EP1606473A1

EP1606473A1 - Floor panel with sealing lip

Info

Publication number: EP1606473A1
Application number: EP04722935A
Authority: EP
Inventors: Keith Meanwell
Original assignee: Kingspan Holdings IRL Ltd
Current assignee: Kingspan Holdings IRL Ltd
Priority date: 2003-03-24
Filing date: 2004-03-24
Publication date: 2005-12-21
Also published as: IE20040187A1; GB0406579D0; GB2399834B; GB2399834A; WO2004085764A1

Abstract

A floor panel (1) comprises a substrate (3) with a top surface (2) and side edges (6). An edging strip (7) is applied to at least one of the side edges (6) of the panel. The edging strip (7) has a substantially flat inner face for bonding to a side edge (6) of the panel and has an outwardly projecting sealing lip (8) for sealing between adjacent floor panels, on assembly.

Description

FLOOR PANEL ITH SEALING LIP

Introduction

The present invention relates to floor structures and more specifically to a floor panel for use therein.

Floor panels of the type used in raised access floors supported by pedestals, are often manufactured with a protective strip bonded to the side edges thereof. The strips serve both an aesthetic function, in that it covers unsightly edges, and a practical function, in that it protects the sides of the panel. In known floor panels the edging strip is usually comprised of narrow strips of plastics material which are bonded to the sides of the floor panel with the uppermost edge thereof flush with the upper surface of the decorative surface covering. The narrow strip is typically l-2mm thick.

One problem with floor panels of this type is that a gap is needed for natural expansion of the floor panel, however if the void space under the access floor is to be used as a plenum chamber then this required gap needs to be sealed to hold the air pressure.

EP0313485 describes an arrangement in which a fitting is applied to the edges of a floor panel by means of a tongue which extends from an inner face of the fitting and is received in a groove in the panel edge. Sealing lips extend from the outer and inner surfaces of the fitting. US3759005 describes a similar edging arrangement in which a seal extends outwardly from an outer face of the edging and a tongue for engagement with a panel extends from the inner face. Such peripheral fittings however have the disadvantage of having a complex structure. Furthermore the panel needs to be modified to receive the strips. It is an object of the present invention to provide an improved construction of floor panel which will address these issues.

Statements of Invention

According to the invention there is provided a floor panel comprising a planar substrate having an edging strip applied to at least one of the side edges thereof, characterised in that the edging strip has a substantially flat inner face for bonding to a side edge of the panel and has a sealing lip projecting from an opposite face thereof for sealing between adjacent panels, on assembly.

In one embodiment the sealing lip is integral with the edging strip. The edging strip may be of plastics material. For example, the edging strip is moulded from a plastics material. The edging strip may be an extrusion.

In one embodiment the edging strip is adhesively bonded to the substrate.

The planar substrate may be a core material. In one embodiment the planar substrate is a core material which is at least partially covered by an envelope. The planar substrate may be a core material encapsulated in an envelope. The envelope may be of metal such as steel. The core may be of wood, concrete or the like.

In one embodiment a decorative surface coating is bonded to the top surface of the substrate. The surface covering may be of a material selected from a floor covering such as vinyl, carpet, laminate, wood, stone or marble.

The invention also provides a floor panel assembly comprising a plurality of floor panels of the invention, the sealing lip of the edging strip projecting towards an adjacent edge of an adjacent floor panel. In one embodiment adjacent edges of adjacent panels have edging strips attached thereto and the sealing lips of the adjacent edging strips project towards one another to seal a gap between the panels.

Brief Description of the Drawings

The invention will be more clearly understood from the following description thereof given by way of example only, with reference to the accompanying drawings, in which: -

Fig. 1 is a cross-sectional view through a floor panel according to one embodiment of the invention;

Fig. 2 is a cross-sectional view through portion of a floor panel according to another embodiment of the invention;

Figs. 3 and 4 are cut away perspective views of alternative floor panels of the invention;

Figs. 5 and 6 are perspective views of a joint between two adjacent floor panels of an access floor system according to the invention;

Fig. 7 and 8 are cross sectional views of joints between two adjacent floor panels according to of the invention; and

Figs. 9 and 10 are sectional views of two alternative floor panel edges seals according to the invention; Detailed Description

Referring to Fig. 1 a floor panel 1 according to the invention comprises a substrate having a top surface 2, a core 3 and side edges 6. An edge sealing strip 7 comprising a seal 8 is attached to the side edge 6 of the panel.

Referring to Figs. 2 to 4 a panel 1 of an alternative embodiment comprises a core 3 of a suitable material such as chipboard which in this case is encapsulated in an envelope 4 having a top surface 2 and side edges 6. A decorative surface covering 5 may be bonded to the upper surface 2 of the substrate. The decorative surface covering 5 is typically a floor tile which may be of vinyl, but other suitable materials may be employed. Other suitable materials might include carpet laminate, wood, marble or any other floor covering. The substrate may comprise a block of any suitable material such as chipboard or the like. The envelope 4 may be of metal such as galvanised steel.

The edging strip 7 is applied (for example by a hot melt adhesive) to at least some of the side edges 6 of a panel as shown in Figs. 1, and 5 to 8.

It will be noted that the edging strip 7 has a substantially flat inner face for bonding directly to a side edge 6 of a panel, for example using an adhesive. Thus, the inner face can be fully bonded to the panel along the length thereof and any ingress or egress between the edging strip inner face and the panel edge can be prevented. A flexible sealing lip 8 projects outwardly from one side of the strip 7 while the opposite side is substantially flat to enable secure attachment to the edge 6 of the panel.

The outwardly projecting flexible sealing lip 8 is provided for sealing between adjacent panels, on assembly. The edging strip 7 may be of a plastics extrusion/moulding. The strip may be co-extruded comprising a main body part of relatively hard plastics material such as uPVC which is bonded to the panel edge and a more flexible lip with a shore of typically 30 to 40.

Referring to Figs. 5 to 8 on assembly, the sealing lip 8 from a first panel 1 projects outwardly from the panel edge 6 to engage with a similar sealing lip 8 projecting outwardly from the adjacent panel edge 6.

The sealing lip 8 is flexed/compressed on assembly of adjacent panels, thereby creating an effective seal. The panel of the invention forms an airtight seal, to meet test criteria. The panel will not deform when removed and refitted. The seal allows for variations in gaps between panels. In the event of air pressure coming from underneath the seal lip will have a tendency to deform upwardly, thus creating an even tighter seal. In addition, the invention allows for variations in application positioning of the edgeband during manufacture.

Referring to Figs. 5 and 6 joints between adjacent panels with different constructions of edging strip 7 are shown. Like parts to the panels described above are assigned the same reference numerals. In this case the panels are illustrated with a decorative surface covering 10 and the strip 7 extends to protect the edge of the surface covering. The strip 7 terminates above the bottom face of the panel and the sealing lips 8 are more flexible and more easily engaged to form a seal, on assembly.

Referring to Figs. 7 and 8 floor panels according to the invention with sealing edging strips along at least some side edges are illustrated in use. An access floor system is constructed by providing a series of spaced-apart support pedestals 10 on which adjacent panels 1 are positioned. On assembly it will be noted that the sealing lips 8 of edgings strips 7 from adjacent panels extend towards and sealingly engage with one another creating a substantially air-tight joint between adjacent panels. Thus the access space underneath the panels can be used to provide a plenum chamber. In Fig. 9 there is illustrated an alternative construction of edging strip 7 which in this case has a single lip 8 which may have a slightly wave like profile at the outer face thereof for enhanced flexibility and sealing engagement. One advantage of the sealing strip of Fig. 9 is that it can be readily provided in a coil form for ease of application to an edge of a panel, in manufacture.

An alternative construction of edging strip 7 is shown in Fig. 10. In this case there are a number of, in this case three, projecting lips 8 for enhanced sealing.

The invention is not limited to the embodiments hereinbefore described which may be varied in construction and detail.

Claims

1. A floor panel comprising a planar substrate having an edging strip applied to at least one of the side edges thereof, characterised in that the edging strip has a substantially flat inner face for bonding to a side edge of the panel and has a sealing lip projecting from an opposite face thereof for sealing between adjacent panels, on assembly.

2. A panel as claimed in claim 1 wherein the sealing lip is integral with the edging strip.

3. A panel as claimed in claim 2 wherein the edging strip is of plastics material.

4. A panel as claimed in claim 3 wherein the edging strip is moulded from a plastics material.

5. A panel as claimed in any of claims 2 to 4 wherein the edging strip is an extrusion.

6. A panel as claimed in any preceding claim wherein the edging strip is adhesively bonded to the substrate.

7. A panel as claimed in any preceding claim wherein the planar substrate is a core material.

8. A panel as claimed in any preceding claim wherein the planar substrate is a core material which is at least partially covered by an envelope.

9. A panel as claimed in any preceding claim wherein the planar substrate is a core material encapsulated in an envelope.

10. A panel as claimed in claim 8 or 9 wherein the envelope is of metal such as steel.

11. A panel as claimed in any of claims 7 to 11 wherein the core is of wood or concrete.

12. A panel as claimed in any preceding claim wherein a decorative surface coating is bonded to the top surface of the substrate.

13. A panel as claimed in claim 12 wherein the surface covering is of a material selected from a floor covering such as vinyl, carpet, laminate, wood, stone or marble.

14. A floor panel assembly comprising a plurality of floor panels as claimed in any preceding claim, the sealing lip of the edging strip projecting towards an adjacent edge of an adjacent floor panel.

15. A floor panel assembly as claimed in claim 14 wherein adjacent edges of adjacent panels have edging strips attached thereto and the sealing lips of the adjacent edging strips project towards one another to seal a gap between the panels.

16. A floor panel substantially as hereinbefore described with reference to the accompanying drawings.

17. A floor panel assembly substantially as hereinbefore described with reference to the accompanying drawings.