GB2510724A

GB2510724A - Modular flooring having seperate interlocking boards and connectors

Info

Publication number: GB2510724A
Application number: GB1403691.7A
Authority: GB
Inventors: Andrew Wai Lit Low; Aik Pin Cheah
Original assignee: WAI YING WONG
Current assignee: WAI YING WONG
Priority date: 2014-03-03
Filing date: 2014-03-03
Publication date: 2014-08-13
Anticipated expiration: 2034-03-03
Also published as: WO2015132554A1; GB201403691D0; GB2510724B

Abstract

The system comprises a board base 101 having a plurality of sides and engaging means, and a joining member 201, 300, slidably, attachable to the base and having a connector portion (202, fig 2C) which extends away from the base, wherein the connector portion can, in use, interlock with the engaging means of an adjacent base. The engaging means preferably comprise a T-shaped channel positioned on the underside of the base, in use, adjacent to each edge, which preferably mates with a projection (209, fig 2C) on the connector portion. The joining member may be curved and may have asymmetric spacer portions (2A, 2B, fig 2C) either side of the connector portion. A resilient portion (301, fig 3b) may prevent the joining member from sliding out of the groove. In use, a plurality of joining members are located in each of two channels on adjacent bases such that two rows of joining members face each other (fig 6). A separate elongate member (fig 13) may be provided, having a row of connector portions along two longitudinal edges to form a dividing strip between assembled boards. Structures and kits are also claimed herein. In use, the system can be used to cover a wall, floor or ceiling and provides for increased flexibility and reduced cost by comparison to boards with integral connectors.

Description

CONNECTING BOARDS

Field of Invention

The present invention relates to boards that can be connected together, and be used in flooring, walls and ceilings.

Background

Flooring has developed considerably over recent years. Flooring systems are typically designed such that they can be placed on top of an existing floor surface (e.g. of concrete or wooden floor boards), to provide a hard-wearing surface and remain in place during normal usage. To remain in place during normal usage, numerous systems have been developed. In some, each floor board is adhered to a floor surface below with adhesive and/or with mechanical means, such as nails. Some flooring systems have been developed such that the floor boards do not need to be adhered to the floor below. Such flooring is sometimes termed floating flooring, and the floor boards will often connect to one another. Some employ a tongue and groove connection, with the tongue extending from the edge of one board such that it can slot into a groove on an edge of another board. Such tongue and groove boards are typically made of wood or wood fibre (such as medium density fibre board (MDF) or high density fibre board). To allow for sufficiently strong interconnection between the tongue and groove and for the boards to have sufficient structural integrity, they often have to be relatively thick. Additionally, such boards are often four-sided, with two of the sides having a tongue extending down their entire length and and the other two of the sides having grooves extending down their entire length. This limits the orientation of the boards when laying them. Ideally, any flooring system that is designed should provide a balance of being relatively cost-efficient to produce, easy to interconnect, and durable in normal use.

It would be desirable to provide an alternative to or an improvement upon the flooring

systems of the prior art.

Brief Description of the Figures

Figures 1A, lB and 1C show different views of an embodiment of a base of a board 101 of the present invention.

Figures 2A, 2B and 2C show different views of an embodiment of a joining member of the present invention.

Figures 3A, 33 and 3C show different views of a further embodiment of a joining member of the present invention.

Figure 4 shows the joining members of Figures 2A/B/C and 3AIBIC being inserted into a base to form a board of the present invention.

Figure 5 shows a view from above the bottom face of the board once a joining member has been inserted into the channel on the bottom face.

Figure 6 shows two boards of the present invention being joined along each of their sides; the top part of the Figure shows the boards separated, and the bottom part of the boards show the boards joined together.

Figure 7, like Figure 6, shows two boards of the present invention being joined along each of their sides, except that, in this Figure, the joining members on each side are spaced further apart than in Figure 6.

Figures 8A, SB, SC, SD and SE show a board, viewed from above the bottom face, having joining members on one or more sides of the base.

Figures 9A and 93 shows the possibility of joining boards together having shapes other than rectangular and square; in this case triangular and trapezium shapes are joined together.

Figures 1OA and 103 shows the joining together of boards having triangular and parallelogram shapes.

Figures hA, 113 and 11C shows different views of an embodiment of a joining member of the present invention having a plurality of connector portions.

Figures 12 and 13 show an embodiment of an elongate member described herein, the elongate member being disposed between the longest sides of two rectangular boards of the present invention and having a length greater than the longest sides of the boards, with the boards being separated from the elongate member.

Figure 14 shows an embodiment of an elongate member and the boards of Figures 13 and 14, except that, in this Figure, the elongate member has been connected to each of the boards.

Figure 15 shows an embodiment of an elongate member described herein, the elongate member being disposed between the shortest sides of two rectangular boards of the present invention, with the elongate member having been connected to each of the boards.

Figures 16 and 17 show, respectively, views from above the top face and bottom face of an assembly of square boards that have been joined by elongate members, with each elongate member having a length greater than the length of the side of each board.

Summary of the Invention

In a first aspect, there is provided a board comprising: a base having (i) opposing first and second faces, (ü) a plurality of sides, which, when viewed from above either the first and second faces, define the shape of the board, and (iU) a locking means, a joining member slidably, detachably affixed to the base and having a connector portion extending laterally from one of the sides of the base, wherein the connector portion of the joining member can engage with a locking means of another board of the same description, and the locking means of the board can engage with a connector portion of another board of the same description, so that the boards can be joined along each of one of their sides.

In a second aspect, there is provided a structure comprising a plurality of boards according to any one of the preceding claims comprising at least first and second boards joined together, wherein the connector portion of the joining member of the first board can engage with a locking means of the second board, and the locking means of the first board can engage with a connector portion of the second board, so that the boards are or can be joined together along each of one of their sides.

In a third aspect, there is provided a kit for assembling into a board, the kit comprising a base as defined in the first aspect, and a joining member as defined in the first aspect, the base and joining member being separate from one anothel, but the joining member being slidably, detachably, affixable to the base as described in the first aspect to form the board according to the first aspect.

The present inventors have devised a board that is easy to assemble from its component parts, can be made into a large variety of shapes and can reduce the expensive high-strength material that may be required to join boards together. Two boards of the same description can be joined together easily. In some recent designs of floating floor boards that have joining pieces extending laterally from their sides, such boards generally have the joining pieces integrally formed with the main body of the board. The integral forming of the joining pieces with the main body of the board has advantages in that it maintains a strong connection between the (generally thin) joining piece and the thicker main body of the board. However, it also has disadvantages. Since the joining pieces are, typically, the thinnest part of the boards and need to hold two boards together to restrain their lateral movement, they ideally comprise a strong material, e.g. a strong plastic material. Additionally, since the joining pieces are integrally formed with the main body of the plastic material, this main body is also formed from the same strong material. However, strong plastic materials can be expensive and there is an advantage in being able to reduce the amount of strong plastic material that is required, while still being able to produce a board that can join to other boards and be as durable. Additionally, when laying floor boards, integrally formed joining pieces would need to be removed from sides of the board that may be flush against a wall; this could be difficult if the plastic is very tough and resistant to cutting or snapping. The present inventors have found that they can produce interlocking boards having joining members that connect one board to another, but in which the joining members are separable from a base of the board, and that such boards have considerable advantages associated with them. In particular, the joining members are slidably, detachable from the base of the boards. This has a number of advantages. It allows for a larger variety of shapes of boards to be made more easily, since the production of equipment for manufacturing boards lacking integrally formed outwardly extending joining members is far more straightforward than those having integrally formed outwardly extending joining members. One or more channels can be formed in a face of the base, each channel running parallel to a side, but this is generally less restricting than the formation of integrally formed outwardly extending parts of the base. Joining members can be made separately and then slidably, attached to the base. Additionally, existing equipment for forming boards having grooves or channels therein can be used to (or adapted to a minimal extent and used to) create the base, and the joining members can be made, e.g. by moulding plastic, and then slidably affixed to the base. Being able to use existing equipment to create the base would be an advantage. The number of joining members can be varied as desired along each side of the board. A further advantage is that the joining members can easily be removed from a side of the board when required, for example if it is desired to place that side against a wall, without having to cut or otherwise damage the board.

Embodiments of the present invention are described below. Optional and preferred features are described. Any optional or preferred feature can be combined with any other optional or preferred feature.

Preferably, the joining member can slide in a direction parallel to the side from which the connector portion of the joining member extends.

In an embodiment, the base has two sides parallel to one another, and a plurality of connector portions of the joining member(s) extending from each of the parallel sides, wherein the connector portions on one of the parallel sides are staggered with respect to the connector portions on the other parallel side. In an embodiment, the base is of a rectangular or square shape, and a plurality of connector portions of the joining member(s) extend from each of the two parallel sides of the base, and the connector portions on one of the parallel sides are staggered with respect to the connector portions on the other parallel side. In an embodiment, the base is of a rectangular or square shape, and a plurality of connector portions of the joining member(s) extend from each of the sides of the board, and the connector portions on each side are staggered with respect to the connectol portions on an opposite (parallel) side of the board.

Preferably, the board has a channel extending along the first face, parallel to a side of the board and the joining member slidably engages with the channel, and at least part of the base that defines the channel can act as the locking means for engagement of a connector portion of another board of the same description. In an embodiment, the connector portion comprises a lateral section that extends laterally from the one of the sides of the board and a projection on the lateral section, the projection extending upwardly from the lateral section, when the first face of the board is on a horizontal surface, such that the projection can insert into a channel of another board of the same description; and in an embodiment, the projection is in the form of an elongate strip that is elongate in a direction parallel to the side of the board along which the member can slide. In an embodiment, the joining member has the connector portion that extends from one of the sides of the board and the joining member further comprises first and second spacer portions, each of first and second spacer portions extending away from the connector portion in opposite directions along the channel. Optionally, the first spacer portion is longer than the second spacer portion, when measured along the channel. A plurality of joining members maybe disposed along at least one side of the board, and the first spacer portion of one joining member is adjacent to the second spacer portion of the adjacent joining member.

In an embodiment, the base has in its first face a plurality of channels, each extending in a direction parallel to one of the sides of the base. Optionally, at each corner of the first face is a projection extending away from the first face. Each corner may be defined as the part of the base at which two sides meet.

In an embodiment, the channel is defined by two opposing walls, and, in an embodiment, a further wall that extends laterally and connects the two opposing walls, and the further wall may be termed a lower wall' herein (lower referring to it being lower, i.e. forming a base of the channel, when the channel is viewed from above). In an embodiment projections and/or indentations are provided on the opposing walls, and the projections and/or indentations may extend along the length of the channel, and, when a joining member slidably engages with the channel, the projections and/or indentations cooperate with corresponding indentations and/or projections (respectively) provided on the joining member. In an embodiment, the joining member, once it is slidably engaged with the channel is restrained from moving in a direction perpendicular to the plane of the first face of the base, e.g. by means of interaction between the projections and/or indentations are provided on the opposing walls of the channel and the corresponding indentations and/or projections (respectively) provided on the joining member. Accordingly, the joining member, once slidably engaged with the channel cannot be easily removed by pulling it away from the first face.

In an embodiment, the channel is defined by two opposing walls, and, each opposing wall has projections extending laterally part-way into the channel, and, in an embodiment, the projections may be elongate and extend along at least part, optionally all of the channel; and optionally the channel has a T' shape or an approximate T' shape in cross section, with the stem of the T forming an opening in the first face.

"Extending laterally" indicates that something extends in a direction substantially parallel with the first or second face of the board. In an embodiment, one of the opposing walls of the channel (which may be termed side walls herein) and/or any projections thereon may form the locking means of the base.

In an embodiment, as mentioned, a further wall or surface may extend laterally and connect the two opposing walls of the channel, and, for brevity, this can be termed a lower wall. In an embodiment, an elongate projection extends above the surface of the lower wall and along the channel or an indendation extends into the surface of the lower wall and along the channel, and the joining member has a corresponding indentation or projection, respectively, that cooperates with the projection on or indentation in the surface of the lower wall. The elongate projection on or indentation in the lower wall can act as a guiding means for the joining member when slid into the channel.

In an embodiment, the base may have central support section that projects above the surrounding part of the base. In use, the central support section may rest on a floor surface, and the lower-most surface of the outermost wall of the channel and/or any projections extending therefrom may be above the surface of the floor to allow a connector portion to extend under it (or them).

In an embodiment, the base is made from plastic and the joining member is also made from plastic, which is of higher tensile strength than the plastic of the base.

In an embodiment, the joining member has a connector portion extending from an elongate body. The elongate body may have, extending along its length (i.e. in the direction of slidably engaging the joining member with the base) on each lateral side of the body, indentations or projections, e.g. for cooperating with projections and/or indentations, respectively on the side walls of the channel of the base.

The connector portion may comprises a lateral portion that extends from the elongate body. The lateral portion is in the form of a plate that is flat in cross-section, and has a projection projecting from a flat side of the lateral portion, and optionally the projection is elongate in a direction parallel to the elongate body.

The joining member may have first and second spacer portions (embodiments of which are illustrated as 2A and 2B respectively in the Figure 20) extending away from the connector portion in the direction of insertion of the joining member into the channel of the base. The first spacer portion is longer than the second spacer portion. This results in the projection on the lateral section of the connector portion being positioned closer to one end of the elongate body than the other.

In an embodiment, the elongate body of the joining member has a restraining means in the form of a resilient member that, in use, when the joining member is inserted into the channel of the base, would be biased toward one of the walls, e.g. one of the opposing walls, that defines the channel.

The joining member may comprises a stopping means, which can restrain movement of the joining member along at least one direction parallel to the side from which the connector portion extends. The joining member may have the first and second spacer portions as described above, and the first and/or second spacer portions comprises the stopping means.

In an embodiment, the board has the channel described above and the stopping means comprising at least one resilient member biased toward a wall that defines the channel.

In an embodiment, the base has a plurality of channels in the first face, each extending parallel to a side of base, at least two of the channels intersecting at a corner of the base.

In an embodiment, the number of channels is the same as the number of sides, each channel running parallel to a side, and two channels intersect at each corner of the base.

In an embodiment, the joining member is as defined above having the stopping means comprising at least one resilient member that can be biased toward a wall that defines the channel, wherein each channel is defined by an outer wall and an inner wall, the outer wall being disposed closer than the inner wall to a side of the board to which the channel runs parallel, and, wherein, when the joining member is slidably engaged with a first channel, the stopping member can impinge on the outer wall of a second channel with which the first channel intersects at a corner of the base.

The base and/or joining member may both comprise, consist essentially of or consist of plastic. Consist essentially of' may indicate that the base or joining member comprises at least 90 wt% plastic, optionally at least 95 wt% plastic, optionally at least 98 wt% plastic, optionally at least 98wt% plastic. The base may comprise a different plastic to that of the joining member. The base may comprise a plastic that is of lower tensile strength and/or compressive strength than the plastic of joining member. The base and/or joining member may comprise a thermoplastic or thermosetting plastic.

Preferably, base and/or joining member comprise a thermoplastic material. Preferably, base and/or joining comprises a non-crystalline thermoplastic material. Such non-crystalline thermoplastic materials are sometimes termed amorphous plastics.

Preferably, base and/or joining member comprises one or more plastics selected from polycarbonate, polystyrene, high-impact polystyrene, styrene copolymers, polyamide (PA), acrylonitrile-butadiene-styrene (ABS), vinyl chloride copolymers, and polyvinyl chloride. These plastics are typically non-crystalline plastics. Such plastics have been found to provide a suitable balance of properties for ensuring that, when joining two adjacent floor boards together by sliding them in the same plane, the joining members flex sufficiently and then interconnect with the locking means of another board, but when joined, the connection made is sufficiently rigid for general normal use that the floor boards do not come apart.

Preferably, the base and/or joining member comprises acrylonitrile-butadiene-styrene (ABS) and/ or polystyrene (PS). The ABS may comprise a mixture of acrylonitrile-styrene copolymer (SAN) and acrylonitrile-butadiene copolymer. In a preferred embodiment, ABS includes, but is not limited to, a material including polybutadiene rubber particles in an acrylonitrile matrix. Such a material can be made by mixing styrene and acrylonitrile monomers to a polybutadiene latex, and warming the mixture (e.g. to a temperature of 50 DC or more) if necessary, to allow dissolution of the monomers; the styrene and acrylonitrile monomers are then polymerised. This typically results in a mixture of polybutadiene, polybutadiene grafted with acrylonitrile and styrene, and styrene-acrylonitrile co-polymer.

The base and/or joining member may comprise high-impact polystyrene (HIPS), sometimes termed toughened polystyrene. High-impact polystyrene includes, but is not limited to, a mixture of a rubber (e.g. styrene-butadiene rubber) and polystyrene. High-impact polystyrene may be made, for example, by mixing a rubber material (e.g. styrene-butadiene rubber), with styrene, then polymerising the styrene monomer. This typically results in a mixture of the rubber material, the polystyrene, and a graft polymer in which styrene chains are attached to the backbone of the rubber polymer.

Mechanical properties of High Impact Polystyrene may further be improved by blending with Styrene-Butadiene-Styrene (SBS) copolymers, or by grafting of maleic anhydride (HIPS-g-MA). High Impact Polystyrene and ABS are described in, for example Plastics Materials, Seventh Edition, authored by J.A. Brydson, and published by Butterworth Heinemann, which is incorporated herein by reference in its entirety.

In an embodiment, the base and/or joining member may comprise a wood-plastic composite VPC). Wood plastic composites are composites formed from wood particles or wood flour and a plastic. In some embodiments, the wood-plastic composite may comprise from about 20 wt% to about 95 wt% of at least one polymeric material and from about 5 wt% to about 80 wt% of wood fibre or flour. The polymeric material can be one or more polymers as described above, e.g. one or more polymers having a polyolefin group, such as polyethylene. Other suitable polymers include polypropylene, polyvinyl chloride, copolymer of PVC, and also other suitable thermoplastics. The polymer material to be processed into the wood-plastic composite can be in powder, liquid, cubed, pelletized form and/or any other form. The polymeric material can be virgin, recycled or a mixture of both. The polymeric material can be incorporated with a blowing agent to make a cellular foam structure core.

In an embodiment, the base comprises a wood-plastic composite and the joining member comprises, consists essentially of or consists of a plastic, which may be as described above, for example a plastic selected from polycarbonate, polystyrene, high- impact polystyrene, styrene copolymers, polyamide (PA), aclylonitrile-butadiene-styrene (ABS), vinyl chloride copolymers, and polyvinyl chloride, and the joining member may be substantially free or free of wood materials. "Substantially free" indicates that the joining member contains 5 wt% or less of wood materials, optionally 2 wt% or less of wood materials.

In an embodiment, the base is formed by producing a precursor base having the opposing first and second faces and the plurality of sides, but lacking the locking means, and the locking means is then formed in the base. The precursor base may be cut, moulded or otherwise formed from a material (e.g. a plastic or wood-plastic composite as described above), and the locking means is formed in the base, e.g. a channel is formed in the first face of the base, e.g. by cutting or grinding. In an embodiment, the precursor base has two parallel sides, and two channels are formed simultaneously in the first face of the precursor base, each of the two channels parallel to each side of the parallel sides. In an embodiment, the precursor base is square or rectangular, such that it has two pairs of parallel sides, and two channels are first formed simultaneously in the first face of the precursor base parallel to a first pair of parallel sides of the base, and then two channels are formed simultaneously in the first face of the precursor base parallel to the other (i.e. second) pair of parallel sides of the base, and optionally the base is turned 900 after the channels parallel to the first pair of parallel sides of the base are formed and before the channels parallel to the other (or second) pair of parallel sides of the base are formed.

Preferably, the base and/or joining member comprises a plastic having a Young's modulus of 0.5 to 10 GPa, optionally ito 7 GPa, optionally ito 5 GPa, optionally, 1.8 to 4 GPa, optionally 2 to 3.5 GPa, as measured using ASTM D638-1O test, also identifiable under the digital object identifier (001) number: 10.1520100638-1O. A skilled person can commercially obtain or make plastic materials having such a property.

The base preferably has a thickness, measured from its first face to its second face, of at least 1 mm, optionally at least 2 mm, optionally at least 3 mm, optionally at least 4 mm. The base preferably has a thickness, measured from its first face to its second face, of 1 cm or less optionally 8 mm or less, optionally 6 mm or less, optionally 5 mm or less. The base preferably has a thickness, measured from its first face to its second face, of from 2 mm to 5 mm, optionally from 3 mm to 5 mm, optionally from 3.5 to 4.5 mm, optionally about 4 mm.

In an embodiment, the shape of the board is of a shape, e.g. a regular shape, and a plurality of connector portions extend laterally from each side of the base, the connector portions are spaced apart from each other along each side, and, optionally, the connector portions are asymmetrically aligned on each side, so that the distance of the end of one side of the board to the nearest connector portion to that end is different to the distance of the other end of the same side to the nearest connector portion to the other end.

In an embodiment, the joining member comprises a plurality of connector portions.

The shape of the board may be a shape having 3, 4, 5, 6 or 8 sides, and optionally the shape is a regular shape. The shape of the board is selected from triangular, rectangular, square, trapezium, rhombus, hexagonal and octagonal.

In an embodiment, the connector portion, when viewed from above one of the first or second sides, has a curved end disposed away from the board.

In an embodiment, the joining member has the first and second spacer portions as defined above and, when viewed from above the first or second surface, the first and second spacer portions, e.g. when adjacent to one another, have a curvature corresponding to that of the curved end of the connector portion, such when the connector portion of the board engages with the locking means of another board, also having such joining members, the curved end of the connector portion of one board extends into the curvature of first and second spacer portions of the members of the other board.

As mentioned, the present invention also relates to a structure comprising a plurality of boards according to any one of the preceding claims comprising at least first and second boards joined together, wherein the connector portion of the joining member of the first board can engage with a locking means of the second board, and the locking means of the first board can engage with a connector portion of the second board, so that the the boards are or can be joined together along each of one of their sides. The boards, and their components, e.g. the base and the joining member, may be as defined herein.

In an embodiment, the boards in the structure are joined together by an elongate member, as described herein. For example, in an embodiment, the structure further comprises an elongate member having two parallel sides, at least one connector portion extending from each parallel side, and at least two locking means, wherein the elongate member can be disposed between the sides of two boards, a connector portion and a locking means of the elongate member being able to engage respectively with a locking means and connector portion of each board, and wherein the length of the elongate member, measured along one of the parallel sides, is greater than the length, e.g. at least twice, of both of the sides of the boards disposed closest to the elongate member.

The present invention further relates to a kit for assembling into a board, the kit comprising a base as defined herein, and a joining member as defined herein, the base and joining member being separate from one another, but the joining member being slidably, detachably, affixable to the base as described in herein to form the board according to the first aspect or otherwise described herein.

The second face of the base may be decorative, for example have a desired colour and/or texture in or on its surface, e.g. the colour and/or texture of wood or a stone material, such as marble. In an embodiment, the second face of the board may be adhered to a further material, which may be suitable for use as a floor surface, e.g. for walking upon, or a wall surface or a ceiling surface.

The further material may comprise any suitable material, and may be adhered to the second face by any suitable means, e.g. by adhesive. If the board is for use as a flooring board, the further material should ideally be suitable for walking upon in normal use. The further material may comprise, for example, veneer, cork, vinyl, linoleum, stone, metal, wood, carpet, ceramic material and the like. The further material may comprise a sheet having a printed and/or embossed pattern thereon. The printed and/or embossed pattern may show a pattern such as wood grain or that of a polished stone surface, such as marble.

In an embodiment, the further material comprises one or more sheets of plastic material. If the further material comprises more than one sheet of plastic material, the sheets of plastic material may be put together using any known technique, such as a technique selected from extrusion, calendering, solvent welding, ultrasonic welding and adhesive assisted lamination. The one or more sheets of plastic material may comprise any suitable plastic, including, but not limited to, a plastic selected from polyvinylchloride (PVC), a polyolefin, polyurethane and urethane-acrylate co-polymers.

The polyolefin may be selected from polypropylene, ethylene-propylene copolymers and polyethylene. The upper material may comprise a sheet comprising plastic having a printed pattern thereon. The sheet comprising plastic having a printed pattern thereon may have one or more overlying layers thereon, which are preferably sufficiently transparent that the printed pattern can be seen through the one or more overlying layers.

Optionally, if the further material comprises a sheet having a printed pattern thereon, one or more further sheets may be disposed between the second face of the base, and the sheet having a printed pattern thereon. The one or more further sheets may be made of the same or different type of plastic as the sheet having the printed pattern thereon. The one or more further sheets, the printed sheet, and optionally any overlying layer thereon may all optionally comprise polyvinylchloride (PVC) or a vinylchloride copolymer.

The further material preferably comprises a plurality of sheets comprising plastic material, preferably PVC or a vinylchloride copolymer. The further material preferably comprises at least two, optionally at least three, optionally at least four sheets comprising plastic material, preferably PVC or a vinylchloride copolymer. The total thickness of the plurality of sheets of the upper material is preferably 5 mm or less, optionally 4 mm or less, optionally 3 mm or less, optionally 2 mm or less. The total thickness of the plurality of sheets of the upper material is preferably 0.5 mm or more, preferably 1 mm or more.

Figures 1A, lB and 10 show different views of an embodiment of a base of a board 101 of the present invention. The base is formed from a single piece of plastic. Figure 1A shows a view of the base from above a face 103, which will be termed a first face 103 or a bottom face 103 (since if the board is used as a floor board, it would be on the underside of the board). The face 102 opposing the first face 103 will be termed a second face 102 or a top face 102. Fig 1 B shows a view from the side 105 of the base.

Fig 10 shows a view from the side 104 of the base. The board has in its first face a plurality of channels 106, each extending in a direction parallel to one of the sides of the base. At each corner of the first face is a projection 107. Each channel is defined by a lower surface 111 and two opposing walls 108, with each wall 108 having projections 109 extending laterally part-way into the channel, the channel thus having a T' shape in cross section. "Extending laterally" indicates that something extends in a direction substantially parallel with the first or second face of the board. The base also has a central support section 110 that projects above the surrounding part of the base.

In use, the central support section 110 would rest on a floor surface, and the lower-most surface of the projection 109 would be above the surface of the floor to allow a connector portion to extend under it. On the lower surface 111, an elongate projection 112 extends above the lower surface 111 along the channel.

Figures 2A, 2B and 20 show different views of an embodiment of a joining member 201 of the present invention. The joining member is also made from a single piece of plastic, which is typically of higher tensile strength than the plastic of the base. Figure 2A shows a view from a side of the joining member that would, in use, be on the same side as the lower face 103 of the base. Figure 20 shows a view of the side of the joining member that would, in use, be on the same side as face 102 of the base.

Figure 2B shows a view from the direction in which the joining member 201 would be moved to insert it into a channel 106. The joining member has a connector portion 202 extending from an elongate body 203. The elongate body has, extending along its length on each lateral side 205 of the body, indentations 204. The elongate body 203 also has an indentation 206 in its upper surface 207. In use, when the elongate body 203 is inserted into the channel 106 of the base, the projections 109 of the base project into the indentations 204, and the elongate projection 112 on the lower surface 111 of the base projects into the indentation 206 on the upper surface of the elongate body.

The connector portion 202 comprises a lateral portion 208 that extends from the elongate body 203. The lateral portion is in the form of a plate that is flat in cross-section, as can be seen from Figure 2B, and has a projection 209 projecting from the upper side 210 of the lateral portion. The joining member has first and second spacer portions (2A and 2B respectively in the Figure) extending away from the connector portion in the direction of insertion of the joining member into the channel of the base.

The first spacer portion is longer than the second spacer portion. This results in the projection 209 on the lateral section of the connector portion being positioned closer to one end of the elongate body than the other.

Figures 3A, 3B and 30 show different views of a further embodiment 300 of a joining member of the present invention. This embodiment is similar to that of Figures 2A, 2B and 2C, except that the elongate body 203 has a restraining means 301 in the form of a resilient member that, in use, when the joining member is inserted into the channel of the base, would be biased toward one of the opposing walls that defines the channel.

Figure 4 shows the joining members of Figures 2A/B/C and 3A/B/C being inserted into a base to form a board of the present invention. The joining member of Figures 2A/B/C is being inserted into the left-hand channel, and the joining member of Figures 3A/B/C is being inserted into the right-hand channel in the Figure. The arrows in the Figure show the direction of insertion.

Figure 5 shows a view from above the bottom face of the base once the joining member (e.g. of figure 3AIBIC) has been inserted into the groove on the bottom face.

As can be seen, the joining member, once inserted into the channel can slide in either direction along the channel. If the joining member has a stopping means in the form of a resilient member 301 that is biased against a wall of the channel, after the joining member has been inserted into the channel 106 (in a direction from left to right), and the resilient member 301 passed projection 107 extending from the lower face of the base, the resilient member moves into the space 501 between the projection 107 and wall 108 extending along the direction of insertion. If a user then tries to slide the joining member from a direction right to left, the stopping means would impinge against the wall 107A of the projection 107, thereby preventing the joining member from being slid any further to the left. However, the resilient member would not prevent the joining member from sliding to the right.

Figure 6 shows two boards of the present invention being joined along each of their sides; the top part of the Figure shows the boards separated, and the bottom part of the boards show the boards joined together. Each joining side has a plurality of projections slidably inserted into the channels nearest each side. Each joining member abuts another along the channel. Once the boards are joined together, each projection 209 on the lateral section of one joining member (that is slidably attached to a base) projects into the channel of another base. The bases are prevented from moving laterally apart since the surface 302 (as shown in Figure 3C) of the projection 209 of each elongate body (the surface 302 is the surface that faces the elongate body of the joining member) impinges against one of the outer-most side walls of the channel (i.e. the side wall of the channel nearest to the side of the base), in particular against a sidewall of the projection 109 that extends laterally into the channel.

Figures 8A, BB, 8C, 80 and BE show a board, viewed from above the bottom face, having joining members on one or more sides of the base. In these Figures, the arrangement of the joining members is such that the shorter spacer portion 28 of each joining member abuts a longer spacer portion 2A of an adjacent member. The connector portions are thus asymmetrically aligned on each side of the board. The asymmetry is repeated in rotational symmetric fashion on each side of the board. This is achieved by inserting the shortest spacer portion 28 of each joining member along a channel in each side in a direction that is clockwise when the board is viewed from its bottom surface 103.

Figures 9A and 98 shows the possibility of joining boards together having shapes other than rectangular and square; in this case triangular and trapezium shapes are joined together.

Figures 1OA and 108 shows the joining of boards together having triangular and parallelogram shapes.

Figures hA, 11B and 11 C shows different views of an embodiment of a joining member of the present invention having a plurality of connector portions.

Figures 12 and 13 shows an embodiment of an elongate member 1301 described herein, the elongate member 1301 being disposed between the longest sides 1302 of two rectangular boards 1303 of the present invention. The elongate member has a length greater than the longest sides 1302 of the boards. The boards are shown in Figure 12 separated from the elongate member. The elongate member has lateral sections 1304 extending laterally from an elongate body, with each lateral section having a projection extending upwardly from the elongate body. A channel (not shown) would also be present on the underside of the elongate body of the elongate member.

In connecting the boards 1303 to the elongate member 1301, the upwardly extending projection of the connection portion of each joining member of each side 1302 of each board would insert into the channel of the elongate body, and the upwardly extending projection of each lateral section 1304 would insert into the channel of the base of each board.

Figure 14 shows an embodiment of an elongate member and the boards of Figures 12 and 13, except that, in this Figure, the elongate member has been connected to each of the boards.

Figures 16 and 17 show, respectively, views from above the top face and bottom face of an assembly of nine square boards that have been joined by elongate members, with each elongate member having a length greater than the length of the side of each board.

Claims

CLAIMS1. A board comprising: a base having (i) opposing first and second faces, (ii) a plurality of sides, which, when viewed from above either the first and second faces, define the shape of the board, and (iii) a locking means, a joining member slidably, detachably affixed to the base and having a connector portion extending laterally from one of the sides of the base, wherein the connector portion of the joining member can engage with a locking means of another board of the same description, and the locking means of the board can engage with a connector portion of another board of the same description, so that the boards can be joined along each of one of their sides.
2. A board according to claim 1, wherein the joining member can slide in a direction parallel to the side from which the connector portion of the joining member extends.
3. A board according to claim 1 or claim 2, wherein the board has a channel extending along the first face, parallel to a side of the board and the joining member slidably engages with the channel, and at least part of the base that defines the channel can act as the locking means for engagement of a connector portion ofanother board of the same description.
4. A board according to claim 3, wherein the connector portion comprises a lateral section that extends laterally from the one of the sides of the board and a projection on the lateral section, the projection extending upwardly from the lateral section, when the first face of the board is on a horizontal surface, such that the projection can insert into a channel of another board of the same description as claim 3.
5. A board according to claim 3 or claim 4, wherein the joining member has the connector portion that extends from one of the sides of the board and further comprises first and second spacer portions, each of first and second spacer portions extending away from the connector portion in opposite directions along the channel.
6. A board according to claim 5, wherein the first spacer portion is longer than the second spacer portion, when measured along the channel.
7. A board according to claim 6, wherein a plurality of joining members are disposed along at least one side of the board, and the first spacer portion of one joining member is adjacent to the second spacer portion of the adjacent joining member.
8. A board according to any one of the preceding claims, wherein the joining member comprises a stopping means, which can restrain movement of the joining member along at least one direction parallel to the side from which the connector portion extends.
9. A board according to claim 8, wherein the joining member is as defined in claim 5 having the first and second spacer portions, wherein the first or second spacer portion comprises the stopping means according to claim 8.
10. A board according to claim 8 or 9, wherein the board is as defined in claim 3 having the channel and the stopping means comprising at least one resilient member biased toward a wall that defines the channel.
11. A board according to claim 3, wherein the base has a plurality of channels in the first face, each extending parallel to a side of base, at least two of the channels intersecting at a corner of the base.
12. A board according to claim 11, wherein the number of channels is the same as the number of sides, each channel running parallel to a side, and two channels intersect at each corner of the base.
13. A board according to claim 11 or 12, and the joining member is as defined in claim 10, wherein each channel is defined by an outer wall and an inner wall, the outer wall being disposed closer than the inner wall to a side of the board to which the channel runs parallel, and, wherein, when the joining member is slidably engaged with a first channel, the stopping member can impinge on the outer wall of a second channel with which the first channel intersects at a corner of the base.
14. A board according to any one of the preceding claims, wherein the shape of the board is a regular shape, and a plurality of connector portions extend laterally from each side of the base, the connector portions are spaced apart from each other along each side, and the connector portions are asymmetrically aligned on each side, so that the distance of the end of one side of the board to the nearest connector portion to that end is different to the distance of the other end of the same side to the nearest connector portion to the other end.
15. A board according to any one of the preceding claims, wherein the joining member comprises a plurality of connector portions.
16. A board according to any one of the preceding claims, wherein the shape of the board is a shape having 3, 4, 5, 6 or 8 sides.
17. A board according to any one of the preceding claims, wherein the shape of the board is selected from triangular, rectangular, square, trapezium, parallelogram, rhombus, hexagonal and octagonal.
18. A board according to any one of the preceding claims, wherein the connector portion, when viewed from above one of the first or second sides, has a curved end disposed away from the board.
19. A board according to claim 18, wherein the joining member is as defined in claim 5 having the first and second spacer portions and the first and second spacer portions, when viewed from above the first or second surface, have a curvature corresponding to that of the curved end of the connector portion, such when the connector portion of the board engages with the locking means of another board, also having such joining members, the curved end of the connector portion of one board extends into the curvature of first and second spacer portions of the members of the other board.
20. A structure comprising a plurality of boards according to any one of the preceding claims comprising at least first and second boards joined together, wherein the connector portion of the joining member of the first board can engage with a locking means of the second board, and the locking means of the first board can engage with a connector portion of the second board, so that the boards are or can be joined together along each of one of their sides.
21. A structure comprising plurality of boards according to claim 20, wherein the structure further comprises an elongate member having two parallel sides, at least one connector portion extending from each parallel side, and at least two locking means, wherein the elongate member can be disposed between the sides of two boards, a connector portion and a locking means of the elongate member being able to engage respectively with a locking means and connector portion of each board, and wherein the length of the elongate member, measured along one of the parallel sides, is greater than the length of both of the sides of the boards disposed closest to the elongate member.
22. A kit for assembling into a board, the kit comprising a base as defined in claim 1, and a joining member as defined in claim 1, the base and joining member being separate from one another, but the joining member being slidably, detachably, affixable to the base as described in claim 1 to form the board according to claim 1.
23. A kit according to claim 22, wherein kit comprises at least one base as defined in claim 1 and a plurality of joining members as defined in claim 1 per base.
24. A kit according to claim 22 or 23, wherein the base and joining member(s) are as defined in any one of claims 2 to 19.Amendments to the claims have been filed as followsCLAIMS1. A board comprising: a base having (i) opposing first and second faces, (ii) a plurality of sides, which, when viewed from above either the first and second faces, define the shape of the board, and (iii) a locking means, a plurality of joining members slidably, detachably affixed to the base and, each joining member having a connector portion extending laterally from one of the sides of the base, wherein the connector portion of each joining member can engage with a locking means of another board of the same description, and the locking means of the board can engage with a connector portion of another board of the same description, so that the boards can be joined along each of one of their sides, the base has in its first face a plurality of channels, each extending in a direction ct 15 parallel to one of the sides of the base, and each joining member slidably engages with one of the channels, and at least part of the base that defines the channel can act as the locking means for engagement o of a connector portion of another board of the same description, wherein the connector portion comprises a lateral section that extends laterally from the one of the sides of the board and a projection on the lateral section, the projection extending upwardly from the lateral section, when the first face of the board is on a horizontal surface, such that the projection can insert into a channel of anotherboard of the same description, anda plurality of the connector portions extend laterally from each side of the base, the connector portions are spaced apart from each other along each side, and the connector portions are asymmetrically aligned on each side, so that the distance of the end of one side of the board to the nearest connector portion to that end is different to the distance of the other end of the same side to the nearest connector portion to the other end.2. A board according to claim 1, wherein the joining member has the connector portion that extends from one of the sides of the board and further comprises first and second spacer portions, each of first and second spacer portions extending away from the connector portion in opposite directions along the channel.3. A board according to claim 2, wherein the first spacer portion is longer than the second spacer portion, when measured along the channel.4. A board according to claim 3, wherein the first spacer portion of one joining member is adjacent to the second spacer portion of the adjacent joining member.5. A board according to any one of the preceding claims, wherein the joining member comprises a stopping means, which can restrain movement of the joining member along at least one direction parallel to the side from which the connector portion extends.6. A board according to claim 5, wherein the joining member is as defined in claim 2 having the first and second spacer portions, wherein the first or second spacer portion comprises the stopping means according to claim 5.7. A board according to claim 5 or 6, wherein t the stopping means comprises at least one resilient member biased toward a wall that defines the channel.8. A board according to claim 1, wherein at least two of the channels intersect at a o 20 corner of the base.9. A board according to claim 8, wherein the number of channels is the same as the number of sides, each channel running parallel to a side, and two channels intersect at each corner of the base.10. A board according to claim 8 or 9, and the joining member is as defined in claim 10, wherein each channel is defined by an outer wall and an inner wall, the outer wall being disposed closer than the inner wall to a side of the board to which the channel runs parallel, and, wherein, when the joining member is slidably engaged with a first channel, the stopping member can impinge on the outer wall of a second channel with which the first channel intersects at a corner of the base.11. A board according to any one of the preceding claims, wherein the shape of the board is a regular shape.12. A board according to any one of the preceding claims, wherein the joining member comprises a plurality of connector portions.13. A board according to any one of the preceding claims, wherein the shape of the board is a shape having 3, 4, 5, 6 or 8 sides.14. A board according to any one of the preceding claims, wherein the shape of the board is selected from triangular, rectangular, square, trapezium, parallelogram, rhombus, hexagonal and octagonal.15. A board according to any one of the preceding claims, wherein the base is of a rectangular or square shape, and a plurality of connector portions of the joining member(s) extend from each of the sides of the board, and the connector portions on each side are staggered with respect to the connector portions on an opposite (parallel) side of the board.16. A board according to any one of the preceding claims, wherein the connector o portion, when viewed from above one of the first or second sides, has a curved end disposed away from the board.17. A board according to claim 16, wherein the joining member is as defined in claim 2 having the first and second spacer portions and the first and second spacer portions, when viewed from above the first or second surface, have a curvature corresponding to that of the curved end of the connector portion, such when the connector portion of the board engages with the locking means of another board, also having such joining members, the curved end of the connector portion of one board extends into the curvature of first and second spacer portions of the members of the other board.18. A structure comprising a plurality of boards according to any one of the preceding claims comprising at least first and second boards joined together, wherein the connector portion of the joining member of the first board can engage with a locking means of the second board, and the locking means of the first board can engage with a connector portion of the second board, so that the boards are or can be joined together along each of one of their sides.19. A structure comprising plurality of boards according to claim 18, wherein the structure further comprises an elongate member having two parallel sides, at least one connector portion extending from each parallel side, and at least two locking means, wherein the elongate member can be disposed between the sides of two boards, a connector portion and a locking means of the elongate member being able to engage respectively with a locking means and connector portion of each board, and wherein the length of the elongate member, measured along one of the parallel sides, is greater than the length of both of the sides of the boards disposed closest to the elongate member.N