according to the invention can have various sizes and shapes.

It remains important, however, that the top and bottom joints of the panels are staggered at a comparatively great distance in relation to each other, so that a particularly stable and level floor covering is obtained, even if relatively small panels are used.

Claims

1 . Method for laying a floor covering, by which the floor is first covered with base panels placed with one face on the floor and the sides butting against each other in such a way that (tight) joints are formed, whereupon the other panel faces, which are provided with an adhesive coating, are covered with top panels, characterized in that after the base panels (4) have been laid against each other, the top panels (6) are laid with the joints (7) staggered at comparatively large distances in relation to the joints (5) of the base panels (4), whereupon a virtually unbreakable bond between said base panels (4) and said top panels (6) is obtained by pressing down said top panels (6).

2. Method according to claim 1 , characterized in that the laying joints (7) of said top panels (6) are staggered over approximately % to V_ distance in relation to the joints (5) of said base panels (4).

3. Method according to claims 1 or 2, characterized in that the sides of panels (4, 6) are placed at some distance of the limitations of the room, such as walls (2, 3) and doors, in such a way that covering profiles ( 1 2) can be placed in or across the openings or gaps (8).

4. Method according to one of the preceding claims, characterized in that the (sub)floor (9) is first covered with a water vapour proof foil or an impact sound insulating foam layer ( 1 3) upon which said base panels (4) are laid.

5. Panel to be used for the method according to claims 1 - 4, characterized in that base panels (4) and top panels (6) have the same polygonal shape.

6. Panel according to claim 5, characterized in that the sides of a panel are bevelled.

7. Panel according to claim 5 or 6, characterized in that at least the upper surface (4a) of the base panel (4) is provided with an adhesive coating (10) .

8. Panel according to claims 5 - 7, characterized in that the bottom surface is provided with a sound-proofing layer.

9. Panel according to claims 5 - 7, characterized in that the bottom surface is provided with an insulation layer.

10. Panel according to claim 5 or 6, characterized in that the bottom surface (6a) of said top panel (6) is provided with an adhesive coating ( 10), which forms a virtually unbreakable bond after being pressed onto the adhesive coating of said base panel (4).

1 1 . Panel according to claim 10, characterized in that the upper surface of a top panel (6) is provided with a wear resistant and decorative layer ( 1 1 ).

1 2. Panel according to claim 10 or 1 1 , characterized in that the upper surface of the top panel (6) consists of an elastic or fabric layer ( 1 1 ) .