EP1549486B1 - Floor covering panel with water resistant interlockable edges - Google Patents

Floor covering panel with water resistant interlockable edges Download PDF

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Publication number
EP1549486B1
EP1549486B1 EP02775705A EP02775705A EP1549486B1 EP 1549486 B1 EP1549486 B1 EP 1549486B1 EP 02775705 A EP02775705 A EP 02775705A EP 02775705 A EP02775705 A EP 02775705A EP 1549486 B1 EP1549486 B1 EP 1549486B1
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EP
European Patent Office
Prior art keywords
floor covering
panel
barrier composition
covering panel
abutment surface
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP02775705A
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German (de)
English (en)
French (fr)
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EP1549486A1 (en
EP1549486A4 (en
Inventor
Gregory Fowler
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Shaw Industries Group Inc
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Shaw Industries Group Inc
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Publication date
Application filed by Shaw Industries Group Inc filed Critical Shaw Industries Group Inc
Priority claimed from PCT/US2002/025894 external-priority patent/WO2004016422A1/en
Publication of EP1549486A1 publication Critical patent/EP1549486A1/en
Publication of EP1549486A4 publication Critical patent/EP1549486A4/en
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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N7/00—After-treatment, e.g. reducing swelling or shrinkage, surfacing; Protecting the edges of boards against access of humidity
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/01—Joining sheets, plates or panels with edges in abutting relationship
    • E04F2201/0107—Joining sheets, plates or panels with edges in abutting relationship by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edges
    • E04F2201/0115—Joining sheets, plates or panels with edges in abutting relationship by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edges with snap action of the edge connectors
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/01—Joining sheets, plates or panels with edges in abutting relationship
    • E04F2201/0153—Joining sheets, plates or panels with edges in abutting relationship by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/02—Non-undercut connections, e.g. tongue and groove connections
    • E04F2201/026—Non-undercut connections, e.g. tongue and groove connections with rabbets, e.g. being stepped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/07—Joining sheets or plates or panels with connections using a special adhesive material

Definitions

  • This invention relates generally to floor covering panels for use in commercial, industrial or residential environments. More particularly, this invention relates to a floor covering panel having complementary coupling members with a barrier composition applied to the side edges of the floor covering panel.
  • Fiberboard core laminates used to manufacture flooring products typically include a plurality of layers, including a fiberboard or organic composite core layer, a decorative layer, and a hard and flat protective wear layer of resin-impregnated melamine material. These layered constructions are typically formed into standard-sized panels which are joined together at an installation site to create a floor covering system.
  • the floor covering systems may be vulnerable to water damage at the joints between adjacent floor covering panels that make up the floor covering system. Slight imperfections in the fit (seam) between adjacent floor panels may allow water or other liquids to penetrate into the joints between floor panels, which may, in turn, result in damage, warpage, accelerated wear, or deteriorated fit of individual floor panels.
  • cleaning materials generally comprise surfactants that may accelerate the seepage of water into the seam. Because the materials that make up the inner layers of the floor panels may not be completely impervious to water, those layers may absorb water or other fluids, resulting in damage or decreased product life.
  • paraffin-based materials to floor covering panels in an attempt to improve the water resistance of these products.
  • such materials generally are not durable and, as such, do not provide a good water resistance for the useful life of a floor covering system.
  • such materials also do not provide enough barrier when, for example, cleaning agents are repeatedly used on the floor covering materials or when low surface tension materials are spilled on the floor.
  • WO 03/012224 A WO 03/048481 A1 and EP-A-1 262 609 show floor covering panels, wherein used barrier composition comprises oil, wax, acrylic polymer or silicon polymer. Also, in US-A-6 006 486 , DE 297 03 962 U1 and DE 296 10 462 U1 floor covering panels are shown, which have a barrier composition comprising oil or wax.
  • this invention in one aspect, relates to a floor covering panel.
  • the invention includes a first substantially planar surface and a second substantially planar surface opposed to the first surface. Between the first and second surfaces are a first side edge and an opposed second side edge, respectively.
  • a first coupling member which includes a protrusion extending therefrom and a first abutment surface between the protrusion and the first surface.
  • a complementary second coupling member is defined within the second edge of the panel and includes a recess sized and shaped to receive the first protrusion therein and a second abutment surface between the recess and the first surface.
  • a barrier composition is selectively applied to at least a portion of at least one of the first and second abutment surfaces. and comprises an active ingredient, that comprises a cross linkable fluoro-chemical specifically pre-applied at a factory.
  • a first coupling member of a first panel is received within a second coupling member of a second panel such that the barrier composition is positioned between the respective first and second abutment surfaces of the two panels.
  • a water resistant barrier is thereby formed between the two coupling members in association with the barrier composition applied thereto.
  • a plurality of panels may be joined together in this manner to form a floor covering system.
  • the barrier composition is applied to at least one of the first or second abutment surfaces at a point in the floor covering manufacturing process.
  • a barrier composition may be applied to the entire surface of one or both of the first and second abutment surfaces.
  • the barrier composition provides a water resistant barrier that substantially reduces the possibility of water or other liquids penetrating the seam of two mated floor covering panels under normal use conditions.
  • the present invention in one embodiment, is a floor covering panel 10.
  • the panel 10 includes a first generally planar surface 11 and a second generally planar surface 12 opposed to the first surface 11. Extending between the surfaces 11, 12 are a first side edge 13 and an opposed second side edge 14, respectively, each of which runs the length of the floor covering panel. Defmed within the first side edge 13 is a first coupling member 20, which includes a protrusion 21 extending therefrom. The first coupling member 20 further comprises a first abutment surface 50 between the protrusion 21 and the first surface 11.
  • the second side edge 14 includes a second complementary coupling member 22 defined therein that includes a recess 23 sized and shaped to receive the protrusion 21 of a second one of the floor covering panels therein.
  • the second coupling member 22 also includes a second abutment surface 52 between the recess 23 and the first surface 11.
  • a barrier composition 60 is selectively applied to at least a portion of at least one of the first or second abutment surfaces 50, 52 as desired.
  • a plurality of floor covering panels may be joined together to form a floor covering system 15 as shown in Fig. 1 .
  • the present invention includes floor covering panels of various constructions known in the industry or that may be developed in the future.
  • the floor covering panels may be manufactured from a laminated material having a fiberboard core.
  • the present invention may be constructed of other types of laminates such as high pressure laminates, which have been marketed under such trade names as Formica ® and Wilson Art ® .
  • Other materials may also be used to construct the floor panel such as natural organic, recycled or synthetic materials.
  • the floor covering panel may be a tongue and groove wooden flooring material, such as those manufactured by Bruce Hardwood Floors, a division of Armshong Flooring, Inc. (Lancaster, PA).
  • the present invention is suitable for use on any flooring substrate that may benefit from formation of a non-refastenable bond as set forth in more detail herein.
  • a typical laminate floor panel is constructed of a plurality of discrete layers, which may include some or all of the following: a backing layer 16, a core layer 17, a decorative layer 18, and a wear layer 19.
  • the various layers may be adhered, joined, or coupled to one another by a chemical adhesive, mechanical connection, or other means known in the art for forming the panel.
  • the first generally planar surface 11 is usually the upper surface of the wear layer 19 while the second generally planar surface 12 is typically created by the lower surface of the backing layer 16 as shown in Fig. 2 .
  • the backing layer 16 faces the underlying subfloor (not shown).
  • the backing layer 16 may provide an improved moisture resistance to the floor panel 10 because the core layer 17 typically is not completely impervious to moisture or contaminants. Additionally, the backing layer 16 may improve the structural integrity of the floor panel 10 by increasing overall thickness and reducing the warp and wear tendencies of the uncoated core material.
  • the construction of the backing layer 16 may, for example, comprise a clear sheet of melamine reinforced with aluminum oxide (AlO 2 ) and impregnated with a suitable thermosetting resin. In other embodiments, backing layers 16 may be constructed of other materials providing suitable moisture resistance, such as phenolic resins or other natural, synthetic or recycled materials.
  • the core layer 17 may be formed from medium density or high density fiberboard, such as those marketed by companies such as Louisiana Pacific, Georgia Pacific, Temple Inland, and Weyerhauser.
  • medium density or high density fiberboard such as those marketed by companies such as Louisiana Pacific, Georgia Pacific, Temple Inland, and Weyerhauser.
  • One fiberboard core material found to produce acceptable results is a high density fiberboard, which is a hardwood/softwood fiber compound compressed at 900 - 960 kg/m 3 .
  • Such fiberboard core material is usually available in 4 or 5 feet widths (1.22 - 1.52 meters) and lengths of up to 18 feet (5.49 meters).
  • core layers 17 constructed of different materials or having different properties may be utilized, including but not limited to other timber-based products, such as plywood, chipboard or particleboard.
  • the decorative or "décor" layer 18 comprises a sheet of paper that substantially covers the top surface of the core layer 17.
  • the visible side of the decorative layer 18 displays a desired aesthetic appearance, such as a color or pattern.
  • some currently contemplated patterns include simulated hardwood flooring and simulated ceramic tile, each in a variety of styles, shades and colors.
  • simulated hardwood styles include pine, heart pine, cherry, maple, beech, oak and mahogany.
  • Simulated tile appearances are contemplated in a range of styles, including a variety of marble and ceramic tile colors, including grout lines in ceramic tile styles.
  • Other currently contemplated patterns include floral patterns, abstract designs, geometric designs and company logos. Other patterns may be selected by the manufacturer or user according to their aesthetic preference or design objectives.
  • the decorative layer 18 may be manufactured from paper that is impregnated with a thermosetting resin and provided with the desired aesthetic color and/or pattern. Other materials may make up the decorative layer 18, such as real wood veneer, pulverized stone, or other materials. Additionally, it is possible to achieve a similar decorative appearance by applying a direct or indirect printing process onto the top surface of the core layer 17.
  • the decorative layer 18 comprises the ink, dye, pigment or other marking substances applied to the core layer 17.
  • the decorative appearance may be provided by etching, burning or otherwise marring the top surface of the core layer 17. Any such treatment that supplies such a decorative appearance on the top surface of the core layer 17 is contemplated to comprise the decorative layer 18 as defined herein.
  • a decorative appearance may be imparted directly to the upper surface of the wear layer 19, which may remove the need for a decorative layer 18 within the floor panel 10.
  • the wear layer 19 may be adhered, joined, or coupled to the decorative layer 18 to protect the panel from the ambient environment.
  • the wear layer 19 is substantially transparent so that the aesthetic appearance of the decorative layer 18 is unobstructed by the wear layer 19.
  • a wear layer 19 is optional, the resistance of the floor panel 10 to wear, staining or fading of the aesthetic image imparted to the decorative layer 18 may be generally improved by the inclusion of a wear layer 19 in the floor covering panel 10.
  • the wear layer 19 may comprise a melamine sheet which is reinforced with AlO 2 and impregnated with a thermosetting resin. Alternately, the wear layer 19 may comprise a layer of varnish or other UV curable scratch resistant coating.
  • the wear layer 19 may be made from any material providing suitable moisture resistance and resilience to loads and wear to which a floor is subjected, such as phenolic resins or other natural, synthetic or recycled materials.
  • the coupling members 20 and 22 of the present invention provide a means for joining two adjacent floor covering panels 10a, 10b together as illustrated in Figs. 1 and 3 .
  • One illustrative example of such a means for adjoining adjacent panels is set forth in U.S. Patent No. 6,006,486 to Moriau et al .
  • the first edge 13 of the panel 10 includes the first coupling member 20.
  • the first coupling member 20 includes a protrusion 21 with a rib 30 formed on the underside thereof.
  • the second coupling member 22 includes an upper lip 33, a lower lip 31, and a detent 32 formed within the lower lip 31.
  • the recess 23 is sized and shaped to accept the protrusion 21, and the detent 32 is sized and shaped to accept the rib 30.
  • the detent 32 and the rib 30 represent a locking structure, which will be discussed in greater detail below.
  • the coupling of floor covering panel 10a to adjacent panel 10b is achieved by placing the first coupling member 20 of panel 10a into the second coupling member 22 of panel 10b.
  • the tip of the protrusion 21 of panel 10a is inserted into the recess 23 of panel 10b at an angle above the horizontal, and the panel 10a is then rotated clockwise until the panels 10a and 10b are within substantially the same horizontal plane, as illustrated.
  • contact is made between the complementary coupling members 20, 22 of the two panels 10a, 10b in four contact zones as shown in Fig. 3 .
  • the protrusion 21 of panel 10a contacts the upper lip 33 and the lower lip 31 of panel 10b at contact zones 40 and 41, respectively.
  • Contact zones 40 and 41 help locate the panels into substantially the same horizontal plane.
  • the rib 30 ( Fig. 2 ) of panel 10a engages the detent 32 of panel 10b at contact zone 42.
  • the contact zone 42 is substantially planar; however, any contact zone may be formed in any shape depending on the profile desired.
  • the angle formed by the substantially planar contact zone 42 and the substantially planar second surface 12 forms an acute angle therebetween, when measured from the second surface 12 counterclockwise to the plane of the contact zone 42.
  • This configuration ensures that the contact force between the adjacent panels 10a, 10b at the contact zone 42 urges the panels together and promotes a tight joint.
  • This locking structure defined by the rib 30 of panel 10a and the detent 32 of panel 10b prevents substantial separation of the two panels 10a and 10b in a direction perpendicular to the side edges 13, 14 of the panels 10a, 10b and parallel to the respective first surfaces 11.
  • An additional contact zone 43 is present in the embodiment illustrated in Fig. 3 , adjacent the first surface 11 of each of the panels at the juncture between the first abutment surface 50 of panel 10a and the second abutment surface 52 of panel 10b.
  • floor covering panels 10 may be manufactured in a variety of shapes and sizes, commonly including square, rectangular and other polygonal embodiments. In the case of square and rectangular panels, each panel has four side edges. Thus, according to the invention, each panel 10 may include two first side edges 13, and two opposed second side edges 14, each edge extending between the top and bottom surfaces 11, 12 of the panel 10.
  • Figs. 2 and 3 are for illustrative purposes only, and that the present invention is equally applicable to other coupling profiles known in the industry or that may be developed in the future.
  • the quantity, size and location of the contact zones may vary with the profile as desired, but the different profiles still fall within the scope of the present invention.
  • a tongue and groove profile without a locking structure would benefit from, and fall within the scope of the present invention.
  • a tongue and groove profile in which substantially full contact is maintained along the entire mating edges of the panels is also contemplated as being within the scope of the invention.
  • the barrier composition 60 is selectively pre-applied to the floor covering panels at the factory, at any desired location and in any desired amount, using one of a number of methods known to one of skill in the art.
  • the barrier composition may be applied in spray form at the desired location.
  • the barrier composition 60 is selectively applied to at least a portion of at least one of the first or second abutment surfaces 50, 52, as desired, for example the contact zones 40-43.
  • the barrier composition 60 may be selectively applied to at least a portion of the first abutment surface 50.
  • the barrier composition 60 may be selectively applied to at least a portion of the second abutment surface 52.
  • the barrier composition 60 may be selectively applied to at least a portion of both the first and the second abutment surfaces 50, 52, which portions may correspond with, or be separate of, one another, as desired.
  • the barrier composition 60 may be selectively applied only to substantially all of the first abutment surface 50 at a location corresponding to the contact zone 43.
  • selectively applied it is meant that the barrier composition 60 is applied only to the intended area of application, and that the barrier composition 60 is not applied to neighboring areas or any other areas besides the selected and intended area of application.
  • the barrier composition 60 forms a moisture barrier between the first and the second abutment surfaces 50, 52, such that water and other liquids along the first surface 11 of the adjacent panels 10a, 10b are substantially prevented from seeping past that moisture barrier.
  • the barrier composition 60 may be selectively applied only to substantially all of the second abutment surface 52 at a location corresponding to contact zone 43.
  • the barrier composition 60 may be selectively applied to substantially all of both the first and second abutment surfaces 50, 52 at a location corresponding to contact zone 43.
  • the barrier composition 60 may be applied to some portion of, or the entirety of, one or both of the coupling members 50, 52. As set forth above, in various embodiments, the barrier composition 60 may be selectively applied only to locations on the first abutment surface 50. Alternatively, the barrier composition 60 may be selectively applied only to locations on the second abutment surface 52. In yet another embodiment, the barrier composition 60 may be selectively applied to locations on both the first abutment surface 50 and the second abutment surface 52.
  • the barrier composition 60 may be applied to substantially the entire first edge 13, second edge 14, or both, as desired.
  • a vacuum coating process may be utilized.
  • a floor covering panel is passed through a machine that applies the barrier composition under pressure to one side of a respective edge of a floor covering panel.
  • a vacuum is applied at an opposite side of the edge of the panel to remove excess barrier composition from the floor covering panel.
  • Excess barrier composition is returned to a vessel for re-use.
  • Use of such a vacuum coating method allows for precise application of the barrier composition to a floor covering panel by way of adjusting the pressure/vacuum ratios.
  • a further method that may be utilized to apply the barrier composition to the floor covering panel is the use of a roll coat applicator.
  • a roll coat applicator In this method, several large diameter rollers are made to match the area to be coated on the floor covering panels.
  • the barrier composition may be applied to the floor covering panels by a transfer roller that is supplied with the barrier composition from a supply reservoir.
  • the application of the barrier composition can be precisely controlled by adjusting the parameters used in the application.
  • a further method of applying the barrier composition to the floor covering panels is achieved by use of a multi-spray head applicator.
  • This method will allow application of the amount of barrier composition to the flooring profile with precision and accuracy.
  • multiple spray applicators may be fitted with nozzles and situated to spray the barrier composition on selected portions of the side edges of a floor covering panel.
  • the spray applicators may pulse at a high frequency to apply the barrier composition to the desired position on the floor covering panel, which pulsing action may also assist in keeping the spray head clean.
  • the barrier composition is supplied to the spray head by means of a conventional pump system that draws the composition from a supply tank.
  • Such spray application systems are known to those skilled in the art, and the spray applications are commercially available from manufacturers including Spraymation, Inc. (Ft. Lauderdale, FL).
  • barrier composition Other methods of applying the barrier composition may be utilized according to the invention, including other existing methods of applying the barrier composition, and including methods of applying the barrier composition that may be developed in the future.
  • the amount of barrier composition applied to the floor covering material is not critical, as long as the desired water barrier qualities are provided. Generally, about 0.1, 0.5, 1.0, 2.0, or 5.0 g of composition per 8" x 48" (0.20 x 1.22 meters) board may provide the desired water barrier quality in the finished floor covering material.
  • barrier composition means the composition comprising the active ingredient, i.e., the chemical material providing the primary barrier properties, and any solvent or diluent and other ingredients.
  • the active ingredient may be any material that is suitable for use to provide water resistance or oil resistance to a surface.
  • the following material may be utilized as the active ingredient in the barrier composition: a fluorochemical.
  • the active ingredient for the barrier composition consists essentially of a fluorochemical.
  • a barrier composition comprising the active ingredient disclosed herein will result in a reduction of the wettability of the surface of a floor covering panel. Since the wettability of the floor covering panel is lower, there will be a lesser possibility for water or other damaging materials to migrate through the seam of a mated pair of floor covering panels. This water barrier property is very important so as to allow floor covering materials to be used in locations that are commonly subjected to contact with water, such as bathrooms, kitchens and other areas.
  • the barrier composition for application to the floor covering panels comprises a fluorochemical as an active ingredient.
  • Suitable fluorochemicals are those that can have been used to provide water repellent qualities to textiles and other materials. Such materials are well known to one of ordinary skill in the art. Any fluorochemical that is suitable for use in imparting stain or oil resistance to textile materials may be used in the present invention.
  • the fluorochemical may comprise unbranded generic fluoropolymers.
  • Suitable fluorochemical textile treating agents include, but are not limited to, commercially available fluorochemical compositions.
  • Commercially available fluorochemical compositions may be used in the invention herein such as SCOTCHGUARD FC 255, SCOTCHGUARD FC 214-230, products of 3M Corp. (St. Paul, MN) and TEFLON, TEFLON 8070, and TEFLON 8787 and Zonyl 8412, available from DuPont (E.I. DuPont de Nemours Corp., Wilmington, DE.).
  • fluorochemical compounds include the following: FX-1367F and FX-1355 both from 3M Specialty Chemicals Division, NRD-372 from DuPont Flooring Systems, TG-232D from Advanced Polymers, Inc. (Carlstadt, NJ) and Nuva 3555 from Hoechst Celanese (Munich, Germany). Other similar fluorochemical compounds from these and other manufacturers may also be suitable.
  • the barrier composition does not comprise an organic solvent. Still further, the diluent for the active ingredient of the barrier composition comprises water or, in a further aspect, consists essentially of water. Yet further, the barrier composition comprises an emulsion or dispersion of the active ingredient in water. In a further aspect, the barrier composition is substantially non-flammable and may be utilized in an industrial setting without the use of explosion and fire proof equipment.
  • a polymeric material may be desirable for use as the active ingredient.
  • suitable polymers include fluoropolymers. Such materials will generally have higher molecular weights and, as such, may allow a more durable deposition of the barrier composition to the floor covering panels.
  • the barrier composition provides a treatment that makes a floor covering material durable for at least about 6 months, or at least about 1 year, or at least about 5 years, or at least about 7 years, or at least about 12 years, or for the entire useful life of the floor covering system.
  • the barrier composition comprises a fluoroalkyl acrylate copolymer.
  • the fluoroalkyl acrylate polymer may be formulated in an emulsion.
  • Specific examples of such an emulsion for use in the barrier composition compositions of the present invention are Unidyne TG-572 and TG-472 (Daikin America, Signal Mtn., TN).
  • TG-472 is believed to comprise about 30 % by weight fluoroalkyl acrylate copolymer and emulsifiers, about 5.4% tripropylene glycol, with a balance of the composition comprising water.
  • the composition of TG-572 is believed to be similar.
  • the barrier composition may comprise about 100 % by weight of a composition comprising the active ingredient as supplied by the vendor, i.e . neat.
  • the composition as supplied by a vendor may comprise any amount of active ingredient.
  • such compositions are normally supplied as solutions or dispersions of water barrier chemicals in water or other solvents.
  • the concentration of barrier chemicals as supplied by a vendor is not significant as long as the appropriate dilution may be obtained to provide the barrier compositions suitable for use in the present invention.
  • the composition as provided may be diluted prior to use on the floor covering panels. Any suitable solvent may be used for the dilution but water results in a lesser environmental impact from industrial use of the active ingredient.
  • the barrier composition may comprise water as a primary solvent.
  • the active ingredient for the barrier composition is crosslinkable.
  • Crosslinkable means the active ingredient reacts with or condenses with itself to result in a final product with a molecular weight of at least about 1.5 times or about 2 times or about 3 times the molecular weight of the non-crosslinked active ingredient.
  • the active ingredient may also be crosslinkable in conjunction with a second material, such as melamine/formaldehyde resin.
  • the active ingredient may be crosslinkable by application of energy to the barrier composition after application of the barrier composition to the floor covering panel.
  • the energy can be applied by heat, infrared lamps or microwave energy.
  • the active ingredient may also be crosslinkable by inclusion of a crosslinker in the barrier composition.
  • the active ingredient is substantially crosslinked at the conclusion of the application of heat, however, it will be recognized that with time, some additional crosslinking may occur.
  • the final amount of active ingredient in the barrier composition may vary within a wide range.
  • the amount of active ingredient (that is, the water barrier chemical) in the barrier composition may be about 1, 2, 5, 10, 15, 20, 25, 30, 40 or 50% or by weight of the barrier composition, with any value forming the upper and lower endpoint, as appropriate.
  • the balance of materials in the barrier composition may primarily be water, along with a minor amount of other materials.
  • the barrier composition may include additives as are known to one of ordinary skill in the art.
  • the barrier composition may include one or more of: surfactants, viscosity modifiers, preservatives, surface tension modifiers or opacifiers.
  • any dilution of the active ingredient will depend in large part on the type and amount of active ingredient in the composition as supplied by a manufacturer.
  • the barrier composition provides a durable water resistance or barrier treatment to a floor covering panel or floor covering panel system.
  • “Durable” is used herein to mean that the barrier composition provides a treatment that will substantially reduce the possibility that water or other liquids will penetrate the seam of two mated floor covering panels.
  • the barrier composition should provide a water barrier that lasts at least 2 times as long as the barrier provided by a paraffin-based composition. Still further, the barrier composition of the present invention should reduce the amount of water penetrating a top seam by at least 1/2 or 3/4, even when the water comprises a small amount of surfactant, i.e ., 1 weight percent of the water or less.
  • the barrier composition of the present invention will provide a durable water barrier for one normal mopping cycle per week for about 1 year, or about 2 years, or about 5 years, or about 7 years, or about 12 years, or about as long as the normal useful life of the particular floor covering panel system.
  • the present invention may also be utilized in conjunction with an invention relating to selective application of an adhesive composition to a floor covering panel.
  • the invention relating to this adhesive is described in detail in WO 2004/016873 A1 filed concurrently herewith.
  • the barrier composition may be dried for about 5 seconds, about 10 seconds, about 30 seconds, about 1 minute, about 3 minutes, about 5 minutes, about 10 minutes, or about 20 minutes, with any value forming an upper or lower endpoint, as appropriate.
  • the temperature applied to dry and/or crosslink the active ingredient may be from about 100 of (37.8°C), about 120 of (48.89°C), about 140 °F (60°C), about 160 °F (71.1°C), about 180 of (82.2°C), about 200 of (93.3°C), or about 220 °F (104.4°C), where any value may form an upper and lower endpoint, as appropriate. In some aspects, it is important to heat the floor covering panels to at least about 180 °F (82.2°C) for at least 10 seconds.
  • the barrier composition may include additives as are known to one of ordinary skill in the art.
  • the barrier composition may include one or more of: surfactants, viscosity modifiers, preservatives, surface tension modifiers or opacifiers.
  • the barrier composition can be applied to the entire profile of the floor covering panel so as to provide an exceptionally complete waterproofing to the panel, e.g ., waterproofing will be applied from both above and below.
  • crosslinked polymer forms the active ingredient of the barrier composition of the present invention
  • the barrier composition may be applied to an entire portion of the first or second abutment.
  • the active ingredient of the barrier composition must be crosslinkable or, put another way, crosslinked when the floor covering panels are assembled for use in a commercial or residential establishment.
  • the crosslinkable material may be a fluoropolymer.
  • the crosslinkable material may be a fluoroacrylate polymer as described elsewhere herein.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Civil Engineering (AREA)
  • Forests & Forestry (AREA)
  • Floor Finish (AREA)
  • Road Paving Structures (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
  • Laminated Bodies (AREA)
EP02775705A 2002-08-14 2002-08-14 Floor covering panel with water resistant interlockable edges Expired - Lifetime EP1549486B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2002/025894 WO2004016422A1 (en) 2002-08-14 2002-08-14 Water resistant tongue and groove flooring

Publications (3)

Publication Number Publication Date
EP1549486A1 EP1549486A1 (en) 2005-07-06
EP1549486A4 EP1549486A4 (en) 2006-12-13
EP1549486B1 true EP1549486B1 (en) 2010-05-19

Family

ID=34271619

Family Applications (1)

Application Number Title Priority Date Filing Date
EP02775705A Expired - Lifetime EP1549486B1 (en) 2002-08-14 2002-08-14 Floor covering panel with water resistant interlockable edges

Country Status (8)

Country Link
EP (1) EP1549486B1 (ja)
JP (1) JP2005535809A (ja)
AT (1) ATE468218T1 (ja)
AU (1) AU2002341556B2 (ja)
BR (1) BR0215839B1 (ja)
CA (1) CA2495368C (ja)
DE (1) DE60236464D1 (ja)
MX (1) MXPA05001795A (ja)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016157054A1 (en) * 2015-03-30 2016-10-06 Bordline S.R.L. Method for providing samples of materials with wood effect and sample thus obtained
US11834844B2 (en) 2019-01-30 2023-12-05 I4F Licensing Nv Flooring panel and a floor covering with such panel

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2540743C2 (ru) * 2009-12-17 2015-02-10 Велинге Инновейшн Аб Способы и устройства, связанные с формированием поверхностей строительных панелей
DE202010015754U1 (de) * 2010-11-23 2011-01-20 Akzenta Paneele + Profile Gmbh Fußbodenpaneel mit weichelastischer Nutzschicht

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DE9413059U1 (de) * 1994-08-12 1994-10-06 Ostermann & Scheiwe GmbH & Co, 48155 Münster Bodenpaneel
US5618602A (en) * 1995-03-22 1997-04-08 Wilsonart Int Inc Articles with tongue and groove joint and method of making such a joint
DE29517995U1 (de) * 1995-11-14 1996-02-01 Witex AG, 32832 Augustdorf Fußbodenelement, insbesondere Laminatpaneel oder -kassette aus einer Holzwerkstoffplatte
BE1010487A6 (nl) * 1996-06-11 1998-10-06 Unilin Beheer Bv Vloerbekleding bestaande uit harde vloerpanelen en werkwijze voor het vervaardigen van dergelijke vloerpanelen.
DE19651149A1 (de) * 1996-12-10 1998-06-18 Loba Gmbh & Co Kg Verfahren zum Schutz von Schnittkanten von Bodenbelägen aus Holz, Kork oder Holzwerkstoffen
DE29703962U1 (de) * 1997-03-05 1997-04-24 Witex AG, 32832 Augustdorf Element zur Erzeugung eines Fußboden- oder Wandflächenbelages, insbesondere Laminatpaneel
US6761008B2 (en) * 1999-12-14 2004-07-13 Mannington Mills, Inc. Connecting system for surface coverings
DE10022246A1 (de) * 2000-05-08 2001-11-15 Basf Ag Beschichtungsmittel für die Herstellung schwer benetzbarer Oberflächen
FR2825397B1 (fr) * 2001-06-01 2004-10-22 Tarkett Sommer Sa Element(s) de revetement de sol a joint d'etancheite
SE519791C2 (sv) * 2001-07-27 2003-04-08 Valinge Aluminium Ab System för bildande av en fog mellan två golvskivor, golvskivor därför försedd med tätningsorgan vid fogkanterna samt sätt att tillverka en kärna som bearbetas till golvskivor
DE20122020U1 (de) * 2001-12-04 2003-12-18 Kronospan Technical Co. Ltd. Feuchtigkeitsschutzmittel für Paneele

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016157054A1 (en) * 2015-03-30 2016-10-06 Bordline S.R.L. Method for providing samples of materials with wood effect and sample thus obtained
US11834844B2 (en) 2019-01-30 2023-12-05 I4F Licensing Nv Flooring panel and a floor covering with such panel

Also Published As

Publication number Publication date
EP1549486A1 (en) 2005-07-06
EP1549486A4 (en) 2006-12-13
AU2002341556A1 (en) 2004-03-03
ATE468218T1 (de) 2010-06-15
DE60236464D1 (de) 2010-07-01
BR0215839A (pt) 2005-07-12
CA2495368A1 (en) 2004-02-26
JP2005535809A (ja) 2005-11-24
BR0215839B1 (pt) 2013-11-19
MXPA05001795A (es) 2005-05-05
AU2002341556B2 (en) 2009-11-05
CA2495368C (en) 2012-06-05

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