NZ610176B

NZ610176B - A Flooring System

Info

Publication number: NZ610176B
Application number: NZ610176A
Authority: NZ
Inventors: Young Charles; Mccracken James Ian; Brynjulfsen Roger
Original assignee: Bgc (Australia) Pty Ltd
Priority date: 2012-05-04
Filing date: 2013-05-03
Publication date: 2014-12-02

Abstract

Disclosed is a flooring system (10) comprising a flooring member (12, 14’). The disclosure notes the present flooring system (10) avoids damaging or splitting flooring members as a tongue member (22) of the present flooring system (10) does not exert pressure on the flooring members (12, 14’). The flooring member (12, 14’) has a substantially flat flooring face (20, 20’), a first groove (16, 16’), a second groove (18, 18’) and an elongate tongue member (22). The first groove (16, 16’) extends along a first side of the flooring member (12, 14’). The second groove (18, 18’) extends along a second opposite side of the flooring member (12, 14’). Each of the first (16, 16’) and second (18, 18’) grooves are arranged to receive the elongate tongue member (22) such that the flooring member (12, 14’) is connectable to an adjacently disposed other flooring member (12, 14’) by engaging the tongue member (22) in a first (16, 16’) or second (18, 18’) groove of the adjacently disposed other flooring member (12, 14’). The flooring member (12, 14’) is formed of fibre cement material of density between about 1200 kg/m3 and about 1400 kg/m3. The width of the first groove (16, 16’) is greater than the thickness of the tongue member (22) such that the tongue member (22) is freely receivable in the first groove (16, 16’) and retained in the first groove (16, 16’) by adhesive. flooring member (12, 14’) has a substantially flat flooring face (20, 20’), a first groove (16, 16’), a second groove (18, 18’) and an elongate tongue member (22). The first groove (16, 16’) extends along a first side of the flooring member (12, 14’). The second groove (18, 18’) extends along a second opposite side of the flooring member (12, 14’). Each of the first (16, 16’) and second (18, 18’) grooves are arranged to receive the elongate tongue member (22) such that the flooring member (12, 14’) is connectable to an adjacently disposed other flooring member (12, 14’) by engaging the tongue member (22) in a first (16, 16’) or second (18, 18’) groove of the adjacently disposed other flooring member (12, 14’). The flooring member (12, 14’) is formed of fibre cement material of density between about 1200 kg/m3 and about 1400 kg/m3. The width of the first groove (16, 16’) is greater than the thickness of the tongue member (22) such that the tongue member (22) is freely receivable in the first groove (16, 16’) and retained in the first groove (16, 16’) by adhesive.

Description

A FLOORING SYSTEM Field of the Invention The invention relates to a flooring system and to a flooring member for use with a flooring system.

Background of the Invention It is known to provide a flooring system that includes a plurality of flooring members, each flooring member being formed of wood material and having a groove extending along a first side of the flooring member and a tongue integrally formed with the flooring member and extending along a second opposite side of the flooring member.

Adjacently disposed flooring members are joined together by engaging a tongue of a first flooring member with a groove of an adjacent second flooring member. Adhesive may also be disposed between a groove and engaged tongue so as to retain the tongue in the groove.

However, this type of flooring system can be cumbersome to install in some situations.

Summary of the Invention In accordance with a first aspect of the present invention, there is provided a flooring system comprising: a flooring member having: a substantially flat flooring face; a first groove extending along a first side of the flooring member; and a second groove extending along a second opposite side of the flooring member; and an elongate tongue member received in the first groove such that the flooring member is connectable to an adjacently disposed other flooring member by engaging the 5570096_1 (GHMatters) P89769.NZ MELANIEE.1 tongue member in a first or second groove of the adjacently disposed other flooring member; wherein the flooring member is formed of fibre cement material of density between about 1200 kg/m and about 1400 kg/m ; wherein the width of the first groove is greater than the thickness of the tongue member such that the tongue member is freely receivable in the first groove; and wherein the tongue member is retained in the first groove by adhesive.

In one embodiment, the fibre cement material is uncompressed fibre cement material. The fibre cement material may include a cementitious matrix with reinforced cellulose fibres.

In one embodiment, the fibre cement material includes cellulose, cement, silica, water and alumina.

In one embodiment, the fibre cement material does not include a low density additive, such as low density microspheres.

In one embodiment, the flooring member is generally rectangular, may be between about 2200mm and 2800mm long and about 600mm wide, and may be between about 18.5mm and about 19.5mm thick.

In an embodiment, the system comprises: a plurality of flooring members; wherein at least one tongue member is received in a second groove of an adjacently disposed second flooring member.

In one embodiment, half of the width of the tongue member is less than the depth of each of the first and second grooves such that when first and second flooring members 5570096_1 (GHMatters) P89769.NZ MELANIEE.1 abut each other and the tongue member is received in adjacently disposed first and second grooves of the respective first and second flooring members, a gap for receiving adhesive is defined between the tongue member and each of the first and second grooves.

In one embodiment, the adhesive is disposed in the first and/or second groove in a plurality of beads. The beads may be spaced apart by about 100mm.

In one embodiment, the adhesive is a hot melt adhesive, and may be of a type wherein a skin forms over the adhesive after application and breakage of the skin causes bonding to occur. The hot melt adhesive may comprise HM6516c produced by H.B. Fuller Company Australia Pty Ltd.

In one embodiment, the tongue member is formed of PVC material.

Brief Description of the Drawings The present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a diagrammatic representation of a flooring system in accordance with an embodiment of the present invention; Figure 2 is an enlarged view of part of a groove of a flooring member of the system shown in Figure 1; and Figure 3 is a diagrammatic representation of a flooring system during installation.

Description of an Embodiment of the Invention Referring to the drawings, in Figure 1 there is shown a flooring system 10 that includes a plurality of flooring members 12, 14 configured so as to be disposed during use 5570096_1 (GHMatters) P89769.NZ MELANIEE.1 side by side such that the flooring members 12, 14 together cover a floor area. In this example, only 2 flooring members 12, 14 are shown, although it will be understood that typically more than 2 flooring members would be required to cover a floor area.

Each flooring member 12, 14 includes a first groove 16 extending along a first side of the flooring member, and a second groove 18 extending along a second opposite side of the flooring member 12, 14. Each flooring member 12, 14 also includes a flooring face 20 and a backing face 21.

During use, the backing face 21 is disposed so as to face a floor area to be covered with the flooring members 12, 14, and the flooring face 20 faces upwards.

In this example, each flooring face 20 is generally rectangular, and is typically elongate, for example about 2700mm long and about 600mm wide. Also in this example, each of the flooring members 12, 14 is between about 18mm and about 20mm thick, and may be between about 18.5mm and about 19.5mm thick. However, it will be understood that any suitable shape for the flooring face 20 and thickness are envisaged. An important aspect for the shape of the flooring face 20 is that the shape is capable of tessellating with adjacently disposed flooring members 12, Each flooring member 12, 14 is formed of fibre cement material, in this example including an uncompressed cementitious matrix with reinforced cellulose fibres, for example a material containing cellulose, cement, silica, water and alumina. The mix ratio in this example may be about 30% to about 40% cement, about 50% to about 60% silica, about 6% to about 10% cellulose, and about 3% to about 5% alumina. In the present example, for strength the flooring members 12, 14 do not include low density additives such as low density microspheres. 5570096_1 (GHMatters) P89769.NZ MELANIEE.1 The density of the flooring members 12, 14 is between about 1200kg/m and about 1400kg/m , and in this example each of the flooring members 12, 14 is about 2700mm long and 600mm wide, although it will be understood that flooring members 12, 14 of any suitable dimensions are envisaged.

In this example, the flooring members 12, 14 are made using the Hatschek process, for example wherein cement, silica, cellulose, water and alumina are mixed in a slurry. Solids from the slurry are transferred on an endless felt to an accumulator roller, creating panels of desired thickness. The panels are then precured for a defined period of time, and autoclaved at elevated temperature and pressure for final cure.

In one example, suitable flooring members 12, 14 are produced by precuring panels in a saturated atmosphere of 30ºC for 18 to 24 hours, then autoclaving at 820 to 880 kPa and 170ºC to 180ºC for up to 13 hours for final cure.

In one example, a flooring member 12, 14 manufactured using the Hatcheck process and the above mix ratio has a modulus of rupture (MOR) that is about 12MPa, and an average perpendicular and horizontal deflection that is about 6mm.

The system 10 also includes an elongate tongue member 22 disposed between each adjacent pair of flooring members 12, 14. Each tongue member 22 is configured so as to be freely receivable in a first or second groove 16, 18. It will be understood that the thickness of the tongue member 22 is slightly less than the width of the first and second grooves 16, 18 so that insertion of the tongue member 22 in a groove 16, 18 does not exert pressure on the flooring members 12, 14 that for example may cause the flooring 5570096_1 (GHMatters) P89769.NZ MELANIEE.1 members to split.

Half of the width of the tongue member 22 is slightly less than the depth of a groove 16, 18 so that adhesive is disposable between the tongue member 22 and the first groove 16 and/or between the tongue member 22 and the second groove 18 when adjacently disposed first and second flooring members 12, 14 abut each other and the tongue member 22 is disposed in the respective first and second grooves 16, 18.

In this example, the tongue member 22 is secured to one of the adjacently disposed flooring members 12, 14 using adhesive, and is loosely received in the groove 16, 18 of the other of the flooring members 12, 14 during installation. In this way, the flooring members 12, 14 may be supplied with a tongue member 22 already adhesively fixed to one of the grooves 16, 18. Should it be necessary to abut the flooring member 12, 14 against a wall or other surface that does not have a groove corresponding in shape to the tongue 22, the tongue may be removed from the groove 16, 18. In order for this to be possible, it will be appreciated that the amount and strength of the adhesive is chosen so that the tongue 22 may be removed from the groove 16, 18 by application of manual force, or by using an appropriate tongue removal tool.

In this example, the tongue member 22 is formed of PVC material, although it will be understood that any suitable material is envisaged.

Referring to Figure 2, an enlarged view of part of a groove 18 of a flooring member 12 is shown. Adhesive 24 is disposed in the groove 18 on a rear face 26 of the groove 18. The adhesive 24 is disposed on the rear face 26 in a plurality of beads, in this example spaced apart 5570096_1 (GHMatters) P89769.NZ MELANIEE.1 by between about 70mm and about 100mm.

It will be appreciated that the grooves 16, 18 and the tongue member 22 are configured, and the amount and distribution of adhesive is selected, such that the tongue member 22 is loosely receivable in a groove 16, 18 with the tongue member 22 held relative to the groove substantially by adhesive bonding and not, for example, by friction. As a consequence, the likelihood of causing the flooring member to crack when the tongue member 22 is inserted and/or bonded into the groove 16, 18 is significantly minimised.

It will also be appreciated that the grooves 16, 18 and the tongue member 22 are configured, and the amount and distribution of adhesive is selected such that egression of adhesive from a groove 16, 18 does not occur when the tongue member is fully received in a groove 16, 18.

In this example, the adhesive is a hot melt glue of pressure sensitive type. With this type of adhesive, it is possible to apply the adhesive to a groove 16, 18 and to subsequently cause the adhesive to cure when the adhesive comes into contact with a tongue member 22. This is because a skin formes over the applied adhesive, which is broken when a tongue presses against the skin with sufficient force.

An example hot melt glue of this type suitable for holding a tongue member 22 in a groove 16, 18 is HM6516c produced by H.B. Fuller Company Australia Pty Ltd. However, it will be understood that any suitable adhesive is envisaged.

During use wherein a floor area is desired to be covered by the flooring members 12, 14, sufficient flooring members are provided to cover all of the floor area, and 5570096_1 (GHMatters) P89769.NZ MELANIEE.1 if required one or more of the flooring members are cut to size.

As shown in Figure 3, in this example a suitable sub-frame 30 is constructed, and a flooring member 12 is fixed to the sub frame 30 using suitable fixing devices. In this example, the flooring member 12 is fixed to the sub-frame using screws 32, although it will be understood that other mechanical fixing devices and/or adhesive fixing arrangements may be used.

In this example, each of the flooring members 12 has one tongue member 22 pre-installed by disposing adhesive beads, for example spaced apart by about 100mm, in a groove 16, 18 of the flooring member 12, 14, and inserting one or more tongue member(s) 22 in the groove 16, 18. It will be appreciated that as the tongue member 22 is pushed into the groove 16, 18 the tongue member 22 breaks the skin of the adhesive beads and thereby causes the adhesive to bond the tongue member(s) 22 to the flooring member 12, However, while the present example includes a flooring member 12, 14 with pre-installed tongue member 22, it will be understood that the tongue member 22 may be fixed in the first and/or second groove 16, 18 during installation.

Further flooring members 12, 14 are then attached to the sub-frame adjacent the laid flooring member with a tongue 22 or groove of the laid flooring member engaging with a respective groove or tongue of the further flooring member, and the further flooring member is fixed to the sub-frame 30 using the fixing devices.

This process continues until the desired floor area is completely covered with flooring members 12, 14. 5570096_1 (GHMatters) P89769.NZ MELANIEE.1 If a flooring member is desired to abut against a wall or a different type of flooring member, the installer has the option of removing the tongue member 22, by application of manual force, or by using a suitable tongue removal tool.

The laid flooring members 12, 14 may constitute the desired exposed flooring, or the laid flooring members 12, 14 may serve to receive other flooring finishing products, such as tiles 34 or wood floorboards.

It will be appreciated that since each flooring member 12, 14 does not have an integral tongue, the flooring members are less cumbersome to lay than conventional tongue and groove type flooring members, in particular because the present flooring members are able to sit flush against walls or other types of flooring. With conventional tongue and groove type flooring members, an integral tongue is present at one side of the laid floor, which may prevent the flooring member from sitting flush with an adjacent wall or other flooring member.

It will also be appreciated that the flooring members 12, 14 have superior strength to other flooring materials such as timber particle board flooring and lightweight cementitious flooring, and can be used as finished flooring or flooring substrate in internal and external applications, including in wet areas. The configuration and location of the tongue member 22 enables the flooring member 12, 14 to be compatible with existing tongue and groove flooring.

Furthermore, it will be appreciated that the flooring members 12, 14 have enhanced durability compared to conventional flooring materials including timber and timber based materials. This is because the flooring members 12, 14 are resistant to moisture damage, are resistant to termites and will not burn. 5570096_1 (GHMatters) P89769.NZ MELANIEE.1 Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention. 5570096_1 (GHMatters) P89769.NZ MELANIEE.1

Claims

Claims:

1. A flooring system comprising: a flooring member having: 5 a substantially flat flooring face; a first groove extending along a first side of the flooring member; and a second groove extending along a second opposite side of the flooring member; and 10 an elongate tongue member received in the first groove such that the flooring member is connectable to an adjacently disposed other flooring member by engaging the tongue member in a first or second groove of the adjacently disposed other flooring member; 15 wherein the flooring member is formed of fibre cement material of density between about 1200 kg/m and about 1400 kg/m ; wherein the width of the first groove is greater than the thickness of the tongue member such that the tongue 20 member is freely receivable in the first groove; and wherein the tongue member is retained in the first groove by adhesive.

2. A flooring system as claimed in claim 1, wherein the 25 fibre cement material is uncompressed fibre cement material.

3. A flooring system as claimed in claim 1 or claim 2, wherein the fibre cement material includes a cementitious 30 matrix with reinforced cellulose fibres.

4. A flooring system as claimed in any one of the preceding claims, wherein the fibre cement material includes cellulose, cement, silica, water and alumina.

5. A flooring system as claimed in any one of the preceding claims, wherein the fibre cement material does 5570096_1 (GHMatters) P89769.NZ MELANIEE.1 not include a low density additive.

6. A flooring system as claimed in any one of the preceding claims, comprising: 5 a plurality of flooring members; wherein at least one tongue member is received in a second groove of an adjacently disposed second flooring member. 10

7. A flooring system as claimed in claim 6 or claim 7, wherein half of the width of the tongue member is less than the depth of the first groove such that when the tongue member is received in the first groove, a gap for receiving adhesive is defined between the tongue member 15 and the first groove.

8. A flooring system as claimed in any one of the preceding claims, wherein the adhesive is disposed in the first groove in a plurality of beads.

9. A flooring system as claimed in claim 8, wherein the beads are spaced apart by about 10mm.

10. A flooring system as claimed in any one of the 25 preceding claims, wherein the adhesive is a hot melt adhesive.

11. A flooring system as claimed in claim 10, wherein the adhesive is of a type wherein a skin forms over the 30 adhesive after application and breakage of the skin causes bonding to occur.

12. A flooring system as claimed in any one of the preceding claims, wherein the tongue member is formed of 35 PVC material.

13. A flooring member or flooring system substantially as 5570096_1 (GHMatters) P89769.NZ MELANIEE.1 hereinbefore described with reference to the accompanying drawings. 5570096_1 (GHMatters) P89769.NZ MELANIEE.1 21 21’ 18 16’ 18’