US20140202108A1

US20140202108A1 - Floor panel systems and methods

Info

Publication number: US20140202108A1
Application number: US13/745,202
Authority: US
Inventors: Nils-Erik Engström
Original assignee: Pergo Europe AB
Current assignee: Unilin Nordic AB
Priority date: 2013-01-18
Filing date: 2013-01-18
Publication date: 2014-07-24

Abstract

The present subject matter relates to systems and methods for arranging a plurality of floor panels having a center panel having a perimeter edge and a plurality of first panels each having an inner edge and an outer edge opposing the inner edge. The inner edge of each of the plurality of first panels can be configured for engaging the perimeter edge of the center panel, whereby the plurality of first panels can form a first ring configured to substantially surround the center panel. At least one additional plurality of panels can be configured for engagement together to form at least one additional ring configured to substantially surround the first ring and the center panel.

Description

TECHNICAL FIELD

The subject matter disclosed herein relates generally to floor systems and to floor systems comprising a plurality of individual flooring elements. More particularly, the subject matter disclosed herein relates to floor panel systems and methods comprising a plurality of flooring elements configured to be arranged in a predetermined pattern.

BACKGROUND

Wood or laminate flooring has become increasingly popular. As such, many different types of this flooring have been developed. Generally, this type of flooring is assembled by providing a plurality of similar panels, which interfit or are otherwise secured together and which can “float” above a subfloor (i.e., the flooring is not mechanically attached to the subfloor).
In nearly all of the flooring systems that implement this kind of configuration, the panels are substantially rectangular in shape and are secured together in adjacent linear arrays. Although such linear arrays are generally desirable for most flooring projects, the ability to arrange panels in other configurations or patterns would also be desirable in certain situations.

SUMMARY

In accordance with this disclosure, systems and methods for arranging a plurality of floor panels are provided. In one aspect, a system of floor panels is provided. The system can comprise a center panel having a perimeter edge and a plurality of first panels each having an inner edge and an outer edge opposing the inner edge. The inner edge of each of the plurality of first panels can be configured for engaging the perimeter edge of the center panel, whereby the plurality of first panels can form a first ring configured to substantially surround the center panel.
In another aspect, a system of floor panels can comprise a substantially circular center panel having a perimeter edge and a plurality of first panels each having an inner edge and an outer edge opposing the inner edge. The inner edge of each of the plurality of first panels can be configured for engaging the perimeter edge of the center panel, whereby the plurality of first panels can form a first substantially circular ring configured to substantially surround the center panel.
In yet another aspect, a method for arranging a plurality of floor panels is provided. The method can comprise positioning a center panel on a subfloor, the center panel having a perimeter edge, and positioning a plurality of first panels on the subfloor in a first ring substantially surrounding the center panel. In this way, an inner edge of each of the plurality of first panels can engage the perimeter edge of the center panel.
Although some of the aspects of the subject matter disclosed herein have been stated hereinabove, and which are achieved in whole or in part by the presently disclosed subject matter, other aspects will become evident as the description proceeds when taken in connection with the accompanying drawings as best described hereinbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the present subject matter will be more readily understood from the following detailed description which should be read in conjunction with the accompanying drawings that are given merely by way of explanatory and non-limiting example, and in which:

FIG. 1 is a plan view of a system of floor panels according to an embodiment of the presently disclosed subject matter;

FIGS. 2A through 2E are plan views of individual floor panels that can be incorporated into a system of floor panels according to an embodiment of the presently disclosed subject matter;

FIG. 3A is a side sectional view of mating features of a floor panel for use in a system of floor panels according to an embodiment of the presently disclosed subject matter; and

FIG. 3B is a side sectional view of the engagement of mating features on two floor panels of a system of floor panels according to an embodiment of the presently disclosed subject matter.

DETAILED DESCRIPTION

The present subject matter provides systems and methods for arranging a plurality of floor panels. In one aspect, for example, the present subject matter provides a system of floor panels that can be arranged in an array of concentric rings. Specifically, referring to FIG. 1, a system of floor panels, generally designated 100, can comprise a center panel 110 and a plurality of first panels 120 that can be arranged to form a first ring 128 substantially surrounding center panel 110. Additional groupings of panels can be arranged to form further rings that substantially surround center panel 110 and the first ring 128. In the particular configuration shown in FIG. 1, for example, a plurality of second panels 130, a plurality of third panels 140, and a plurality of fourth panels 150 can be arranged to substantially surround first ring 128 and center panel 110. Specifically, second, third, and fourth panels 130, 140, and 150 can be configured for engagement together to form a second ring 138, a third ring 148, and a fourth ring 158, respectively, which can be arranged to concentrically surround first ring 128 and center panel 110 to thereby form a substantially target-shaped pattern. Regarding the design of the individual panels, referring to FIG. 2A, center panel 110 can be a substantially circular panel having a perimeter edge 112 and a radius 113 (e.g., about 400 mm). Referring to FIG. 2B, each of the plurality of first panels 120 can have a substantially trapezoidal shape corresponding to a segment of a circular ring. In particular, each of first panels 120 can define a first inner edge 122 and a first outer edge 124 that each can be curved such that when first panels 120 are arranged adjacent to each other, the resulting arrangement forms a substantially circular ring (i.e., first ring 128) defined by a first inner radius 123 (e.g., about 400 mm) and a first outer radius 125 (e.g., about 1200 mm). In addition, each of first panels 120 can have a first width 126 (i.e., arc length) at first outer edge 124 that can be varied to control the number of first panels 120 that are used to form first ring 128. In the configuration show in FIG. 1, and for example and without limitation, eighteen of first panels 120 can be used to form first ring 128 where first width 126 is substantially the same for each of first panels 120. In this configuration, each of first panels 120 can have a first width 126 (i.e., arc length) corresponding to a 20° segment of first ring 128, wherein first width 126 for each of first panels 120 is equal to about 1/18 the product of 2π times the dimension of first outer radius 125 (i.e., about 412 mm where outer radius 125 is about 1200 mm). Alternatively, panels 120 can have different values for first width 126 such that first ring 128 is composed of panels having varying sizes. Further, each of first panels 120 can have a first depth 127 (i.e., about the difference between first outer radius 125 and first inner radius 123) that can be varied to control the size of first ring 128.
Similarly, referring to FIG. 2C, each of the plurality of second panels 130 can comprise a second inner edge 132 having an arcuate shape characterized by a second inner radius 133 (e.g., about 1200 mm), a second outer edge 134 opposing second inner edge 132 and having an arcuate shape characterized by a second outer radius 135 (e.g., about 1900 mm), a second width 136 (i.e., arc length) at second outer edge 134 (e.g., about 650 mm), and a second depth 137. Second inner radius 133 of each of second panels 130 can be sized to be substantially equal to first outer radius 125 so that second panels 130 can be arranged substantially seamlessly around first panels 120.
Likewise, FIG. 2D illustrates that each of third panels 140 can have a third inner edge 142 having a third inner radius 143 that can be substantially equivalent to second outer radius 135 of second panels 130 (e.g., about 1900 mm), a third outer edge 144 having a third outer radius 145 (e.g., about 2500 mm), a third width 146 (i.e., arc length) at third outer edge 144 (e.g., about 856 mm), and a third depth 147. FIG. 2E illustrates that each of fourth panels 150 can have a fourth inner edge 152 having a fourth inner radius 153 that can be substantially equivalent to third outer radius 145 of third panels 140 (e.g., about 2500 mm), a fourth outer edge 154 having a fourth outer radius 155 (e.g., about 3000 mm), a fourth width 156 (i.e., arc length) at fourth outer edge 154 (e.g., about 1028 mm), and a fourth depth 157.
As shown in FIG. 1 and discussed above, the assembled combination of center panel 110, first panels 120, second panels 130, third panels 140, and fourth panels 150 can form a pattern of substantially concentric rings resembling a shooting target, with center panel 110 positioned at the “bull's-eye”. The particular pattern formed can be varied by changing the relative sizes of first panels 120, second panels 130, third panels 140, and fourth panels 150. For example, the number of each of first panels 120, second panels 130, third panels 140, and fourth panels 150 that are used to form first ring 128, second ring 138, third ring 148, and fourth ring 158, respectively, can be selected (e.g., by varying the widths of the respective groups of panels). As shown in FIG. 1, for example, each of first ring 128, second ring 138, third ring 148, and fourth ring 158 can be composed or consist of the same number of panels (i.e., 18 panels in each ring), which can result in the panels in each successive ring being wider than those in the previous ring (i.e., second width 136 of each of second panels 130 is greater than first width 126 of each of first panels 120). Alternatively, first width 126, second width 136, third width 146, and fourth width 156 can all be selected to be approximately the same size such that each successive ring has more panels than the next most inner ring (e.g., third ring 148 has a number of third panels 140 that is greater than a number of second panels 130 in second ring 138).
Alternatively or in addition, to further control the pattern of flooring panels created, each of first depth 127, second depth 137, third depth 147, and fourth depth 157 can be sized to be approximately the same such that first ring 128, second rind 138, third ring 148, and fourth ring 158 are spaced from center panel 110 in substantially uniform increments. Alternatively, as shown in FIG. 1, for example, these depths can be non-uniformly sized such that the innermost panels (i.e., center panel 110 and first panels 120) can be proportionally larger than the outermost panels in the overall flooring design, which can draw more attention to the center of the pattern defined by system 100. The widths and depths of the flooring panels can be selected to have any of a variety of relative dimensions to create a desired pattern for system 100.
Furthermore, depending on whether system 100 is incorporated into an overall flooring design, a rim 160 can be disposed around a perimeter of system 100. Rim 160 can be comprised of a durable material that can protect the flooring material from chips or other damage. In addition, rim 160 can be shaped or otherwise configured to provide a substantially smooth transition between the outermost ring (e.g., fourth ring 158 in FIG. 1) of system 100 and any other flooring in the overall flooring design. For example, the rim can comprise metal, plastic, rubber, or any other kind of material known to those in the art. Rim 160 can be divided into a plurality of connected segments in a manner similar to the rings discussed above, or rim 160 can be a continuous or substantially continuous ring of material. Additionally, rim 160 can be formed to define a channel into which the outer edge of each of the outermost panels of system 100 can be inserted. Alternatively or in addition, rim 160 can be coupled to the outermost panels of system 100 (e.g., to fourth ring 158 in the configuration shown in FIG. 1) using an adhesive material, such as a glue known to those having skill in the art.
Regardless of how the rings of panels are sized, the flooring panels can all be configured to interconnect together to maintain system 100 in a desired arrangement. As discussed above, the plurality of first panels 120 can be arranged to form first ring 128 substantially surrounding center panel 110. In particular, first inner edge 122 of each of first panels 120 can be configured for engaging perimeter edge 112 of center panel 110. For example, each of center panel 110 and first panels 120 can have one or more elements of an interlocking floor panel, generally designated 10. As used herein, the term “interlocking” can be understood to include mechanical locking configurations for floor panel 10 that allow system 100 to be locked or otherwise securely held in its installed condition.
As shown in FIGS. 3A and 3B, such features can include a core 12, which can be composed or consist of a wood-based material like fiber board, particle board, chip board, oriented strand board, or massive wood, and a decorative surface layer 15, which can comprise one or more laminated paper layers having a pattern printed or otherwise formed thereon. Further, one or more edges of interlocking floor panel 10 can be milled or otherwise formed to define male and female mating features, such as a tongue 13 (e.g., protruding about 4 mm from core 12) and a complementary groove 14 (e.g., extending about 6.5 mm into core 12). In this configuration, an edge of interlocking floor panel 10 defining a tongue 13 can be engaged with an edge of an additional interlocking floor panel 10′ that defines a complementary groove 14′. To secure this connection between interlocking floor panel 10 and additional interlocking floor panel 10′, the joining edges can furthermore be provided with one or more heels intended to snap-join with recesses adapted thereto which, by being provided with essentially horizontal locking surfaces, limits vertical movement between two joined adjacent panels. Alternatively, a lower lip of groove 14 (i.e., a portion of core 12 below groove 14) can be configured to flex downwardly in order to allow tongue 13 to slide into place.
Alternatively, any of a variety of other known mating features can be used for interlocking adjacent floor panels. Where center panel 110 and first panels 120 have mating features such as those described above, perimeter edge 112 of center panel 110 and first inner edge 122 of each of first panels 120 can comprise complementary mating features (e.g., a tongue and a groove, respectively) that can be engaged to couple first panels 120 around center panel 110. Likewise, second panels 130 can have mating features (e.g., one of a tongue or a groove) on second inner edge 132 that are configured to correspondingly engage mating features on first outer edge 124 of one or more of first panels 120.
In such a configuration, assembly of system 100 can comprise positioning center panel 110 on a subfloor and positioning a plurality of first panels 120 on the subfloor in a ring substantially surrounding center panel 110 (i.e., first ring 128) with first inner edge 122 of each of first panels 120 engaging perimeter edge 112 of center panel 110. For example, center panel 110 can comprise a groove 14 along perimeter edge 112, and each of first panels 120 can comprise a tongue 13 positioned at first inner edge 122 such that engaging first inner edge 122 of each of first panels 120 with perimeter edge 112 of center panel 110 can comprise inserting tongue 13 into groove 14. Once all of first panels 120 are securely engaged with center panel 110, at least one additional plurality of panels can be arranged in at least one additional ring. In this way, a pattern of substantially concentric rings about center panel 110 can be incrementally constructed to form system 100.
In addition, the lateral edges (i.e., the edges connecting the inner edge to the outer edge and defining a depth) of each of the panels can similarly be configured to interconnect with adjacent panels. For example, first ring 128 can comprise alternating “male” panels having a tongue on each lateral edge (e.g., substantially downward-facing) and “female” panels having a groove on each lateral edge (e.g., substantially upward-facing). In this configuration, once a first inner edge 122 of one of first panels 120 is engaged with perimeter edge 112 of center panel 110, the panel can be “folded down” such that the lateral edges of the panel engage the lateral edges of adjacent panels that have already been installed. For example, all of the “female” panels in first ring 128 can be engaged with center panel 110 and spaced around center panel 110. Then, each “male” panel in first ring 128 can be engaged with center panel 110 and folded down between and into engagement with two of the “female” panels. By assembling the system 100 in this manner, there is no need to alter the final one of first panels 120 (i.e., the “keystone”) installed in first ring 128. Alternatively, each of first panels 120 can comprise one “male” mating feature on one lateral edge and one “female” mating feature on the opposing lateral edge.
In an alternative configuration, a “four sided” fold down assembly can be utilized (i.e., system 100 is assembled solely through relative vertical movement of the panels). In such a system, first inner edge 122 of each of first panels 120 comprises a “male” mating feature, and a corresponding first outer edge 124 of each of first panels 120 comprises a “female” mating feature (or vice versa). Each of these first panels 120 can then be designated as a “male” panel (i.e., a first lateral edge and an opposing second lateral edge of first panel 120 both comprise a tongue) or a “female” panel (i.e., a first lateral edge and a second lateral edge of first panel 120 both comprise a groove). Alternatively, each of first panels 120 may have a “male” mating feature (e.g., a tongue) on one of the first or second lateral edges and a “female” mating feature (e.g., groove) on the other of the first or second lateral edges. Accordingly, in either configuration, each of first panels 120 will have a mating feature defined on each of its edges/sides.
In yet a further alternative configuration, the panels of a given ring can be configured for a horizontal assembly, where system 100 is assembled solely through relative horizontal movement of the panels. In this variation, however, it is noted that some type of tapping block may be needed in order to install the keystone. In still a further assembly variation, the panels can be configured as part of an angled system assembly, in which “male” mating features (e.g., tongues) and “female” mating features (e.g., grooves) of the keystone of each consecutive ring of panels is modified so that each keystone can be slid into place and correspondingly engaged with adjacent panels.
Alternatively or in addition to any of the connection configurations and methods discussed hereinabove, one or more panels of system 100 can be coupled to adjacent panels using an adhesive material, such as a glue known to those having skill in the art. It should be recognized, however, that although a number of possible configurations are disclosed hereinabove, any of a variety of other known mating assemblies can be used for assembly of interlocking adjacent floor panels. Therefore, regardless of the type of assembly used the flooring panels can all be configured to interconnectedly form the desired arrangement for system 100.
The present subject matter can be embodied in other forms without departure from the spirit and essential characteristics thereof. The embodiments described therefore are to be considered in all respects as illustrative and not restrictive. Although the present subject matter has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art are also within the scope of the present subject matter.

Claims

What is claimed is:

1. A system of floor panels comprising:

a center panel having a perimeter edge; and

a plurality of first panels each having an inner edge and an outer edge opposing the inner edge, the inner edge of each of the plurality of first panels being configured for engaging the perimeter edge of the center panel, whereby the plurality of first panels forms a first ring configured to substantially surround the center panel.

2. The system of claim 1, wherein the center panel is substantially circular.

3. The system of claim 1, wherein the perimeter edge of the center panel comprises at least one of a tongue or a groove; and

wherein the inner edge of each of the plurality of first panels comprises one of a tongue or a groove configured to complementarily engage the tongue or groove of the perimeter edge of the center panel.

4. The system of claim 1, wherein each of the plurality of first panels and the center panel comprise a core and a decorative surface.

5. The system of claim 1, wherein each of the plurality of first panels has a substantially similar shape.

6. The system of claim 1, wherein the plurality of first panels is configured to form a first substantially circular first ring around the center panel.

7. The system of claim 1, comprising at least one additional plurality of panels configured for engagement together to form at least one additional ring configured to substantially surround the first ring and the center panel.

8. The system of claim 7, wherein the at least one additional ring is configured to be substantially concentric with the first ring.

9. The system of claim 7, wherein the at least one additional plurality of panels comprises a second plurality of panels having an inner edge and an outer edge opposing the inner edge, the inner edge of each of the second plurality of panels being configured for engaging the outer edge of one or more of the first plurality of panels.

10. A system of floor panels comprising:

a substantially circular center panel having a perimeter edge; and

a plurality of first panels each having an inner edge and an outer edge opposing the inner edge, the inner edge of each of the plurality of first panels being configured for engaging the perimeter edge of the center panel, whereby the plurality of first panels forms a first substantially circular ring configured to substantially surround the center panel.

11. A method for arranging a plurality of floor panels, the method comprising:

positioning a center panel on a subfloor, the center panel having a perimeter edge; and

positioning a plurality of first panels on the subfloor in a first ring substantially surrounding the center panel, wherein an inner edge of each of the plurality of first panels engages the perimeter edge of the center panel.

12. The method of claim 11, wherein positioning a plurality of first panels on the subfloor in a first ring comprises positioning the plurality of first panels in a substantially circular ring around the center panel.

13. The method of claim 11, wherein the perimeter edge of the center panel comprises at least one of a tongue or a groove, and the inner edge of each of the plurality of first panels comprises one of a tongue or a groove configured to complementarily engage the tongue or groove of the perimeter edge of the center panel; and

wherein positioning the plurality of first panels on the subfloor in a first ring comprises engaging the tongue or groove of each of the plurality of first panels with the tongue or groove of the center panel.

14. The method of claim 11, comprising positioning at least one additional plurality of panels on the subfloor in at least one additional ring substantially surrounding the first ring and the center panel.

15. The method of claim 14, wherein positioning at least one additional plurality of panels on the subfloor in at least one additional ring comprises positioning the at least one additional plurality of panels substantially concentric ring with the first ring.