KR20100080538A - Floor covering system - Google Patents

Abstract

A floor covering system (10) including a first layer (14) of planar material and a second layer (12) of planar material. At least a portion of the second layer (12) is adapted for laminating engagement with the first layer (12) to define a floor covering. The system further includes a locating means for locating two or more of the second layers in a substantially aligned configuration, wherein the second layer (12) is adapted to receive the locating means.

Description

Floor covering system {FLOOR COVERING SYSTEM}

The present invention relates to a floor covering system.

The present invention is primarily developed as a floating floor covering system and will be described below in connection with the present application. However, it will be appreciated that the invention is not limited to this particular field of use.

The prior art described below is intended to explain the present invention in appropriate technical context and to fully understand the related advantages. However, any prior art described herein should not be considered to recognize that such techniques are generally well known or form part of general knowledge in the art.

Floor covering systems are known that do not have a fixed part in a building structure or that are "subfloor". Floor cladding systems of this type are free to remain floating above the subfloor and are often referred to as "floating floors." As an advantageous effect, the floating floor structure is relatively easy to install and can expand and shrink humidity and temperature, resulting in long life and minimal spacing during use.

Floating floor structural systems generally include an underlay formed of a resilient, moisture resistant material, and a series of floor planks located above and interconnected to define a major floor surface. Floor planks usually consist of a thin layer of soft or hard wood bonded to a high density fiberboard substrate. They are also often pre-coated to improve durability (polyurethanes are used predominantly), but they can also be coated after installation.

In an alternative type of floating floor structure system, the floor planks are in the form of plywood tiles formed primarily of polyvinyl chloride (PVC), which have a design pattern drawn on their upper surface to resemble the desired surface finish. This alternative type of floating floor structure has the advantage of being more suitable for installation in quieter, softer and moist areas when walking, as well as greater durability compared to the above-described wooden type floating floor structure. Such flooring systems are disclosed in US Pat. No. 7,155,871, the patent holder of Tru Woods Limited.

In such a system, the laminated tile is formed of a soft PVC material consisting of two layers, which consists of a lower layer which functions as a lower layer and an upper layer having a desired pattern on the upper surface. These two layers are plywooded together in an offset arrangement to define two perimeters along the long edge of each tile. This periphery includes an adhesive coating that allows adjacent tiles to be connected in a lap joint formation manner, thereby constructing a floating floor structure.

However, a problem with this system is that a considerable amount of skill and attention is required for the arrangement of adjacent tiles during installation. In addition, the small error of the arrangement during installation can be greatly amplified when the bottom member installation is completed. This misalignment can lead to a number of gaps at the border of the finished floor.

The present invention aims to overcome or ameliorate at least one of the disadvantages of the prior art or to provide a useful substitute.

It is also an object of the present invention to provide a floating floor structure system that can maintain alignment relatively easily between components during installation.

According to a first aspect, the invention is:

A first layer consisting of a planar material;

A second layer of planar material, the second layer being configured to define a floor covering at least partially covering the fastening with the first layer; And

Installation means for installing two or more of said second layers in a substantially array configuration,

The second layer provides a floor covering system configured to receive the installation means.

In one embodiment, the floor covering system includes one or more mounting protrusions extending from one side of the first layer. Preferably, the second layer includes one or more mounting holes disposed on one surface thereof, the holes configured to complementarily engage the mounting protrusions.

Preferably, the mounting hole extends from the top surface of the second layer to the bottom surface. More preferably, the first layer comprises four mounting protrusions. Even more preferably, the second layer comprises four mounting holes.

In one embodiment, the mounting protrusions are arranged symmetrically with respect to the first layer.

In one embodiment, the mounting protrusions are arranged asymmetrically with respect to the first layer.

In one embodiment, the mounting holes are arranged symmetrically with respect to the second layer.

In one embodiment, the mounting holes are arranged asymmetrically with respect to the second layer.

In one embodiment, the mounting holes are cut from the second layer to form two or more off-cut portions, and the cut portions are joined to one side of the first layer to form mounting protrusions. define.

In one embodiment, the second layer includes a pair of interconnects disposed at its long opposite edges. Preferably, the interconnects are configured to substantially laterally constrain the long adjacent pair of second layers during installation.

According to a second aspect, the present invention provides:

A first layer consisting of a planar material;

A second layer of planar material, the second layer defining a modular floor tile laminated with the first layer; And

A floor covering system is provided that includes an installation member that engages at least a portion of the modular floor tiles to install two or more of the modular floor tiles in a substantially arranged configuration.

In one embodiment, the modular floor tile includes one or more mounting holes disposed on one side thereof. The one or more holes preferably comprise one or more elongate slots.

In one embodiment, the mounting member comprises one or more mounting protrusions extending from one surface thereof, the protrusions being configured to position a fastening portion with the mounting holes. One or more mounting protrusions preferably comprise one or more elongated flanges.

In one embodiment, the mounting member is configured in the shape of an extruded track substantially formed of a plastic material.

In one embodiment, the mounting member is configured in the shape of an extrusion track substantially formed of aluminum for extrusion.

In one embodiment, either one of the first or second layers comprises a design pattern on its top surface. The design pattern is preferably formed to resemble a wood, marble, ceramic or slate surface.

In one embodiment, the design pattern is engraved on a supplemental layer bonded to one side of the first or second layer.

In one embodiment, the second layer comprises adhesive means for bonding the second layer to the first layer.

In one embodiment, the first or second layer has a size corresponding to the dimensions of a standard ceramic, slate, marble tile or wood plank.

In one embodiment, the first and second layers are formed of an elastic plastic material, such as PVC.

In one embodiment, the first layer is a floor plank and the second layer is an underlayer.

In one embodiment, the floor covering system includes incidental adhesive means for joining the installation member to one or more of the modular floor tiles. In this embodiment, the second bonding means is disposed on the installation member.

According to a further aspect, the present invention provides a method of installing a floor covering system according to the first aspect, the method comprising:

Installing two or more second layers on the subfloor; And

Installing a first layer over the two or more second layers such that the installation means installs the second layers in an arranged configuration.

According to a further aspect, the present invention provides a modular underlayer tile for a floor system, wherein the underlayer tile is:

A substantially planar top and bottom surfaces, wherein the underlayer tile is configured for substantial aligned engagement with one or more other modular underlayer tiles to form a underlayer for the floor system.

In one embodiment, the modular underlayer tile includes two or more interconnects disposed on two or more corresponding edges of the tile. The interconnects are preferably configured to substantially limit at least adjacent lower layer tile pairs upon installation.

In one embodiment, the lower layer tile is formed of an elastic plastic material, such as PVC.

As used throughout the specification, "an embodiment", "some embodiments" or "any embodiment" is described in connection with a particular feature, structure, or embodiment included in at least one embodiment of the present invention. Means features. Thus, the phrases "in one embodiment", "in some embodiments" or "in any embodiment" used in various places in the specification of the present invention do not necessarily all refer to the same embodiment. In addition, certain features, structures, or features may be combined in any suitable manner in one or more embodiments, as will be apparent to one of ordinary skill in the art.

Preferred embodiments of the invention will now be described with reference to the accompanying drawings, by way of example only.
1A is a plan view of a lower layer according to the first embodiment of the present invention.
FIG. 1B is a side view of the lower layer of FIG. 1A.
1C is a perspective view of the lower layer of FIG. 1A.
Figure 2a is a plan view of a floor plank according to an embodiment of the present invention.
FIG. 2B is a side view of the floor plank of FIG. 2A.
FIG. 2C is a bottom view of the floor plank of FIG. 2A.
FIG. 2D is a partially exploded perspective view of the floor plank of FIG. 2A. FIG.
3A is a partial assembly view of a floor covering system in accordance with one embodiment of the present invention.
3B is a bottom view of the floor covering system of FIG. 3A.
4A is a plan view of a lower layer according to a second embodiment of the present invention.
4B is a side view of the lower layer of FIG. 4A.
4C is a perspective view of the lower layer of FIG. 4A.
5A is a plan view of a floor plank according to a second embodiment of the present invention.
5B is a side view of the floor plank of FIG. 5A.
5C is a bottom view of the floor plank of FIG. 5A.
5D is a partially exploded perspective view of the floor plank of FIG. 5A.
6A is a partial assembly view of a floor covering system according to a second embodiment of the present invention.
FIG. 6B is a bottom view of the floor covering system of FIG. 6A.
7A is a plan view of a lower layer according to a third embodiment of the present invention.
FIG. 7B is a side view of the lower layer of FIG. 7A.
FIG. 7C is a perspective view of the lower layer of FIG. 7A. FIG.
8A is a plan view of a floor plank according to a third embodiment of the present invention.
8B is a side view of the floor plank of FIG. 8A.
8C is a bottom view of the floor plank of FIG. 8A.
8D is a partially exploded perspective view of the floor plank of FIG. 8A.
9A is a partial assembly view of a floor covering system according to a third embodiment of the present invention.
FIG. 9B is a bottom view of the floor covering system of FIG. 9A.
10A is a plan view of a lower layer according to the fourth embodiment of the present invention.
FIG. 10B is a side view of the lower layer of FIG. 10A.
10C is a perspective view of the lower layer of FIG. 10A.
11A is a plan view of a floor plank according to a fourth embodiment of the present invention.
FIG. 11B is a side view of the floor plank of FIG. 11A.
FIG. 11C is a bottom view of the floor plank of FIG. 11A.
FIG. 11D is a partially exploded perspective view of the floor plank of FIG. 11A. FIG.
12A is a partial assembly view of a floor covering system according to a fourth embodiment of the present invention.
12B is a bottom view of the floor covering system of FIG. 12A.
FIG. 13 is an additional partial assembly view of the floor covering system of FIG. 12A. FIG.
14A is a plan view of a lower layer according to the fifth embodiment of the present invention.
FIG. 14B is a side view of the lower layer of FIG. 14A.
14C is a partially exploded perspective view of the lower layer of FIG. 14A.
15A is a plan view of a floor plank according to a fifth embodiment of the present invention.
FIG. 15B is a side view of the floor plank of FIG. 15A.
15C is a bottom view of the floor plank of FIG. 15A.
15D is a partially exploded perspective view of the floor plank of FIG. 15A.
16A is a partial assembly view of a floor covering system according to a fifth embodiment of the present invention.
FIG. 16B is a bottom view of the floor covering system of FIG. 16A.
FIG. 17 is an additional partial assembly view of the floor covering system of FIG. 16A. FIG.
18 is a partial assembly view of a floor covering system according to a sixth embodiment of the present invention.

Referring first to FIGS. 1-3, there is provided a floor covering system 10 according to one embodiment of the present invention. The system includes a plurality of planar bottom plates 12 in contact with the subfloor, and a plurality of planar floor planks 14 overlying the engagement with the bottom plates.

Each bottom plate comprises four mounting holes 16 arranged symmetrically with respect to its surface 18. In the embodiment shown, the holes extend in all directions across the bottom plate. However, in another embodiment not shown, the holes may not extend in all directions across the bottom plate.

Covering over the fastening, these holes engage with complementary mounting protrusions 20 extending from the bottom 22 of the floor planks 14. In this respect, the installation means is provided by the protrusions, which are received by the lower layer 12. The lower layer includes an adhesive coating on its upper side 14 such that when covering over the fastening the floor planks are fixedly bonded along the plane or "laminated" to the lower layers. Alternatively, the adhesive coating can be applied to the underside of the floor plank.

This arrangement allows the mounting protrusions 20 to engage with the mounting holes 16 so that a single floor board is positively and accurately in side-by-side configuration of two or more adjacently located lower layers 12. And / or in an end-to-end configuration. In this way, floor coverings are defined and a complete floor can be completed gradually, with each sublayer being precisely arranged with adjacent sublayers.

As shown in FIG. 2, each floor plank 14 includes a design pattern 24 printed on its top surface, for example, to simulate a surface having a texture of marble, ceramic or wood. Alternatively, the design pattern may be printed on a supplemental layer laminated to the top surface of the floor plank. In the embodiment shown in Figs. 1 to 3, the lower and floor planks have a rectangular shape, which can be used as marble, slate, ceramic or other types of rectangular floor tiles.

As is well known in the art, the lower layer 12 and the floor planks 14 are mostly formed of a soft polyvinyl chloride material known as PVC or vinyl. Thus, the finished floor is long lasting, comfortable for walking and suitable for wet areas. In addition, the use of elastic polyvinyl chloride material makes it possible to compensate for irregularities in the bottom surface when a degree of planar compliance is installed. Of course, other materials can be used with PVC without being separated within the scope of the present invention, for example resins and / or polyurethanes can be used.

As shown in FIG. 2D, in the preferred form of manufacture, the apertures 16 are cut out of the underlying layer to define the cut locations 26, and the protrusions 20 use suitable adhesives or any other well known in the art. It is formed by joining the cut portion 26 to the lower side 22 of the floor plank using a fixing method of. This cutting and joining process will generally be performed during automated production and, as a result, the holes and protrusions will be positioned accurately within the required error.

Referring to FIG. 3, to assemble the floor covering system 10, the four lower layers 12 are first placed on the subfloor adjacent to each other, ideally starting from the wall 28 or other arrangement feature. . In this step, it is only necessary to arrange the bottom plates roughly with respect to each other. In addition, no fastening procedure is required to secure the bottom plate to the subfloor, since the floor system 10 is a "floating type", thus enabling contraction and expansion of the assembled floor during use. do.

Then, a single floor plank 14 is placed above the lower layer 12 so that the protrusions 20 can engage with one hole 16 from each lower layer. Then, the other two lower layers 12 are again arranged in an adjacent formation manner by roughly arranged in an arrangement arranged with one edge or with an end of the lower layer already installed. Then, another floor plank is positioned so that the protrusions 20 engage with one or more holes 16 from each lower layer. Due to the fastening between the corresponding protrusion and the hole, the installed lower layer will move in the correct relative arrangement. At the same time, the corresponding floor planks 14 will also be precisely arranged relative to the lower floor.

This process continues until the lower layer 12 and the floor planks 14 cover the desired floor surface. Upon completion, the remaining floor gaps are covered by half-sized floor planks, which are cut at that location or supplied in half size. In addition, edge trim (not shown) or molding may also be provided to fill any small peripheral gaps in a manner well known in the art.

As mentioned above, an adhesive coating is provided on the upper side 14 of each lower layer 12. Such coatings are proposed to be exposed to the removal of disposable cover pieces (not shown). The coating may be of a type that reacts when in contact with the floor planks, such that the formed bonds become stronger over time. Preferably, this feature will allow any installation mistake to be easily corrected.

4-6, a second embodiment of a floor covering system 10 of the present invention is provided. This embodiment shows that both the lower layer 12 and the floor planks 14 now have a rectangular shape with substantially the same dimensions, so that the finished assembly can more easily mimic a common wood type floor covering. Similar to the first embodiment.

As shown in FIG. 6, the assembly process for this embodiment is described above, except that the lower layer 12 is now installed and does not fully extend to the bottom boundary 32 where longer edges 30 are required. It is essentially the same as in the first embodiment. Instead, the floor planks 14a located at the periphery are covered so that the long edge 34 continues to the boundary 32. For this reason, only two of the projections 20 of the floor planks located at the boundary are engaged with the lower holes 16 located at the boundary, and the remaining unfastened projections 20 are directly on the subfloor. It is supported so as to support the hanging portion of the floor plank 14a.

Of course, in this embodiment, it will be required to cut some of the floor planks to achieve a zigzag pattern. This situation is illustrated with reference to floor plank 14b, which is cut along line 15 to terminate flush generally using wall 28. Alternatively, half-sized floor planks can be supplied.

7-9, a third embodiment of the floor covering system of the present invention is shown. This embodiment provides a lower layer and floor plank similar in form to the second embodiment except that the lower layer 12 now includes a pair of complementary interconnects 36 disposed at their long opposing ends. It starts. As shown in FIG. 9, each interconnect 36 joins in an assembly to provide additional lateral restraint between adjacent bottom plates of the long side upon installation.

Thus, the assembly process for this embodiment is essentially the same as the second embodiment described above except for the trimming of a certain degree of interconnect 36 near the wall 28. To aid in any trimming, cutting lines or perforation lines (not shown) may be provided on the interlocks.

10 to 13, a fourth embodiment of the present invention is provided. This embodiment is similar to the second embodiment of the present invention, wherein the lower plate 12 and the floor plank 14 have a rectangular shape with substantially the same dimensions. However, in this embodiment, the protrusions 20 are arranged asymmetrically with respect to each floor plank 14. For this reason, small modifications to the assembly process are required. As best shown in FIGS. 12 and 13, the short side edge 38 of the bottom plate of the boundary is also offset from the required bottom side boundary, and the short side edge of the floor plank extends to the boundary 32. Preferably, this embodiment allows the floor plank 14 to always cover the area 40 to which the short side end of the lower layer 12 engages.

14 to 17, a fifth embodiment of the present invention is provided. This embodiment is similar to the fourth embodiment in that the protrusions are arranged asymmetrically with respect to the floor plank. However, in this embodiment, the holes 16 are now arranged asymmetrically with respect to the lower layer 12. Despite this difference, the installation in this embodiment is substantially the same as described for the fourth embodiment. Preferably, this embodiment has a greater extent to cover the lower end joining region.

During the installation of the fourth and fifth embodiments, a certain degree of trimming to both the lower layer 12 and the floor planks 14 may be required.

All of the above embodiments define that the protrusion 20 extends from the underside of the floor plank 14 and the holes 16 are arranged in the underlayer 12, but this structural arrangement is not departing from the scope of the present invention. Can be reversed. In other words, in another embodiment not shown, the holes may be disposed in the floor planks and the protrusions may extend from one side of the underlying layer.

Referring to FIG. 18, another embodiment of a floor covering system 10 of the present invention is shown. In this embodiment, the floor planks 14 and the lower layer 12 are already laminated and joined to define a modular floor tile 41. Alternatively, another form of this embodiment is that the modular floor tiles are integrally formed to include both lower and floor plank portions. Such modular floor tiles are generally formed of the same material as the floor planks and bottom layers of the five embodiments described above, and include a design pattern on the top surface of the floor plank portion.

In this embodiment, the installation member is provided in the shape of an aluminum or plastic extrusion track 42. The track includes a flange portion 44 for engaging with corresponding slots 46 arranged in the transverse and long side vicinity of the modular floor tile. In this fastening, the longitudinally or laterally adjacent modular floor tiles are generally positioned in an arrayed configuration with respect to each other.

An adhesive coating 44 is placed on top of the track 42 to create a permanent bond between the track and the adjacent modular floor tiles upon assembly. In this way, the floor covering can be built gradually by further installing tracks 42 between adjacent pairs of modular floor tiles 41.

The six embodiments described above present alternating structural forms of the present invention. Since accurate arrangement occurs between adjacent components during assembly, the disclosed embodiments preferably provide a floating floor structure system that is relatively easy to install. Preferably, the system is provided in the form of a kit, which includes both lower and floor planks, or includes modular floor tiles and extruded tracks, the assembly of which is only a knife or scissors to trim any edges. Only a single tool such as Thus, the cladding system of the present invention does not necessarily require any skilled work for assembly, and is therefore particularly suitable for home repair and / or construction of "do-it-yourself".

Ideally the components are formed from standard materials suitable for high speed automated manufacturing, and are therefore relatively inexpensive to manufacture.

Although the present invention has been described with respect to specific examples, those skilled in the art will recognize that the present invention may be implemented in many other forms. In particular, the underlays, floor planks, holes and protrusions may take on a variety of shapes and configurations except as specifically described.

In addition, the lower layer 12 may be used in isolation without having a corresponding floor plank 14. This 'modular' type of sublayer assembly can be used for applications of common floating floor structures, such as underlayers for floor plates and / or vinyl sheets. In this situation, the lower layer would not be required, and no mounting holes 16 would be provided. However, they can include complementary interconnects 36 disposed at their long or potentially transverse ends to provide a relative arrangement between adjacent sublayers.

10: floor covering system
12: second layer
14: first layer

Claims (37)

A first layer consisting of a planar material;
A second layer of planar material, the second layer configured to define a floor covering by at least partially laminating a fastening with the first layer; And
Installation means for installing two or more of said second layers in a substantially arranged configuration,
And the second layer is configured to receive the installation means. The method of claim 1,
A floor covering system comprising one or more mounting protrusions extending from one side of the first layer. The method of claim 2,
And the second layer comprises one or more mounting holes disposed on one surface thereof, the holes configured to complementarily engage with the mounting protrusions. The method of claim 3, wherein
And said mounting hole extends from an upper surface of said second layer to a lower surface. The method according to any one of claims 2 to 4,
And said first layer comprises four said mounting protrusions. The method according to any one of claims 3 to 5,
And said second layer comprises four said mounting holes. The method according to any one of claims 3 to 6,
The mounting hole is cut from the second layer to form two or more off-cut portions, the bottom portions being bonded to one side of the first layer to define the mounting protrusion. . The method according to any one of claims 2 to 7,
And the mounting protrusion is disposed symmetrically with respect to the first layer. The method according to any one of claims 2 to 7,
And said mounting protrusion is disposed asymmetrically with respect to said first layer. The method according to any one of claims 3 to 9,
The mounting hole is disposed symmetrically with respect to the second layer. The method according to any one of claims 3 to 9,
And said mounting hole is disposed asymmetrically with respect to said second layer. The method according to any one of claims 1 to 11,
And the second layer includes a pair of interconnects disposed at opposite long edges thereof. The method of claim 12,
And the interconnects are configured to substantially laterally constrain the pairs of laterally adjacent second layers upon installation. A first layer consisting of a plane;
A second layer having a planar surface and having a fastening portion laminated with the first layer to define a modular floor tile; And
A mounting member engageable with at least a portion of the modular floor tile for installing two or more of the modular floor tiles in a substantially arranged configuration;
Floor covering system comprising a. The method of claim 14,
And said modular floor tile comprises one or more mounting holes disposed on one side thereof. The method of claim 15,
And said mounting member comprises one or more mounting protrusions extending from one surface thereof, said protrusions being configured to engage said mounting holes. The method according to claim 14 or 15,
And the one or more holes comprise one or more elongated slots. The method according to claim 16 or 17,
And the one or more mounting protrusions comprise one or more elongated flanges. The method according to any one of claims 14 to 18,
And said mounting member is in the form of an extruded track substantially formed of a plastic material. The method according to any one of claims 14 to 18,
And said mounting member is in the form of an extrusion track formed of substantially extruded aluminum. The method according to any one of claims 1 to 20,
And the first or second layer includes a design pattern on its top surface. The method of claim 21,
The design pattern is a floor covering system substantially similar to wood, marble, ceramic or slate surfaces. The method of claim 21 or 22,
And the design pattern is printed on a supplementary layer bonded to one side of the first or second layer. The method according to any one of claims 1 to 23,
And said second layer comprises an adhesive means for bonding said second layer to said first layer. The method according to any one of claims 1 to 24,
And the first or second layer is sized to substantially correspond to the dimensions of a standard ceramic, slate, marble tile or wood plank. The method according to any one of claims 1 to 25,
And the first and second layers are substantially formed of an elastic plastic material such as polyvinyl chloride. The method according to any one of claims 1 to 26,
Wherein said first layer is a floor plank and said second layer is a lower layer. The method according to any one of claims 14 to 27,
Floor covering system comprising incidental adhesive means for joining the mounting member to one or more of the modular floor tiles. The method of claim 28,
The incidental adhesive means is disposed on the mounting member. Floor covering system as substantially described with respect to any one of the embodiments of the invention shown in the accompanying drawings and / or examples. 31. A method of installing a floor covering system according to any of claims 1 to 30, wherein
i) placing two or more second layers in a subfloor; And
ii) placing a first layer over the two or more second layers so that the means for installation installs the second layers in an arranged configuration;
Floor covering system installation method comprising a. A method of installing a floor covering system as substantially described for any of the embodiments of the invention shown in the accompanying drawings and / or examples. In the modular underfloor tiles for floor systems,
A modular underlayer tile comprising a substantially planar top and bottom surfaces and configured for substantial arrayed engagement with one or more modular underlayer tiles to form an underlayer for the floor system. 34. The method of claim 33,
A modular underlayer tile comprising two or more interconnects disposed at two or more corresponding edges of the tile. The method of claim 34,
And wherein the interconnects are configured to substantially constrain at least adjacent pairs of the lower layer tiles upon installation. The method according to any one of claims 33 to 35,
The lower layer tile is formed of an elastic plastic material, such as polyvinyl chloride. Modular underlayer tile as substantially described with respect to any of the embodiments of the invention shown in the accompanying drawings and / or examples.

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