KR20020021339A - Multidirectional Panels - Google Patents

Abstract

PURPOSE: A multidirectional panel is provided to achieve floor panels which do not have a "handed" configuration. CONSTITUTION: The multi-directional laminate flooring panel(20) for use in constructing a floor comprises a top surface, a bottom surface and sides extending between the top and bottom surfaces, and the sides have identical recessed or grooved profiles. The thickness of the panel ranges from about 6.1mm (0.240inches) to about 8.1mm (0.320inches).

Description

Multidirectional Panels

The present invention is partly a continuation of US patent application Ser. No. 09 / 436.317, filed November 8, 1999.

The present invention relates to a floor surface, preferably a decorative floor surface. The invention also relates to a system for constructing a floor surface, such as a decorative floor surface. More specifically, the present invention preferably relates to a laminated floor surface comprising essentially decorative top wear surfaces, a substrate reinforcement material or layer, and optionally a support material or layer. The present invention relates to components, systems and methods for constructing decorative laminated floor surfaces capable of dismantling from individual floor panels. The invention also relates to decorative laminated flooring products such as, for example, panels and elements for connecting the panels.

In an attempt to provide a means of easily constructing a floor surface, various systems have been proposed. However, nothing has so far been found to be overwhelmingly used in the market related to laminated "floating floor" surfaces capable of dissociation.

Typically, manufacturers of laminated floor panels produce floor products having tongue and groove shapes in the same floor panel. The tongue shape is machined to one side and end of the panel, and the groove is machined to the opposite side and end of the same panel. This type of manufacturing method produces a panel having a directional arrangement or "left-handedness" (left-right arrangement).

In conventional systems, panels with upper wear surfaces are manufactured. After manufacture, the panel is machined at the corners to remove part of the top wear surface to form tongue extensions for insertion into adjacent grooves of adjacent panels. To form these tongues, the wear surface at the top must be machined out, thus reducing the amount of square feet of marketable floor per panel. In addition, the removal of more upper wear surfaces promotes wear of the tool, causing the tool to require more maintenance and / or replacement. As a result, manufacturing costs and time increase. Likewise, in conventional systems, a reinforcing substrate material is produced, and then a portion thereof is machined to remove the grooves.

Typically, when constructing a floor surface with multidirectional tongue / groove panels using prior art systems, the construction starts from one wall and passes through a space to another wall. Further, the space in which the floor is to be constructed does not have dimensions that can be equally divided by the size of the floor panel. That is, the panel at one end wall must be cut in the longitudinal or transverse direction to fit. In prior art systems using left-handed panels, there is considerable functionality that once the panel is cut, the rest cannot be used. For example, in a prior art system using rectangular panels each having tongues and grooves on opposite cross edges, two panels with each long edge being tongue or groove when the panel is cut longitudinally. Pieces are formed. At the end walls, some of the panels may need to have grooves at the long edges, which are fitted. As a result, only one piece of panel with tongue at the long edge is left without the long groove edge.

Many prior art systems, such as those disclosed in US Pat. Nos. 5,706,621 and 5,860,266, are mechanically secured under a portion of the first panel while holding new panels that are coupled at an angle to the major plane of the first panel in which they are located. It is necessary to move the new panel downward as far as possible. This operation is repeated until the floor is constructed. If the fifth of the twenty consecutive panels needs to be replaced, for example for damage reasons, the sixth to twentyth panels must be removed in reverse order until the fifth panel is reached. This is particularly ineffective in large floor systems that are subject to excessive wear in certain areas, such as retail space environments.

Many systems known and proposed are discussed to provide a background of the invention.

U.S. Patent No. 3,310,919, entitled " Transportable Floors, " adjoins such that a plurality of similar panels having a straight side and adjacent coupling elements on the side to form a coupling arrangement with the interactive coupling elements on adjacent panels. A floor is disclosed that includes means for operatively engaging a coupling element for removably securing a panel. As shown in Fig. 2, the panels are joined to each other by fixing screws 19 and nails 15.

US Pat. No. 3,657,852, entitled “Floor Tiles,” refers to a floor or tile composed of a single piece comprised of any one within a range of different materials or a plurality of overlapping laminated structures each comprised of any one within a range of different materials. It is starting. The floor tile is formed to have a plurality of identical tongues projecting in the transverse direction, and at the bottom thereof, having the same number of identical pockets open to the periphery of the tile and alternately positioned around the periphery of the tongue. The tongue and the pocket are formed such that any tongue of any one tile is designed to engage and fit with any pocket of any other tile, and when so joined, resists retraction from the pocket towards the end, Therefore, relative movement between the common planes is prevented when the two tiles are located in the common plane.

US Pat. No. 4,449,346, entitled "Panel Assembly," discloses a panel assembly having at least two panels and a connector member for mounting the panels to a support surface. The panels are positioned next to each other in coplanar relation with each facing edge spaced apart, and the connector members are interlocked by being positioned between the facing panel edges and fixedly joined to the support surface. Each panel has a first and a second surface in the first and second parallel planes and a tongue and a groove in each corner. The tongue and groove extend along the panel edge between the first and second faces, and project and open in an angular outward direction, respectively, towards the first face. The connector member has an elongated body that fills the space between the opposing panel edges, and has tongues and grooves each protruding and opening angularly outwardly towards the second face on each side. The tongues and grooves on each side are complementary to fixably engage the tongues and grooves on respective adjacent opposing edges of the panel. The connector member interacts with the panel to mutually squeeze the panel in a tightly fixed state by a compressive force acting on the member in the direction toward the support surface when secured to the support surface. The patent requires that such connector members eliminate the conventionally known practice of driving nails and screws in the panel edges to secure the panel to the support surface, while still providing a rigid clamping state between the panels. It is disclosed that. As shown in Fig. 2, the connecting member is fixedly coupled to the support surface using screws 86. In addition, “the upper surface 56 of the connector member 14 is coplanar with the upper planes 16, 18 of the panels 10, 12”, thus forming part of an easily visible upper wear surface. .

U.S. Patent No. 4,135,339, entitled "Slatted Floor System," discloses a slat floor system, which can be easily assembled, provides a firm foothold and comfort for limited animals, withstands corrosion and It can be used to prevent the stacking of animal feces, to be easily washed, and to fill significantly greater distances than the prior art slats. This slat floor system is disclosed as having a plurality of long, spaced and usually parallel slats. Each slat has an upper load bearing surface with spaced opposite outer edges. Each slat also has a bottom surface substantially parallel to the top surface and a pair of side surfaces integral with the top surface and the bottom surface. This side engages the top face along a line recessed from the outer edge of the top face. This side is described as extending further taper towards each other in the first portion adjacent the upper surface and extending substantially parallel to each other and perpendicular to the lower surface in the second portion. It is usually said to be Y-shaped and form an enclosed main element as the top and bottom surfaces. This patent includes a first pair of protrusion receiving means each longitudinally extending along the tapered first portion of the side and a second pair of protrusion receiving means extending longitudinally along the second portion of the side. It starts by doing. Adjacent slats are disclosed to be connected and secured in spaced relation within a plurality of connectors. Each connector includes a pair of protrusions that can each be received by one of the first pair of protrusion receiving means on each slat of two adjacent slats, and a second pair of protrusion receiving means on each slat of two adjacent slats. Have At least one of the first and second pair of protrusions on the connector is designed to interlock with corresponding protrusion receiving means on the adjacent slat. As described above and shown in Figures 1 and 4, the top wear surfaces of the slats are spaced to facilitate the purpose of the present invention, i.e. to prevent stacking of animal feces. Further, as shown in the figure, the protrusions and the connector means can only be assembled by sliding the connector of the slats with the edges of the slats when the coplanar relationship parallel to each other is maintained. Also, as shown, the connector member does not extend by the entire length of the slat members.

US Pat. No. 4,461,131, entitled “Panel Interconnect System,” discloses an assembly of rectangular shaped panels, such as floors, which extend along adjacent edges of adjacent panels and between edges of panel sheets. Upper and lower ridged sheets separated by elongated cored fittings with transverse extension receiving means. Each fitting has an upward open channel located beyond the edge of the associated panel. Adjacent fittings and adjacent panels are secured to each other by elongated connector strips with long parallel lugs received in the channels of the adjacent fittings. As shown in FIG. 3, the strip 40 forms part of the upper wear surface and is visually distinguished from the upper surface 10 of the floor panel P. As shown in FIG.

U.S. Pat. No. 4,796,402, entitled "Parquet Floor Paquet Floor," describes a surface in a support structure layer in which a stepped sound, which can be heard from one room to another, is provided beneath the wear surface layer of the parquet board. Disclosed is a stepped sound insulation paka floor, which is sound insulation by using a pressurized heterogeneous fiber board. This patent discloses the board interacting with adjacent boards to form magnetic sound insulation paca floors by having longitudinal sides and ends formed with tongues and grooves.

U.S. Patent No. 5,022,200, entitled "Interlocking Parts, such as Transportable Floors," discloses an improved engagement mechanism having first and second members interfitted for engagement purposes. The second fastening member has a pin mounted therein for movement along a defined path between the first and second positions, referred to herein as the closed and open positions. This patent discloses means for normally pressing this pin into a closed position. The first fastening member is disclosed to have means for moving the pin to the open position when the two fastening members move together and returning the pin to the closed position after engagement of the first and second fastening members. The first fastening member has a mating surface that contacts the pin when a force is applied to separately move the first and second fastening members. The shape and inclination of these engagement surfaces relative to the fin's defined travel path are such as to cause substantial interference to the first retaining pin to prevent the pin from moving to the open position, ie to prevent removal of the retaining member. . Separate fixed disengagement mechanisms are provided to move the pin to an open position to allow disengagement of the instrument. According to a preferred embodiment disclosed in this patent, the first fastening member has a flange and the second fastening member has a means for forming a recess for receiving the flange. The pin is usually located in the receiving space and the flange has a hook-like portion having a mating surface that engages the pin in a fixed position with a surface on the outer edge for moving the pin to the open position. In addition, the present patent discloses an improved panel in which the panel is formed in a single molding process that encloses the core member with urethane and recesses formed therein with recesses formed therein for receiving the fixing member and joins the decorative durable floor surface. The structure is disclosed.

US Pat. No. 5,157,890, entitled “Floor,” discloses a floor system of individual panel assemblies that may be interchanged. This patent discloses that the periphery of each panel is defined by a frame member having two spaced normally parallel flanges and a generally vertical web extending therebetween. On one side of the web and between the upper and lower flanges, the frame member has a track for receiving the key block. This key block includes a generally rectangular base from which the key tongue extends from the base. The base is slotted in a track of one frame member and the tongue is received in a track of an adjacent frame member. The frame member may be a miter cut to a predetermined length or a corner fastened together by a corner fastener.

U.S. Patent No. 5,179,812, entitled "Floor Products", discloses a floor product comprising a wood panel having an L-shaped surround whose base is located below the wood panel. This patent discloses the use of a plurality of parallel aluminum battens connected to the base of the panel. This baton is disclosed to include a groove. In fact, the patent discloses that two floor products with similar joint arrangements are secured to one another by positioning the base of each product's surround into a groove in the elongate member of the other product. This connection does not disengage unless one of the floor panels is inclined relative to the other.

U.S. Pat.No. 5,295,341, entitled "Snap Floor System", is secured to an outer edge by a base member having four outer edges spaced apart in an upper side, a lower side, and circumferentially, and interlocking ribs and grooves. A tongue connector and a groove connector secured to the other outer edge by interlocking ribs and grooves, the tongue connector having a forward-converging compression side terminated in the rear transverse fixing surface, the groove connector having a large inner opening And a floor system having a small outer opening. The tongue sidewall in the compressed position is smaller than the groove outer opening to pass through the outer opening, but is elastically expandable to be larger than the outer opening to secure the groove and tongue. This patent discloses that the connector is preferably attached to the recess and base member of the outer edge by additional tongues and grooves and to the base member at the factory during manufacture.

US Pat. No. 5,736,227, entitled Laminated Wood Floor Products and Wood Floors, discloses a flooring product having a top decoration layer, an intermediate layer bonded to the top layer, and a base layer bonded to the intermediate layer. The top, middle and base layers are joined to form a long laminated wood floor strip. The tongue and groove are formed on each side edge of the floor strip. The tongue and groove extend along the length of the floor strip and mutually secure adjacent floor strips side by side to form an assembled wood floor. The base layer is cut transversely to the length of the floor strip along the substantially entire length of the floor strip and has a plurality of closely spaced scores. This score relieves the stress of the wood strip and increases its flexibility in order to adhere more tightly to the non-uniformity of the auxiliary floor.

US Pat. No. 3,694,983, entitled "Applications for Floor Laminates or Plastic Tiles, etc.," discloses tiles designed to juxtapose to form continuous, plain or various carpets or fabrics, plastics or other materials. . Each tile is fixed to a support having the same dimensions, but protrudes along two adjacent edges of the tile to form an embedded strip. Each strip is provided with means for enabling mutual coupling of the fastening means provided in the embedded state below the corners of the two sides of the adjacent tile. This fastening means has a thickness that is less than the thickness of the support so that no additional thickness occurs with respect to the usual support thickness in the embedded state.

US Pat. No. 3,859,000, entitled “Road Structure and Panels for Manufacturing the Same,” discloses a road structure composed of a plurality of convertible identical polygonal panels. Each panel includes a plurality of single piece peripheral frame members fixed to each other to form a polygonal shape, each frame member having a substantially L-shaped protrusion extending therefrom. This protrusion is designed to be mutually fixed with the same protrusion of the associated member. Each panel also has a pair of load bearing sheets fixed to opposite sides of the frame member.

U.S. Patent No. 5,706,612, entitled "Building Board Joining System," discloses a system for arranging and mechanically joining building panels, especially thin and strong floating floors. This patent discloses joining adjacent joint edges of two panels together to provide a first mechanical connection for securing the joint edge in a first direction perpendicular to the main plane of the panel. It is disclosed that each joint is provided with a strip integrated with or integral with one joint edge and protruding behind the other joint edge. The strip also has an upwardly projecting fastening element that engages in a fastening groove in the rear side of the other joint edge to form a second mechanical connection for securing the panel at right angles to the joint in a second direction parallel to the main plane of the panel. Is disclosed. The first and second mechanical connections allow mutual movement in the direction of the joints of the panels which are jointly coupled. The strip is mounted at the bottom of the panel at the factory and extends over the entire joint edge. This patent discloses that the strip is preferably made of flexible, elastic aluminum and can be mechanically attached by adhesive or any suitable method. Optionally, this strip may be formed integrally with the strip panel. According to this patent, "anyway, the strip 6 must be integrated with the panel 1, ie it must not be mounted on the strip panel due to the arrangement."

US Pat. No. 5,860,266, entitled "Method for Joining Building Boards," discloses a method for mechanically joining rectangular building panels in parallel. This patent discloses the following steps. That is, (a) the new panel is spaced from its final longitudinal position relative to the second panel, and the long edge of the new panel so that the new panel is disposed in the second row while maintaining the predetermined angle with respect to the major plane of the first panel. Position the new panel of the panels adjacent to the long edge of the pre-placed first panel in the first column and place the second panel already arranged so that has a fixing groove positioned in contact with the fixing strip at the adjacent long edge of the first panel. Positioning the panel adjacent to the short edge of the second column adjacent to (b) moving the new panel downward to accommodate the fastening elements of the strip of the first panel into the fixing grooves of the new panel; The first panel is mechanically connected to each other in the second direction with respect to the long edge to which it is connected, and the downward angled portion and the long edge of the new panel are joined to each other in the first direction Mechanically fixed to each other, and (c) moving one of the new panels longitudinally relative to the first panel toward the final longitudinal position and the fastening elements of the new panel and one short edge of the first panel to the other. Mechanically interconnecting in the first and second directions with respect to the short edge to which the new panel and the second panel are connected by snapping into the fixing groove of the short edge. In this patent it is disclosed that the strip 6 protrudes horizontally from the panel and is factory mounted at the bottom of the panel and extends the entire edge of the panel. The strip 6 may be made of flexible, elastic aluminum and attached by an adhesive or any other method. Other strip materials such as aluminum or plastic parts as well as other sheet metals can be used. Optionally, it is disclosed that the strip 6 may also be formed integrally with the strip panel. The patent also states that "anyway, the strip 6 must be integrated in the strip panel, i. It should not be mounted on the ".

Japanese Patent Application No. 56-5347, entitled "Method for Partially Repairing a Floor Plate," discloses a floor plate in which a tongue joint is disposed on a floor bed in which a tongue joint is joined with a groove joint. The patent discloses that a saw is inserted into the gap A between the two side floor plates of the floor plate to be replaced so that the tongue joint is cut, thereby cutting the connection between the floor plates and removing the floor plate to be replaced. . Subsequently, it is disclosed that the left tongue joint in the groove joint of the adjacent floor plate is removed. The portion where the tongue joint was present in the floor plate is cut and a groove joint is newly formed. 4 shows a novel floor plate, and it is disclosed that a relatively shallow and wide slot is formed in a relatively deep recess along both sides of the floor plate. The lower portion of the recess is recessed to hold the foamed synthetic resin. Subsequently, the new floor plate is inserted into the position where the removed floor plate was located while being at the same level as the adjacent floor plate. The foamed resin is foamed and cured. The cured foamed resin expands in the tongue joint to form the tongue joint. It can be seen that the floor plate in contact with the floor bed is secured by the adhesive.

Japanese Patent Application No. 1-30691, entitled “Floor Plate”, discloses a floor plate disposed on a ground floor, characterized by having a thin wood decorative plate in the form of a sheet laminated on the surface layer of the base material. . The engaging projection is formed on one side of the base material, while the engaging recess to which the engaging projection may be joined is formed on the other side of the base material. This patent discloses that the floor plate has a stopper projection formed on one side of the engaging projection and one side of the engaging recess. Further, the stopper recess to which the stopper protrusion is coupled is formed on the other side of the coupling protrusion and the other side of the coupling recess.

German Patent No. 200949 describes a tooth formed in FIGS. 1 and 2 with two corners having an upper groove for insertion into the bottom of the adjacent panel and the other two corners being inserted below the upper groove portion of the adjacent panel during assembly. A floor panel having four corners having an extension portion is disclosed.

German Patent No. 1 534 278 discloses assembling two adjacent structures in Figs. 1 to 3 with grooves and notches for receiving corresponding tongues and teeth of the adjacent structure to which the first structure is connected.

German Laid-Open Publication No. 25 02 992 discloses a floor panel which is particularly suitable for use in manufacturing temporary floors, for example camping tents. The floor panel is shown to have a flat screw surface that is bent back on at least two corners, one with a clear profile and the other with a corresponding profile fitted. This patent favorably locates these bends on two opposite sides, one of which is approximately U-shaped with an outer shank, with the final slotted opening pointing upwards and the corresponding profile at an angle of 90 degrees to the threaded surface. It is disclosed to have a shank. This patent discloses that such a profile may optionally be provided at all four corners of the panel. It is also described that the panel may be formed of plastic, preferably in a single piece of corrugated protrusions made of soft material. As shown in Figure 3, the panels are assembled together using a groove and tongue arrangement.

Published German publication 30 41 781 is provided with grooves at one corner and grooves at another corner to provide an interlocking connection between two panels, in particular used to build a skating rink or skittle alley. Disclosed is the connection of two panels. The patent discloses that there are two parallel sides at the root of the tongue where the opposite pieces are aligned 90 degrees to the edges of the same thickness. It is also disclosed that the groove has two initial parallel sidewalls to stop the tongue side piece. It is disclosed that a part of the groove is connected by a recess that is half trapezoidal or a recess that is completely trapezoidal. This patent discloses that the tongue may be rounded on the side opposite the side of the acute angle.

Published German Publication 35 44 845 discloses a board for use in the manufacture of solid wood panels consisting of bonded boards in combination with complementary profiles. The longitudinal edge of this board has a joint profile extending at an angle to the vertical board edge. This application discloses that the joint profile has two parallel straight laterally moved upright flanks which are connected to the inner end via straight transverse flanks. Inward and upward flanks surround the acute angled board surface, while the other flanks form an obtuse angled board surface. Upright flanks and transverse flanks enclose an acute angle.

European Patent Application No. 0248127, entitled "Table Top for Motor Rows", discloses a motor table top consisting of a plurality of plans fixed to at least two beams forming part of a motor roller chassis. . The plate consists of extruded aluminum and is secured to the chassis by the chip with the plates fixed to each other to protect the plates from relative movement therebetween.

Swedish International Application No. 843067 (PCT / SE83 / 00423) discloses a means for interlocking adjacent panels with corners and grooves at the edges of the panels to be joined. In addition, a recess formed in the panel for receiving the U-shaped metal clamp means for retaining the two panels at the tongue and groove joints is located on each side of the tongue and groove joints of the two connected panels.

French application 2 697 275 discloses forming a surface from a slab of rectangular shape located on a flat horizontal plane. This application provides that the body of the slab has a shaped portion on all four sides and is mutually mechanically secured through a plurality of ribs running longitudinally along the shaped slab so that the slab can slide into a mating groove in the adjacent slab. It is disclosed that it can. 2 seems to show a member 33 for connecting two adjacent slabs. As shown, the upper surface of the member 33 forms part of the upper wear surface of the final floor. This can also be seen from Figure 1 where the members 5, 6 are shown to form part of the upper wear surface.

Japanese application 54-65528 shows a specific tongue and groove arrangement for fixing two adjacent panels to each other in Figs.

French application 2 568 295 discloses a prefabricated floor system consisting of a series of flat panels placed directly on the ground. This panel is made of a resin compound that holds, for example, a reinforcement or mixes grains of durable material such as quartz or carborundum. This patent application has interlocking joints made in the form of protrusions and recesses at all corners and the bottom surface of each panel is covered with a layer made of non-corrosive porous and flexible material that can compensate for non-uniformity of the ground surface. It is disclosed.

U. S. Patent Application No. 424,057 discloses a parka floor comprising the use of a reversible rectangular block, each having a protruding flange on each side of the four sides forming a wedge shaped groove each extending across the entire side on which it is located. A method of configuration is disclosed. The patent claims that the mouth of two grooves on two sides beneath the bottom so that a plurality of such blocks can be formed into a floor covering where each block is secured on each side disposed adjacent to the side of one block. A groove on two sides that borders the border with the mouth portion facing upward when facing is disclosed. The method also discloses the use of a connecting member having a flange designed to be joined under the suspended flange of two adjacent blocks requiring a change in placement direction.

British Patent No. 1,237,744, entitled “Improved Building Structure”, discloses a first tongue with elements located in the plane of the building structure and a second tongue with elements positioned perpendicular to the plane as well as by groove connections. And a panel structure composed of a panel joined at a corner by a groove connecting portion.

British Patent No. 1,430,423, entitled "Joint Structure", discloses in Figures 1 and 2 specific tongue and groove / notch and tooth joint structures for the interlocking of plastic and metal materials.

British Patent Application No. 2 117 813, entitled “Pivot Assembly for Simulated Wall Panels,” is fixed to the edge of each panel by folding the skin of the panel by a dovetail joint in the foam insulation material in the panel. A joint assembly comprising a pair of strips is disclosed. This application discloses that the connecting strip provides curved tongues and grooves. This application discloses that a fixing strip is provided to be inserted into a groove for fixing the panels to each other.

British Patent Application No. 2 256 023, entitled “Joint”, discloses a channel recess in which one panel is open toward the front to limit the separation of the panel to provide a predetermined expansion gap between adjacent side edges. And another panel discloses a joint between the mating side edges of two similar panels with ribs facing the rear face for receipt into the recess. This application discloses that it may for example be a board having tongues and grooves for constructing a door. This application also discloses certain tongue and groove / notch and tooth joints in the figures.

Patent (Utlengningsskrift) no. Connection of adjacent members is shown in the drawings.

Utlaggningsskrift 7141900-9 discloses in Figures 1-3 the means for connecting two adjacent members using connecting blocks 2, 5, 9 forming part of the upper wear surface. This application discloses a U-shaped member for insertion into the rear of the panel to hold the two panels mutually in the position where the joint block is present.

WO 84/02155, entitled “Devices for Interconnecting Building Boards, such as Floor Boards,” discloses an apparatus for mutually joining building boards, such as floor boards, from an edge surface to an edge surface. This application is designed so that the boards have grooves on the rear side of each board that extend over the entire length of the board parallel to the joining edges, and the legs are each designed to engage the grooves of one board, Discloses a substantially U-shaped spring device that is prestressed to securely clamp each other from the edge surface to the edge surface.

German Patent No. 200949 discloses in Figures 1 to 6 an interconnecting panel having extending tongue strips on two crossing edges and extending groove strips on the other crossing edge.

WO 93/13280, entitled " Floor Board Joining Device, " for joining a floor board comprising a long, flat body having legs configured to engage longitudinal grooves within each joining floor board. Disclosed is an apparatus for. This leg portion is formed at a distance from the end of the plate-shaped body such that the plate-shaped body supports the board on each side of the groove.

US Pat. No. 3,538,665, entitled Paka Floor, discloses a floating Paka Floor comprising a double layer rectangular floor unit consisting of a Pakei layer and a support layer. The bottom surface of the support layer has peripheral recesses along the four sides of the unit, and a strip made of support layer material is inserted into the space formed by these peripheral recesses to connect the joints between adjacent units. This patent discloses that the support layer material has a tensile modulus of elasticity not exceeding 5000 kg / cm 2.

German Laid-Open Publication No. 26 16 077 discloses a connecting web in which a plate connecting flange is located proximately on a supporting substrate. This patent application discloses that the arrangement is particularly useful for connecting prefabricated Pakei floor elements. This application discloses that a flexible connection arrangement is provided that replaces a rigid connector such as an adhesive or nail. The application discloses that the system is effective because it accommodates expansion and contraction stresses to prevent cracking. In addition, the connecting web prevents overlapping plate edges on uneven substrates and a tensile force is applied to the web in use when the plate is expanded. Upon contraction of the plates, the connecting webs pull the plates together to prevent gap formation.

French application 1 293 043 discloses a tile having four corners in FIGS. With grooves. 4-6 of the application show a tile with four corners, two crossing edges having notches and grooves open towards the top side of the panel, and the other two crossing edges the bottom side of the panel. It has a notch and a groove open toward the side.

Utlaggningsskrift 8206934-5 discloses a combination of two panels in which tongue and groove arrangements are used. In the figures of the patent, there is shown a U-shaped clip for insertion into panels on each side of the joint to hold the two panels together at the joint.

WO 97/47834, entitled "Floor Covering Composed of Rigid Floor Panels and Methods for Manufacturing Such Floor Panels," discloses rigidity with engaging portions interacting at least at the corners of two opposing sides. The floor covering comprised of the floor panel of this invention is disclosed. This coupling is in fact in the form of tongue and groove and is characterized by having integrated mechanical fastening means. This fastening means prevents the movement of the two joined floor panels in a direction perpendicular to the associated edge and parallel to the bottom of the joined floor panels.

Considering the prior art, there is a need for floor panels that do not have a "left-right" shape.

SUMMARY OF THE INVENTION An object of the present invention is a method of constructing a floor surface on a lower floor support, the lower floor support comprising a first panel having an upper surface, a lower surface and side surfaces extending between the upper and lower surfaces and having grooves. And a second panel having a top surface, a bottom surface, and a side surface extending and having a groove between the top and bottom surfaces, the bottom panel being disposed thereon; And disposing a groove on the second panel and the connector on the support, wherein the mated connector is below the top surface of the first and second panels.

According to the invention, the method further comprises placing the first and second panels flat on the lower puller support during mating of the first and second panels.

Another object of the invention is a method of constructing a floor surface, comprising: mating a connector with a groove of a first panel having a top surface, a bottom surface and a side surface extending between the top and bottom surfaces and having a groove And positioning a second panel having an upper surface, a lower surface, and a side surface extending between the upper and lower surfaces and having a groove in the same plane as the first panel, wherein the first and second panels are coplanar And mating the connector with the groove of the second panel while in the mat, wherein the mated connector provides a method under the top surface of the first and second panels.

Another object of the invention is to provide a floor system in which each concave profile comprises a groove.

Another object of the present invention is to provide a floor system in which each concave profile extends to and intersects with the concave profile on the other side.

It is another object of the present invention to provide a floor system further comprising channels at the bottom surface of each panel corresponding to the sides of the panel.

It is another object of the present invention to provide a floor system in which one channel in the bottom surface of each panel extends to the full length of the corresponding side.

It is another object of the present invention to provide a floor system in which one channel in the bottom surface of each panel extends to and crosses the other channel.

Another object of the present invention is to provide a floor system wherein the connector is a longitudinal connector.

Another object of the present invention is to provide a floor system wherein the connector is a transverse connector.

Another object of the present invention is that each panel further comprises an intermediate substrate between the upper and lower surfaces, the intermediate substrate being a medium density fiberboard, a high density fiberboard, wood / plastic composite, wood, ceramics, unfilled plastic, filled plastic To provide a floor system consisting of a material selected from the group of materials consisting of a closed cell rigid foam, and combinations thereof.

Another object of the present invention is to provide a channel in which the panel comprises a top surface, a bottom surface and side surfaces extending between the top and bottom surfaces, each side having a groove, the bottom surface extending parallel to each groove. It is to provide a multidirectional laminated floor panel having.

1 shows an embodiment of a connector according to the present invention;

Figure 2 shows one embodiment of a connector according to the present invention.

Figure 3 shows an embodiment of a connector according to the present invention.

Figure 4 shows an embodiment of a connector according to the present invention.

Figure 5 shows one embodiment of a connector according to the present invention.

Fig. 6 shows a preferred embodiment of the connector according to the present invention.

Figure 7 shows an embodiment of a connector according to the present invention.

Figure 8 illustrates one embodiment of a connector according to the present invention.

Figure 9 illustrates one embodiment of a connector according to the present invention.

Figure 10 illustrates one embodiment of a connector according to the present invention.

Figure 11 shows an embodiment of a connector according to the present invention.

Figure 12 illustrates one embodiment of a connector according to the present invention.

Figure 13 illustrates an embodiment of a connector according to the present invention.

Fig. 14 shows a particularly preferred embodiment of the connector according to the invention (9 times magnification, 1.00 = 1 in).

Figure 15 is a shaded view of a preferred embodiment of a connector according to the present invention.

Figure 16 illustrates an embodiment of a connector according to the present invention.

Figure 17 illustrates an embodiment of a connector according to the present invention.

Figure 18 illustrates a preferred embodiment of the connector and panel according to the present invention.

Fig. 19A is a plan view of a panel having a truncated groove in the backing layer.

Fig. 19B is an end view of the panel of Fig. 19A.

20A is a plan view of a connector with angled ends;

Fig. 20B is an end view of the connector shown in Fig. 20A.

20C is a side view of the connector shown in FIGS. 20A and 20B.

Figure 21 is a plan view of a partially assembled portion of the floor with a connector and a square panel with angled ends.

Figure 22 is a plan view of a partially assembled portion of the floor with a connector with angled ends and square and triangular panels.

Figure 23 is a plan view of a partially assembled portion of the floor with rectangular panels, transverse connectors and longitudinal connectors.

Fig. 24A is a plan view of the transverse connector.

Fig. 24B is an end view of the transverse connector shown in Fig. 24A.

Fig. 24C is a side view of the transverse connector shown in Figs. 24A and 24B.

Figure 25 is a side view of the transverse connector assembled with the longitudinal connector shown in the form of an end view.

Fig. 26A is a plan view of a rectangular panel with complete grooves.

FIG. 26B is an end view of the panel shown in FIG. 26A;

Figure 27 is a plan view of a partially assembled floor system with hexagonal and triangular panels.

<Explanation of symbols for main parts of the drawings>

1: Connector

2: donate

3: support part

4, 5: flange

6, 7: Ridge

15: extension part

20: panel

21: upper wear surface

22: intermediate substrate

23: support layer

30: longitudinal connector

31: transverse connector

33: notch

According to one embodiment, the present invention includes a releasable interconnect floor system used to form a temporary or permanent floor surface from a separate floor panel on top of a support structure. The system preferably includes two or more floor panels having a lower surface and an upper wear surface that engage the support structure. The panel according to this embodiment has at least three corners with the same groove or recess formed therein to receive the projection from the connector. Preferably, the groove or recess extends over substantially the entire length of the edge of the panel. The preferred connector includes a base and an extension spaced from and substantially parallel to the base and extending vertically from the base. The extension is configured to be received into at least one recess of the at least one panel in a releasable vertical connection.

According to a preferred embodiment, the preferred connector of the system according to the invention further comprises an extension configured to be received into at least one groove or recess of the panels in a releasable horizontal connection manner.

According to another embodiment of the present invention, the base of the novel connecting element has a groove or other recess formed therein, and the corners of the at least one panel have a groove or recess of the base of the connecting element in a detachable horizontal connection manner. It is formed to be received inside. The groove or recess may be formed in the base or formed as part of the extension described above.

According to a further embodiment of the invention, the extension of the connector according to the invention has a groove or recess formed therein, and the at least one panel is to be received into the groove or other recess of the extension in a removable horizontal connection manner. Is formed.

According to another embodiment of the invention, the distance from the base of the connector to the top or top point of the extension of the connector, preferably tongue-shaped, is less than the distance from the bottom surface of the panel to the top wear surface.

According to another embodiment of the present invention, a releasable interconnect floor system is provided for use in forming a temporary or permanent floor surface on top of a support structure from a separate floor panel. The system preferably comprises two or more floor panels stacked and at least one elongated connector, for example a track. The floor panel preferably has an upper wear surface, an intermediate reinforcing substrate and a lower surface for contacting the support floor structure. The panel preferably has four corners with identical grooves formed therein at all corners, preferably to accommodate the vertical extension of the track. The panel also has a notch or other recess, such as a channel, for example, formed in a bottom surface formed to receive a node, ridge or other protrusion from the connector. Preferably, the grooves and channels extend over substantially the entire length of the edge of the panel.

The connector according to an embodiment of the present invention has a base, which is formed to be received into a recess or other recess of the edge of the panel in a releasable vertical connection manner and preferably has a single extension extending vertically from the base. Preferably, the connector has substantially the same length, although not the same as the panel edge to be connected. Preferably, the extension extends over the entire length of the connector. The base of the connector further has two nodes, ridges, or two other protrusions extending vertically from both sides of the base spaced from the single extension. The protrusions or ridges are formed to be received in a notch or other recess in the bottom surface of the panel, for example in a channel, in a releasable horizontal connection manner. Preferably, the protrusion or ridge extends over the entire length of the edge of the panel. When panels are connected using connectors, the only noticeable floor surface is the upper wear side of the panel.

According to another embodiment of the present invention, there is provided a vertical and horizontal interconnect floor system used to form a floor surface on top of a support surface. The system comprises at least one connecting track and at least two individual floor panels which are preferably laminated floor panels having a predetermined thickness. The floor panel has a lower surface and an upper wear surface intended to contact the support surface. The panel has at least three corners with a first identical recess or groove formed therein. The first recess or groove is formed to receive the first connecting protrusion or flange from the track. The panel also has a second recess, for example a channel, located along the bottom surface of the panel which is open in the direction of the ground or support surface for receiving the second connecting protrusion or ridge from the track. According to this embodiment, the track has a base, a first connecting protrusion or a flange, and a second connecting protrusion or a ridge. The first connecting protrusion or flange is connected to the base and extends a predetermined distance perpendicularly therefrom and is formed to be received in the first recess or groove of the panel to form a vertical connection between the panels. The second connecting protrusion or ridge extends a predetermined distance, preferably shorter than the first protrusion, at a right angle from the base, and a second recess or channel of the panel to form a horizontal connection between the panels. It is formed to be accommodated in. According to this embodiment, the distance from the base of the track to the vertical top of the first protrusion or flange is such that when the two panels are connected the first and second connections form a floor surface consisting of only the top wear surface of the panel. Less than the distance between the top wear surface and the bottom surface of the panel in contact.

According to another embodiment of the present invention, there is provided a decoupling decorative laminated floor system for application to conventional floor surfaces without the use of adhesives or traditional fastening devices. The system includes a plurality of identical individual floor panels and connectors. This individual floor panel has an upper decorative wear surface and includes at least three corners each having the same enclosure located within the corners. That is, each edge of each panel has the same shape. This connector preferably comprises a rail having a length substantially equal to the edge of the panel. The rail has a first protrusion and a second pair of protrusions extending vertically therefrom. The first protrusion is formed to be inserted into a receptacle for disengageable vertical interconnection of the individual floor panels at the corners. The second pair of protrusions are formed to be inserted into the enclosure for disengageable horizontal interconnects of the individual floor panels at the corners. Preferably, the first protrusion and the second pair of protrusions extend substantially the entire length of the rail. And when the panels are interconnected using the connector, according to this embodiment, the prominent final floor system comprises only the upper decorative wear surface, ie no part of the connector forms part of the prominent floor surface. Do not.

According to one embodiment, the present invention relates to a connector that can be dismantled to interconnect individual floor panels horizontally and vertically to form a laminated floor surface of a support structure. This connector preferably includes a base for contacting the support structure. According to this embodiment, the base has a protrusion or extension extending vertically away from the support structure. This protrusion or extension has an upper part and a lower part consisting of the same left and right halves, each of which preferably comprises a tongue-shaped extension or flange which extends substantially parallel to the base and is spaced upwardly therefrom. Optionally, according to certain preferred embodiments, the base includes two additional protrusions or ridges extending vertically therefrom. This protrusion or ridge is spaced apart and is located on each side of the protrusion or extension.

According to another embodiment, the present invention is directed to an individual floor panel used to form a floor surface in a support structure, the floor surface comprising horizontally and vertically disassembleable interconnected panels. The panel according to the embodiment includes an upper surface, a lower surface and corners therebetween. The top surface comprises a decorative wear surface. The edges comprise the same grooves and / or recesses extending over substantially the entire length of the edges. The bottom surface includes the same channel formed therein that opens toward the support structure or away from the top surface. The channels preferably extend over and substantially parallel over substantially the entire length of the edges.

According to another aspect of the present invention, there is provided a multidirectional laminated floor panel for floor construction, comprising a top surface, a bottom surface, and a side surface extending between the top and bottom surfaces and having the same groove profile.

According to another aspect of the invention, at least two panels each having a top surface, a bottom surface, and sides extending between the top and bottom surfaces and having the same groove profile, and at least two said panels to form a floor. Provided is a multidirectional laminated floor system comprising a connector separate from at least two of said panels for connecting.

According to another aspect of the invention, there is provided a top surface, a bottom surface, and side surfaces extending between the top and bottom surfaces, each side having a groove, the bottom surface having a channel extending parallel to each groove. There is provided a multidirectional laminate floor panel having.

According to another aspect of the present invention, there is provided a method, comprising: disposing a first panel on the lower floor support, the first panel having a top surface, a bottom surface, and a side surface extending between the top and bottom surfaces and having a groove; Mating a groove and a connector, and disposing a second panel on the bottom floor support having a top surface, a bottom surface, and a side surface extending between the top and bottom surfaces and having a groove; And mating the connector with the grooves of the panel, wherein the mated connector is below the upper surface of the first and second panels.

According to another aspect of the present invention, there is provided a method comprising: mating a connector with the groove of a first panel having a top surface, a bottom surface and a side surface extending between the top and bottom surfaces and having a groove; And positioning a second panel having a grooved side surface extending between the upper and lower surfaces in the same plane as the first panel, while the first and second panels are in the same plane. And mating the groove with the connector, wherein the mated connector is below the top surface of the first and second panels.

The present invention preferably relates to a unique and novel system for easily joining or dismantling a thin laminated floor surface [less than 25.4 mm (1 in.) Thick) of "floating" type. The system is designed to eliminate the need for additional traditional fastening means, i.e. no nails, screws, adhesives and staples, etc. The system according to the invention can complete the task without any special tooling or floor construction experience. The system according to the invention achieves the advantage that even beginners preferably use the same joining panel, which preferably has the same and novel edges, which makes the assembly easy and flexible. Moreover, the system according to the invention provides a single connection means adapted to be used at all corners of the new panel again to facilitate assembly and disassembly. Due to the fact that at least two edges of the panel have recesses formed therein during manufacture, less intermediate reinforcing substrate is needed to manufacture the panel, thus saving resources. In addition, less decorative topside material is wasted. That is, there is no need to remove that much upper wear surface portion to provide the interconnect system of the present invention.

Another advantage of the present invention is that the panel can be oriented in any direction (during installation) without the need to mechanically modify the profile of the factory-made tongue or groove. These panels can be manufactured in a cost effective manner (there is no profile of the tongue to be machined). Materials of the size required to mechanically form the tongue profile (approximately 3.18 mm (about 1/8 in) wide) do not need to be removed by machining. As a result, significant cost is reduced because no machining work is required to produce the tongue profile. In addition, a commercially available surface area of 3.18 mm (approximately 1/8 in) is added. The material [3.18 mm (approximately 1/8 in) wide] that had been removed by prior machining to form the tongue profile is now machined into the groove profile. In contrast to tongues, the formation of grooves further increases the surface area. Since the surface area can be sold without being removed or disposed of by machining, the larger the surface area, the greater the income.

In addition, the system according to the present invention eliminates the "joint swell phenomenon" or "peaking phenomenon" caused by conventional tongue and groove systems. When moisture (moisture) enters the seam from the top of the floor or reaches the seam from the bottom of the floor panel, the seam profile expands. According to the above description, the tongue profile is expanded, and the profile of the groove is retracted. This changes (thickness expansion) the overall panel thickness in the seam area. Since the present invention uses a connector with a flange to make a joint between two panels, the flange is no longer a moisture absorbing material. As such, since there is no tongue expanding upon moisture absorption, the "peaking phenomenon" is no longer a problem when using the system according to the invention.

The preferred embodiment system according to the invention relates to a decorative laminated floor panel, square, tile, rectangular, etc., each of which has an upper wear surface, an intermediate substrate or reinforcement under the upper wear surface, and optionally a support or existing floor. Or a backing layer attached to the intermediate substrate in contact with the ground.

The upper wear surface of the panel according to the invention preferably comprises a decorative laminate or a general laminate produced by a combination of predetermined heat and pressure. These panels have been commercially manufactured for many years and have been widely adopted in the building and furniture industry, such as counter and table tops, work surfaces in bathrooms and kitchens, wall panels, partitions and doors. Such decorative laminates can be described as including multiple laminates merged to form a composite or unitary structure having a variety of surface decorations, from simple as solid to complex as embossed imitation woodwork finishes.

In particular, decorative laminates useful in the present invention generally comprise a plurality of layers of synthetic resin containing paper sheets that are merged or joined together in a single structure under a given heat and pressure. In the usual case, the decorative laminate assembly comprises a core of one or more sheets containing phenolic resin from below, on which a decorative sheet containing melamine resin and / or an overlay containing melamine resin is placed. The core or base member functions to provide the laminate with a certain stiffness and usually includes a solid base material which may or may not be formed prior to the initial lamination step. Prior to lamination, the sheet of core member is to be contained in an alcohol reservoir of phenol and formaldehyde or formaldehyde precursor, dried and partially cured in a hot air oven, and finally cut into sheets. Examples of such base or core members include: (1) 40.8 to 68.0 kg (90 to 150 pounds) soft kraft paper containing substantially the entire cured phenolic resin that has been converted to a thermoset state during the initial lamination step and bonded therewith; (2) pre-cured plastic laminates, such as thermoset polyester resin laminates reinforced with glass fibers, (3) wooden products such as cardboard, fiberboard, woodwest, particleboard, plywood, (4) ) Seals for mineral bases such as cement-asbestos boards, sheet locks, gypsum boards, (5) plastic boards, (6) plastic / wood composite materials, (7) plastic composite materials, (8) RIM foam, etc. Bubble polyurethane foam, (9) urethane-containing boards, (10) combinations of the above substrates, or (11) any material suitable for performing the desired function of the base or core member.

Decorative sheets useful in the panel according to the invention generally function not only to give the laminate a good appearance but also to provide surface properties (ie chemical resistance, heat resistance, light resistance, impact resistance and abrasion resistance). Decorative sheets typically contain alcohol reservoirs of melamine-formaldehyde resins, dried, partially cured and finally cut into sheets, with high quality α filled pigments with very good 50 to 125 ream weight. -Cellulose paper. The decorative sheet may be monochromatic, or include decorative designs or patterns or photographic replicas of natural materials such as wood, marble, leather, and the like. As mentioned above, the decorative sheet and / or overlay sheet may contain melamine resin.

Decorative laminates useful for the manufacture of panels according to the invention generally have sufficient time to place the resin-containing cores and decorative sheets between steel coated plates, steel sheets or stainless steel sheets, and to merge the laminates to cure the resin ( Obtained by applying a temperature in the range of about 65.6 to about 260 ° C. (about 150 to about 500 ° F) and a pressure in the range of about 5.52 to 11.0 MPa (about 800 to about 1600 psi) for about 25 minutes to 1 hour) But is not limited thereto. This allows the resin in the paper sheet to flow and cure into a composite material or monolithically stacked mass, referred to in the art as a high-pressure decorative laminate (HPDL), to merge. One or more stacks can be formed at one time by inserting a plurality of assembled sheets into the stack such that each assembly can be separated by a disassembly sheet that allows the individual stacks to separate after merging. Finally, the decorative laminates are further machined and generally are made of high density fibreboards, wood / plastic composites, wood, plywood, cardboard, asbestos boards, particle boards, ceramics, filled plastics or non-filled plastics, or independent foam rigid foams, etc. To a reinforcing substrate as a medium. If a cushioning effect is desired, the reinforcing substrate may be composed of open cell foam.

In addition, decorative laminates useful in the practice of the present invention range from about 65.6 to about 260 for a time sufficient to place the resin-containing core and decorative sheet between steel coated plates, steel sheets or stainless steel sheets, and merge the laminates to cure the resin. It may also be obtained by applying a temperature in the range of ° C (approximately 150 to about 500 ° F) and a pressure in the range of approximately 5.52 to 11.0 MPa (approximately 800 to about 1600 psi) to the laminate. It flows and cures the resin in the paper sheet into a synthetic material or monolithically stacked mass, referred to in the art as a low pressure decorative laminate (LPDL).

In addition, the reinforcing substrate of one embodiment according to the present invention may be made of any suitable extrudable thermoplastic material if desired to have the structural and mechanical properties necessary for end use. In particular, the substrate preferably has a compression test set that is approximately equal to or better than conventional media, high density fiberboard or particle boards, as the thickness decreases as a function of compressive stress, the compression test set measured according to ASTM F970. . Preferably, the thickness reduction at 13.8 MPa (2000 psi) is at most 0.254 mm (0.01 in) or less, preferably 0.127 mm (0.005 in) or less, and most preferably 0.0254 mm (0.001 in) or less.

Where possible, reinforcing substrates useful in the practice of the present invention include poly (acrylonitrile / butadiene / styrene), such as rigid urethanes (eg, RIM foams), flame retardant ABS resins, and glass filled ABS resins ( Hereinafter, it includes at least one member selected from the group consisting of ABS) resin, polycarbonate, high impact polystyrene (HIPS), polystyrene, polyphenylene oxide (PPO) and polyvinyl chloride (PVC). Preferably, the reinforcing substrate is made from, but not limited to, a resin system mixed with one or more of the above polymers. In addition, filled polymers are best in terms of impact resistance and physical properties, but they may not be filled. Preferred fillers include calcium carbonate, talc, silica, glass fibers, alumina and wollastonite, with better fillers being calcium carbonate and wollastonite and the best fillers being calcium carbonate. Non-limiting examples of reinforcing agents include high molecular weight inorganic or organic, including glass microspheres, glass fibers, asbestos, boron fibers, carbon and graphite fibers, whiskers, quartz and silica fibers, alumina fibers, molten fiber materials, and organic fibers. Product is included. When such conventional materials are used, they are generally present in the range of about 0.01 to about 50 weight percent of the total weight of the reinforcing substrate member, and preferably in the range of about 1 to about 25 weight percent.

An additional optional layer may be inserted between the core member and the decorative surface member at the rear or decorative surface member of the reinforcing substrate member. It should be understood that the backing layer and / or the decorative layer may be extruded together with the reinforcing substrate member or applied after the extrusion step by any suitable method.

The panel of one embodiment according to the invention is preferably resistant to water and most preferably waterproof. As in a conventional floor panel, the panel according to the invention comprises a decorative layer, a substrate and a backing layer. The decorative and backing layers are each bonded to the substrate in a conventional manner to form a panel according to the invention. According to a preferred embodiment of the invention wherein the material of the reinforcing substrate is a fiberboard, the backing layer comprises three layers of kraft paper containing a hydrophobic waterproof layer and a phenol formaldehyde resin from the bottom. As in the resin-containing lower layer of the decorative layer, the resin-containing upper layer of the backing layer is polished to bond with the substrate. The hydrophobic waterproofing layer may be a compound such as DYLARK. DYLARK is a styrene-maleic anhydride copolymer manufactured by Nova Chemical. DYLARK exhibits excellent bonding properties with kraft paper impregnated with phenolic resin. Good binding properties are presumed to be the result of the carboxyl groups in the male anhydride of the DYLARK copolymer. The carboxyl group combines with the phenolic resin to produce a very stable laminate. DYLARK is disclosed as a good material for the underlying layer of the backing layer, but other polymers that are functionally and structurally equivalent may be used without departing from the spirit of the invention. In addition to preventing moisture from penetrating into the backing layer, it is also desirable to maintain the moisture content in the manufacture of the panel to prevent the panel from twisting.

In addition, although phenol formaldehyde resin-containing kraft paper is used according to a preferred embodiment of the present invention, other resin-containing paper (or similar materials) may be used without departing from the spirit of the present invention. The resin containing layer is retained in the backing layer according to the invention so as to balance with the resin containing layer which is common in decorative layers which may be used with the backing layer. That is, the resin-containing layers of the decorative layer and the backing layer are expanded and contracted in a similar manner with temperature in order to maintain a substantially flat configuration of the floor panel. If the resin containing layer of the backing layer was not included, the decorative panel would expand and contract at a different speed than the backing layer. This would have distorted the floor panel in an undesirable way. As such, it will be understood by those skilled in the art that the phenol layer can be varied to maintain a balanced relationship between the backing layer and the decorative layer.

As described according to one aspect of the invention, the substrate is a poly (acrylonitrile-c-butadiene-c-styrene) (ABS) foam. The construction of the backing layer and substrate results in a waterproof floor panel that is not sensitive to the harmful environmental conditions common in any environment. In particular, the ABS substrate and the styrene-maleic anhydride copolymer layer form a moisture barrier that protects the resin containing layer from the effects of undesirable moisture.

The floor panel described above is manufactured using techniques known in the art. During manufacture, the panel may be machined to form a suitable recess at the corners. Preferably, during the manufacture of the panel, the panel may be manufactured to have recesses formed therein at at least two corners to reduce the size of material required to manufacture the panel. In addition, the panels of one embodiment according to the invention may be manufactured using injection molding techniques, with recesses formed in all corners.

The connector of the present invention includes a plurality of embodiments. 1 through 18, wherein like reference numerals refer to like elements in the connector of the present invention, end views of various embodiments of the connector 1 are shown. The connector 1 comprises a base 2 and an extension 15. Base 2 is a substantially flat portion for positioning on a floor or surface covered by assembled panels and connectors. The extension 15 is a "T-shaped" projection with a vertical support 3 and two horizontal flanges 4 and 5. The support 3 is a vertical portion of the "T-shaped" projection, and the flanges 4 and 5 are the portions extending horizontally from the top of the "T-shaped" projection. As can be seen in most of the above embodiments, the connector 1 extends perpendicularly from the base 2 near the distal end of the base 2 away from the center where the support 3 is attached to the base 2. Ridges 6, 7. In another embodiment, the connector has recesses 8, 9 on the top surface of the base 2 directly adjacent to both sides of the support 3. At the distal end of the flanges 4, 5 of the T-shaped extension 15, the connector 1 of some embodiments has vertically extending projections 10, 11. In some embodiments a slot 12 is formed on top of the T-shaped extension 15 between the vertically extending protrusions 10, 11. In some embodiments, the connector 1 has a notch 13, 14 located on the lower side of the proximal end of the flange 4, 5 adjacent to where the flanges 4, 5 are connected to the support 3. It further includes. Preferably, the system according to the invention can be releasably interconnected using connectors 1 with T-shaped extensions and ridges 6 and 7 and connectors in the horizontal and vertical directions without the use of adhesives or the like. So that it includes a panel with recesses and channels.

It is to be understood that Figures 1-18 are not intended to limit the scope of the present invention but to provide an embodiment that includes preferred embodiments of various components of the novel connector of the present invention. Indeed, various combinations of different embodiments of the various individual components of the connector according to the invention can be used. That is, although the exact combination is not shown in the drawings, the configuration of the various bases 2 shown in Figs. 1, 2, 7-12, and the like is shown in Figs. 1-3, 5, 6, 16-Figs. 18 may be used with embodiments of the various extensions shown. Of course, the base and extension are not limited to the figure. Preferably, the connector is less than 6.1 mm (0.240 in).

The connector according to the invention may be made from a material selected from filled or unfilled plastics, rubber, wood composite materials, ceramics, metals and combinations thereof. Preferably, when used with good laminated floor panels, the connectors of the present invention are made from metal or plastic materials. Depending on the material and the size, the connector may be manufactured using techniques known in the art. For example, the connector is preferably made from aluminum.

The panel of the present invention includes a recess in the shape of accommodating the connector therein such that the conspicuous upper floor surface, when connected, consists only of the upper wear face, i. E. Preferably the decorative layer. The protrusion of the connector and the recess of the panel are such that when the two panels are joined together using the connector of the present invention, the panels are connected perpendicular to each other, i.e. the corners of the opposing panels are mutually opposite when the two panels are connected at their corners. It is formed so as not to move up and down (vertical direction) relative to the two panels to provide a seam of equal height between the two panels. For example, in a preferred embodiment, the panels once connected are joined to prevent movement relative to each other in the direction of the plane extending vertically from the support surface and at right angles to the panels.

In a preferred embodiment, in addition to the vertical connection, the panel and the connector provide a horizontal connection between adjacent panels at their corners, i.e., when the two panels are connected at their corners, the corners move horizontally from each other so that the adjacent panels It is formed so that a predetermined gap cannot be generated between them. For example, in a preferred embodiment, the panels once connected are joined to prevent movement relative to each other horizontally to the support surface and horizontally relative to the panels.

Various non-limiting embodiments of the connector according to the invention have been described and, although not shown, the panel according to the invention is configured to correspond to the connector, for example in order to achieve the advantages of the invention. It should be understood that the panel according to the present invention can be configured to provide an accurate or incorrect fit to the connector as long as the advantages of the present invention are achieved. For example, where a permanent structure is desired, embodiments may be suitable that allow space for adhesive to accumulate between the panel and the connector. In addition, when using certain reinforcing substrates, it may be desirable for the panels and connectors to be precisely fitted together, particularly when a temporary structure is desired. For example, the space between the protrusion of the connector and the predetermined portions of the recess of the panel is acceptable, especially if it is a floor where only the upper wear surface is visible with the same height and uniform seams, as long as the object of the invention is achieved. Can be.

The panel according to the invention is configured to be releasably interconnected with the connector of the invention. That is, with the connector and panel firmly connected to perform the function of the floor surface, the panel is configured to be removed by lifting it up and withdrawing it away from the connector, ie by breaking the interconnect of the panel / connector.

The panel of one embodiment according to the invention is configured to always form a firm, uniform and equal height between the panels when connected to each other using the connector of the invention. The panel of the preferred embodiment is configured such that the depth of the recess or channel at the bottom face of each panel is always a certain distance from the top wear face. As mentioned above, such recesses or channels are formed to receive protrusions protruding from the base of a connector (preferably a track) for releasably interconnecting the two panels to each other horizontally. As such, at the interconnection point, the panel lies in the connector. After all, even if the support structure or ground floor is not uniform, the joints are always firm, uniform and of the same height. As such, even if the thickness of the panel changes, the depth of the recess or channel in the lower surface of each panel is formed to be at a predetermined distance from the upper wear surface, so that when the two panels are interconnected, a uniform and equal height joint is formed. Is provided. Thus, the upper wear face of the two adjacent panels will always be at the same height, ie a distance from the base protrusion of the connector. Preferably, the panel of the system according to the invention is in the thickness range of about 0.610 cm to about 0.823 cm (about 0.240 in to about 0.320 in). According to another embodiment of the present invention, the panel has a thickness of less than 2.54 cm (1 in).

In addition, the system according to the present invention provides a panel that provides economic advantages over many conventional systems by using the top wear surface of substantially all manufactured laminates. Using the system according to the invention, the amount of upper wear face of the panel that needs to be machined to remove a predetermined portion of the decorative upper wear face that is already manufactured and used is greatly reduced. Virtually all manufactured decorative top wear surfaces are sold to the end user. In other words, the waste experienced in conventional systems is eliminated. As a result, the total area of salable floors produced in the factory is increased and costs are reduced.

Furthermore, the connector according to the invention does not need to be applied with any adhesive or other fastening means since it is not fixed to the panel at the factory. In other words, the material costs, labor costs and time required to manufacture the system according to the invention are reduced. In a preferred embodiment, the panel is manufactured with all the necessary recesses formed therein using injection molding techniques. In another preferred embodiment where the intermediate reinforcing substrate of the panel is extruded, only two corners should be machined to form recesses therein. That is, the other two edges extending in the machine direction are formed during extrusion. They provide additional savings due to the fact that the amount of material of the intermediate reinforcing substrate used is reduced, i.e. the material of the intermediate reinforcing substrate is not used.

The system according to the present invention also provides a panel that is less susceptible to damage than prior art tongue and groove systems. For example, it is known that the tongue of the panel is susceptible to damage during shipping, handling and even assembly and disassembly. If the tongue is pulled out or substantially deformed, the panel cannot be joined to the groove of the adjacent panel and becomes useless. The panel according to the invention does not comprise tongues. That is, the panel according to the invention has only recesses or grooves formed therein. It is not impossible but difficult to damage the recess or groove during shipping, handling, assembly and disassembly. As such, the panel according to the invention is more durable than many panels of the prior art. This is an important advantage with respect to the use of panels for "floating floor" surfaces or temporary floor constructions that are removed and reassembled several times. The system according to the invention provides a connector (preferably made of metal) which is very tough, easy to replace and economical when compared to the cost of a new panel. The system according to the invention significantly reduces the risk of not damaging the panel to the point of inoperation.

The floor system according to the present invention provides a floor surface that is easy to repair and / or replace. The panels of the system according to the invention can be removed or replaced by removing adjacent panels in any direction since they do not require a one-way placement process. Adjacent panels may be removed in the direction with the fewest number of panels to simplify the removal and replacement process. The system according to the invention substantially reduces the time and effort of removing and replacing panels. In addition, the floor can be constructed in multiple directions, so that more than one person can construct different parts of one floor surface at the same time. According to one assembly process, the panel is placed in the center portion of the floor space and panels are added from the center outwards. This is particularly advantageous with regard to the installation of large floor surfaces such as retail spaces.

In addition, the panel according to the invention provides substantially aesthetic adaptation than the panel according to the prior art. For example, since the panel according to the invention is multidirectional due to the identity of each corner rather than in the left or right direction, ie in one direction, each individual panel can be placed on the floor surface to be constructed in a visually best way. Moreover, the panels of the system according to the invention allow for adaptability in the design and construction of parquet or wood carving floor surfaces. For example, the panels are usually made so that the wood grain extends in the machine direction, but since the panel according to the invention is multidirectional, the wood grain direction of the floor surface is easy to form a parquet floor or a floor having any wood grain design. can be changed.

In addition, the panel according to the invention reduces waste during floor construction. By means of the panel according to the invention, i.e. each panel is constructed with grooves of all corners, the part remaining after completing the floor to part of the end wall can be used to complete another part of the floor to the end wall. .

The panel of the system according to the invention is configured such that it is not necessary to keep one panel at an angle with respect to the other panel and to tilt the new panel down to the predetermined position in order to assemble the two panels. The fact that the two panels can be interconnected by pressing each other in the same plane lies very much in connection with the construction of certain parts of the floor surface as required at various physical boundaries, for example at the interface between the floor surface and the hearth. It is advantageous.

Referring to Fig. 6, the connector 1 of the preferred embodiment of the present invention has a base 2, an extension 15, and ridges 6, 7 which protrude vertically from the base 2, spaced apart from both sides thereof. Include. The ridges 6, 7 are preferably reduced in height as the upper part is rounded and away from the center of the base 2 towards the end of the base as shown. In this way, the ridge of the part closest to the center of the base 2 and the extension part 15 extends at the largest vertical distance.

A connector 1 of a particularly preferred embodiment of the invention is shown in FIG. Accumulation in Fig. 14 is nine times the real. However, although not shown, it should also be understood that the base 2 of the connector 1 may be configured so that it does not come into contact in a completely enclosed by a support structure, ie two connecting panels.

19A and 19B, a plan view and an end view of the rectangular panel 20 are shown, respectively. The panel 20 includes an upper wear surface 21, an intermediate substrate 22 and a backing layer 23. In the embodiment shown, the panel 20 has four grooves 24 in the intermediate substrate 22 of each of the four sides. The panel 20 also has four channels 25 in the backing layer 23 extending in parallel slightly spaced from each of the four sides.

In another embodiment (not shown), two or more channels 25 are formed in the backing layer 23 adjacent each side of the panel 20. Of course, in this embodiment, the connector 1 has two or more corresponding ridges 6 or 7 on each side.

Connectors for joining panels as shown in FIGS. 19A and 19B are shown in FIGS. 20A-20C. The top, end and side views of the connector 1 are respectively shown. The connector 1 has a base 2 and an extension 15 as described above. The base 2 has two ridges 6, 7 at the top surface. The extension 15 has a support 3 and two flanges 4, 5. The extension 15 has a slot 12 at the top. The end of the connector 1 is angled at 45 ° as shown in FIG. 20A to form the end face 16. Since the end faces 16 of the same end are each cut at 45 °, an angle point of 90 ° is formed in the middle of the connector 1 at each end.

As shown in Fig. 21, the assembly section of the floor includes rectangular panels 20 joined to each other by a connector 1. The end faces 16 of the two connectors 1 lie in contact with one another where the connectors are fixed to the adjacent sides of one panel 20. The advantage of this configuration is that even at the corner where the connectors 1 meet, the upper wear surface of the panel 20 is fully supported by the connector 1.

In other embodiments, some panels 20 are made of triangles. The triangles increase the decorative possibilities for the assembled floor covering. One possible arrangement of the assembled part of the floor is shown in FIG. Of course, another connector 1 is required to join the triangular panel. They in some cases have end faces cut at 22.5 ° and in other cases end faces cut at 45 °.

In another embodiment, the panel has square, rectangular, triangular, pentagonal, hexagonal and octagonal geometric shapes. According to the assembly system of the present invention, since the panel and the connector are assembled with the panel laid flat on the auxiliary floor support surface, it is possible to assemble the panel having the above geometric shape. For example, FIG. 27 shows a top view of hexagonal panel 20 in a partially assembled floor system. The connector 1 is used to connect the panels 20 but will not be shown for simplicity. Panel 20b is in position to connect to panels 20f and 20g. Since the panels 20f and 20g are already assembled, they are placed flat on the auxiliary floor support surface. The panels 20f and 20g are connected by laying the panel 20b flat on the auxiliary floor. Contact with the panels 20f and 20g is made simultaneously, and the panel 20b is snapped into the connector (not shown) between the panels. Similarly, panel 20a is in a position to connect to panels 20c, 20d, 20e. Panel 20a lies on an auxiliary floor support surface adjacent to other panels so that they are in the same plane as the other panels. Next, the panel 20a slides toward the panels 20c, 20d, and 20e until contact with the panels is made at the same time.

Figure 18 best illustrates the panel / connector assembly. The panel 20 is coupled to the connector 1 by "snapping" the flanges 4, 5 of the connector 1 into its grooves 24. Initial contact is made by inserting the flanges 4, 5 into the groove 24. As the panel 20 and connector 1 move further toward each other, the ridges 6 and 7 slide across the backing layer 23 of the panel. When the panel 20 and the connector 1 are completely moved from each other, the flanges 4, 5 extend completely into the grooves 24, and the ridges 6, 7 "snap" into the channel 25. Throughout the process, the base 2 of the connector 1 and the panel 20 are kept in substantially the same plane. Since the connector 1 and the panel 2 are held in the same plane during assembly, it is possible to simultaneously connect a plurality of different panels to one panel. The single planar “snap coupled” assembly process enables the use of panels of various geometric shapes as described above.

Referring to Fig. 23, another configuration for the floor covering of the present invention is shown. The configuration includes a rectangular panel. In this embodiment, the panel 20 is joined by two different kinds of connectors, the longitudinal connector 30 and the transverse connector 31. In one embodiment of the invention, the longitudinal connector 30 connects several panels 20 and is much longer in the longitudinal direction than a given panel. In another embodiment of the present invention, the longitudinal connector 30 is approximately equal in length to the length of the panel 20. The transverse connector 31 extends at right angles between two adjacent parallel longitudinal connectors 30. In the configuration shown in FIG. 23, each set of longitudinally extending panels 20 is offset from an adjacent set of longitudinally extending panels 20. Since the panels end up in different locations on both sides of a particular longitudinal connector, the assembly becomes quite strong as the joints are evenly distributed throughout the assembly. If the ends of all panels are not offset from one row to another, the floor may be vulnerable in the "four corners" area where adjacent transverse connectors 31 are coupled to one longitudinal connector 30. Also for the same reason, in the embodiment of the present invention, the end of the longitudinal connector 30 does not coincide with the longitudinal end of the panel 20 such that the connectors connect at least two continuous panels 20.

24A-24C, top and end views, respectively, of the transverse connector 31 are shown. Like the connectors described above, the transverse connector 31 has a base 2 and an extension 15. The extension 15 comprises a support 3 and flanges 4, 5. The transverse connector 31 further comprises ridges 6, 7 located on both sides of the base 2. An important feature of the transverse connector 31 is that the extension 15 is longer than the base 2. As such, the extensions 15 extend beyond the base 2 at both ends. As shown in Fig. 24C, there are cutouts 32 and 33 at both ends of the extension 15. The shape and dimensions of the cutouts 32, 33 are opposite to the ridges 6, 7.

A transverse connector 31 assembled to two longitudinal connectors 30 is shown in FIG. The longitudinal connector 30 is seen from the end and the transverse connector 31 is seen from the side. The longitudinal connectors 30 are parallel and the transverse connectors 31 are located at right angles between the longitudinal connectors 30. The cutout 32 of the transverse connector 31 is located directly above the ridge 7 of the longitudinal connector on the right side. As shown in Fig. 25, the cutout 33 of the transverse connector 31 is directly above the ridge 6 of the longitudinal connector 30 on the left side. As described above, the extension 15 of the transverse connector 31 extends over a portion of the base 2 of the longitudinal connector 30.

26A and 26B, a plan view and an end view of a rectangular panel are shown. The panel 20 is particularly suitable for assembling with the longitudinal and transverse connectors shown in FIGS. 23-25. Like the panel described above, the panel has an upper wear surface 21, an intermediate substrate 22 and a backing layer 23. The panel 20 also has a groove 24 adapted to engage the flanges 4, 5 of the connectors 30, 31. The grooves 24 extend throughout the periphery of the panel 20. The panel 20 also has four channels 25 extending parallel to each of the four sides of the panel. The channel 25 is machined or formed in the lower or backing layer 23 of the panel 20. The channel 25 extends throughout in the left and right directions of the panel. The channels 25 of the panel 20 are configured to engage with the ridges 6, 7 of the longitudinal and transverse connectors 30, 31.

While the embodiments for the floor system and its components, as shown and described in detail herein, can fully achieve the objects and advantages of the present invention described above, they are only intended to illustrate preferred embodiments of the present invention and are included in the appended claims. It should be understood that no limitation should be imposed by the details of the construction or design shown herein other than the configuration as described in the claims.

Since the panels of the system according to the invention do not require a one-way placement process, they can be removed or replaced by removing adjacent panels in any direction. Thus, the floor system according to the present invention provides a floor surface that is easy to repair and / or replace. In addition, adjacent panels are removed in the direction with the fewest number of panels to simplify the removal and replacement process. Thus, the system according to the invention substantially reduces the time and effort of removing and replacing panels. Moreover, since the floor can be constructed in multiple directions, more than one person can construct other parts of one floor surface at the same time. Thus, the workability is particularly excellent with respect to the installation of the large floor surface. In addition, since the panel according to the invention does not include a tongue, i.e. has only recesses or grooves formed therein, damage of the recesses or grooves during shipping, handling, assembly and disassembly is very difficult and as a result the It is significantly more durable than many panels.

Claims (10)

In the multidirectional laminate floor panel used for floor construction, Top view, Bottom view, A side surface extending between the upper and lower surfaces and having the same recess or groove profile Panel comprising a. The panel of claim 1, wherein the panel thickness is in the range of 6.1 mm (0.240 inch) to 8.1 mm (0.320 inch). The panel according to claim 1 or 2, wherein the groove or recess profile of each side extends over the entire length of the side. A panel according to claim 1 or 2, wherein the groove or recess profile of each side extends and intersects with the groove or recess profile of the adjacent side. A panel according to claim 1 or 2, further comprising channels on the bottom surface of the panel, the channels extending parallel to each side thereof. 6. The panel of claim 5, wherein the channels in the bottom surface of the panel extend over the entire length of the side surface. 6. The panel of claim 5, wherein each channel in the bottom surface of the panel extends to and intersects with another channel. The panel according to claim 1 or 2, wherein the panel has a geometric shape selected from the group of geometric shapes consisting of square, rectangle, triangle, pentagon, hexagon and octagon. 3. The method of claim 1 or 2, further comprising an intermediate base material between the upper and lower surfaces, wherein the intermediate base material of the panel is medium density fiberboard, high density fiberboard, wood / plastic composite, wood, ceramic, unfilled plastic And a material selected from the group of materials consisting of filled plastics, closed cell rigid foams, and combinations thereof. In a multidirectional laminate floor system, At least two panels each having an upper surface, a lower surface and side surfaces extending between the upper and lower surfaces and having the same recess profile; Separate connectors from the at least two panels to connect the at least two panels together to form a floor. System comprising a.