US20150218812A1 - Panel for Covering a Surface or Support and an Associated Joint System - Google Patents
Panel for Covering a Surface or Support and an Associated Joint System Download PDFInfo
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- US20150218812A1 US20150218812A1 US14/428,705 US201314428705A US2015218812A1 US 20150218812 A1 US20150218812 A1 US 20150218812A1 US 201314428705 A US201314428705 A US 201314428705A US 2015218812 A1 US2015218812 A1 US 2015218812A1
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- male
- panels
- female
- panel
- major
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/02038—Flooring or floor layers composed of a number of similar elements characterised by tongue and groove connections between neighbouring flooring elements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/072—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of specially adapted, structured or shaped covering or lining elements
- E04F13/076—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of specially adapted, structured or shaped covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0889—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections
- E04F13/0894—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections with tongue and groove connections
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/02005—Construction of joints, e.g. dividing strips
- E04F15/02033—Joints with beveled or recessed upper edges
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/04—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G23/00—Working measures on existing buildings
- E04G23/006—Arrangements for removing of previously fixed floor coverings
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G23/00—Working measures on existing buildings
- E04G23/02—Repairing, e.g. filling cracks; Restoring; Altering; Enlarging
- E04G23/0285—Repairing or restoring flooring
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2002/001—Mechanical features of panels
- E04C2002/004—Panels with profiled edges, e.g. stepped, serrated
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F2201/00—Joining sheets or plates or panels
- E04F2201/01—Joining sheets, plates or panels with edges in abutting relationship
- E04F2201/0138—Joining sheets, plates or panels with edges in abutting relationship by moving the sheets, plates or panels perpendicular to the main plane
- E04F2201/0146—Joining sheets, plates or panels with edges in abutting relationship by moving the sheets, plates or panels perpendicular to the main plane with snap action of the edge connectors
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F2201/00—Joining sheets or plates or panels
- E04F2201/02—Non-undercut connections, e.g. tongue and groove connections
- E04F2201/023—Non-undercut connections, e.g. tongue and groove connections with a continuous tongue or groove
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F2201/00—Joining sheets or plates or panels
- E04F2201/04—Other details of tongues or grooves
- E04F2201/042—Other details of tongues or grooves with grooves positioned on the rear-side of the panel
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F2201/00—Joining sheets or plates or panels
- E04F2201/04—Other details of tongues or grooves
- E04F2201/043—Other details of tongues or grooves with tongues and grooves being formed by projecting or recessed parts of the panel layers
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24008—Structurally defined web or sheet [e.g., overall dimension, etc.] including fastener for attaching to external surface
Abstract
A panel 10 is formed with first and second joint systems 20 and 22 to enable engagement of a plurality of panels 10 along their sides 16 and 18. The first joint system 20 has a laterally extending tongue 24 a along one longitudinal side 16 a and a groove 24 b along an opposite longitudinal side 16 b. The second joint system 22 is a vertical joint system having mutually engageable male and female parts Jm and Jf respectively. The male part Jm is formed on one transverse the side 18 a, while the female part Jf is formed on an opposite transverse side 18 b.
Description
- The present disclosure relates to a panel for covering a surface or support such as floor, wall or frame. Also disclosed are joint systems of various structures and configurations enabling mechanical joining of the panels.
- A typical panel for covering or lining a floor is in the form of a rectangular plank or strip of material having opposed substantially planar first and second major surfaces with a first and second pairs of opposite sides extending between the first and second major surfaces. Multiple panels are joined to form a floor covering. In order to join panels together each panel is provided with a joint system having joint members that extend from or along the sides. The joint members enable coupling of adjacent substrates.
- Joint systems for flooring panels may be generally categorised as tongue and groove systems or vertical joint systems. In this context, the term “tongue” is understood in the industry as meaning ‘a protrusion extending distally from a side of a panel spaced inwardly from the top and bottom surfaces of the panel’. This definition was provided by the Honourable Rudolph T. Randa, Chief Judge in the Markman Claim Construction decision in Order nos. 02-C-1266, 03-C-342, 04-C-121-Mar. 6, 2007 in relation to U.S. Pat. Nos. 6,006,486 and 6,490,836 assigned to Unilin Beheer B.V. Indeed in the Markman hearing Unilin themselves proposed the term “tongue” be construed as “a protrusion extending distally form a side spaced inwardly form the top and bottom surfaces and including at least one locking element”. Similarly in US International Trade Commission Investigation no. 337-TA-545 it was held that ‘tongue’ means ‘a coupling part extending from the edge of a board, where the coupling part provides primary coupling in the horizontal direction and primary locking the vertical direction’ and ‘groove’ means ‘a coupling part that cooperates with the tongue to connection two panels together’.
- Tongue and groove systems are available in two main configurations, horizontal systems and lay down systems. In the horizontal system tongues and grooves of like panels are engaged by motion in a plane substantially parallel to a plane containing a major surface of the flooring panel (i.e. a horizontal plane). In a lay down system the tongue and groove are configured to engage by inserting the tongue of one panel into the groove of another like panel with the major surfaces of the respective panels at an acute angle to each other and subsequently pivoting the one panel relative to the other so that the panels are coplanar in order to effect the engagement of joints on adjacent substrates.
- Vertical joint systems on the other hand require motion and/or force in a plane perpendicular to a major surface of the substrates to effect engagement of the joints. Thus it should be understood that the expression “vertical” in the context of the present type of joint system, and as used in this specification, does not mean absolutely vertical but rather substantially perpendicular to a major surface of a substrate. During such motion the panels are orientated generally parallel to an underlying surface/support on which they are to be laid.
- The above reference to the Background Art is not intended to limit the application of the panels and joint systems disclosed herein.
- In a first aspect there is disclosed a panel for a surface covering system composed of a plurality of like panels, the panel comprising:
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- opposed substantially planar major first and second surfaces, and a plurality of sides extending between the first and second surfaces, the sides including a first pair of opposite sides, and a second pair of opposite sides;
- a tongue and groove joint system comprising a tongue extending laterally parallel to the major surfaces from one of the sides of the first pair and a groove in another one of the sides of the first pair the groove extending parallel to the major surfaces into a body of the panel, the tongue and groove relatively configured to enable mutual engagement by locating the tongue of the panel in a groove of a second like panel; and
- a vertical joint system extending along opposite sides of the substrate and having mutually engagable male and female parts wherein the male part on one of the sides of the second pair of sides and the female part in on another of the sides of the second pair of sides, the male and female parts being configured to enable mutual engagement in response to a force applied in an engagement direction which is substantially perpendicular to the major surfaces;
- the male part having: a male protrusion extending perpendicular to the major surfaces and provided with a distal end; and a male recess inboard of the male protrusion, the female part having: a female protrusion extending perpendicular to the major surfaces and provided with a distal end; and a female recess inboard of the female protrusion, wherein each protrusion has a rounded corner portion at each side of its distal end and the male and female parts are relatively configured so that when in a joined condition at least one space is formed between each protrusion and a surface of a recess in which the protrusion is engaged; and
- wherein the male and female parts are further relatively configured such that in when in a joined condition the one of the parts overhang the other of the parts about each of a first locking plane that passes through an outer most side of the male protrusion and a second locking plane that passes through an outer most side of the female protrusion, each of the first and second locking planes being perpendicular to the major surfaces.
- In one embodiment the overhang of the male and female parts about the first locking plane is between 6% and 18% of the thickness of the panel measured perpendicular to and between the first and second major surfaces.
- In one embodiment the overhang of the male and female parts about the second locking plane is between 6% and 18% of the thickness of the panel measured perpendicular to and between the first and second major surfaces.
- In one embodiment the male protrusion comprises a planar surface that is contiguous with one of its rounded corner portions and is inclined at an angle γ in the range of 50°±30° and orientated to form part of a concavity on an outermost side of the male protrusion.
- In one embodiment the male recess comprises a planar surface that is inclined at an angle φ in the range of 50°±30° and orientated to under lie a rounded corner portion on an outermost side of the female protrusion.
- In one embodiment the male and female protrusion each comprise respective mutually facing planar surfaces that face each other when the parts are in a joined condition the respective mutually facing planar surfaces located between the first and second locking planes and lying in a plane that it substantially perpendicular to the major surfaces or inclined thereto in a direction to create a further overhang that acts to inhibit separation of the joined male and female parts.
- In one embodiment the mutually facing planar surfaces that face each other have a face to face length of 6% to 18% of the thickness of the panel.
- In one embodiment the mutually facing planar surfaces that face each other have a common plane of tangency extending at an angle in the range of 90° to 120° with reference to a plane containing a major surface such that the facing planar surface on the female part overhangs the facing planar surface on the male part when this angle is greater than 90°.
- In one embodiment the panel is made of a plastics material including vinyl and PVC and has a thickness of less than 5 mm.
- In one embodiment the panel has a thickness in the range of 4 mm to 2 mm inclusive.
- In one embodiment the panel has a length to width ratio of less than 1:6 to 1:1.
- In one embodiment the male part is provided with an inner most male locking surface on its male recess and the female part is provided with an outermost female locking surface on its male protrusion, the inner most male locking surface and the outermost female locking surface arranged to engage to create the second locking plane, and wherein the outermost female locking surface comprises a convexly curved portion that overhangs a convexly curved portion of the inner most male locking surface.
- In one embodiment the inner most male locking surface and the outermost female locking surface are each provided with respective a planar surface portion located between their respective convexly curved portions and a common major surface, the respective plane surfaces being parallel to each other when male and female parts are in the joined condition and juxtaposed with the first major surfaces parallel to each other.
- In one embodiment the planar surface of the inner most male locking surface lies inboard of a lateral most point on the convexly curved portion of the inner most male locking surface.
- In one embodiment the planar surface of the outer most female locking surface lies inboard of a lateral most point on the convexly curved portion of the outer most female locking surface.
- In one embodiment the respective parallel planar surfaces are spaced apart by a distance of between 0.02 mm and 0.2 mm inclusive.
- In one embodiment the male and female parts are further configured to form an upper gap between two connected panels when the second major surfaces of the two panels are coplanar, the upper gap comprising a visible portion that is visible at the first major surfaces of two connected panels and extends both in a direction parallel to the first major surfaces and in a direction from the upper surface towards the second major surface and a second contiguous portion that extends from the visible portion to a first contact region between the connected panels.
- In one embodiment the visible portion of the gap is widest at the first major surfaces of two connected panels and reduces in width in the direction from the first surface towards the second surface.
- In one embodiment the gap is configured to prevent a direct line of sight from the first major surface to the first contact region when the gap is viewed from a standing position on the panels.
- In one embodiment the gap follows a path of a configuration such that the direct line of sight impinges a surface of the first or second panel at a location intermediate of the upper surfaces and the first contact region; wherein the visible portion of the gap extends from the first major surface to the intermediate location and the second portion extends from the intermediate location to the first contact region.
- In one embodiment the path comprises a bend at the intermediate a location, wherein the visible portion of the gap extends from the upper surfaces to the bend and the bend prevents the direct line of sight from the first major surface to the first contact region.
- In one embodiment the bend is created by a surface portion one of the male and female parts that overlies a surface portion of the other of the male and female parts in a plane lying perpendicular to the major upper surfaces.
- In one embodiment the female part comprises an inner surface having a first surface portion extending from the upper surface at an obtuse included angle, a second contiguous surface portion extending toward the lower major surface at a steeper angle than the first surface portion, and a contiguous third surface portion that extends toward the male part of a connected second panel.
- In one embodiment the female part comprises a fourth surface portion that extends between the third surface portion and the first contact region.
- In one embodiment the contact region comprises a datum surface formed on the female part and lying substantially parallel with the first major surface of the corresponding panel the datum surface forming a contact surface for the male part, the male and female parts arranged so that when the male part rests on the datum surface and the second major surfaces of respective corresponding connected panels are parallel, the respective first major surfaces of the connected panels are flush with each other.
- In one embodiment the male part comprises an outer surface having first surface portion extending from the first major surface at an obtuse included angle, and an associated contiguous second surface portion extending toward the lower major surface at a steeper angle than the associated first surface portion, the second portion of the female part arranged to overhang the third surface portion of the male part.
- In one embodiment the path is a linear path that is inclined relative at an acute angel relative to the first major surfaces, the acuate angle arranged so that a direct line of sight impinges the surface of the first or second panel at the intermediate location, wherein the visible portion of the gap extends from the first major surfaces to the intermediate location and the second portion extends from the intermediate location to the first contact region.
- In one embodiment the upper gap extends to a depth D1 measured perpendicular from the first major surface of a panel wherein: 0.3T≧D1≧0.1T, where T is the thickness of the panel measured perpendicular to the first major surface.
- In one embodiment the visible part of the upper gap extends to a depth of between 0.4D1 to 0.8D1.
- In one embodiment of the panel the male and female parts are further configured to form a lower gap that extends from the contact region toward the second major surface.
- In one embodiment the upper gap a minimum of 0.15 mm-0.2 mm measured parallel to the first major surface.
- In one embodiment the lower gap a minimum of 0.15 mm-0.2 mm measured parallel to the first major surface.
- In a second aspect there is disclosed a vertical joint system for a panel of a surface covering system the panel having a first major surface and an opposite second major surface and a first pair of opposite sides that lie between the first and second major surfaces, the vertical joint system comprising:
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- mutually engagable male and female parts wherein the male part is on one of the sides of the first pairs of sides and the female part in on another of the sides of the first pairs of sides, the male and female parts being configured to enable mutual engagement in response to a force applied in an engagement direction which is substantially perpendicular to the major surfaces;
- the male part having: a male protrusion extending perpendicular to the major surfaces and provided with a distal end; and a male recess inboard of the male protrusion, the female part having: a female protrusion extending perpendicular to the major surfaces and provided with a distal end; and a female recess inboard of the female protrusion, wherein each protrusion has a rounded corner portion at each side of its distal end and the male and female parts are relatively configured so that when in a joined condition at least one space is formed between each protrusion and a facing surface of a recess in which the protrusion is engaged;
- wherein the male and female parts are further relatively configured such that in when in a joined condition one of the parts overhang the other of the parts about each of a first locking plane that passes through an outer most side of the male protrusion and a second locking plane that passes through an outer most side of the female protrusion, each of the first and second locking planes being perpendicular to the major surfaces; and
- wherein the overhang of the male and female parts about the first and second locking planes is between 4% and 18% of the thickness of the panel measured perpendicular to and between the first and second major surfaces.
- In a third aspect there is disclosed a vertical joint system for a panel of a surface covering system the panel having a first major surface and an opposite second major surface and a first pair of opposite sides that lie between the first and second major surfaces, the vertical joint system comprising:
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- mutually engagable male and female parts wherein the male part is on one of the sides of the first pairs of sides and the female part in on another of the sides of the first pairs of sides, the male and female parts being configured to enable mutual engagement in response to a force applied in an engagement direction which is substantially perpendicular to the major surfaces;
- the male part having: a male protrusion extending perpendicular to the major surfaces and provided with a distal end; and a male recess inboard of the male protrusion, the female part having: a female protrusion extending perpendicular to the major surfaces and provided with a distal end; and a female recess inboard of the female protrusion, wherein each protrusion has a rounded corner portion at each side of its distal end and the male and female parts are relatively configured so that when in a joined condition at least one space is formed between each protrusion and a facing surface of a recess in which the protrusion is engaged;
- wherein the male and female parts are further relatively configured such that in when in a joined condition one of the parts overhang the other of the parts about each of a first locking plane that passes through an outer most side of the male protrusion and a second locking plane that passes through an outer most side of the female protrusion, each of the first and second locking planes being perpendicular to the major surfaces; and
- the male protrusion comprises a planar surface that is contiguous with one of its rounded corner portions and is inclined at an angle γ in the range of 50°±30° and orientated to form part of a concavity on an outermost side of the male protrusion.
- In a fourth aspect there is disclosed a vertical joint system for a panel of a surface covering system the panel having a first major surface and an opposite second major surface and a first pair of opposite sides that lie between the first and second major surfaces, the vertical joint system comprising:
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- mutually engagable male and female parts wherein the male part is on one of the sides of the first pairs of sides and the female part in on another of the sides of the first pairs of sides, the male and female parts being configured to enable mutual engagement in response to a force applied in an engagement direction which is substantially perpendicular to the major surfaces;
- the male part having: a male protrusion extending perpendicular to the major surfaces and provided with a distal end; and a male recess inboard of the male protrusion, the female part having: a female protrusion extending perpendicular to the major surfaces and provided with a distal end; and a female recess inboard of the female protrusion, wherein each protrusion has a rounded corner portion at each side of its distal end and the male and female parts are relatively configured so that when in a joined condition at least one space is formed between each protrusion and a facing surface of a recess in which the protrusion is engaged;
- wherein the male and female parts are further relatively configured such that in when in a joined condition one of the parts overhang the other of the parts about each of a first locking plane that passes through an outer most side of the male protrusion and a second locking plane that passes through an outer most side of the female protrusion, each of the first and second locking planes being perpendicular to the major surfaces; and
- wherein the male recess comprises a planar surface that is inclined at an angle φ in the range of 50°±30° and orientated to under lie a rounded corner portion on an outermost side of the female protrusion.
- In a fifth aspect there is disclosed a vertical joint system for a panel of a surface covering system the panel having a first major surface and an opposite second major surface and a first pair of opposite sides that lie between the first and second major surfaces, the vertical joint system comprising:
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- mutually engagable male and female parts wherein the male part is on one of the sides of the first pairs of sides and the female part in on another of the sides of the first pairs of sides, the male and female parts being configured to enable mutual engagement in response to a force applied in an engagement direction which is substantially perpendicular to the major surfaces;
- the male part having: a male protrusion extending perpendicular to the major surfaces and provided with a distal end; and a male recess inboard of the male protrusion, the female part having: a female protrusion extending perpendicular to the major surfaces and provided with a distal end; and a female recess inboard of the female protrusion, wherein each protrusion has a rounded corner portion at each side of its distal end and the male and female parts are relatively configured so that when in a joined condition at least one space is formed between each protrusion and a facing surface of a recess in which the protrusion is engaged;
- wherein the male and female parts are further relatively configured such that in when in a joined condition one of the parts overhang the other of the parts about each of a first locking plane that passes through an outer most side of the male protrusion and a second locking plane that passes through an outer most side of the female protrusion, each of the first and second locking planes being perpendicular to the major surfaces; and
- the male and female parts are further configured to form an upper gap between two connected panels when the second major surfaces of the two panels are coplanar, the upper gap comprising a visible portion that is visible at the first major surfaces of two connected panels and extends both in a direction parallel to the first major surfaces and in a direction from the first major surface towards the second major surface and a second contiguous portion that extends from the visible portion to a first contact region between the connected panels.
- In a sixth aspect there is disclosed a vertical joint system for a surface covering system the panel having a first major surface and an opposite second major surface that in use lies on or faces a support and at least two opposite sides that lie between the first and second major surfaces, the vertical joint system comprising:
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- male and female parts that extend along the first and second sides respectively, the male and female parts configured to enable two like panels to connect to each other with the male part of one panel engaging with the female part of a second panel in a manner to resist separation of the connected panels in a plane parallel to the first major surface and in a plane perpendicular to the first major surface;
- the male and female parts further configured to form an upper gap between two connected panels when the second major surfaces of the two panels are coplanar, the upper gap comprising a visible portion that is visible at the first major surfaces of two connected panels and extends both in a direction parallel to the first major surfaces and in a direction from the first major surface towards the second major surface and a second contiguous portion that extends from the visible portion to a first contact region between the connected panels.
- In a seventh aspect there is disclosed a flooring panel comprising:
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- an first major surface and an opposite second major surface that in use lies on or faces a support;
- first and second edges that lie between the first and second major surfaces; male and female parts that extend along the first and second edges respectively, the male and female parts configured to enable two like panels to connect to each other with the male part of one panel engaging with the female part of a second panel in a manner to resist separation of the connected panels in a plane parallel to the first major surface and in a plane perpendicular to the first major surface;
- the male part having a recess formed in a direction from the first major surface toward the second major surface and a protrusion extending from the second major surface toward the first major surface and the female part having a recess formed in a direction from the second major surface toward the first major surface and a protrusion extending from the first major surface toward the second major surface; the protrusions of each parts of two like panels configured to fit within the recesses of the other to enable coupling of the two like panels by insertion in a direction perpendicular to the first major surfaces of the panels;
- the recess of the male part having an inner most surface and the protrusion of the second coupling having an outer most surface, the male and female parts configured so that when the male part of one panel is engaged with the female part of a like panel the inner and outer surfaces are in mutual facing relationship and are spaced from each other in a direction parallel to the first major surfaces to provide rotational play enabling one of the connected panels to rotate by up to ±3° from a common lay flat condition relative to the other of the connected panels prior to bringing previously spaced portions of the inner and outer surfaces into contact with each other.
- In an eight aspect there is disclosed a flooring panel comprising:
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- a first major surface and an opposite second major surface that in use lies on or faces a support;
- first and second edges that lie between the first and second major surfaces;
- male and female parts that extend along the first and second edges respectively, the male and female parts configured to enable two like panels to connect to each other with the male part of one panel engaging with the female part of a second panel in a manner to resist separation of the connected panels in a plane parallel to the first major surface and in a plane perpendicular to the first major surface;
- the female part having a recess adjacent the first major surface and a protrusion spaced from the first major surface toward the first edge by the recess, and an inner female recess surface extending from the first major surface to a base of the recess, the inner female recess surface having a datum surface lying parallel to the first major surface;
- the male part having a protrusion adjacent the first major surface and a recess inboard of the protrusion, the protrusion having an outer male protrusion surface extending from the first major surface toward the second major surface;
- male and female parts further configured so that the when the male and female part of like panels are engaged an intermediate portion of the outer male protrusion surface abuts the datum surface, and respective portions of the inner female recess surface and the outer male protrusion surface extending from the first major surface to the datum surface are spaced from each other.
- In a ninth aspect there is disclosed a flooring panel comprising:
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- an first major surface and an opposite second major surface that in use lies on or faces a support;
- first and second edges that lie between the first and second major surfaces;
- male and female parts that extend along the first and second edges respectively, the male and female parts configured to enable two like panels to connect to each other with the male part of one panel engaging with the female part of a second panel in a manner to resist separation of the connected panels in a plane parallel to the first major surface and in a plane perpendicular to the first major surface;
- the female part having: an inner female surface extending from the first major surface toward the second major surface and including a datum surface lying parallel to the first major surface; and, a protrusion spaced form the inner female surface and extending from the second major surface toward the first major surface;
- the male part having: an outer male surface extending from the first major surface toward the second major surface; and, a recess spaced from the outer male surface;
- the male and female parts being further configured so that the when the male and female part of like panels are engaged, the recess contacts opposite sides of the protrusion, an intermediate portion of the outer male surface abuts the datum surface, and respective portions of the outer male and inner female surfaces extending from the first major surface to the datum surface are spaced from each other.
- In a tenth aspect there is disclosed a flooring panel comprising:
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- an first major surface and an opposite second major surface that in use lies on or faces a support;
- first and second edges that lie between the upper and second major surfaces;
- male and female parts that extend along the male and second edges respectively, the male and female parts configured to enable two like panels to connect to each other with the male part of one panel engaging with the female part of a second panel in a manner to resist separation of the connected panels in a plane parallel to the first major surface and in a plane perpendicular to the first major surface;
- the female part having a recess adjacent the first major surface and a protrusion spaced from the first major surface toward the first edge by the recess, and a recess surface extending from the first major surface to a base of the recess, the recess surface having a datum surface lying parallel to the first major surface;
- the male part having a protrusion adjacent the first major surface and a recess inboard of the protrusion, and a protrusion surface extending from the first major surface toward the second major surface;
- male and female parts further configured so that the when the male and female part of like panels are engaged, an intermediate portion of the protrusion surface abuts the datum surface, and respective portions of the recess surface and the protrusion surface from the datum surface to the recess base are spaced from each other.
- The features of the embodiments of the first aspect of the disclosure as they relate to the vertical joint system of the first aspect or the associated male and female parts, may also constitute features the vertical joint system or the associated male and female parts of the second to tenth aspects.
- Notwithstanding any of forms which may fall within the scope of the panels and joint systems as set forth in the Summary, specific embodiments will now be described, by way of example only, with reference to the accompanying drawings in which:
-
FIG. 1 a is a plan view of a panel in accordance with a first embodiment of the disclosed panel and associated joint systems; -
FIG. 1 b is an isometric view of the panel shown inFIG. 1 a; -
FIG. 1 c is an enlarged view of one short end of the panel; -
FIG. 1 d is an enlarged view of one longitudinal side of the panel; -
FIG. 1 e is an enlarged view of an opposite longitudinal side of the panel; -
FIG. 1 f is an enlarged view of an opposite short side of the panel; -
FIG. 2 illustrates a manner of engagement of a plurality of panels to form a floor; -
FIGS. 3 a-3 c depict the engagement of longitudinal sides of two panels; -
FIGS. 4 a-4 c depict sequentially the engagement of short sides of two panels; -
FIG. 5 is an enlarged view of the opposite longitudinal sides of the panel; -
FIG. 6 is an enlarged view of one of the short sides of the panel; -
FIG. 7 is an enlarged view of an opposite short side of the panel; -
FIG. 8 illustrates the short sides of two panels in an engaged state; -
FIG. 9 a depicts a person walking on a floor composed of the panels; -
FIG. 9 b depicts the effect on the joints at the short sides of two joined panels of the person walking on the floor; -
FIG. 9 c depicts a foot of a person being lifted from a floor composed of the panels; -
FIG. 9 d depicts the effect of the release of the person's foot from the floor in the region of a join between the short sides of two panels; -
FIG. 10 a illustrates a second form of vertical joint system that may be incorporated in a second embodiment of the panel; -
FIG. 10 b depicts a male part of the vertical joint system shown inFIG. 10 a; -
FIG. 10 c illustrates a female part of the vertical joint system shown inFIG. 10 a; -
FIG. 11 a depicts a third form of the vertical joint system that may be incorporated in a third embodiment of the panel; -
FIG. 11 b depicts a male part of the vertical joint system shown inFIG. 11 a; -
FIG. 11 c illustrates a female part of the vertical joint system shown inFIG. 11 a; -
FIG. 12 a illustrates a fourth form of vertical joint system that may be incorporated in a second embodiment of the panel; -
FIG. 12 b depicts a male part of the vertical joint system shown inFIG. 12 a; -
FIG. 12 c illustrates a female part of the vertical joint system shown inFIG. 12 a; -
FIG. 13 a illustrates the effect of relative rotation in a first direction of the joined panels shown inFIG. 12 a; -
FIG. 13 b illustrates the effect of relative rotation in an opposition direction of the joined panel shown inFIG. 12 ; -
FIGS. 14 a-14 s depict a sequence of steps for the removal and replacement of an embodiment of the disclosed panel, made of a rigid materiel such as natural timber, bamboo or wood laminate having any one of the disclosed vertical joint systems on all of its sides; -
FIGS. 14 t-14 y depict a sequence of steps for the removal and replacement of a disclosed panel being made of plastics material and having any one of the disclosed vertical joint systems on all of its sides; -
FIG. 15 a is a side elevation of a jack that may be used in the removal of a panel in accordance with the sequence of steps shown inFIGS. 14 a-14 s; -
FIG. 15 b is a plan view of the jack shown inFIG. 15 a; -
FIG. 16 a is a side elevation of a wedge that may be used in conjunction with the jack shown inFIGS. 15 a and 15 b for the removal of an engaged panel; -
FIG. 16 b is a top elevation of the wedge shown inFIG. 16 a; -
FIGS. 17 a-17 f depict in sequence the disengagement of male and female parts of a vertical joint system that may be incorporated in embodiments of the panel; -
FIG. 18 illustrates a further embodiment of a vertical joint system that may be incorporated in a fifth embodiment of the panel; -
FIGS. 19 a-19 c depict the phenomenon of peaking that may occur in panels made from plastics material and provided with prior art joint systems; and -
FIGS. 20 a-20 c illustrate the phenomenon of peaking of panels made from plastics material having joint systems in accordance with the vertical joint depicted inFIG. 18 . -
FIGS. 1 a-1 f depict an embodiment of apanel 10 for a surface or support covering system composed of a plurality of like panels. By way of example the panels may be used to cover or line a floor, a wall, a ceiling whether pitched or horizontal or a frame such as created by floor or ceiling joists and batons. However for ease of reference the panels will be described in the context of covering a floor. - The
panel 10 is in the form of a plank or strip of material and has opposed substantially planar major first andsecond surfaces first surface 12 may be considered as an upper surface of thepanel 10 and the secondmajor surface 14 can be considered as the bottom surface. When thepanel 10 is laid in a floor covering system the firstmajor surface 12 is upper most while the secondmajor surface 14 faces a substrate on which the flooring system is laid. A plurality of sides extend between themajor surfaces opposite sides opposite sides sides panel 10. The second pair ofsides panel 10. - When the
panel 10 is a rectangular panel, thesides 16 extend parallel to each other and perpendicular to thesides 18. - The
panel 10 is formed with first and secondjoint systems panels 10 along theirsides joint system 20 comprises afirst member 24 a extending along theside 16 a, and asecond member 24 b extending along theside 16 b. Themembers members 24”) are relatively configured to enable them to engage each other. Depending on their particular form, themembers 24 can interlock so as to resist separation in both a direction parallel to themajor surfaces first member 24 a of one panel is configured to engage asecond member 24 b on one or more anadjacent panels 10. Both of thejoint systems joint systems - The second
joint system 22 is formed with mutually engageable male and female parts Jm and Jf respectively. The male part Jm is formed on theside 18 a, while the female part Jf is formed onside 18 b. - The first and second
joint systems joint system 20 operates by locating thelongitudinal sides adjacent panels 10 parallel and adjacent to each other and then inserting thefirst part 24 a into thesecond part 24 b. Thepart 24 a may be considered to be a tongue that extends laterally along thesides 16 a in a plane generally parallel to themajor surfaces second part 24 b can be considered to be a groove formed along theopposed side 16 b. - Depending on the specific configuration of the tongue and
groove panels 10 in a common plane toward each other so that thetongue 24 a locates into thegroove 24 b. The later engagement procedure will for example be possible where the tongue is a simple laterally extending tongue lying between upper and lower surfaces of the panel and having a generally rectangular configuration with planar upper and lower faces. -
FIG. 2 illustrates the laying of a floor using a plurality of thepanels 10. Here, the firstjoint system 20 engages via the lay down method. The floor inFIG. 2 comprising a plurality ofpanels 10 all of the same configuration including previously laid and engagedpanels 10 x 1, 10 x 2, and 10 z.Panel 10 w is now being laid so as to engage each of thepanels 10 x 1, 10 x 2, and 10 z. The first and second members 24 (i.e.tongue 24 a andgroove 24 b) are configured so that thepanel 10 w is inclined at an obtuse angle to thepanels 10 x 1 and 10 x 2 to facilitate insertion of thetongue 24 a intorespective grooves 24 b. Engagement of the first and second parts is complete by now laying down thepanel 10 w so that it is co-planar with the previously laid panels. This action is equivalent to pivoting thepanel 10 w relative to thepanels 10 x 1, 10 x 2, and 10 z so that they are co-planar. This process of engagement of the first joint system on thepanels 10 x 1 and 10 x 2 with thepanel 10 w is depicted sequentially inFIGS. 3 a-3 c. - The male and female parts Jm and Jf of the second
joint system 22 are configured to engage each other in response to a force applied in an engagement direction shown by arrow D which is substantially perpendicular to themajor surfaces panels FIGS. 4 a-4 c. This will be explained later. - The configuration of the first and second joints profiles 22 and 24 will now be described in greater detail.
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FIG. 5 depicts the firstjoint system 20 along different longitudinal sides on twoidentical panels 10 prior to engagement. For ease of reference these two panels are separately designated aspanels 10 x 1 and 10 w.Side 16 a is depicted ofpanel 10 x 1 andside 16 a is depicted ofpanel 10 w. The firstjoint system 20 in general comprises atongue 24 a and agroove 24 b along thesides tongue 24 a extends generally laterally fromside 16 a and lies between the upper andmajor sides - Looking at
sides 16 a first, it is seen that this side initially comprises a substantiallyvertical surface 30 depending at right angles from themajor surface 12. Moving in the direction of themajor surface 14, an inwardly slopedsurface 32 is formed contiguously with thesurface 30. Thesurface 32 slopes inwardly into the body of apanel 10. Thereafter there is a further substantially verticalplanar surface 34 formed contiguously with thesurface 32. A lower end ofsurface 34 terminates is formed contiguously with upperplanar surface 36 of thetongue 24 a. Thesurface 36 lies parallel to themajor surface 12 and forms a right angle withsurface 34. Asmall ridge 40 is formed on theupper surface 36 at adistal end 38 of thetongue 24 a. A small slopedtransition surface 42 extends between theridge 40 and thesurface 36. Thetransition surface 42 slopes at an obtuse angle relative to theupper surface 36. - The
distal end 38 is formed by aplanar surface 44 that extends substantially parallel to thesurfaces major surfaces planar surface 44 leads to an undersurface 46 of thetongue 24 a. The undersurface 46 is formed with a wave like profile comprising contiguous convex and concave surfaces. In particular the wave like undersurface 46 is formed with three successivelylower troughs upper surface 12 toward thelower surface 14. Thus the term “successively lower” means either successively closer to themajor surface 14, or successively more distant from themajor surface 12. - In between the
troughs troughs further peak 56. Thepeak 56 is below thepeak 54. Following thetrough 52 the wave likesurface 56 is provided with afurther peak 58 that is higher than both of thepeaks surface 46 is formed with a generally planarvertical surface 60 that leads to themajor surface 14. - The
side 16 b immediately adjacent theupper surface 12 is formed with a substantially vertical downwardly extendingsurface 62. Moving in the direction of the correspondingmajor surface 14, and formed contiguous with thesurface 62 is an inwardly slopedsurface 64. Thesurface 64 slopes inwardly into the body of the panel. Contiguous with thesurface 64 is a further substantially verticalplanar surface 66.Surface 66 transitions at a right angle to a planarupper surface 68 of thegroove 24 b. Theupper surface 68 extends inwardly of the body of panel for a distance longer than the distance betweensurfaces tongue 24 a. Thesurface 68 lies in a plane generally parallel to themajor surfaces surface 68, thegroove 24 b is formed with a contiguous substantially vertical surface 70. The lower end of the surface 70 is formed contiguously with alower surface 72 of the groove 64 b. Thelower surface 72 has a wave like profile which is substantially although not precisely complementary to the wave like profile ofsurface 46. - When viewed in a direction form the
upper surface 12 toward thelower surface 14, the wave likelower surface 72 is formed with a plurality oftroughs surface 72 is also formed with threepeaks peak 80 is between the twotroughs peak 82 is betweentroughs peak 84 follows from thetrough 78. Following from thepeak 84, theside 16 b terminates with a verticalplanar surface 86 that leads to themajor surface 14. - The
peak 84 is raised above or at a level higher than thepeaks surfaces tongue 24 a is fully engaged with thegroove 24 b thesurfaces troughs peaks FIG. 3 c. It will be appreciated that when the joint 20 is engaged in this manner thetongue 24 a andgroove 24 b interlock to resist separation of the engagedpanels major surfaces major surfaces planar surfaces planar surfaces surface 44 and 70. Planar surfaces 30 and 62 are in face to face contact. - The second
joint system 22 is shown in more detail inFIGS. 6 to 8 . As previously described, the secondjoint system 22 comprises a male part Jm and a female part Jf. The male part Jm is formed on the short ortransverse side 18 a of thepanel 10 while the female part Jf is formed on the opposite short ortransverse side 18 b. - The male part Jm comprises a male protrusion Pm and a male recess Rm, while the female Jf comprises a female protrusion Pf and a female recess Rf. The male part Jm is notionally designated as the male joint by virtue of its protrusion Pm depending from the upper
major surface 12. The second part Jf is notionally designated as the female joint by virtue of its recess Rf being configured to receive the protrusion Pm. - When describing features or characteristic common to all protrusions, the protrusions will be referred to in general in this specification in the singular as “protrusion P”, and in the plural as “protrusions P”. When describing features or characteristic common to all recesses, the recesses will be referred to in general in this specification in the singular as “recess R”, and in the plural as “recesses R”. When describing features or characteristic common to both part Jm and Jf, the parts will be referred to in general in this specification in the singular as “part J”, and in the plural as “parts J”.
- The male part Jm has first (or outer most), second (or inner most) and intermediate male locking surfaces ML1, ML2 and ML3 respectively (referred to in general as “male locking surfaces ML”). Each of the male locking surfaces ML extends continuously in the general direction perpendicular to the major surfaces. Similarly the female part Jf has first (or inner most), second (or outer most) and intermediate female locking surfaces FL1, FL2 and FL3 respectively, (referred to in general as “female locking surfaces FL”). The male and female locking surfaces collectively and generally are referred to locking surfaces L. Each of the locking surfaces L extends continuously in the general direction perpendicular to the major surfaces.
- The male locking surface ML1 extends from an edge of the
major surface 12 adjacent the protrusion Pm and down the adjacent side of the protrusion Pm. The locking surface ML1 extends continuously in the general direction perpendicular to themajor surface 12, without returning upon itself. Thus every point on the surface ML1 lies on a different horizontal plane. In contrast, in the event that a hook or barb like structure were provided then the corresponding surface would turn upon itself and a plane parallel to themajor surface 14 would insect the surface at three different locations. Further no point along the surface ML1 extends in a lateral direction beyond a plane containing the adjacent edge ofsurface 12 and lying perpendicular to thesurface 12. - The male locking surface ML2 extends from the second
major surface 14 up along an adjacent side of the recess Rm to a point prior to the recess Rm. The intermediate male surface ML3 extends along a shared or common surface between a protrusion Pm and Rm. - As will be explained shortly, the first and second male and female locking surfaces engage about respective locking planes inhibiting vertical separation of engaged parts Jm and Jf. The intermediate male and female locking surfaces ML3 and FL3 may also be configured to form a third locking plane. Also, the locking surfaces L in various embodiments comprise inflexion surfaces which in turn may comprise transverse outward extending surfaces which may take the form of convex or cam surfaces, or bulges. The relationship between the locking surfaces L, inflexion surfaces and transverse outward extending surfaces will be apparent in the following description.
- Looking at the configuration of the male and female parts Jm and Jf (referred to in general as “parts J”) more closely, it will be seen that each of these parts is provided with two laterally spaced apart transversely outward extending surfaces or bulges. The transversely extending surfaces bulges may also be considered and termed as “cam surfaces” as they move across and in contact with each other and at times often with a rolling or pivoting action. The transversely extending surfaces are designated as Cm1 and Cm2 on the male part Jm and Cf1 and Cf2 on the female part Jf. In some embodiments transversely extending surfaces are smoothly curved convex surfaces. However as will be apparent from the following description is some embodiments the transversely extending surfaces are of other configurations. For example a transversely extending surface may be generally convex in that the surface is not continuously or smoothly curved for its entire length but is composed of one or more straight/planar surfaces. For ease of reference the transversely extending surfaces on the male part Jm will be referred to “surface Cmi” where i=1,2 and similarly the transversely extending surfaces on the female part Jf will be referred to “surface Cfi” where i=1,2.
- The surface Cm1 is formed on an outermost side of male protrusion Pm while the surface Cm2 is formed in an innermost side of male recess Rm. Similarly the surface Cf2 is formed on an outermost side of female protrusion Pf while the surface Cf1 is formed in an innermost side of the female recess Rf. (For ease of description the surfaces Cm2 and Cm1 will be referred to in general as “surfaces Cm”; surfaces Cf1 and Cf2 will be referred to in general as “surfaces Cf”; and collectively the surfaces Cm2, Cm1, Cf1 and Cf2 will be referred to in general as “surfaces C”).
- The protrusion Pm is provided with rounded or curved corners by virtue of the smoothly curved can surfaces Cm1 and Cm2. Likewise the protrusion Pf is provide with rounded or curved corners by virtue of the smoothly curved can surfaces Cf2 and Cf3. Also the distal ends of the protrusions Pm and Pf between their respective corners are each of a generally convex shape or configuration.
-
FIG. 8 depicts the secondjoint system 22 and in particular male and female parts Jm and Jf in an engaged state. As is evident when the parts J are engaged their respective transversely extending surfaces Cm2, Cm1, Cf1 and Cf2 are located relative to each other to form respective first and second locking planes LP1 and LP2 which inhibit the separation of the engaged parts in a direction opposite the engagement direction. - Each locking plane LP1, LP2 lies parallel to the engagement direction D. The transversely extending surfaces Cm1, Cf1, Cm2, Cf2 associated with each locking plane extend laterally toward each other from opposite sides of the locking plane with the transversely extending surfaces of the second or female part (i.e. Cf1 and Cf2) overhanging the transversely extending surfaces of the first or male part (i.e. Cm1 and Cm2). This inhibits separation of the engaged parts Jm and Jf. It will also be noted that at least one of the transversely extending surfaces associated with each locking plane has a curved profile. In this instance the both surface Cm1 and Cf1 associated with locking plane LP1, and both surfaces Cf2 and Cm2 associated with locking plane LP2 have convexly curved profiles.
- During the engagement of the parts Jm and Jf the surfaces Cm1 and Cm2 pass and snap over the surfaces Cf1 and Cf2. This action is enabled by one or both of resilient compression of the protrusions Pm and Pf and resilient tension in the recesses Rm and Rf as the surfaces Cm pass the surfaces Cf in response to application of the force F. Whether there is one or both of resilient compression of the protrusions Pm and Pf and resilient tension in the recesses Rm and Rf during the engagement process is dependent on the material from which the
panel 12 is made. (As explained later after engagement there may not necessarily be any substantive compression or tension in the joint.) For example in the case of a panel made from a very stiff or hard material such as compressed bamboo or non-compressed bamboo (hereinafter referred to in general as “bamboo”) during engagement there would be very little compression of the protrusions P but tension in the recess R which results in its opening or widening would allow for the engagement. - The ability for the protrusions P to enter the recesses R may be assisted by optional provision of a lubricant such as but not limited to wax, graphite, talcum powder, petroleum jelly such as marketed under the trade mark VASELINE and other oil based products, water based products, silicon based products on the parts Jm and Jf. In particular it is believe that lubricants such as petroleum jelly and other oil based products, water based products, silicon based products are well suited to panels made from plastics material including vinyl, PVC and Luxury Vinyl Tile “LVT”. When applying petroleum jelly to plastics material panels, the jelly can first be heated to transition from its room temperature solid state to a liquid state product. The liquid state product is then sprayed onto one or both if the parts Jm and Jf and subsequently allowed to cool and refrom as a solid coating on the parts Jm and Jf. This may be achieved by use of a machine such as or similar to the flooring wax machine KFL 1300 manufactured by the WUXI SHENGJIN MACHINERY Co. LTD.
- When the
panels 10 are made of hard wood, bamboo or manufactured hard wood such as, laminates, MDF, HDF, the provision of the lubricant, particularly in the case of wax, also assists completing a mechanical engagement between the joints Jm and Jf by filling voids or other spaces formed by virtue of the non-complementary configuration of the joints Jm and Jf. In addition to the materials mentioned above, embodiments of thepanels 10 disclosed herein may be made from other materials such wood plastic composite (WPC), masonry plastic composite, bamboo plastic composite and plastics materials including vinyl and Luxury Vinyl Tile (“LVT”); and natural or synthetic rubber and rubber compounds. The wood or wood bases panels are typically rigid whereas the plastics and composite material (including plastic composites) panels may be either rigid or pliable depending on their specific composition. Also while a plastics panel may be quite rigid it may nonetheless have pliablejoint systems - One example of a pliable plastics material that may be used for the surface covering panels is described in U.S. Pat. No. 8,156,710. In brief this panel comprises of a wear layer, a pattern layer, a base layer, and a backing layer including a bottom surface. The base layer is made of a mixture comprised of ilmenite powder and is sandwiched between the pattern layer and the backing layer, so that the base layer is covered on one side by the pattern layer and on an opposing side by the backing layer. However the pattern layer and the backing layer do not include ilmenite. The bottom surface of the backing layer is exposed and includes a plurality of hexagonal shaped devices that form a honeycomb structure. In use the honeycomb structure contacts an underlying surface on which the panels are laid.
- An example of a plastics composite material that may be suitable for manufacture of the disclosed panels is described in GERFLOR European publication number EP2611961. This publication describes a floor covering of the type including skid-resistant particles in the surface layer and is characterized in that the coating consists of a flexible and resilient material, and in that said particles are made of a ground glass core coated all or part of its surface with a metal coating, the particles being sprinkled in a flexible PVC base without finishing work.
- Yet another example of a plastics material suitable for manufacture of the disclosed panels is described in WINDMOLLER publication no. US 2008/0138560. This document describes a floor panel in the form of a multilayer, rectangular laminate with a soft core of plastic, a décor film on the upper side of the core, a transparent finishing layer and a transparent lacquer layer applied on the finishing layer as well as a back-pull layer on the back of the core.
- Embodiments of the parts Jm and Jf and the tongue and
groove surface 12. As an alternative surface décor or patterns may be provided by application of printed plastic film or paper film either of which may be adhered to the upper surface of the panel. When paper film is used it is typically overlayed with a protective clear sealant or plastics film. - The surfaces Cm and Cf constitute portions of respective inflexion surfaces, which in turn form portions of respective locking surfaces L. Specifically, the surface Cm1 constitutes a part of an inflexion surface Im1 (indicated by a phantom line) which in turn forms part of an outer most locking surface ML1 (indicated by broken dot line) on an outer most side of the protrusion Pm.
- The surface Cm2 constitutes a portion of inflexion surface Im2 (indicated by a phantom line) which in turn forms part of an inner most locking surface ML2 (indicated by broken dot line) on an inner most side of the male recess Rm and depends generally in the direction D from near a
root surface 92 of the recess Rm. - The surface Cf2 constitutes part of an inflexion surface If2 (indicated by a phantom line) which in turn forms part of outer most locking surface FL2 (indicated by broken dot line) formed on an outer most side of the projection Pf and extending generally in the direction parallel to the direction D.
- The surface Cf1 constitutes part of the inflexion surface If1 (indicated by a phantom line) which in turn forms part of an inner most locking surface FL1 (indicated by broken dot line) on an inner most side of female recess Rf. Surface FL1 extends from a surface planar 94 that depends at right angles form
major surface 12 onside 18 b. The surface FL1 extends toward aroot surface 96 of the recess Rf. - Looking at
FIG. 8 , it will be seen that the surfaces Cm1, Im1 and ML1 engage the surfaces Cf1, If1 and FL1 respectively; and the surfaces Cm2, Im2 and ML2 engage the surfaces Cf2, If2 and FL2 when the joints Jm and Jf are engaged. The engagement of these surfaces forms or creates the first and second locking planes LP1 and LP2. The locking planes LP1 and LP2 form the inner and outer most locking planes of thejoint system 22 and lies in planes perpendicular to themajor surfaces - The first and second male locking surfaces ML1 and ML2, and indeed the associated surfaces Cm1 and Cm2 and corresponding inflexion surfaces Im1 and Im2 constitute at least a part of the extreme (i.e. innermost and outermost) transversely extending and inflexion surfaces of the male part Jm. The first and second female locking surfaces FL1 and FL2, and the associated surfaces Cf1 and Cf2 and inflexion surfaces If1 and If2 constitute at least a part of the extreme transversely extending and inflexion surfaces of the female part Jf. These extreme transversely extending and inflexion surfaces form respective surface pairs which create the extreme (i.e. inner most and outer most) locking planes LP1 and LP2 in mutually engaged joints Jm and Jf. This is clearly evident from
FIG. 8 . Specifically the surface pairs are in this embodiment: Im1 and If1, or Cm1 and Cf1; and, Im2 and If2, or Cm2 and Cf2. - The surfaces Cm1 and Im1 form part of an outermost side surface of the protrusion Pm. The protrusion Pm has a generally ball like or bulbous profile which depends in the direction D from
major surface 14. Asmall notch 98 is formed at adistal end 99 of the protrusion Pm. Save for thenotch 98 thedistal end 99 of the protrusion Pm facing theroot 96 of recess Rf has a surface of a generally convex configuration and is smoothly rounded or curved. This in part arises from the provision of curved surfaces orcorners distal end 99. Thesurfaces notch 98 forms areservoir 100 against theroot surface 96 of the recess Rf. The first male locking surface ML1 comprises the combination ofsurface 90 and the inflexion surface Im1. - The
notch 98 andcorresponding reservoir 100 may be used for various different purposes. These include but are not limited to receiving adhesive and/or sealing compound; acting as a reservoir for debris which may have fallen into the recess Rf during installation, or both. It is expected that most debris falling into the recess Rf will collect at the lowest point on theroot 96 and thus be captured in the subsequently createdreservoir 100. In the absence of such a feature, it may be necessary to clean the recess Rf for example by blowing with compressed air, use of a vacuum or a broom to remove debris which may otherwise interfere with the engagement process. - The
surface 103/Cm3 leads to a contiguousplanar portion 104 that extends generally perpendicular to themajor surface 12. - The
surface 104 leads to a concavely curved surface orcorner 105 of recess Rm and associatedroot surface 92. A further concavely curved surface orcorner 107 is formed on an opposite side of the recess Rm. The inflexion surface Im3 is a “shared” surface between the protrusion Pm and recess Rm and comprisescorners planar surface 104. The intermediate male locking surface ML3 is substantially co-extensive with the inflexion surface Im3. - It will be noted that the protrusion Pm is formed with a
neck 106 having a reduced width in comparison to other portions of the protrusion Pm. It will be seen that the surface Cm1 is adjacent an outer most side of theneck 106. Moreover, a portion of the inflexion surface Im1 adjacent theplanar surface 90 forms the outer most side of theneck 106. Further, a portion of the inflexion surface Im3 forms the opposite side ofneck 106. In this embodiment aline 108 of shortest distance across theneck 106 is inclined relative to themajor surface 12. - The
root surface 92 smoothly curves via itscorner 105 to meet with and join inflexion surface Im2. The surface Im2 extends generally in the direction D leading to an inclinedplanar surface 110 which leads to themajor surface 14. The second male locking surface ML2 extends from above the inflexion surface Im2 and along thesurface 110 to themajor surface 14. - The recess Rm is formed with a
neck 112 between the surfaces Cm2 and Cm3. A line of shortest distance across theneck 112 is also inclined relative to themajor surface 12. - Looking at the configuration of the joint Jf (see
FIG. 6 ) onside 18 b ofpanel 10, it can be seen that the surface Cf1 and corresponding inflexion surface If1 extend generally in the direction D from theplanar surface 94. The inner most locking surface FL1 comprises the combination ofsurfaces 94 and If1. The inflexion surface If1 leads to theroot surface 96 of recess Rf. Theroot surface 96 has opposite roundedcorners corner 113 leads toplanar surface 114. Theplanar surface 114 lies in a plane substantially perpendicular tomajor surface 12 and leads to convexly curved surface Cf3. - Surface Cf2 forms one rounded corner of
distal end 116 of the protrusion Pf. Thedistal end 116 has a second opposite rounded and convexly curved corner Cf2. By virtue of the surfaces Cf2 and Cf3 thedistal end 116 is of a generally convex shape or configuration. Following the surface Cf2 is aconcave surface 117 that leads to aplanar surface 118 that is perpendicular to thesurface 14. Thereafter there is a planartapered surface 119 that leads to themajor surface 14. The outer most locking surface FL2 on the protrusion Pf comprises the combination of surfaces Cf2 and 117. - The recess Rf is configured to receive the protrusion Pm. Moreover, the recess Rf is formed with a
neck 120. Theneck 120 forms a restricted opening into the recess Rf. Aline 122 of shortest distance across theneck 120 is in this embodiment inclined relative to themajor surface 12. More particularly, theline 122 is inclined at substantially the same angle as theline 108. - The protrusion Pf like protrusion Pm is of a ball like or bulbous configuration. Further, similar to the protrusion Pm, the protrusion Pf is formed with a
neck 124 of reduced width. Aline 126 of shortest distance across theneck 124 is inclined to themajor surface 12. However in this embodiment theline 126 is inclined at a different angle to thelines - The male and female joints Jm and Jf are of different shape and configuration. That is, these joints are not symmetrical or non-complementary so that when a protrusion P of one part is engaged by a recess R of the other part, one or more spaces or gaps are formed between the engaged parts. For example, with reference to
FIG. 8 ,gaps Gap 130 is between surface Cm1 and a portion of the recess Rf below the surface Cf1.Gap 132 exists between an upper part of the surface Cf1 and an adjacent side of the protrusion Pm. Gaps 134 and 136 are formed between theroot surface 92 of recess Rm and thesurface 116 of the protrusion Pf. The gaps 134 and 136 are on opposite sides of a peak of thesurface 116. - The provision of the spaces or gaps assists in: the engagement and disengagement of parts Jm and Jf; accommodating dimensional changes in the panels for example due to changes in temperature or humidity; and enabling a degree of movement between the joints Jm and Jf to accommodate for uneven substrates on which
panels 10 may be laid. - As further shown in
FIG. 8 , in this particular embodiment when the joints Jm and Jf are engaged, the protrusion Pf is contacted on opposite sides by the joint Jm. In particular, the surface Cm2 contacts the protrusion Pm in a region adjacent and below the surface Cf2, while the twoplanar surfaces planar surfaces surfaces surfaces surface 114 is located above or otherwise overhangs thesurface 104. This creates an overhang that inhibits vertical separation. - Further when the male and female parts Jm and Jf are engaged the surface Cm1 on protrusion Pm abuts a lower portion of the surface Cf1. The second
joint system 22 may be manufactured to either have thesurfaces panels 10 at a location immediately adjacent themajor surfaces 12 do not contact each other. - The process of engaging the male and female parts Jm and Jf is shown in
FIGS. 2 and 4 a-4 c. These Figures depict apanel 10 w being engaged withpanels 10 x 1, 10 x 2 and 10 z.Panels 10 x 1 and 10 x 2 are on the same side ofpanel 10 w and are collectively referred to herein after as panels “10 x”. Each of thepanels panel 10. Thepanel 10 w is inclined at an obtuse angle topanels 10 x and thetongue 24 a has been inserted into thegroove 24 b ofpanels 10 x. Thepanel 10 w is located so that itsside 18 a is adjacent and located directly above theside 18 b ofpanel 10 z. Theside 18 a is provided with the male part Jm while theside 18 b is provided with the female part Jf. - An initial small length of the male part Jm is inserted into the female part Jf immediately adjacent the
panel 10 z. This is achieved by applying a downward force D on thesurface 12 ofpanel 10 w. This force results in the recesses Rm and Rf resiliently opening to receive the protrusions Pm and Pf. In particular, during this process the surface Cm1 contacts and rolls or otherwise passes over the surface Cf1, while the surface Cm2 contacts and passes or otherwise rolls over the surface Cf2. Due to their relative disposition, the surface Cm1 passes over the surface Cf1 before the surface Cm2 passes over the surface Cf2. Also as the protrusions Pm and Pf are being received in their respective recesses Rm and Rf, theplanar surfaces panel 10 w progressively along theside 18 a as apanel 10 w is being laid down, the entire length of the male part Jm progressively engages the length of the female part Jf. - Once the necks of the protrusions P have passed through the necks of the corresponding recesses R, the recesses R resiliently spring back and contact the opposite sides of the engaged protrusion P. In this way, the engagement of the parts achieved in a progressive manner similar to that used for sealing plastic bags. Further, the passing of the necks of the protrusions Pm and Pf past the necks of the recesses Rm and Rf produces a snap lock of the male and female parts Jm and Jf.
- To release engaged joints Jm and Jf of panels made from hard rigid materials such as wood, a panel containing the male part Jm is rotated relative to adjacent connected panel to partially disengage the protrusions Pm and Pf from their recesses Rf and Rm. This may be considered as a “dislocation” in similar terms as to that understood for human body joints in that there remains a degree of coupling or engagement but this is not full coupling or engagement. Thereafter a downward force applied to the panel with the female part Jf will result in full disengagement. The amount of force required to achieve the engagement and disengagement of the male and female parts Jm and Jf can be managed by appropriately dimensioning the protrusions P and recesses R.
- For panels made from a pliable material such as vinyl and PVC, or at least having pliable
joint systems 22 simply pulling up along the side having the male part Jm will release the engaged. - As an alternative for any panel materials (e.g. wood based panels and LVT panels), the engaged parts Jm and Jf can be disengaged by sliding one panel relative to another while keeping the pales in the same plane.
- Due to the configuration of the male and female parts Jm and Jf the transverse joint between
panels 10 is able to resist accidental decoupling which at times prevalent with LVT floor panels having different joint systems. The prevalence of this decoupling arises due to LVT floor panels being relatively thin, for example approximately 2-3 mm, and made from plastics material which becomes increasingly pliable as temperature increases. -
FIGS. 9 a-9 d depict a scenario where a force is applied between the sideways joinedpanels FIG. 9 a shows a person stopping quickly on the floor covering with theirshoe 160 contacting thepanel 10 w in a manner so as to apply a lateral force F on thepanel 10 w tending to move thepanel 10 w away from thepanel 10 z. When thepanels 10 are made from a plastics material such as LVT this has the effect of causing deformation and movement of the parts Jm and Jf. This is predominantly manifested by the part Jm rotating slightly in a clockwise direction as well as moving laterally away from thepanel 10 z. This leads to the momentary creation of a gap G between thepanels - Also, as the
panel 10 w is being moved slightly in a direction of the force F the protrusion Pm which abuts the protrusion Pf by virtue of contactingsurfaces joint system 22 is self-supporting because lateral force causes substantially uniform displacement of the recess Rm and the protrusion Pf. - In contrast in other joint systems where a substantive space exists between a feature equivalent to the protrusion Pf and feature equivalent to the recess Rm on an outermost side of the protrusion Pf, the protrusion Pf may be able to pivot into that space which consequentially results in an opening of the recess Rf. This in turn may allow decoupling and separation of the male and female parts Jm and Jf.
- As shown in
FIGS. 9 c and 9 d once theshoe 160 has been lifted from thepanel 10 a and the force F removed, the resilience of the material from which thepanels 10 are made and the inherent structure of thejoint system 22 results in a springing back of the male and female parts Jm and Jf to their normal state. This is facilitated at least in part by the provision of the curved corners of the recess Rm. - The second
joint system 22 can be made with male and female parts of numerous different configurations which nonetheless operate in a substantially identical manner and in particular form a vertical joint system. Example of such male and female parts are described in international application no PCT/AU2012/000280 the contents of which is incorporated herein by way of reference. However several further new configurations will now be disclosed. - The following disclosed
joint systems 22 a-22 d can be applied to panels of various thicknesses (for example 2 mm-20 mm). However some are particularly well suited to very thin panels of a thickness for example of 2-4 mm. Due to material properties and manufacturing techniques the joint systems for very thin panels (e.g. 2-4 mm) are well suited for panels are made from plastics or composite materials such as vinyl, PVC or WPC (although they may still be applied to rigid or hard materials). Such thin panels have manufacturing/commercial benefit in terms of using less material for manufacture and providing greater meterage per container. For example a shipping container can carry twice the meters of say a 3 mm thick flooring panel than 6 mm thick flooring panel. -
FIGS. 10 a-10 c illustrates a further embodiment of a secondjoint system 22 a. In describing thejoint system 22 a features which are the same or equivalent to features in thejoint system 22 will be denoted with the same reference numbers except that for ease of reference the panel on which thesystem 22 a is incorporated will be designated aspanel 10 a. - The
joint system 22 a comprises a male part Jm and a female part Jf. InFIG. 10 the parts Jm and Jf are depicted in an engaged condition and on each of twoseparate panels 10 a. When thejoint system 22 a is incorporated in panels for a lay down flooring system as depicted inFIGS. 1-4 the joints Jm and Jf will be formed on opposite transverse orshort sides 18 of the panel. (However as will be explained in greater detail later in this specification thejoint system 22 a can be used on all four sides of apanel 10 a to produce a true vertical flooring surface covering system similar to those disclosed in aforementioned International application no. PCT/AU2012/000280). -
FIG. 10 a shows the oppositetransverse sides 18 of twoadjacent panels 10 a in a joined condition. Eachpanel 10 a is depicted in two thicknesses, T1 and T2. By way of example only, the thickness T1 may be 4 mm while the thickness T2 may be 5 mm. It will be noted that irrespective of the thickness T1 or T2, the configuration and operation of thejoint system 22 a and in particular the male and female parts Jm and Jf are the same. - The male part Jm has a protrusion Pm and an adjacent inboard recess Rm. The female part Jf has a protrusion Pf and a recess Rf. The parts Jm and Jf are relatively configured so that when engaged at least inner most and outer most locking planes LP1 and LP2 are formed. These locking planes are in substantially the same location as those in the embodiment of the
system 22 depicted inFIG. 8 . It will be further noted that the parts Jm and Jf are non-complimentary or symmetrical so that a plurality of gaps are formed between the parts Jm and Jf when engaged. Thus the male and female parts Jm and Jf ofsystem 22 a (as with the parts Jf and Jm of system 22) do not provide a “form fit”. - A substantive additional feature of the
joint system 22 a in comparison to thesystem 22 is the provision of a femalejoint datum surface 200 that lies parallel to thesurface 12 and is arranged to abut aportion 202 of the male part Jm when the parts Jm and Jf are engaged. Moreover, thedatum surface 200 and the part Jm are relatively configured so that when in abutment, thesurfaces 12 of corresponding joinedpanels 10 a are substantially flush (assuming that thepanels 10 a are laid on a flat substrate or underlying surface). Thus, thedatum surface 200 provides a datum to facilitate joining ofpanels 10 a in a manner so that their respective first major surfaces lie flush with each other. To this end thedatum surface 200 is formed a prescribed and known vertical distance D1 from thesurface 12 of thecorresponding panel 10 a. - The
surface 200, prior to engagement with part Jm, is exposed and extends laterally from an edge of thesurface 12. Thus surface 200 can be directly contacted by aplanar surface 202 formed on the male part Jm when the part Jm is inserted in a direction perpendicular to thesurface 12 into the female part Jf. Thesurface 202 is also a planar surface and lies parallel to thesurface 12 of thepanel 10 a. Thesurface 202 is formed a distance substantially equal to the distance D1 from thesurface 12. By provision of thedatum surface 200 it is not required for the protrusions P to have face to face contact at theirdistal ends flush surfaces 12 across thejoint system 22 a. Nevertheless in thesystem 22 a as shown inFIG. 10 the distal ends of the protrusions Pm and Pf are shown as contacting or immediately adjacent the root surfaces of the recesses Rf and Rm. - The parts Jm and Jf in
system 22 a are provided withplanar surfaces system 22. The common plane of tangency/locking plane LP3 extends at an angle β of 90° with reference to thesurfaces 12 of thepanels 10 a. As previously described however this angle may be varied so that thesurface 114 overlies thesurface 104 to create an overhang that inhibits vertical separation. This is shown more clearly inFIG. 10 a by way of the plane LP3′. This plane is inclined at an angle β′ toward thedatum surface 200. In this instance the plane LP3′ and the correspondingsurfaces - In this embodiment the face to face length SL of the
surface - A further difference between the
system planar surface portion 204 on the surface Cm1 at an intermediate location between thesurface 202 anddistal end 99 of the protrusion Pm. Acontiguous surface portion 208 of Cm1 between theplanar surface 204 and thedistal end 99 remains curved. Accordingly a small nib orpoint 210 is formed on surface Cm1 at the junction of thesurfaces surface 204 may be inclined at an angle γ in the range of 50±30°, or any sub range there between. Nevertheless the protrusion Pm at opposite sides of thedistal end 99 maintains rounded corners. The nib orpoint 210 created by virtue of the provision of theplanar surface 204 may provide greater separation resistance in the vertical direction betweenjoin panels 10 a. - The provision of the
nib 210 may assist in providing greater resistance to vertical separation between the male and female parts Jm and Jf. There is an overhang OH1 of the female part Jf over the male part Jm in a region between thedatum 202 and thenib 210. More particularly, the overhang OH1 is the transverse or lateral distance between: a line perpendicular to thesurface 12 that intersects thenib 210; and, a further line that extends perpendicular to thesurface 12 and is tangent to a lateral most extensive point of the surface Cf1. The overhang OH1 is may range from 4% to 18% (or any sub range within that range) of the thickness of thepanel 10 a for panels with a thickness less than or equal to 6 mm (for example 6 mm, 5 mm, 4 mm, 3.5 mm, 3 mm, 2.8 mm 2.2 mm and 2 mm). - In the male part Jm of
system 22 a the surface profile of the inner most side of the recess Rm is modified by the provision of aplanar surface 212 leading to and comprising a part of the surface Cm2 in the male part Jm. Thesurface 212 is inclined at an angle φ in the range of 50°±20°, or any sub range there between. The part Jf has aplanar surface portion 213 in theconcavity 117 which is also inclined at angle φ and overliessurface 212. Moreover the surfaces Cf2 and Cm2 are arranged to provide an overhang OH2 in the range from 4% to 18% (or any sub range within that range) of the thickness ofpanel 10 a for panels with a thickness less than or equal to 6 mm (for example 6 mm, 5 mm, 4 mm, 3.5 mm, 3 mm, 2.8 mm, 2.2 mm and 2 mm). The overhang OH2 is the lateral overhang of the surface Cf2 over the surface Cm2. - The overhang of the surface Cf2 over Cm2 may also be calculated in terms of the height H1 of the protrusion Pf above the
root surface 96 of the recess Rf. This overhang is designated as the overhang OHp and in this instance is in the order of 30%±10%. - It will also be noticed that the
joint system 22 a is arranged to produce agap 214 between the parts Jm and Jf at a location below thesurface 12 but above thedatum 200. Afurther gap 216 is created between the parts Jm and Jf adjacent the surface Cf1. - In a specific but non limiting example for the
panels 10 a ofFIG. 10 a with a thickness T1 of 4 mm: -
- γ=50°
- φ=50°
- OH1=0.35 mm (=8.75% of T)
- OH2=0.45 mm (=11.25% of T)
- H1=1.53 mm and therefore OHp=0.45 mm (=29% of H1)
- SL=0.36 mm (=9% of T)
-
FIGS. 11 a-11 c depicts a further embodiment of the second (vertical) joint system designated as 22 b. In describing thejoint system 22 b features which are the same or equivalent to features in thejoint system system 22 b is incorporated will be designated aspanel 10 b. Thesecond joints 22 b are particularly well suited for verythin panels 10 b for example in the order of 2-2.2 mm. Such panels may be made of materials such as plastics including vinyl, PVC, bamboo plastic composites, or WPC. - The
system 22 b has a male part Jm comprises a male protrusion Pm and a male recess Rm inboard of the protrusion. The protrusion Pm extends downwardly from thesurface 12 of correspondingpanel 10 b adjacent an outer most edge formed at the junction ofsurfaces surface 14 ofpanel 10 b and an inboard recess Rf. As with the previously described second joints systems, thesystem 22 b can be used on the two opposedtransverse sides sides - The
joint systems joint system 22 b is formed so that the male part Jm hasplanar surfaces joint system 22 a. Due to the relative thinness of thepanel 10 b the angles γ and φ as well as the overhangs OH1, OH2 and OHp are different to those of thejoint system 22 a. Nevertheless the angles γ and φ and overhangs still lie in same range as specified above forsystem 22. This arises from the flattening of the protrusions Pm and Pf and consequential widening of the recesses Rf and Rm to accommodate the reduced material thickness of thepanel 10 b while maintaining vertical grab or decoupling resistance. - In the specific example of a
panel 10 b on whichjoint system 22 b is provided having a thickness T of 2.2 mm: -
- γ=56°
- φ=45°
- OH1=0.2 mm (=9.1% of T)
- OH2=0.19 mm (=8.6% of T)
- H1=0.69 mm and therefore OHp=0.19 mm (=27.5% of H1)
- SL=0.32 mm (=14.5% of T)
- Notwithstanding the provision of the
planar surfaces system 22 b there is at least one rounded corner at locations where the male and female parts contact each other during the engagement process; and gaps between the parts Jm and Jf after full engagement. Moreover each of the protrusions Pm and Pf insystem 22 b are provided with rounded corners on opposite sides of their distal ends. -
FIGS. 12 a-12 c show a further embodiment of a second (vertical) joint system 22 c. In describing the joint system 22 c features which are the same or equivalent to features in thejoint systems panel 10 c. As with the previously described second joints systems, the system 22 c can be used on the two opposedtransverse sides sides - As will be seen from these Figures, the male and female parts Jm and Jf are configured to form an upper gap Gu between the
connected panels 10 c when the respective lowermajor surfaces 14 are co-planar. The upper gap Gu has avisible portion 230 that is visible from theupper surfaces 12 of theconnected panels 10 c. Thevisible portion 230 extends in a lateral direction K parallel to theupper surfaces 12; and also in a downward direction V, from theupper surface 12 toward thelower surface 14. - The gap Gu also includes a second
contiguous portion 232 that extends from thevisible portion 230 to afirst contact region 234 between theconnected panels 10 c. - Thus, when the parts Jm and Jf are engaged with each other the
visible portion 230 of gap Gu will appear along the adjacent sides of the respective joinedpanels 10 c containing the parts Jm and Jf. Accordingly there is no lateral abutment between thepanels 10 c at the mutually facing surfaces ML1 and FL1 along the sides having the joint system 22 c. Thus notwithstanding any coupling forces that may exist between the joints Jm and Jf when engaged with each other, these forces do not bias or urge the corresponding sides of the joined panels together, and more particularly do not cause contact and are not designed to cause contact between the adjoined panels in the vicinity or region of the upper surfaces 12. It should be noted that this effect will also occur when the system 22 c is incorporated on all four sides of a panel to form a full vertical surface covering system. In that event there is in substance no contact in the direction K parallel to thesurfaces 12 between thepanels 10 across an interface where the upper surfaces of the panels lies closest together when the male and female parts Jm and Jf are mutually engaged and lie in mutually coplanar juxtaposition. There is however contact in a perpendicular direction V at least at thecontact region 234. - From
FIG. 12 a it is also evident that the male and female parts Jm and Jf are configured to produce a lower gap GI that extends from thecontact region 234 to, in this embodiment, asecond contact region 238 between the parts Jm and Jf. Thesecond contact region 238 also provides contact in the direction V in the vicinity of theroot surface 96 recess Rf in the female part Jf. - The upper and lower gaps Gu and GI assists in enabling
connected panels 10 c to rotate, one relative to the other, from a coplanar or common laid flat position in both a positive and negative direction up to approximately 3°. More particularly the gaps and the configuration of the joints enables rotation in one direction rotates the upper surfaces toward each other by up to 3′; and rotation in an opposite direction that rotates the lower surfaces toward each other by up to 7°-10°. This rotation may be of greater benefit when the system 22 c is used on all four sides of a panel creating a vertical panel/surface covering system, than when applied only to the transvers sides 18 a, 18 b of a lay down surface covering system. - The upper gap Gu is widest at the
upper surfaces 12 of the twoconnector panels 10 c and reduces in width in the direction V from theupper surface 12 to thelower surface 14. Further, the gap Gu is configured to prevent a direct line of sight LS from theupper surface 12 to thefirst contact region 234 when the gap Gu is viewed from a standing position on thepanels 10 c. The obstructing of the direct line of sight mentioned above is facilitated in the embodiment shown inFIG. 12 a by forming the gap Gu to follow a path such that the direct line of sight impinges on a surface of the side of one of thepanels 10 c at a location intermediate theupper surface 12 and thefirst contact region 234. Indeed this defines thevisible portion 230 of the upper gap Gu. Thesecond portion 232 of the gap Gu extends from this intermediate location to thefirst contact region 234. - The line of sight LS impinges on a surface of the
side 18 b of the female part Jf at a location intermediate theupper surface 12 and thefirst contact region 234. In this embodiment the path of the upper gap Gu is formed with a bend at theintermediate location 240 that prevents a direct line of sight LS from theupper surface 12 to thefirst contact region 234. - The female part Jf has an inner female joint surface FL1 that extends from the
upper surface 12 in a generally downward direction V toward thelower surface 14. The male part Jm has an outer male joint surface ML1 that extends from theupper surface 12 down theside 18 a toward thelower surface 14. The joint surfaces MI1 and FL1 are arranged so that when the male and female parts Jm and Jf are engaged the surfaces FL1 and ML1 face each other and are spaced apart by the upper gap Gu and the lower gap GI. Thus, in the direction K which lies parallel to thesurfaces 12, the surfaces FL1 and ML1 are spaced apart. There is contact between the surfaces FL1 and ML1 however this contact is at the first andsecond contact regions surface 12. - With reference to
FIG. 12 b the inner female joint surface FL1 is composed of a plurality of contiguous surface portions. Afirst portion 246 extends from theupper surface 12 of acorresponding panel 10 c at an obtuse included angle θ and in a general downward direction toward thelower surface 14. A secondcontiguous surface portion 248 extends from thesurface 246 toward thelower surface 14 but at a steeper angle than thefirst surface portion 246. Contiguous with thesecond surface portion 248 is athird surface portion 250. Thesurface portion 250 extends generally toward the male part Jm of connectedsecond panel 10 c and, in this embodiment lies in a substantially horizontal plane. Contiguous with thethird surface portion 250 is afourth surface portion 252 that again extends downwardly toward thelower surface 14 and at an angle substantially parallel to that ofsecond surface portion 248. Thefourth surface portion 252 transitions at an angle of slightly more than 90° to thefirst datum surface 200 that forms part of thefirst contact region 234. Thedatum surface 200 extends in a plane substantially parallel to theupper surface 12. - A distant end of the
datum surface 200 transitions at an angle of about 90° to a fifth surface portion Cf1. The surface Cf1 initially curves in a slightly convex manner to a lateralmost point 257 before smoothly transitioning to a concave curve. This combination of curves forms an inflection in the outer female joint surface FL1 between the first andsecond contact regions surfaces point 257. - With reference to
FIG. 12 c the outer male joint surface ML1 likewise comprises a plurality of contiguous surface portions. Afirst surface portion 258 extends at an obtuse included angle θ from theupper surface 12. This is followed by a contiguoussecond surface 260 that extends in a direction substantially perpendicular to theupper surface 12. This is then followed by athird surface portion 262 that cuts back inwardly into the male part Jm and extends substantially parallel to thesurface portion 250. Athird surface portion 262 leads to afourth surface portion 264 that is inclined at an angle substantially parallel to that of thesurface portion 252 and extends toward thecontact region 234. Thesurface portion 264 turns at an angle of just over 90° todatum surface portion 202. Thesurface portion 202 lies on a plane substantially parallel to theupper surface 12 and is configured to abut with face to face contact with thedatum surface 200. Thesurface 202 transitions to a smoothly curvedconcave surface 268.Surface 268 extends to theplanar surface 204. Theplanar surface 204 meets at an inflexion point ornib 210 with a smoothly curvedconvex surface 208. Thesurface 208 forms a rounded corner of the protrusion Pm and leads todistal end 99 of the protrusion Pm and thesecond contact region 238. Thus the outer male joint surface comprises thesurface portions nib 210. The surface Cm1 comprises thesurfaces - There is no direct line of sight from the
upper surface 12 to the bottom of the gap Gu due to (a) thesurface portion 260 overhanging thesurface portion 250 when viewed in the direction of the line of sight LS; and (b) the juxtaposition and orientation ofsurfaces bend 240. These individually or in combination may be considered as forming the intermediate location where thevisible portion 230 of gap Gu transitions to the contiguous second (invisible)portion 232. It will be further noted that in the direction K (substantially parallel with the upper surface 12) the inner female joint surface FL1 and outer male joint surface ML1 are separated by the upper gap Gu and the lower gap GI. - The
datum surface 200 provides a datum to facilitate the joining ofpanels 10 c in a manner so that theupper surfaces 12 are flush with each other. To this end thedatum surface 200 is formed a prescribed and known vertical distance D1 (shown inFIG. 12 b) from theupper surface 12 of thecorresponding panel 10 c. This sets a thickness of a portion of the male part Jm of thepanel 10 c from thesurface 12 to thesurface 202. By ensuring that these two distances are substantially the same, when thesurface 202 abuts thesurface 200 to form thecontact region 234, surfaces 12 of adjoiningpanels 10 c should be flush with each other. - The inner female joint surface FL1 forms an inside surface of the female recess Rf and transitions in the region of the
second contact area 238 to theroot surface 96. Thesurface 96 has concave roundedcorners upper surface 12. Thecorner 113 transitions to theplanar surface 114 that extends perpendicular to theupper surface 12. Thesurface 114 then leads to a domed distal end surface orhead 116 of the protrusion Pf forming a smooth rounded convex corner Cf3. - The
domed head 116 transitions to an outer female joint surface FL2. The surface FL2 includes a smooth rounded corner Cf2 that is contiguous with thedomed head 116 and a subsequent contiguous concavelycurved surface 270. The curvature and juxtaposition of the surfaces Cf2 and 270 is such to create a small butdistinct transition point 272 there between in theconcavity 117. An end of thesurface 270 nearest thelower surface 14 is formed contiguously with a planar surface 274. The surface 274 extends in a plane perpendicular to theupper surface 12. Thereafter, the outer female joint surface FL2 tapers back into theside 16 via a planar inclined surface 276. The surface 276 subsequently transitions to thelower surface 14. - With reference to
FIG. 12 c the outer male joint surface ML1 forms an outer surface of the male protrusion Pm. Inboard of the protrusion Pm there is formed the male recess Rm. The protrusion Pm extends from theupper surface 12 toward thelower surface 14. Conversely, the recess Rm extends from thelower surface 14 toward theupper surface 12. That is, the protrusion Pm and the recess Rm extends generally in the opposite directions both of which are perpendicular to theupper surface 12. - The
distal end 99 of protrusion Pm is formed with the notch orgroove 98 and has (save for the notch 98) a generally convex shape or configuration. Thedistal end 99 transitions via a smoothrounded surface 103/Cm3 on protrusion Pm toplanar surface 104 extending perpendicular to theupper surface 12. Thesurface 104 transitions to a convexlycurved root surface 92 creating a curved dome like roof of the recess Rm. The concavesurface root surface 92 creates smoothlycurved corners corner 107 transitions to a convexly curved surface Cm3. The curvature of thecorner 107 and surface Cm2 and their juxtaposition are such that at the resultant inflection is not, in this embodiment, smoothly curved but rather is formed with a small nib orpoint 278. The surface Cm2 leads to a shallowconvex surface 280 and subsequently to a planartapered surface 282. Thesurface 282 slopes in a direction inward of thepanel 10 c and terminates at thelower surface 14. - From
FIGS. 12 a-13 b it can be seen that the upper gap Gu extends for a depth D1 from theupper surface 12. The lower gap GI extends for a distance D2 from thefirst contact region 234 to thesecond contact region 238. The depth D1 coincides with the depth of formation of thedatum surface 200 on the female part Jf. This depth also coincides with the perpendicular distance between theupper surface 12 and thesurface 202 on the male part Jm. The distance D2 corresponds with the vertical distance between thedatum surface 200 and the commencement of the horizontal portion of theroot surface 96. - In this embodiment, though it need not necessarily be so, the depth D2 is also the vertical depth of the portion of the male protrusion Pm from the plane of
surface 202 to the commencement of the horizontal portion of thedistal end 99. In this regard in alternate embodiments the straight line or perpendicular distance between thesurface 202 and thedistal end 99 may be D2−Δ where Δ>0 mm; for example Δ=0.2 mm, or 0.5 mm, or 1 mm. In such an arrangement the protrusion Pm will have a depth less than that of the recess Rf so that thedistal end 99 will be spaced from theroot surface 96. - It will also be noted that the actual length of the gaps Gu and GI is greater than the depths D1 and D2 respectively. In the present embodiment this arises due to the gaps Gu and GI following paths that comprise one or more bends; and/or comprise sections that extend in an inclined path relative to the perpendicular of the
panel 10. - Embodiments of the
panel 10 c bearing the joint system 22 c may be provided with various relationships between the D1, D2 and the overall thickness T of thepanel 10. Examples of such relationships are as follows: - In one embodiment the depths D1, D2 and D3 may have a following relationship;
-
- 0.3T≧D1≧0.1T,
- 0.7T≧D2≧0.4T and
- 0.85≧D1+D2≧0.65T
- Further, the
visible portion 230 of the upper gap Gu may extend it to a depth of between 0.4 D1 to 0.8 D1. - The above relationships are exemplary only as to possible ranges and is not intended to limit embodiments to only these ranges. Specifically, the above disclosed ranges are intended to delimit the boundary of these other ranges but to also include any sub-range within the above disclosed ranges. Further this relationship between D1, D2 and T applies to all embodiments having the
datum surface 200 such assystem 22 a. - In one example, T=12 mm, D1=2.26 mm and D2=6.78 mm. However, it is envisaged that the
panel 10 may be made of various thicknesses from about 20 mm for example for a timber or wood based panel, down to at least 2.0-2.2 mm for panels made from for example plastics materials, including vinyl, PVC, bamboo plastic composites and wood plastic composites. - The transverse separation between the inner female joint surface FL1 and outer male joint surface ML1 is a minimum of about 0.1 mm-0.2 mm for panels with a thickness at least in the range of 12 mm to 2 mm inclusive (and any sub range within that range) for example 12 mm, 10 mm, 8 mm, 6 mm, 5 mm, 4 mm, 3.5 mm, 2.8 mm, 2.2 mm and 2 mm. Indeed this separation may also be used for panels having a thickness of up to about 20 mm.
- The male and female parts of the vertical
joint systems system 22 d described later in this specification may each be modified to incorporate an upper gap Gu of the same or similar structure and configuration as that described in relation to the system 22 c. - In each embodiment of the second joint system 22 (i.e.
systems surface 12 and provide resistance to separation of corresponding joinedpanels 10 in planes both perpendicular and parallel to thesurface 12. Thus assuming that thepanel 10 is laid say on a floor, this will provide both horizontal and vertical separation resistance. It should however be recognised that gravity and the weight of thepanel 10 itself also aids in preventing vertical separation. - When the male recess Rm engages the female protrusion Pf there is initially an elastic widening of the recess Rm to enable the surface Cm2 to pass or roll down the surface Cf2. Additionally or alternately, the passage of the protrusion Pf into the recess Rm may be achieved by an elastic compression of the protrusion formed by the surface Cm2 and/or the portion of the protrusion Pf adjacent to surface Cf2. It would be appreciated by those skilled in the art that the engagement process will involve an over centre snap action as a lateral most extensive point of the surface Cm2 passes the laterally most extensive point of surface Cf2. This is accompanied by a relatively rapid seating of the surface Cm2 in the
concavity 117. Simultaneously, theplanar surfaces - As in the
system surfaces lower surface 14 of a corresponding panel where 110°≧β≧90°. - In each of the embodiments of the second system 22 (i.e. 22, 22 a, 22 b and 22 c) the male and female parts Jm and Jf are configured so that when engaged horizontal separation is resisted by the abutment or at least very close positioning of at least the
surfaces joint panels 10 due to the abutment of these surfaces. Vertical separation is also resisted by, in addition to the force required to counteract the action of gravity: (a) the force required to distort or spring open the recess Rm so as to cause the surface Cf2 to ride up and over surface Cm2; and (b) the abutment or eventual abutment (in the event of system 22 c due to gap GI) of the surface Cm1 with the surface Cf1. - Notwithstanding the above, it should also be noted that in some embodiments it is not a requirement for there to be any substantive pressure exerted by the opposite sides of the recess Rm on the protrusion Pf when the parts Jm and Jf are engaged. More specifically in such embodiments, there is no requirement for the coupling to generate a force such as to cause the
upper surfaces 12 of adjoiningpanels 10 to bear against each other to form a gap free continuous surface. - Indeed, such contact is impossible with the embodiment of system 22 c and
panel 10 c due to the provision of the upper gap Gu. Further in system 22 c there is no force generated by engagement of the joints Jm and Jf in any of thesystems 22 that will result in an abutment of the inner female joint surface FL1 and the outer male joint surface ML1 in planes that lie parallel to thesurface 12. The only abutment between the surfaces is in planes that extend perpendicular to thissurface 12 being in theregions - In each of embodiments of the systems 22-22 c, once the parts Jm and Jf are engaged, there is no portion of either part that is maintained in a bent or a partially bent condition relative to its pre-coupling configuration. That is not to say that a portion of a joint may not be under some compression if the opposite sides of the recess do exert some pressure on the protrusion Pm. But compression and bending are very different and result in different effects. It clearly possible and very common for an article to be under compression but not to be bent.
- In the system 22 c the gaps Gu and GI may assists in facilitating a rotational motion of joined
panels 10 c relative to each other. This property may be more useful when the system 22 c is used on all four sides of a panel to form a vertical surface covering system than when used on the transverse ends only for a lay down system as depicted inFIGS. 1-3 . The effect of the rotational motion is depicted inFIGS. 13 a and 13 b. InFIG. 13 a onepanel 10c 2 is shown coupled with apanel 10c 1 but rotated by +α° relative to thepanel 10c 1. The designation of a positive degree of rotation is intended to denote a relative rotation betweenpanels 10 such that theupper surfaces 12 of the panels are rotated toward each other. InFIG. 13 a this is represented by the excluded or outer angle between thesurfaces 12 ofpanels 10 c 1 and 10 c 2 reducing from a common laid flat condition of 180° to 180°−α°. -
FIG. 13 b illustrates rotation in an opposite direction where thepanel 10c 2 is rotated by −φ° relative to thepanel 10c 1. The designation of a negative degree of rotation is intended to denote a relative rotation betweenpanels 10 such that theupper surfaces 12 of the panels are rotated away from each other; or equivalently thelower surfaces 14 are rotated toward each other. InFIG. 14 b this is represented by the excluded or outer angle between thesurfaces 12 ofpanels 10 c 1 and 10 c 2 increasing from a common laid flat condition of 180° to 180°+φ°. - Thus, if the
panels 10 c 1 and 10 c 2 are initially in a common laid flat condition which would correspond to a situation where their respectivelower surfaces 14 are coplanar, the panels can rotate by −α° to +φ° relative to the other from that initial lay flat condition. The maximum of α° and φ° are not the same, rather the maximum of the angle φ° is greater than the maximum of α°. In one example α°≦3° (i.e. α° is up to 3°); while φ°≦7° to 10° (i.e. φ has a maximum, of up to about 7° to 10°). - The ability for the panels to rotate by ±3° (i.e. α=φ=3° is useful to accommodate the laying of panels on undulating or uneven surfaces. The ability for the panel rotate by up to −7° to −10° (i.e. φ=7° to 10°) facilitates decoupling or removal of connected panels particularly for a vertical surface covering system where the system 22 c is used on all sides of a panel (e.g. part Jm on two adjacent sides such as 16 a and 18 a and part Jf on the remaining two
adjacent sides - With reference to
FIG. 13 a, it will be seen that when thepanel 10c 2 is rotated α=+3° relative to thepanel 10c 1, eventually portions of the inner female joint surface FL1 and the outer male joint surface ML1 that were previously spaced by the upper gap Gu come into contact. The pivoting or rotational motion is at least to an extent levered about thefirst contact region 234. As thepanel 10c 1 is rotated in a positive direction there is increased pressure between thedatum surface 200 andoverlying surface 202. As the pivoting action continues eventually thesurface 260 will come into contact and abut thesurface 248 and thesurface 264 will abut thesurface 252. While this is occurring the surface Cf2 will commence to slide up the surface Cm2, and theplanar surface 114 will also slide up along and relative to thesurface 104. However, the sliding motion of the surface Cf2 over the surface Cm2 will terminate prior to the laterally outer most point of Cm2 passing the laterally outer most point of Cf2 thereby maintaining a vertical grab. - With reference to
FIG. 13 b, when thepanel 10c 2 is rotated by φ=−3° the upper gap Gu widens and the inner female joint surface FL1 comes into contact with the outer most male joint surface ML1 at a location below thefirst contact region 234. This is accompanied by a lifting of thedistal end 99 from the root surface of recess Rf. Additionally, the surface Cm2 slides down the surface Cf2 toward thelower surface 14 of thepanel 10c 1. Horizontal separation remains inhibited due to the locating of the protrusions Pm and Pf in the recesses Rf and Rm respectively. Vertical separation is also maintained by action of the engagement of: thesurface 204 with the surface Cf1; and, the surface Cm2 with the surface Cf2. - When the panels are formed with the female and male joints Jm and Jf of any of the second systems 22-22 c extending along each of two sides of a panel such that for example male part Jm along sides 16 a and 18 a and the female part Jf along
sides panel 10 is a true vertical panel and can be installed and withdrawn by motion in a plane perpendicular to thesurface 12. As is understood by those in the art this means that the panels are disposed in an orientation such that theirmajor surfaces major surfaces surfaces - The procedure for engagement and disengagement of panels provided with the second
joint systems - The engagement of the female and male parts Jm and Jf of a plurality of
panels 10 is a particularly simple process. This process is the same irrespective of the material from which the panel is made, e.g. wood, manufactured wood, bamboo, plastics materials or composite materials. The protrusion Pm to be located above and in rough alignment with the recess Rf and consequently for the recess Rm to be located roughly above the protrusion Pf. It should be noted that at this time the panels to be engaged lie either substantially coplanar, or with the panel to be engaged will lie in a slight negative plane with reference to a previously laid panel. This is shown for example inFIGS. 14 p-14 r. - A downward pressure is applied in a direction perpendicular to the
surface 12. This has the effect of springing open the recess Rm temporarily to snap over the protrusion Pf and also temporarily elastically opening the recess Rf to accommodate the protrusion Pm. This results in the panels moving with a combined motion both laterally toward each other and vertically toward each other. This motion is arrested when thesurface 202 abuts thedatum surface 200. This provides a self-flushing feature of thepanel 10 where thesurfaces 12 of the adjoinedpanels 10 should now be flushed with each other on the assumption that thepanels 10 are laid on a flat substrate. (Withsystems datum surface 200, this vertical motion is arrested by thedistal end 99 of protrusion Pm abutting theroot surface 96 of recess Rf.) - Once engaged, no portion of either the male or female parts Jm and Jf will be in a bent condition with reference to its unjoined or disengaged configuration for any of systems 22-22 c. Further, the engagement of the protrusion Pf in the recess Rm does not generate a tension force which brings together the
upper surfaces 12 on thepanels 10 c for system 22 c. Assuming a flat substrate, upper and lower gaps Gu and GI exist between the respective facing surfaces FL1 and ML1 of theconnected panels 10 c. The only contact in this mutually facing region is in a direction perpendicular to thesurface 12 by way of contact betweensurfaces first contact region 234, and between thedistal end 99 androot surface 96 of recess Rf. There is no contact between portions of the surfaces FL1 and ML1 a direction K parallel to thesurface 12. - The process of removal of a damaged panel when the panel is made of a rigid material such as hard wood, bamboo, laminate, HDF or MDF laminate or manufactured wood will now be described with particular reference to
FIGS. 14 a-16 b. (The removal process for panel made of pliable materials such as vinyl and PVC will be described later.) As will become evident from the following description the removal process of a damaged panel relies on the relative rotation enabled between the joined panels by virtue of the configuration of thejoint system 10.FIGS. 14 a-14 s depict in sequence various steps in the removal and replacement of a damaged panel. The removal and replacement is facilitated by use of an extraction system which comprises in combination ajack 300 shown inFIGS. 15 a and 15 b and awedge tool 302 shown inFIGS. 16 a and 16 b. - The
jack 300 is a simple hand screw jack which is applied to a panel being removed. Thescrew jack 300 is provided with an elongated threadedshaft 304 provided at one end with across bar handle 306. The thread of theshaft 304 is engaged within a threadedboss 308 formed centrally on asquare clamp plate 310. Theboss 308 overlies a through hole in theplate 310 through which theshaft 304 can extend. Distributed about theplate 310 are four throughholes 312 for receiving respective fastening screws 314. - The
wedge tool 302 comprises awedging block 316 coupled at one end to ahandle 317. The wedgingblock 316 is formed with abase surface 318 which in use will bear against a surface on which thepanels 10 are installed, and anopposite surface 320 which lies beneath and contacts thelower surface 14 of thepanel 10 adjacent the panel being removed. Thesurface 320 includes the relativelyinclined portion 322 and aland 324 that lies parallel to thebase surface 318. Theinclined portion 322 extends from aleading edge 326 of thewedge block 316 toward thehandle 317. Thehandle 317 is bent intermediate of its length and has afree end 330. Notwithstanding the bend thehandle 317 lies in a plane through a line of symmetry of thewedge block 316. -
FIG. 14 a depicts an area of flooring including a damagedpanel 10 w which is connected along each side withadjacent panels 10v v panels 10 have a male part Jm along one longitudinal side and one short or transverse side; and a female part Jf along the other longitudinal side and the other short or transverse side. - In order to replace the damaged
panel 10 w, a drill 350 (seeFIG. 14 d) is used to drill ahole 352 through thepanel 10 w for eachjack 300 used in the extraction process. As illustrated inFIGS. 14 c-14 k eachhole 352 is formed along a longitudinal centre line of thepanel 10 w. Thehole 352 is formed of a diameter sufficient to enable the passage ofshaft 304. The length of thepanel 10 w being removed dictates the number ofjacks 300 that may be required. Thus in some instances, extraction can be effected by the use of onejack 300 whereas others may require two or more jacks. In this particular instance twojacks 300 are used as shown inFIG. 14 c, but for ease of description the extraction process refers to only one of thejacks 300. - Upon completion of the
hole 352, theclamp plate 310 is placed on thepanel 10 w with itsboss 308 overlying thehole 352 hole as shown inFIG. 14 e. Theplate 310 is fixed to thepanel 10 w by way of the four self-tappingscrews 314 that pass through correspondingholes 312. This is illustrated inFIG. 14 f. The screws may be screwed in by using a screw bit in place of the drill bit in thedrill 350; or by using a manual screwdriver. - The next stage in the removal process is shown in
FIGS. 14 g and 14 h involves engaging theshaft 304 with the threadedboss 308 and then screwing down theshaft 304 by use of thehandle 306 to lift thepanel 10 w aboveunderlying surface 354. It should be immediately recognised that this action requires the relative rotation negative rotation described above with reference toFIG. 13 b. Although, as will be explained shortly the negative rotation goes beyond the 3° ofFIG. 13 b and to about 7° to 10°. The negative rotation relative topanel 10 w and is experienced bypanels 10v v panels panels 10v v panel 10 w. - The
jack 300 is operated to lift the damagedpanel 10 w vertically upward by a distance sufficient to effect a negative rotation between the damagedpanel 10 w and the adjacent adjoining panels. During this lifting thepanel 10 w, as depicted in the Figures, remains parallel to its original connected condition where it lays flat on thesurface 354. The negative rotation is in the order of 7°-10°. This is explained with particular reference toFIG. 14 h which shows an angle θ1=180+φ between theupper surfaces 12 ofpanels 10v panels 10 v) and 10 w; and an angle θ2=180+φ betweenupper surfaces 12 ofpanels 10 w and ofpanels 10 x 1 and 10 x 2 (hereinafter referred to collectively aspanels 10 x). Prior to lifting of thepanel 10 w, it should be understood that the angles θ1 and θ2 will be 180° assuming that thesurface 354 is flat. Further as is evident from the Figures during the lifting θ1=θ2. Indeed this follows from thepanel 10 w being lifted vertically as distinct from being lifted at an angle or inclined disposition relative to thesurface 354. The amount by which the angles θ1 and θ2 exceed 180° during the disengagement is equated to the angle φ° of negative rotation of the panels during this process. For example if angle θ1 (and thus θ2) is say 187° then the relative negative rotation betweenpanels - It will be understood by those skilled in the art that vertically raising of any prior art system having a lateral projection (e.g. a tongue) that seats in a groove or recess of an adjacent panel is virtually impossible without breaking the tongue or fracturing the panel with the groove. Thus this action if attempted with a prior art system is very likely to result in the damaging (for example fracturing of the tongue) of one more panels which were not previously damaged or in need of replacement.
- The ability for the
panels 10 to be removed by vertical lifting is a direct result and consequence of the configuration of the parts Jm and Jf. It will also be recognised by those skilled in the art that the relative movement betweenpanels 10 being disengaged is directly opposite that of “lay-down” tongue and groove panels; and even then such systems can only be disengaged where the disengaged panel already has one free longitudinal side that is not connected to an adjacent panel. Embodiments of thepresent panel 10 and male and female engaging parts Jm and Jf provide the ability to disengage a panel connected on all four sides with other panels without damaging those panels by virtue of this vertical lifting. Further the repair of a floor can now be achieved in a world's best practice manner fully reinstating the integrity of the floor without the need to peel back the entire floor from one wall to the damaged panel(s), and/or hire a professional installer. - The
jack 300 mechanically lifts and self supports thepanel 10 w and allother panels 10 connected to it. Thus the installer does not need to rely on their own strength to lift and hold the panels. In contrast some prior art systems use suction cups for example as used by glaziers to hold glass sheets to grip a panel to be removed. The installer must then use their strength to lift the panel. While this is difficult enough it becomes impossible if the panel is also glued to thesurface 354. Thejack 300 which provides a mechanical advantage is able to operate in these circumstances. In addition as the jack self supports thepanels 10 the installer is free to use both hands in the repair process and indeed is free to walk away from the immediate vicinity of thepanel 10 b. - The
jack 300 is operated to lift thepanel 10 w vertically upwards to a location where the negative rotation between thepanel 10 w andadjacent panels FIGS. 14 h and 17 d. In this position, there is partial dislocation of the parts Jm and Jf betweenpanels FIG. 17 d this partial dislocation arises from the surface Cm1 riding along surface Cf1 with thepoint 210 snapping past a laterally mostextensive point 257 on the surface Cf1. Notwithstanding this dislocation the panels remain engaged due to the pinching of protrusion Pf between opposite surfaces of the recess Rm. - The
jack 300 can be provided with a scale to give an installer an indication of the when the negative rotation is in the order of 7° to 10°. The scale could comprise for example a coloured band on theshaft 304 which becomes visible above theboss 308 when shank has been screwed down to lift the panel sufficiently to create the above mentioned negative rotation. Several bands could be provided on the shank for panels of different thickness. - In
order disengage panel 10 w one must first disengage whichever of thepanels panel 10 w. In this instance this ispanel 10 v. Working above thepanels 10 an installer will not immediately know that it ispanel 10 v. But this can be easily determined by either: lightly tapping on bothpanels panel 10 w fully disengaging in the vicinity of the tapping. Thereafter as shown inFIG. 14 i, applying a downward force or pressure on thepanel 10 w at other locations along its length will result in a total disengagement of parts Jm and Jf on thepanels - The interaction between the respective surfaces on the parts Jm and Jf on the
panels FIG. 14 f to the point of disengagement shown inFIG. 14 i will be described in more detail with reference toFIGS. 17 a-17 e. -
FIG. 17 a illustrates thepanels jack 300. This equates with the relative juxtaposition of the panels shown inFIGS. 14 a, 14 b, and 14 d-14 g. As thejack 300 is operated to progressively lift thepanel 10 w from thesurface 354, there is a gradual rotation between the respective parts Jm and Jf.FIG. 17 b illustrates the part Jm ofpanel 10 w and part Jf ofpanel 10 v at relative rotation of approximately −2°. Here the upper gap Gu commences to open up and the recess Rm rotates about the domed head of the protrusion Pf. This has the effect of sliding thesurface 104 in a generally upward direction alongsurface 114 and the surface Cm2 riding down and pressing harder against surface Cf2. Thus as this part of the disengagement proceeds there is increased compression on or pinching of the protrusion Pf. The rotational freedom to move in this manner is facilitated at least in part by the lower gap GI between the inner female joint surface FL1 and the outer male joint surface ML1. Also this rotation is now pivoted in the contact region of surface Cm2 and Cf2. -
FIG. 17 c shows the effect of continued lifting of thepanel 10 w to a position where the relative negative rotation between thepanels lower contact regions distal end surface 99 is lifted from theroot surface 96. Thesurface 104 continues to ride upsurface 114 there is increased pressure exerted by surface Cm2 on surface Cf2. Moreover because the protrusion Pm now contacts the opposite surfaces of the recess Rf not only is there compression in the protrusion Pf, there is also compression in the protrusion Pm. Indeed there is increased tension and pressure along a “line” 360 containing contact points between the surfaces MI1 and FL1; 104 and 114; and Cm2 and Cf2. - Continued operation of the
jack 300 increases the angle between thepanels FIG. 17 d. At this point, thepoint 210 has elevated up past the lateral most point 57 on surface Cf1/FL1. This releases some of the tension in theconnected panels 10 at the parts Jm and Jf and would ordinarily be indicated to the installer by an audible “clunk”. However the protrusion Pf remains compressed or pinched on opposite sides by the recess Rm. Thus while at this −7° disposition, the parts Jm and Jf are still partially engaged and in the absence of any external force, maintain vertical and horizontal locking of thepanels - The application of a downward pressure or force on the
panel 10 v results in one or both of: compressing the protrusion Pf; or, opening of the recess Rm to enable the protrusion Pf to escape the recess Rm. Now thepanel 10 v is free to fall back to thesurface 354 as shown inFIG. 17 f andFIG. 14 i. Thus at this point in time thepanels - However removal of the
panel 10 w also requires disengagement of the part Jf ofpanel 10 w from the part Jm ofpanel 10 x. This process is shown inFIGS. 14 j to 14 l. - Immediately after disengagement of
panels panel 10 w is held abovesurface 354 by thejack 300. To continue the replacement process thepanel 10 w is lowered back to thesurface 354 by unscrewingshaft 304 from theboss 308 of theclamp plate 310. An installer next grips and lifts the joint Jm ofpanel 10 w to insert thewedge tool 302 between the disengaged joints of thepanels land 324 ofsurface 320 is in contact with themajor surface 14 ofpanel 10 x and inside of the joints Jm and Jf. This is shown inFIG. 14 j. - Disengagement of the
panel 10 w from thepanel 10 x is now effected by initially rotating thepanel 10 x 10 w by about −7° to −10° to effect a disengagement of the surface Cm1 ofpanel 10 x from the surface Cf1 in the joint Jf ofpanel 10 w. Thewedge tool 302 is configured to assists the installer in achieving this rotation. This is also depicted inFIG. 14 j. Moreover when thewedge block 316 is under theunder panel 10 x slightly inboard of its joint Jm, and thepanel 10 w is rotated in the anti-clockwise direction toward thehandle 317, thepanel 10 w will rotate or pivot by 7° to 10° prior to or by the time it abuts thehandle 317. The reaching of this position is ordinarily denoted by an audible “clunk” as the surface Cm1 passes from below to above surface Cf1. This juxtaposition of the joints Jm and Jf is as shown inFIG. 17 d. - Subsequent application of downward pressure or force for example by way of rubber mallet M or pushing by hand as shown in
FIG. 14 k will result in total disengagement of the joints Jf and Jm ofpanels FIG. 14 i. Now the damagedpanel 10 w is totally disengaged from bothadjacent panels - To replace the damaged
panel 10 w with anew panel 10w 1 an installer now removes thewedge tool 302, lifts the edge ofpanel 10 x by hand and slides anew panel 10w 1 beneath the raisedpanel 10 x so that the joint Jm lies above the joint Jf. The opposite side ofpanel 10w 1 rests on panel 12 a. This sequence of events is shown inFIGS. 14 m-14 p. - The installer now lowers the
panel 10 x onto thepanel 10w 1. When this occurs, the male joint Jm ofpanel 10 x rests on theneck 120 of female joint Jf ofpanel 10 wi; and the joint Jm ofpanel 10w 1 will rest on theneck 120 of the joint Jf of previously laidpanel 10 v. This is shown inFIG. 14 q. - To fully engage the
panel 10w 1 downward force or pressure is applied on the male joints Jm ofpanels w 1. This can be done in either order, i.e.panel 10 x thenpanel 10w 1 orpanel 10w 1 thenpanel 10 x.FIG. 14 q shows the configuration when joint Jm ofpanel 10 x is first engaged with joint Jf ofpanel 10w 1.FIG. 14 r depicts the joint Jm ofpanel 10w 1 now engaged with joint Jf ofpanel 10 v, reinstating the floor as shown inFIG. 14 s. - It should be understood that the force described in the previous paragraph for engaging
panels 10w panels 10. While this occurs a first length of the panels is fully engaged while a second length is fully disengaged. Progressively the first length increase and the second length decreases until the full length of the panels is engaged. This is different to the process of engaging a tongue and groove joint in a lay down system where generally the full length of a tongue must be fully located in a groove before the laying down of the panel with the tongue can occur. This can become problematic when engaging long panels as there are often some panels which are bowed or otherwise of imperfect manufacture which requires several installers to push, tap and wriggle the full length of the tongue in the groove before lying down. - When the panels are made of a plastics or composite material such as vinyl and PVC the removal process is much simpler and does not require the
jack 300 orwedge tool 302. Rather all that is needed is a box cutter or Stanley knife to cut a corner of the aconnected panel 10, lift up the cut corner to create an access hole, then insert ones fingers into the hole and pull up the panel to progressively disengage the engaged parts Jm and Jf. However one difference with in this process is that due to the flexibility and pliability of the panels and/or the male and female parts, the angle between joined panels to effect disengagement is higher, for example 10°-40°. Indeed the presently disclosed vertical joints system is adaptable as described later and shown inFIG. 18 to deliberately require the much higher relative angle between engaged panels to effect disengagement for pliable/plastics panels. -
FIGS. 14 t-14 x depict a sequence of steps for replacing apanel 10 w made from a plastics material and having one of the joint systems 22-22 c on all four sides and thus forming a true vertical system.FIG. 14 t depicts a floor composed of a plurality of panels in which onepanel 10 w sustains surface damage D. All of the panels are formed with the same vertical joint system (one of systems 22-22 c). - To replace the
panel 10 w a box cutter orStanley knife 430 is used to cut and remove a small corner piece of thepanel 10 w.FIG. 14 v depicts apanel 10 w with acut corner 432. Indeed this Figure depicts the cut corner being pulled upwardly from the remainder of the floor. When the corner ofpanel 10 w has been cut and removed, a person can insert a number of fingers through an access hole formed by the removal of the corner. With the fingers laying underneath thepanel 10 w a person can now exert upward pressure so as to progressively disengage the parts Jm and Jf of adjoining panels. When this is done, thepanel 10 w can be removed leaving a void 434 as shown inFIG. 14 w. -
FIG. 14 x illustrates afresh panel 10w 1 being inserted into thevoid 434. When inserting thefresh panel 10w 1adjacent panels 10v adjacent panel 10 z) are lifted to enable the female part Jf along two adjacent sides of thepanel 10 w to lie beneath the male parts Jm of thepanels 10v v panel 10 w is orientated so that its parts Jm on its two other adjacent sides lie immediately above the parts Jf ofadjacent panels 10 x 1, 10 x 2 and 10 y. Thereafter, as shown inFIG. 14 y, in order to reinstate the floor to its original condition downward pressure is applied along the overlying parts Jm and Jf so as to re-engage thepanel 10w 1 with each of the six adjacent joiningpanels 10 x 1, 10 x 2, 10 y, 10v v -
FIG. 18 shows an embodiment of a verticaljoint system 22 d specifically adapted for use with panels made from plastics or otherwise pliable materials including but not limited to vinyl, PVC, the material of herein before disclosed U.S. Pat. No. 8,156,710, and pliable plastic composites. Thesystem 22 d can be used (a) on two sides for a lay down surface covering system (b) on all four side of a rectangular/square true vertical surface covering system.FIG. 18 shows thesystem 22 d for two different panel thickness T1 an T2 which for example may be 4 mm and 5 mm respectively, although the panel is not limited to these thicknesses and may for example have a thickness of 12 mm to 2 mm. - The
system 22 d differs fromsystem 22 a only in the configuration of the part Jm in the region of thesurfaces panels 10 d to come into contact with each other in the vicinity ofsurfaces - In the
system 22 d for the part Jf theconcavity 117 below the surface Cf2 curves inwardly to an innermost point 400 then curves outwardly to aplanar surface 118 that is perpendicular to surface 14. Thesurface 118 lies inboard of the lateral outermost point of the surface Cf2. For a panel thickness T1 thesurface 118 leads directly tomajor surface 14. But for a panel of thickness T2 thesurface 118 leads to a shortinclined surface 119 and then directly tosurface 14. - In the part Jm below the surface Cm2 there is a
concave recess 402 which then leads to aplanar surface 404. Thesurface 404 is perpendicular to themajor surface 14. Thesurface 404 lies inboard of the lateral outermost point of the surface Cf2. For a panel thickness T1 thesurface 404 leads directly tomajor surface 14. However for a panel of thickness T2 thesurface 404 leads to a shortinclined surface 110 which then leads directly tosurface 14. - The
surface 118 from part of the outer most female locking surface FL2. Thesurface 404 forms part of the inner most male locking surface ML2. - Irrespective of the panel thickness T1 or T2 the
surfaces small gap 406. For a panel of thickness from 5 mm to 2 mm thegap 406 may be up to from 0.02 m to 0.2 mm. The idea here is that thesurfaces panels 10 d or bending of an individual panel. This contact will set up internal forces within the joinedpanels 10 d that assist in reducing the likelihood of peaking and gapping at theupper surface 12 and vertical separation of the engaged parts Jm and Jf ofpanels 10 d. - The above effect is illustrated in
FIGS. 19 a-20 c.FIGS. 19 a-19 c depict a prior art “drop lock” which is often used in laydown systems to facilitate engagement of the short or transverse sides of twopanels 10 u. The drop lock comprises male andfemale hook parts panels 10 u. Themale hook 440 fits inside thefemale hook 442 with resistance to vertical motion being provided mainly by way of a compression fit between thehook parts panels 10 u against vertical separation. -
FIG. 19 a depicts the drop lock whengood quality panels 10 u are laid on a well prepared underlying surface or substrate and there is no peaking between thepanels 10 u at their short sides which contain thehook parts -
FIG. 19 b however depicts the scenario when peaking occurs. The peaking may occur for various reasons including: poor manufacturing quality which may arise for example for from use of recycled floor materials or the emission of stabilising layers within the substrate; uneven loading on the surface formed by thepanels 10 u, for example by reason of the dragging of heavy furniture or equipment; thermal expansion in hot weather conditions; or poor quality underlying substrate. - When peaking occurs, the transverse sides of the
panels 10 u which contain theparts hook parts parts surface 447 of thepart 440 contacts a surface 449 ofpart 442. Due to the substantial gap between these surfaces when the parts are in their designed engaged juxtaposition shown inFIG. 19 a the degree of peaking may be relatively substantial. This is illustrated in particular inFIG. 19 c which depicts that engagement is now essentially only at three spaced apart point locations 446 a, 446 b and 446 c. As a result, the compression forces between thepanels 10 u which generate friction opposing the vertical separation of theparts panel 10 u having the illustratedfemale hook part 442 in the downward direction is illustrated byarrow 448 may result in a separation of the entirety of the joint between thepanels 10 u. -
FIGS. 20 a-20 c depict a similar scenario wherepanels 10 d are connected utilising thejoint system 22 d. ThusFIG. 20 a depicts thejoint panels 10 d in an ideal situation.FIG. 20 b depicts the effect of peaking. This is shown in an enlarged form inFIG. 20 c. The abutment ofsurfaces particular locations surface surfaces panels 10 d maintain very effective grip between each other and substantially reduces any substantive opening of the recesses Rm and Rf. Such an opening may otherwise occur if it were not for the abutment ofsurfaces panels 10 d would be able to otherwise rotate further prior to contact. - As a result of the above in order to disengage the joined parts Jm and Jf of
system 22 d in plastics or pliable panels a greater degree of angular offset or rotation between joinedpanels 10 d is required than the 7°-10° described in relation toFIGS. 14 a-14 s. This is because the properties of the material form which thepanel 10 d is made can accommodate a high degree of angular offset or rotation without causing disengagement. Of course this is a positive feature because it is this that provides the advantages of thesystem 22 d over the prior art in terms of unintended disengagement during peaking. - The above described modifications to the in the configuration of the part Jm in the region of the
surfaces system 22 a to arrive at thesystem 22 b may also be applied to each of thesystems - Referring back to
FIG. 2 it is common for surface covering panels to be made with a length to width ratio of about 1:6 to 1:8 (i.e. ratio of length ofside 16 to length of side 18). Thus for example a panel with of a length (i.e. side 16) of say 1200 mm may have a width (i.e. side 18) 150 mm (ratio 1:8) to 200 mm (ratio 1:6). In the lay down configuration the tongue andgroove system 20 is invariable along thelongitudinal sides 16 while thevertical system 22 is along the shortertransverse sides 18. Due to the brick bonding (i.e. staggered) laying pattern the short sides are not, particularly in the prior art, required to provide substantial vertical separation resistance. This resistance being predominately provided by the tongue and groove ofsystem 20 on the longitudinal sides. As such in the prior art vertical resistance can be provided on the short sides by way of say a compression fitting or joint. - Various companies manufacture proprietary clips to provide engagement of flooring panels. The company Välinge licenses a developed clip (known as the “5G” clip) that is inserted into one of the short side and is arranged to engage an opposite short side of another panel. This provides a mechanical joint or engagement that gives very good vertical separation resistance. Such clips can be used in wood based, plastics or composite material panels. Nevertheless the inclusion of this or other types of clips does add to manufacturing costs. The clips can be inserted by a dedicated machine that can be bolted onto one specific manufacture's profiling machine. For manufacturers that use other profiling machines the clips by and large are inserted by hand. Also at times the clips can dislodge during transport of panels and either need to be re-inserted manually at the point of use; or simply left missing thus degrading the quality of the engagement. Another drawback of such clips is that they often become damaged during disengagement of panels.
- To provide context to this discussion it is estimated that about 275 million square meters of flooring with this type of clip is manufactured each year. Thus having a joint system, particularly, though not limited to use, for the transverse sides of a lay down surface covering system that avoids the costs of the clip and its insertion as well as being able to be engaged and disengaged multiple time without damage or degradation of quality of the engagement provides massive benefits to manufacturers, retailers and consumers.
- The vertical system 22-22 d provide an integrated (i.e. formed as one piece with the panels 10) mechanical locking system for
panels 10. The mechanical locking provided by the overhanging surfaces of parts Jm and Jf enables panels to be manufacture in previously unavailable sizes and configuration such as 1 m×1 m tiles or panels of length to width ratio of less than 1:6 to 1:1; for example 1:5 to 1:1 or 1:4 to 1:1 or 1:2 to 1:1. This is the case even for laydown systems where the joint 22-22 d is only on two opposed sides (with the tongue and groove on the other two sides). - Embodiments of the above described
panels 10 particularly when having joint systems 22-22 d on all sides (thus forming a true vertical surface covering system) are also well suited to application of a pre-laid re-stickable flexible adhesive to provide the benefits of a direct stick flooring system while avoiding their disadvantages. The expression “re-stickable adhesive” throughout the specification and claims is intended to mean adhesive which is capable of being able to be removed and re-adhered, does not set or cure to a solid rigid mass and maintains long term (e.g. many years) characteristics of flexibility, elasticity and stickiness. The characteristic of being re-stickable is intended to mean that the adhesive when applied to a second surface can be subsequently removed by application of a pulling or shearing force and can subsequently be reapplied (for example up to ten times) without substantive reduction in the strength of the subsequent adhesive bond. Thus the adhesive provides a removable or non-permanent fixing. The characteristics of flexibility and elasticity require that the adhesive does not solidify, harden or cure but rather maintains a degree of flexibility, resilience and elasticity. Such adhesives are generally known as fugitive or “booger” glues and pressure sensitive hot melt glues. Examples of commercially available adhesives which may be incorporated in embodiments of the present invention includes, but are not limited to: SCOTCH-WELD™ Low Melt Gummy Glue; and GLUE DOTS™ from Glue Dots International of Wisconsin. - Others have in the past used glues to adhere flooring panels to an underlying surface or substrate. In particular adhesives have been used to glue wooden floor boards to an underlying surface. However to the best of the inventor's knowledge, all such systems use glues which are specifically designed to set or cure to a solid unyielding bonded layer. In the art of timber or wooden flooring, this is known as “direct stick” flooring. Some have proposed to utilize adhesives which take up to an hour or two to set or cure to enable installers to move the flooring panels during installation to ensure correct alignment. Indeed others propose using adhesives which may take up to 28 days to fully cure or harden.
- Some consumers prefer direct stick flooring to floating flooring as it provides a harder more solid feel and significantly does not provide bounce when being walked on and does not generate noise such as creaking or squeaking. A disadvantage however of the direct stick flooring is that it is very messy to apply, and once the adhesive has cured, which it is specifically designed to do, removal and/or repair of one or more damaged panels is problematic. The removal of a direct stick panel generally requires the use of power tools to initially cut through a section of the panel, and then much hard labour in scraping the remainder of the plank and adhesive from the underlying subsurface. This generates substantial dust and noise and of course usually comes at substantial expense due to the associated time required.
- Use of the re-stickable adhesive as described hereinabove with the
panels 10 provides a semi-floating surface covering system having the benefits of both traditional floating surface coverings and direct stick coverings but without the substantial disadvantages of direct stick surface coverings. Specifically, the use of the re-stickable adhesive eliminates bounce and noise often found with conventional floating flooring, but still provides a degree of cushioning due to the flexible and elastic characteristics of the adhesive which does not set or cure. Further the characteristics of the adhesive also enable movement ofpanels 10 due to changes in environmental condition such as temperature and humidity. This is not possible with direct stick flooring. Indeed recently, the world market has been having problems with direct sticking of compressed bamboo substrates due to the completely rigid and inflexible bond created by the traditional adhesives. Accordingly, should the compressed bamboo need to move or expand due to variations in environmental conditions it is restricted from doing so by the direct stick adhesive. Consequently it has been suggested by multiple flooring associations around the world that compressed bamboo should not be direct stuck to substrates but limited to application in floating floor systems which enable it to move in response to dynamic seasonal changes. - The benefits and advantages of the use of re-stickable adhesive as herein before described in their own right give rise to a floor covering systems comprising substrates which may be tessellated and on which the adhesive is applied. Such systems do not necessarily require the tongue and groove or vertical joints systems of the type described hereinabove and may also be used with other types of joints systems. Indeed in certain circumstances, it is believed that the re-stickable adhesive concept gives rise to a surface covering system with joint-less substrates. Thus in one embodiment there would be provided a semi-floating surface covering system which comprises a plurality of substrates each substrate having first and second opposite major surfaces, the first major surface arranged to lie parallel to and face a surface to be covered; a quantity of re-stickable adhesive as herein before described bonded to the first major surface; and one or more release strips covering the removal adhesive.
- The tackiness/holding strength of adhesive material need only be sufficient to prevent lifting or separation between the
panel 10 and from the underlying surface under normal use conditions while enabling removal of a panel if required (for example to repair a floor) with use of a simply tool such as a lever. The idea here is to not hold thepanel 10 down so hard that it cannot be removed in one piece and/or without the use of a power tool. - All such modifications and variations together with others that would be obvious to persons of ordinary skill in the art are deemed to be within the scope of the present invention the nature of which is to be determined from the above description and the appended claims.
Claims (22)
1.-63. (canceled)
64. A surface covering panel comprising:
a first major surface and an opposite second major surface that in use lies on or faces a support;
first and second edges that lie between the first and second major surfaces;
male and female parts that extend along the first and second edges respectively, the male and female parts being configured to enable two like panels to connect to each other with the male part of one panel engaging with the female part of a second panel in a manner to resist separation of the connected panels in a plane parallel to the first major surface and in a plane perpendicular to the first major surface;
wherein the female part has a recess adjacent to the first major surface and a protrusion spaced from the first major surface toward the first edge by the recess, and an innermost female locking surface on the recess extending from the first major surface to a base of the recess, the recess surface having a datum surface lying parallel to the first major surface;
wherein the male part has a protrusion adjacent the first major surface and a recess inboard of the protrusion, and an outermost male locking surface on the protrusion extending from the first major surface toward the second major surface; and
wherein the male and female parts are further configured so that the when the male and female parts of like panels are engaged, an intermediate portion of the outermost male locking surface abuts the datum surface, and respective portions of the innermost female locking surface and the outermost male locking surface from the datum surface to the recess base are spaced from each other.
65. The surface covering panel according to claim 64 , wherein the male and female parts form a vertical joint system, and wherein the male and female parts are configured to enable mutual engagement in response to a force applied in an engagement direction which is substantially perpendicular to the major surfaces, the male part having a male recess and the female part having a female protrusion.
66. The surface covering panel according to claim 65 , wherein the male and female parts are further relatively configured such that when in a joined condition one of the parts overhangs the other of the parts about each of a first locking plane that passes through an outermost side of the male protrusion and a second locking plane that passes through an outermost side of the female protrusion, each of the first and second locking planes being perpendicular to the major surfaces
67. The surface covering panel according to claim 66 , wherein the male part is provided with an innermost male locking surface on its male recess and the female part is provided with an outermost female locking surface on its male protrusion, the innermost male locking surface and the outermost female locking surface being arranged to engage to create the second locking plane.
68. The surface covering panel according to claim 67 wherein the outermost female locking surface comprises a convexly curved portion that overhangs a convexly curved portion of the inner most male locking surface.
69. The surface covering panel according to claim 68 , wherein the innermost male locking surface and the outermost female locking surface are each provided with a respective planar surface portion located between respective convex curved portions and a common major surface, the respective planar surface portions being parallel to each other when male and female parts are in the joined condition and juxtaposed with the first major surfaces parallel to each other.
70. The surface covering panel according to claim 69 , wherein the planar surface portion of the innermost male locking surface lies inboard of a lateral most point on the convex curved portion of the innermost male locking surface.
71. The surface covering panel according to claim 70 , wherein the planar surface portion of the outer most female locking surface lies inboard of a lateral most point on the convex curved portion of the outermost female locking surface.
72. The surface covering panel according to claim 69 , wherein the respective parallel planar surface portions are spaced apart by a distance of between 0.02 mm and 0.2 mm inclusive.
73. The surface covering panel according to claim 64 , wherein the male and female parts are further configured to form an upper gap between two connected panels when the second major surfaces of the two panels are coplanar, the upper gap comprising a visible portion that is visible at the first major surfaces of two connected panels and extends both in a direction parallel to the first major surfaces and in a direction from the first surface towards the second major surface and a second contiguous portion that extends from the visible portion to a first contact region between the connected panels, the first contact region comprising the datum surface.
74. The surface covering panel to claim 73 , wherein the visible portion of the gap is widest at the first major surfaces of two connected panels and reduces in width in the direction from the first major surface towards the second major surface.
75. The surface covering panel according to claim 73 , wherein the gap is configured to prevent a direct line of sight from the first major surface to the first contact region when the gap is viewed from a standing position on the panels.
76. The surface covering panel according to claim 73 , wherein the gap follows a path of a configuration such that a direct line of sight impinges a surface of the first or second panel at a location intermediate of the first major surfaces and the first contact region; wherein the visible portion of the gap extends from the first major surface to the intermediate location and the second portion extends from the intermediate location to the first contact region.
77. The surface covering panel according to claim 76 , wherein the path comprises a bend at an intermediate location, wherein the visible portion of the gap extends from the first major surfaces to the bend and the bend prevents the direct line of sight from the first major surface to the first contact region.
78. The surface covering panel according to claim 77 , wherein the bend is created by a surface portion one of the male and female parts that overlies a surface portion of the other of the male and female parts in a plane lying perpendicular to the first major surfaces.
79. The surface covering panel according to claim 77 , wherein the innermost female locking surface comprises an inner surface having a first surface portion extending from the upper surface at an obtuse included angle, a second contiguous surface portion extending toward the lower major surface at a steeper angle than the first surface portion, and a contiguous third surface portion that extends toward the second part of a connected second panel.
80. The surface covering panel according to claim 79 , wherein the innermost female locking surface comprises a fourth surface portion that extends between the third surface portion and the first contact region.
81. The surface covering panel according to claim 76 , wherein the path is a linear path that is inclined at an acute angle relative to the first major surfaces, the acute angle being arranged so that a direct line of sight impinges the surface of the first or second panel at the intermediate location, wherein the visible portion of the gap extends from the first major surfaces to the intermediate location and the second portion extends from the intermediate location to the first contact region.
82. The surface covering panel according to claim 73 , wherein the upper gap extends to a depth D1 measured perpendicular from the first major surface of a panel wherein: 0.3T≧D1≧0.1 T, where T is the thickness of the panel measured perpendicular to the first major surface.
83. The surface covering panel according to claim 82 , wherein the visible part of the upper gap extends to a depth of between 0.4 D1 to 0.8 D1.
84. The surface covering panel according to claim 64 , wherein the male and female parts are configured so that when two like panels are connected to each other with the male part of one panel engaging with the female part, and an upward motion is induced on the engaged parts, the male and female parts compress against each other at four spaced locations.
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
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AU2012904096A AU2012904096A0 (en) | 2012-09-19 | A Panel for a Flooring System | |
AU2012904096 | 2012-09-19 | ||
AU2012904235 | 2012-09-27 | ||
AU2012904235A AU2012904235A0 (en) | 2012-09-27 | A Panel for a Flooring System | |
PCT/AU2013/001073 WO2014043756A1 (en) | 2012-09-19 | 2013-09-19 | A panel for covering a surface or support and an associated joint system |
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Application Number | Title | Priority Date | Filing Date |
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PCT/AU2013/001073 A-371-Of-International WO2014043756A1 (en) | 2012-09-19 | 2013-09-19 | A panel for covering a surface or support and an associated joint system |
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US15/450,730 Continuation US9885187B2 (en) | 2012-09-19 | 2017-03-06 | Panel for covering a surface or support and an associated joint system |
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US15/450,730 Active US9885187B2 (en) | 2012-09-19 | 2017-03-06 | Panel for covering a surface or support and an associated joint system |
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EP (2) | EP2898156B1 (en) |
CN (1) | CN104870726B (en) |
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- 2013-09-19 US US14/428,705 patent/US20150218812A1/en not_active Abandoned
- 2013-09-19 PL PL13838589T patent/PL2898156T3/en unknown
- 2013-09-19 WO PCT/AU2013/001073 patent/WO2014043756A1/en active Application Filing
- 2013-09-19 EP EP13838589.3A patent/EP2898156B1/en active Active
- 2013-09-19 AU AU2013317701A patent/AU2013317701B8/en active Active
- 2013-09-19 EP EP18181637.2A patent/EP3450650B1/en active Active
- 2013-09-19 CA CA2924702A patent/CA2924702C/en active Active
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2017
- 2017-03-06 US US15/450,730 patent/US9885187B2/en active Active
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Cited By (8)
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US9885187B2 (en) | 2012-09-19 | 2018-02-06 | Inotec Global Limited | Panel for covering a surface or support and an associated joint system |
US11203875B2 (en) * | 2018-03-05 | 2021-12-21 | Tarkett Gdl S.A. | Set of tiles adapted to cover a surface such as a floor |
WO2020209785A1 (en) | 2019-04-11 | 2020-10-15 | Eazy Coating Electric Ab | A releasable fastening arrangement |
EP3953996A4 (en) * | 2019-04-11 | 2022-12-28 | Eazy Coating Electric AB | A releasable fastening arrangement |
US20220412101A1 (en) * | 2019-11-25 | 2022-12-29 | Flooring Industries Limited, Sarl | Panel comprising coupling parts |
US20230046217A1 (en) * | 2020-01-16 | 2023-02-16 | Flooring Industries Limited, Sarl | Reversible floor covering element |
US20220356716A1 (en) * | 2020-09-17 | 2022-11-10 | Surface Technologies Gmbh & Co. Kg | Panel |
CN113147618A (en) * | 2021-05-19 | 2021-07-23 | 刘永强 | Vibration noise suppression structure for automobile body structure |
Also Published As
Publication number | Publication date |
---|---|
CN104870726A (en) | 2015-08-26 |
AU2013317701B8 (en) | 2019-11-21 |
CN104870726B (en) | 2017-11-07 |
AU2013317701A1 (en) | 2015-05-14 |
EP3450650B1 (en) | 2024-03-06 |
EP2898156A1 (en) | 2015-07-29 |
EP2898156A4 (en) | 2016-05-18 |
US9885187B2 (en) | 2018-02-06 |
AU2013317701A8 (en) | 2019-11-21 |
CA2924702C (en) | 2020-07-07 |
WO2014043756A1 (en) | 2014-03-27 |
CA2924702A1 (en) | 2014-03-27 |
AU2013317701B2 (en) | 2018-03-15 |
PL2898156T3 (en) | 2018-12-31 |
EP3450650A1 (en) | 2019-03-06 |
US20170175401A1 (en) | 2017-06-22 |
EP2898156B1 (en) | 2018-07-18 |
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AS | Assignment |
Owner name: INOTEC GLOBAL LIMITED, HONG KONG Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:KELL, RICHARD WILLIAM;REEL/FRAME:035705/0307 Effective date: 20150408 |
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |