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
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
  • E04F15/182—Underlayers coated with adhesive or mortar to receive the flooring
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F2201/00—Joining sheets or plates or panels
  • E04F2201/05—Separate connectors or inserts, e.g. pegs, pins, keys or strips
  • E04F2201/0511—Strips or bars, e.g. nailing strips
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F2203/00—Specially structured or shaped covering, lining or flooring elements not otherwise provided for
  • E04F2203/06—Specially structured or shaped covering, lining or flooring elements not otherwise provided for comprising two layers fixedly secured to one another, in offset relationship in order to form a rebate

Definitions

• the present invention relates to floor covering systems.
• the invention has been developed primarily as a floating floor covering system and will be described hereinafter with reference to this application. However, it will be appreciated that the invention is not limited to this particular field of use.
• subfloor are known. These types of flooring systems are free to float above the subfloor and are often referred to as “floating floors”.
• floating floors are relatively easy to install and are able expand and contract with changes in humidity and temperature and as a result, are hard wearing and develop minimal gaps during use.
• Floating floor systems typically include an underlay formed from a resilient and moisture repellent material, and a series of floor planks, which are laid over the underlay and interconnect to define the main floor surface.
• the floor planks normally consist of a thin layer of softwood or hardwood bonded to a high-density fibreboard substrate. They are also often pre-coated to enhance their wearability (polyurethane is common), but it's possible to coat after installation.
• the floor planks are in the form of laminate tiles formed primarily from polyvinyl chloride (PVC), which have a design pattern printed on their upper surface to resemble a desired surface finish.
• PVC polyvinyl chloride
• This alternate type of floating floor has the advantage of being harder wearing than the above- mentioned wood type floating floor as well as being quieter and softer to walk on and better adapted for installation in wet areas.
• Such a flooring system is disclosed in United States Patent No. 7,155,871 in the name of Tru Woods Limited.
• a laminate tile is formed from two layers of flexible PVC material, with the lower layer performing the underlay function and the top layer having the desired pattern on its upper surface.
• the two layers are laminated together in an offset arrangement to define two marginal portions along the long edges of each tile. These marginal portions include an adhesive coating to allow adjacent tiles to be joined in a lap joint formation thereby to progressively build up the floating floor.
• the invention provides a floor covering system including:
• a second layer of planar material at least a portion of the second layer being adapted for laminating engagement with the first layer to define a floor covering
• a locating means for locating two or more of the second layers in a substantially aligned configuration
• the second layer is adapted to receive the locating means.
• the floor covering system includes one or more locating protrusions extending from one surface of the first layer.
• the second layer includes one or more locating apertures disposed on one surface thereof, the apertures being adapted for complementary engagement with the locating protrusions.
• the locating apertures extend from the top to the bottom surface of the second layer. More preferably, the first layer includes four of the locating protrusions. Even more preferably, the second layer includes four of the locating apertures.
• the locating protrusions are symmetrically disposed about the first layer.
• the locating protrusions are asymmetrically disposed about the first layer.
• the locating apertures are symmetrically disposed about the second layer.
• the locating apertures are asymmetrically disposed about the second layer. In one embodiment, the locating apertures are cut from the second layer to form two or more off-cut portions and wherein the off-cut portions are bonded to one surface of the first layer to define the locating protrusions.
• the second layer includes a pair of interlocking portions disposed at its longitudinally opposed edges.
• the interlocking portions are preferably adapted to substantially laterally restrain longitudinal adjacent pairs of the second layers upon installation.
• the invention provides a floor covering system including:
• a locating member engageable with at least a portion of the modular floor tile for locating two or more of the modular floor tiles in a substantially aligned configuration.
• the modular floor tile includes one or more locating apertures disposed on one surface thereof.
• the one or more apertures preferably include one or more elongate slots.
• the locating member includes one or more locating protrusions extending from one surface thereof, the protrusions being adapted for locating engagement with the locating apertures.
• the one more locating protrusions preferably include one or more elongate flanges.
• the locating member is in the form of an extruded track substantially formed from a plastics material.
• the locating member is in the form of an extruded track substantially formed from extruded aluminium.
• one of the first or second layers includes a design pattern on its top surface. The design pattern preferably resembles a wood, marble, ceramic or a slate surface.
• the design pattern is printed on a supplementary layer, which is bonded to one surface of the first or second layer.
• the second layer includes an adhesive means for bonding the second layer to the first layer.
• the first or second layer is sized to correspond to standard ceramic, slate, marble tile or wood plank dimensions.
• the first and second layers are substantially formed from a resilient plastics material such as polyvinyl chloride.
• the first layer is a floor plank and the second layer is an underlay.
• the floor covering system includes a secondary adhesive means for bonding the locating member to one or more of the modular floor tiles.
• the secondary adhesive means is disposed on the locating member.
• the invention provides a method for installing a floor covering system in accordance with the first aspect, the method including the steps of:
• the invention provides a modular underlay tile for a floor system, the underlay tile including:
• the underlay tile being adapted for substantial aligned engagement with one or more other modular underlay tiles to form an underlay for the floor system.
• the modular underlay tile including two or more interlocking portions disposed on two or more corresponding edges of the tile. The interlocking portions are preferably adapted to substantially restrain at least adjacent pairs of the underlay tiles, upon installation.
• the underlay tile is substantially formed from a resilient plastics material such as polyvinyl chloride.
• Figure Ia is a plan view of an underlay in accordance with a first embodiment of the invention.
• Figure Ib is an elevation view of the underlay of Figure Ia;
• Figure Ic is a perspective view of the underlay of Figure Ia;
• Figure 2a is a plan view of a floor plank in accordance with a first embodiment of the invention
• Figure 2b is an elevation view of the floor plank of Figure 2a;
• Figure 2c is an underside view of the floor plank of Figure 2a;
• Figure 2d is a partly disassembled perspective view of the floor plank of Figure 2a;
• Figure 3 a is a partly assembled view of a floor covering system in accordance with a first embodiment of the invention
• Figure 3b is an underside view of the floor covering system of Figure 3a;
• Figure 4a is a plan view of an underlay in accordance with a second embodiment of the invention.
• Figure 4b is an elevation view of the underlay of Figure 4a;
• Figure 4c is a perspective view of the underlay of Figure 4a;
• Figure 5a is a plan view of a floor plank in accordance with a second embodiment of the invention.
• Figure 5b is an elevation view of the floor plank of Figure 5a;
• Figure 5c is an underside view of the floor plank of Figure 5a;
• Figure 5d is a partly disassembled perspective view of the floor plank of Figure 5a;
• Figure 6a is a partly assembled view of a floor covering system in accordance with a second embodiment of the invention.
• Figure 6b is an underside view of the floor covering system of Figure 6a;
• Figure 7a is a plan view of an underlay in accordance with a third embodiment of the invention.
• Figure 7b is an elevation view of the underlay of Figure 7a;
• Figure 7c is a perspective view of the underlay of Figure 7a;
• Figure 8a is a plan view of floor plank in accordance with a third embodiment of the invention
• Figure 8b is an elevation view of the floor plank of Figure 8a;
• Figure 8c is an underside view of the floor plank of Figure 8a;
• Figure 8d is a partly disassembled perspective view of the floor plank of Figure 8a;
• Figure 9a is a partly assembled view of a floor covering system in accordance with a third embodiment of the invention.
• Figure 9b is an underside view of the floor covering system of Figure 9a;
• Figure 10a is a plan view of an underlay in accordance with a fourth embodiment of the invention.
• Figure 10b is an elevation view of the underlay of Figure 10a;
• Figure 10c is a perspective view of the underlay of Figure 10a;
• Figure 11a is a plan view of a floor plank in accordance with a fourth embodiment of the invention.
• Figure 1 Ib is an elevation view of the floor plank of Figure 11a;
• Figure 1 Ic is an underside view of the floor plank of Figure 11a;
• Figure Hd is a partly disassembled perspective view of the floor plank of Figure 11a;
• Figure 12a is a partly assembled view of a floor covering system in accordance with a fourth embodiment of the invention.
• Figure 12b is an underside view of the floor covering system of Figure 12a;
• Figure 13 is a further partly assembled view of the floor covering system of Figure 12a;
• Figure 14a is a plan view of an underlay in accordance with a fifth embodiment of the invention
• Figure 14b is an elevation view of the underlay of Figure 14a;
• Figure 14c is a partly disassembled perspective view of the underlay of Figure 14a;
• Figure 15a is a plan view of a floor plank in accordance with a fifth embodiment of the invention.
• Figure 15b is an elevation view of the floor plank of Figure 15a;
• Figure 15c is an underside view of the floor plank of Figure 15a;
• Figure 15d is a partly disassembled perspective view of the floor plank of Figure 15a;
• Figure 16a is a partly assembled view of a floor covering system in accordance with a fifth embodiment of the invention.
• Figure 16b is an underside view of the floor covering system of Figure 16a;
• Figure 17 is further partly assembled view of the floor covering system of Figure 16a.
• Figure 18 is a partly assembled view of a floor covering system in accordance with a sixth embodiment of the invention.
• a floor covering system 10 in accordance with a first embodiment of the present invention.
• the system includes a plurality of planar underlays 12 for contact with a subfloor, and a plurality of planar floor planks 14 for overlaying engagement with the underlays.
• Each underlay includes four locating apertures 16 symmetrically disposed about its surface 18.
• the apertures extend all the way through the underlay.
• the apertures may not extend all the way through the underlay.
• these apertures engage with four complementary locating protrusions 20 extending from the undersides 22 of the floor planks 14.
• a locating means is provided by the protrusions, which in turn, is received by the underlays 12.
• the underlays further include an adhesive coating on their upper side 14 so that upon the overlaying engagement, the floor plank is securely bonded along its planar surface or "laminated" with the underlays. Alternatively, the adhesive coating may be applied to the underside of the floor planks.
• the arrangement is such that the locating protrusions 20 engage with the locating apertures 16 to allow a single floor plank to positively and accurately position two or more adjacently located underlays 12 in a respectively aligned side-by-side and/or end- to-end configuration.
• a floor covering is defined and a complete floor can be built up progressively with each underlay being accurately aligned with adjacent underlays.
• each floor plank 14 includes a design pattern 24 printed on its upper surface so as to resemble, for example, a marble, ceramic or wood textured surface.
• the design pattern may be printed on a supplementary layer, which is laminated to the floor plank's upper surface.
• the underlays and floor planks have a square shape and therefore would most likely be used to resemble a marble, slate, ceramic or other type of square type floor tile.
• the underlays 12 and floor planks 14 are predominantly formed from a flexible polyvinyl chloride material, otherwise known as PVC or vinyl. The completed floor is therefore hardwearing, easy to walk on and suitable for wet areas.
• a resilient polyvinyl chloride material allows a degree of planar compliance to compensate for floor surface irregularities when laid.
• other materials could be used in combination with the PVC such as for example, resins and/or polyurethane, without departing from the scope of the invention.
• the apertures 16 are cut from the underlay to define cut portions 26, and the protrusions
• underlays 12 are first laid onto a subfloor in an adjacent formation, ideally starting from a wall 28 or other aligning feature. It should be understood that at this stage, it is only required to approximately align the underlays relative to each other. Also, no fixing is required to secure the underlays to the subfloor because the flooring system 10 is a "floating type" and therefore, allows for contraction and expansion of the assembled floor during use.
• a single floor plank 14 is then placed down onto the underlays 12 allowing the protrusions 20 to engage one aperture 16 from each underlay.
• Another two underlays 12 are then laid down in an adjacent formation again only approximating an aligned configuration with one edge or end of the already laid underlays.
• Another floor plank can then be placed down so that the protrusions 20 engage one or more apertures 16 from each underlay. It will be appreciated that as a result of the engagement between corresponding protrusions and apertures, the laid underlays will move into exact relative alignment. At the same time, the corresponding floor planks 14 will be also accurately aligned with respect to the underlays. This process continues until the underlays 12 and floor planks 14 cover the desired floor surface.
• each underlay 12 there is an adhesive coating disposed on the upper side 14 of each underlay 12. It is proposed that this coating will be exposed by the removal of a disposable cover strip (not shown).
• the coating may also be of the type that reacts when in contact with the floor plank such that the bond formed becomes stronger over time.
• this feature will allow any laying mistakes to be easily corrected.
• FIG. 4 to 6 there is provided a second embodiment of the floor covering system 10 of the present invention.
• This embodiment is similar to the first embodiment except that both of the underlays 12 and floor planks 14 now have a rectangular shape of substantially identical dimensions so that the completed assembly more readily resembles typical wood type flooring.
• the assembly procedure for this embodiment is essentially identical to that described above for the first embodiment except that the underlays 12 are now laid such that their longer edges 30 do not continue all the way to the periphery 32 of the desired flooring surface. Instead, the peripherally located floor planks 14a are overlaid so that their longer edges 34 continue to the periphery 32. For this reason, only two of the peripheral floor plank's protrusions 20 engage with the peripheral underlay's apertures 16, with the remaining unengaged protrusions 20 resting directly on the subfloor to support the overhung portion of the floor planks 14a.
• FIG. 7 to 9 there is depicted a third embodiment of the floor covering system of the present invention.
• This embodiment discloses similar shaped underlays and floor planks to the second embodiment except that the underlays 12 now include a pair of complementary interlocking portions 36 disposed at their longitudinally opposed ends. As can be seen in Figure 9, the respective interlocking portions 36 engage upon assembly to provide an extra degree of lateral restraint between longitudinally adjacent underlays upon installation.
• the assembly procedure for this embodiment is essentially identical to that described above for the second embodiment except that a certain degree of trimming of the interlocking portions 36 may be required proximate the wall 28.
• a cut or perforation line (not shown) may be provided on the interlocking portions.
• FIG. 10 to 13 there is provided a fourth embodiment of the present invention.
• This embodiment is similar to the second embodiment in that, the underlays 12 and the floor planks 14 have a rectangular shape of substantially identical dimensions.
• the protrusions 20 are asymmetrically disposed about each floor plank 14. For this reason, a slight modification to the assembly procedure is now required.
• the short edges 38 of the peripheral underlays are now also offset from the periphery of the desired floor surface, and the short edges of the floor planks continue to the periphery 32.
• this embodiment allows for a floor plank 14 to always cover the region 40 where the short ends of the underlays 12 join.
• FIG. 14 to 17 there is provided a fifth embodiment of a present invention.
• This embodiment is similar to the fourth embodiment in that, the protrusions are asymmetrically disposed about the floor plank. However, in this embodiment, the apertures 16 are now also asymmetrically disposed about the underlay 12. Notwithstanding this difference, installation of this embodiment is substantially identical to that described for the fourth embodiment.
• this embodiment provides even a greater degree of covering of the end join region of the underlay.
• the protrusions 20 extend from the underside of the floor plank 14 and that the apertures 16 are disposed in the underlay 12, it should be appreciated that this structural arrangement may be reversed without departing from the scope of the invention. That is, in other not shown embodiments, the apertures may be disposed in the floor plank and the protrusions may extend from one side of the underlay.
• the floor plank 14 and underlay 12 are already in laminated engagement to define a modular floor tile 41.
• the modular floor tile is integrally formed to include both underlay and floor plank portions. It should be noted, that these modular floor tiles are generally formed from the same materials as the floor planks and underlays of the first five embodiments and include a design pattern on the upper surface of the floor plank portion.
• a locating member in the form of an aluminium or plastic extruded track 42.
• the track includes flange portions 44 for engagement with corresponding slots 46 disposed near the lateral and longitudinal sides of the modular floor tiles. Upon this engagement, either longitudinally or laterally adjacent modular floor tiles are positioned in a generally aligned configuration relative to each other.
• An adhesive coating 44 is located on the upper side of the track 42 to create a permanent bond between the track and the adjacent modular floor tiles upon assembly. In this way, a floor covering can be gradually built up by laying down more and more tracks 42 in between adjacent pairs of the modular floor tiles 41.
• the above six embodiments demonstrate alternate structural forms of the present invention.
• the disclosed embodiments advantageously teach a floating flooring system that is relatively easy to install because exact alignment between the adjacent components occurs automatically upon assembly.
• the system is supplied in kit form, which includes both the underlays and floor planks, or modular floor tiles and extruded tracks, and assembly may only require a single tool, such as a knife or scissors, to trim any edges. Consequently, the flooring system of the present invention advantageously does not necessarily require any skilled labour for assembly and is therefore particularly suited to "do-it-yourself home renovators and/or builders.
• the components are formed from standard materials, which are well suited to high-speed automated manufacture and, accordingly, are relatively inexpensive to manufacture.
• the underlays 12 may be used in isolation without the corresponding floor planks 14. It has been found that an assembly of these 'modular' type underlays may be used in normal floating floor applications such as an underlay for floorboards and/or vinyl sheets. Under these circumstances, the underlays would not require, and would not be provided with, any locating apertures 16. However, they may include the complementary interlocking portions 36 disposed at its longitudinal or potentially lateral ends to provide relative alignment between adjacent underlays.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Floor Finish (AREA)

Applications Claiming Priority (2)

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• 2008
  • 2008-06-12 CN CNA2008101114521A patent/CN101392590A/zh active Pending
  • 2008-09-18 CA CA2697530A patent/CA2697530A1/en not_active Abandoned
  • 2008-09-18 EP EP08800022A patent/EP2220307A1/de not_active Withdrawn
  • 2008-09-18 MX MX2010002933A patent/MX2010002933A/es not_active Application Discontinuation
  • 2008-09-18 US US12/678,468 patent/US20100205889A1/en not_active Abandoned
  • 2008-09-18 AU AU2008301227A patent/AU2008301227A1/en not_active Abandoned
  • 2008-09-18 KR KR1020107008357A patent/KR20100080538A/ko not_active Application Discontinuation
  • 2008-09-18 WO PCT/AU2008/001387 patent/WO2009036508A1/en active Application Filing

Non-Patent Citations (1)

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