WO2004057131A1 - Panel assembly for wall or floor surfaces - Google Patents

Panel assembly for wall or floor surfaces Download PDF

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Publication number
WO2004057131A1
WO2004057131A1 PCT/CA2003/001905 CA0301905W WO2004057131A1 WO 2004057131 A1 WO2004057131 A1 WO 2004057131A1 CA 0301905 W CA0301905 W CA 0301905W WO 2004057131 A1 WO2004057131 A1 WO 2004057131A1
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WO
WIPO (PCT)
Prior art keywords
joint
panel
base member
wall
anyone
Prior art date
Application number
PCT/CA2003/001905
Other languages
French (fr)
Inventor
Francis Gagnon
Original Assignee
Tuile Bois Franc Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tuile Bois Franc Inc. filed Critical Tuile Bois Franc Inc.
Priority to AU2003291878A priority Critical patent/AU2003291878A1/en
Publication of WO2004057131A1 publication Critical patent/WO2004057131A1/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/02005Construction of joints, e.g. dividing strips
    • E04F15/02016Construction of joints, e.g. dividing strips with sealing elements between flooring elements

Definitions

  • This invention relates to panel assemblies for floor and wall surfaces and particularly relates to a joint for assembling panels used to cover a floor or a wall surface.
  • Tiled walls and floors have long been popular, particularly for bathrooms, kitchens and the like. In spite of their popularity, tiled walls and floors present several problems. First, the grout used between tiles may become a breeding place for stain producing mildew. It is extremely difficult to clean the stained grout because it is a porous material and the stain may permeate therethrough. Secondly, the grout may loosen and fall out of the spaces between the tiles. Once the grout is cracked, moisture may seep behind the tiles and loosen them from the supporting base. Furthermore, it is difficult to install tiles in perfectly straight lines.
  • Koenig et al. describe an extension joint simulating grout lines for wall boards.
  • Koenig et al.'s extension joint comprises a long narrow strip of material having two spaced apart base sections and a raised ridge section connecting the two base sections. The top outer surface of the ridge section is concave to simulate a grout line when the extension joint is disposed between two adjoining wallboard panels or tiles.
  • the wall board panels or tiles are supported at the edges thereof on the base sections of the extension joint and are spaced apart from the supporting wall to which the base sections of the extension joints are attached. This configuration cannot be used with flooring panels or flooring tiles because the panels are not firmly supported by the supporting base and will be permanently damaged under load.
  • a joint for use to tightly assemble panels on a wall or a floor surface.
  • the joint comprises a base member having a substantially fiat lower surface and a ridge member extending upwardly from the base member. At least one longitudinal surface of the ridge member intersects with the base member to form a longitudinal edge, thereby defining an engaging portion.
  • the engaging portion is adapted for mating a corresponding abutting side of a panel.
  • a kit to cover wall and floor surfaces comprises at least two panels at least one joint to tightly assemble the panels on the wall or floor surface to be covered.
  • Each panel has a substantially flat lower surface and at least three abutting sides.
  • Each joint includes a base member having a substantially flat lower surface and a ridge member extending upwardly from the base member. At least one longitudinal surface of the ridge member intersects with the base member to form a longitudinal edge, thereby defining an engaging portion.
  • the engaging portion is adapted for mating a corresponding abutting side of a panel.
  • a method for covering wall and floor surfaces with panels At least two panels are provided, each panel has a substantially flat lower surface and at least three abutting sides.
  • One panel is disposed on ,the wall or floor surface, the lower surface of the panel adjoining the wall or floor surface.
  • At least one joint is provided to tightly assemble the panels on the wall or floor surface to. be covered.
  • Each joint includes a base member having a substantially flat lower surface and a ridge member extending upwardly from the base member. At least one longitudinal surface of the ridge member intersects with the base member to form a longitudinal edge, thereby defining an engaging portion. The engaging portion is adapted for mating a corresponding abutting side of a panel.
  • a joint is disposed on the wall or floor surface beside one abutting side of the panel, mating the abutting side ofthe panel into the engaging portion of the joint.
  • the remaining panels and joints are disposed side-by-side until the wall or floor surface is covered, the abutting side of a panel mating the engaging portion ofthe joint to form a tight assembly.
  • an assembly that covers a wall or a floor surface with panels.
  • the assembly comprises a plurality of panels and a plurality of joints that tightly assembles the panels together on the covered wall of floor surface.
  • Each panel has a substantially flat lower surface and at least three abutting sides, the lower surface of each panel adjoining the wall or floor surface to be covered.
  • Each joint includes a base member having a substantially flat lower surface and a ridge member extending upwardly from the base member. At least one longitudinal surface of the ridge member intersecting with the base member to form a longitudinal edge, thereby defining an engaging portion.
  • the engaging portion is adapted for mating a corresponding abutting side of a panel.
  • Fig. 1 is a perspective view of a joint according to one embodiment of the present invention.
  • Fig. 2 is a perspective view of a joint according to another embodiment ofthe present invention.
  • Fig. 3 is a perspective view of a joint according to another embodiment of the present invention.
  • Fig. 4 is a perspective cross-sectional view of two adjacent panels joined together with the joint of Fig. 1 disposed therebetween;
  • Fig. 5 is a perspective view of a laminate panel having abutting sides according to one embodiment ofthe present invention.
  • Fig. 6 is a perspective cross-sectional view of a panel adjoining a vertical surface limitation with the joint of Fig. 2 disposed therebetween.
  • a joint 10 is an elongate structure made of a flexible and resilient material.
  • Joint 10 has a longitudinally extending base member 12 having a substantially flat lower surface 14, an upper surface 16, and two opposite longitudinal side walls 18, 20.
  • a ridge 22 extends upwardly from upper surface 16 of base member 12 and is provided longitudinally in the middle thereof to form a substantially reversed T-shaped cross-section.
  • Ridge 22 has a top surface 24 and two opposite side surfaces 26, 28, one on each side of top surface 24.
  • Side surfaces 26, 28 of ridge 22 intersect upper surface 16 of base member 12, thereby forming two concave edges 30, one on each side of ridge 22, and dividing upper surface 16 into two portions 16a, 16b.
  • both engaging portions 32, 34 have the same width and height and each side of joint 10 are symmetrical about an axis of symmetry(not shown), longitudinally and vertically disposed in the middle of joint 10.
  • Each engaging portion 32, 34 intersects one longitudinal side wall 18, 20, thereby forming a convex edge 36.
  • side surfaces 26, 28 of ridge 22 extend parallel to each other and perpendicular respectively to upper surface 16.
  • Upper surfaces 16a, 16b are disposed parallel respectively to lower surface 14 of base member 12.
  • Side walls 18, 20 of base member 12 are disposed parallel to each other and perpendicular respectively to lower surface 14. Consequently, upper surfaces 16a, 16b of base member 12 intersect at right angle with both side surfaces 26, 28 and longitudinal side walls 18, 20.
  • side surfaces 26, 28, upper surface 16, and longitudinal side walls 18, 20 may be disposed in an alternative manner such that they do not intersect at right angle.
  • Top surface 24 of ridge 22 can be flat, concave, convex, or of any other desired shapes.
  • Fig. 2 illustrates another embodiment of the present invention, in which a joint 10a includes a base member 12 and a ridge 22, which are similar to those of joint 10 shown in Fig. 1 and are indicated with the same numerals. Other elements and features similar to those of joint 10 shown in Fig. 1 are also indicated by similar numerals and will not be redundantly described herein.
  • ridge 22 extends upwardly from base member 12.
  • one side surface 26 of ridge 22 is parallel and contiguous to one longitudinal side wall 18 of base member 12 to form a contiguous side wall 38.
  • Side wall 38 extends from the lower surface 14 of base member 12 to top surface 24 of ridge 22.
  • a single concave edge 30 and a engaging portion 32 are formed on the opposite side of joint 10a respectively to side wall 38 and are similar to those of joint 10 in Fig. 1.
  • Side wall 38 is substantially perpendicular with respect to lower surface 14, as explained more in detail later. Therefore, the resulting cross-section of joint 10a is substantially L- shaped.
  • Fig. 3 illustrates another embodiment of the present invention, in which a joint 10b includes a base member 12 and a ridge 22, which are similar to those of joints 10 and 10a shown in Figs. 1 and 2 and are indicated with the same numerals.
  • a joint 10b includes a base member 12 and a ridge 22, which are similar to those of joints 10 and 10a shown in Figs. 1 and 2 and are indicated with the same numerals.
  • ridge 22 extends upwardly from base member 12.
  • base member 12 has a trapezoidal cross-section.
  • Side surface 28 of ridge 22 intersects with longitudinal side wall 20 of base member 12, thereby forming a concave edge 30.
  • Longitudinal side wall 20 and side surface 28 forms an engaging portion 32.
  • side surface 26 of ridge 22 is parallel and contiguous to longitudinal side wall 18 of base member 12 and forms contiguous side wall 38.
  • Side wall 38 is perpendicular to lower surface 14 of base member 12.
  • Joint 10b could also be symmetrical about an axis of symmetry(not shown), . longitudinally and vertically disposed in the middle of joint 10b, such as joint 10.
  • Joints 10, 10a and 10b are preferably made by extrusion from a flexible and resilient material, such as rubber, to allow deformation when pressure is applied thereon. It can also be made with a polymeric thermoplastic material such as styrene, acrylonitrile and butadiene resins, polyolefins such as polyethylene, polypropylene and olefins copolymers and blends, polymethyl methacrylate, polystyrene, polyvinyl chloride, and polyvinylidene chloride, and the like.
  • a polymeric thermoplastic material such as styrene, acrylonitrile and butadiene resins, polyolefins such as polyethylene, polypropylene and olefins copolymers and blends, polymethyl methacrylate, polystyrene, polyvinyl chloride, and polyvinylidene chloride, and the like.
  • Fig. 4 illustrates a panel assembly 50 wherein joint 10 of Fig. 1 in use to assemble panels 52, 54.
  • Panel assembly 50 is placed upon a floor surface 56, which is substantially flat, and forms a covered surface 58.
  • the joint 10 can also be used to assemble panels in order to cover a wall or any other substantially flat surface.
  • Panels 52, 54 are preferably made of a square wood plate, a low, medium or high density fiber square plate which has higher soundproof properties than any other material available on the market.
  • it can also consist of laminate composite panels 80 (Fig. 5) such as the ones well known to those skilled in the art.
  • a composite panel 80 according to a preferred embodiment consists of a first layer 82 which can be made of wood or wood agglomerate and which is disposed on floor surface 56.
  • a second layer 84 is laminated on the first layer 82 and consists of high density fiberboard (HDF) or any other similar material known to one skilled in the art.
  • HDF high density fiberboard
  • a third layer 86 is laminated on the second layer and can consist of a wood coating.
  • the panel can consist of wood plates, laminate panels, solid wood panels, derived timber panels, tiles which can be made of ceramic, synthetically produced material, recycled material, porcelain, and the like.
  • each panel 52, 54 has a lower surface 60 and a plurality of abutting sides 64 (only one is shown).
  • Abutting side 64 consists of a lower side wall 66, an upper side wall 68, and a shoulder 70 connecting lower and upper side walls 66, 68.
  • lower side wall 66 intersects shoulder 70, forming a concave edge 72 and upper side wall 68 intersects shoulder 70 forming a convex edge 74.
  • joint 10 is engaged between two adjoining panels 52, 54 and is compressed laterally inwardly from opposed sides by the adjoining panels 52, 54 such that the laterally deformed joint 10 applies a reactive lateral force on abutting sides 64 of adjoining panels 52, 54.
  • a plurality of abutting sides define the periphery of each panel 52, 54.
  • a panel 52, 54 comprises four abutting sides 64, opposed pair-by-pair.
  • Each panel 52, 54 is stably secured in place by the reaction forces exerted by joints 10 surrounding the periphery thereof, while being firmly supported on surface 56.
  • a panel can also be secured in place by only two joints engaged to mate with a pair of opposed abutting sides of the panel.
  • An adhesive can be applied under panel 52, 54 or under joint 10, the adhesive allowing a firm adhesion of the panel or the joint on the wall or floor surface.
  • joint 10a is for use with a panel assembly 100 and is engaged between an abutting side 64 of panel 52 and a surface limitation 102 which can be a wall structure.
  • Surface limitation 102 is usually perpendicular respectively to surface 56 and on which side wall 38 of joint 10a abuts.
  • Joint 10a is disposed on the surface 56 and is pressed laterally by adjoining panel 52 against surface limitation 102.
  • the angle between side wall 38 and lower surface 14 the joint 10a must be substantially the same as the one between surface limitation 102 and surface 56.
  • surface limitation 102 is substantially perpendicular to surface 56, thus side wall 38 is perpendicular to lower surface 14.
  • Joint 10a is laterally pressed against surface limitation 102 by panel 52 adjacent to surface Umitation 102.
  • the reaction force produced by the deformation of the joint 10a secures the panel assembly 100 upon the surface 56.
  • joints 10 and 10a have a height from lower surface 14 to the top surface 24 of ridge 22 which is preferably slightly smaller than the thickness of panels 52, 54. Therefore, when joints 10 and 10a are deformed, their height is slightly increased as a result of the lateral force applied thereto, but do not protrude above the surface 58.
  • joint 10a may have a height which is equal to or even greater than the thickness of panel 52 to form a projection line (not shown) surrounding panel assembly 50 along surface limitations 102 ofthe covered surface.
  • An alternative panel could consist of a first layer made of any suitable material to cover a wall or a floor surface.
  • the first layer is mounted on a second layer made of a rubberlike material.
  • the rubberlike material is disposed on the floor or wall surface to improve the soundproofing properties ofthe assembly.
  • the dimension ofthe first layer is smaller or larger than the dimension of the second layer in a manner such as the assembly of the first and the second layers has at least one abutting side comprising a lower side wall, an upper side wall, and a shoulder connecting lower and upper side walls.
  • joint 10 can be dimensioned to have a base member width 9mm and a ridge width 3mm, a total height 7mm and a base member thickness of 3mm.
  • Joint 10a can be dimensioned similarly with one side of the base member 12 being cut off.
  • the joints are usually dimensioned according to the thickness of panels 52, 54.
  • the joints can be manufactured in a relatively large longitudinal dimension and can be cut into sections on site in order to meet installation requirements. For example, some sections of the joints may have a length crossing the entire room and some sections may have a length equal to the length of an abutting side of only one panel 52, 54.
  • joints 10, 10a and 10b can also be dimensioned to provide a small free space between side walls 18, 20 of the base member 12 and the corresponding lower side wall 66 of abutting side 64 of panels 52, 54. This small free space also reduces the total height increase ofthe joints when assembled.
  • the panel can comprise a plurality of grooves on lower surface 60.
  • the adhesive for affixing the panels on the on wall or floor surface can be applied in these grooves.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Floor Finish (AREA)
  • Building Environments (AREA)
  • Finishing Walls (AREA)

Abstract

A flexible and resilient joint to tightly assemble panels on a wall or a floor surface. The joint has an elongate shape and comprises a base member having a substantially flat bottom and a ridge extending upwardly from the base member to form a reversed T-shaped or L-shaped cross-section, thereby providing at least at one side of the joint with an engaging portion. The engaging portion is adapted for mating with a corresponding abutting side of a panel when the joint is used for panel assembly.

Description

PANE ASSEMBLY FOR WALL OR FLOOR SURFACES
TECHNICAL FIELD
This invention relates to panel assemblies for floor and wall surfaces and particularly relates to a joint for assembling panels used to cover a floor or a wall surface.
BACKGROUND ART
Tiled walls and floors have long been popular, particularly for bathrooms, kitchens and the like. In spite of their popularity, tiled walls and floors present several problems. First, the grout used between tiles may become a breeding place for stain producing mildew. It is extremely difficult to clean the stained grout because it is a porous material and the stain may permeate therethrough. Secondly, the grout may loosen and fall out of the spaces between the tiles. Once the grout is cracked, moisture may seep behind the tiles and loosen them from the supporting base. Furthermore, it is difficult to install tiles in perfectly straight lines.
Efforts have been made to overcome these problems. For example, in United States Patent 5,263,294, issued on November 23, 1993, Koenig et al. describe an extension joint simulating grout lines for wall boards. Koenig et al.'s extension joint comprises a long narrow strip of material having two spaced apart base sections and a raised ridge section connecting the two base sections. The top outer surface of the ridge section is concave to simulate a grout line when the extension joint is disposed between two adjoining wallboard panels or tiles. However, the wall board panels or tiles are supported at the edges thereof on the base sections of the extension joint and are spaced apart from the supporting wall to which the base sections of the extension joints are attached. This configuration cannot be used with flooring panels or flooring tiles because the panels are not firmly supported by the supporting base and will be permanently damaged under load.
To avoid the above mentioned problems, in US patent application
US 2002/0007606, published on January 24, 2002, Kettler et al. describe a floor tile with an edge profile on at least two opposite edges in the form of a modified groove and tongue joint for the purpose of connecting adjacent tiles. However, these floor tiles are more complicated and expensive to produce and the tolerances for the modified groove and tongue joint are smaller.
Therefore, there is a need for an alternative configuration of joints which can be used to tightly assemble panels to cover walls surfaces as well as floor surfaces
DISCLOSURE OF INVENTION
It is an object of the present invention to provide a simple means for installing with convenience a panel assembly on a floor or a wall surface and which simulates panels or tiles imbedded in grout.
It is an object ofthe present invention to provide a joint to tightly assemble panels that cover wall and floor surfaces.
It is another object of the present invention to provide an inexpensive joint which is not porous and cannot loosen or crack. It is further object of the present invention to provide a joint which allows to install panels in perfectly straight lines and which does not allow permanent damages ofthe panels under load.
In accordance with one aspect ofthe present invention, a joint for use to tightly assemble panels on a wall or a floor surface. The joint comprises a base member having a substantially fiat lower surface and a ridge member extending upwardly from the base member. At least one longitudinal surface of the ridge member intersects with the base member to form a longitudinal edge, thereby defining an engaging portion. The engaging portion is adapted for mating a corresponding abutting side of a panel.
In accordance with another aspect of the present invention, a kit to cover wall and floor surfaces. The kit comprises at least two panels at least one joint to tightly assemble the panels on the wall or floor surface to be covered. Each panel has a substantially flat lower surface and at least three abutting sides. Each joint includes a base member having a substantially flat lower surface and a ridge member extending upwardly from the base member. At least one longitudinal surface of the ridge member intersects with the base member to form a longitudinal edge, thereby defining an engaging portion. The engaging portion is adapted for mating a corresponding abutting side of a panel.
In accordance with a further aspect of the present invention, a method for covering wall and floor surfaces with panels. At least two panels are provided, each panel has a substantially flat lower surface and at least three abutting sides. One panel is disposed on ,the wall or floor surface, the lower surface of the panel adjoining the wall or floor surface. At least one joint is provided to tightly assemble the panels on the wall or floor surface to. be covered. Each joint includes a base member having a substantially flat lower surface and a ridge member extending upwardly from the base member. At least one longitudinal surface of the ridge member intersects with the base member to form a longitudinal edge, thereby defining an engaging portion. The engaging portion is adapted for mating a corresponding abutting side of a panel. A joint is disposed on the wall or floor surface beside one abutting side of the panel, mating the abutting side ofthe panel into the engaging portion of the joint. The remaining panels and joints are disposed side-by-side until the wall or floor surface is covered, the abutting side of a panel mating the engaging portion ofthe joint to form a tight assembly.
In accordance with a further aspect of the present invention, an assembly that covers a wall or a floor surface with panels. The assembly comprises a plurality of panels and a plurality of joints that tightly assembles the panels together on the covered wall of floor surface. Each panel has a substantially flat lower surface and at least three abutting sides, the lower surface of each panel adjoining the wall or floor surface to be covered. Each joint includes a base member having a substantially flat lower surface and a ridge member extending upwardly from the base member. At least one longitudinal surface of the ridge member intersecting with the base member to form a longitudinal edge, thereby defining an engaging portion. The engaging portion is adapted for mating a corresponding abutting side of a panel.
Other and further advantages and features ofthe invention will be apparent to those skilled in the art from the following description thereof, taken in conjunction with the accompanying drawings. BRIEF DESCRDPTION OF DRAWINGS
The present invention will be described in detail with reference to the accompanying drawings in which like numerals denote like parts in several views and in which:
Fig. 1 is a perspective view of a joint according to one embodiment of the present invention;
Fig. 2 is a perspective view of a joint according to another embodiment ofthe present invention;
Fig. 3 is a perspective view of a joint according to another embodiment of the present invention;
Fig. 4 is a perspective cross-sectional view of two adjacent panels joined together with the joint of Fig. 1 disposed therebetween;
Fig. 5 is a perspective view of a laminate panel having abutting sides according to one embodiment ofthe present invention; and
Fig. 6 is a perspective cross-sectional view of a panel adjoining a vertical surface limitation with the joint of Fig. 2 disposed therebetween.
MODES OF CARRYING OUT THE INVENTION
Embodiments of the invention will now be described with reference to the drawings wherein like numerals refer to like parts.
Referring to Fig. 1, it will be seen that a joint 10 according to one embodiment of the present invention is an elongate structure made of a flexible and resilient material. Joint 10 has a longitudinally extending base member 12 having a substantially flat lower surface 14, an upper surface 16, and two opposite longitudinal side walls 18, 20. A ridge 22 extends upwardly from upper surface 16 of base member 12 and is provided longitudinally in the middle thereof to form a substantially reversed T-shaped cross-section. Ridge 22 has a top surface 24 and two opposite side surfaces 26, 28, one on each side of top surface 24. Side surfaces 26, 28 of ridge 22 intersect upper surface 16 of base member 12, thereby forming two concave edges 30, one on each side of ridge 22, and dividing upper surface 16 into two portions 16a, 16b. Sides surfaces 26, 28 of ridge 22 and upper surface 16 forms two engaging portions 32, 34. Preferably, both engaging portions 32, 34 have the same width and height and each side of joint 10 are symmetrical about an axis of symmetry(not shown), longitudinally and vertically disposed in the middle of joint 10. Each engaging portion 32, 34 intersects one longitudinal side wall 18, 20, thereby forming a convex edge 36.
Preferably, side surfaces 26, 28 of ridge 22 extend parallel to each other and perpendicular respectively to upper surface 16. Upper surfaces 16a, 16b are disposed parallel respectively to lower surface 14 of base member 12. Side walls 18, 20 of base member 12 are disposed parallel to each other and perpendicular respectively to lower surface 14. Consequently, upper surfaces 16a, 16b of base member 12 intersect at right angle with both side surfaces 26, 28 and longitudinal side walls 18, 20. Nevertheless, side surfaces 26, 28, upper surface 16, and longitudinal side walls 18, 20 may be disposed in an alternative manner such that they do not intersect at right angle. Top surface 24 of ridge 22 can be flat, concave, convex, or of any other desired shapes.
Fig. 2 illustrates another embodiment of the present invention, in which a joint 10a includes a base member 12 and a ridge 22, which are similar to those of joint 10 shown in Fig. 1 and are indicated with the same numerals. Other elements and features similar to those of joint 10 shown in Fig. 1 are also indicated by similar numerals and will not be redundantly described herein. Referring to Fig. 2, it will be seen that ridge 22 extends upwardly from base member 12. However, unlike the configuration of the joint 10 in Fig. 1, one side surface 26 of ridge 22 is parallel and contiguous to one longitudinal side wall 18 of base member 12 to form a contiguous side wall 38. Side wall 38 extends from the lower surface 14 of base member 12 to top surface 24 of ridge 22. A single concave edge 30 and a engaging portion 32 are formed on the opposite side of joint 10a respectively to side wall 38 and are similar to those of joint 10 in Fig. 1. Side wall 38 is substantially perpendicular with respect to lower surface 14, as explained more in detail later. Therefore, the resulting cross-section of joint 10a is substantially L- shaped.
Fig. 3 illustrates another embodiment of the present invention, in which a joint 10b includes a base member 12 and a ridge 22, which are similar to those of joints 10 and 10a shown in Figs. 1 and 2 and are indicated with the same numerals. As for Fig. 2, other elements and features similar to those of joint 10 and 10a are also indicated by similar numerals and will not be redundantly described herein. Referring to Fig. 3, it will be seen that ridge 22 extends upwardly from base member 12. However, unlike the configuration ofthe joints 10 and 10a in Figs. 1 and 2, base member 12 has a trapezoidal cross-section. Side surface 28 of ridge 22 intersects with longitudinal side wall 20 of base member 12, thereby forming a concave edge 30. Longitudinal side wall 20 and side surface 28 forms an engaging portion 32. As for embodiment shown on Fig. 2, side surface 26 of ridge 22 is parallel and contiguous to longitudinal side wall 18 of base member 12 and forms contiguous side wall 38. Side wall 38 is perpendicular to lower surface 14 of base member 12. Joint 10b could also be symmetrical about an axis of symmetry(not shown), . longitudinally and vertically disposed in the middle of joint 10b, such as joint 10.
Joints 10, 10a and 10b are preferably made by extrusion from a flexible and resilient material, such as rubber, to allow deformation when pressure is applied thereon. It can also be made with a polymeric thermoplastic material such as styrene, acrylonitrile and butadiene resins, polyolefins such as polyethylene, polypropylene and olefins copolymers and blends, polymethyl methacrylate, polystyrene, polyvinyl chloride, and polyvinylidene chloride, and the like.
Fig. 4 illustrates a panel assembly 50 wherein joint 10 of Fig. 1 in use to assemble panels 52, 54. Panel assembly 50 is placed upon a floor surface 56, which is substantially flat, and forms a covered surface 58. However, it should be understood that the joint 10 can also be used to assemble panels in order to cover a wall or any other substantially flat surface.
Panels 52, 54 are preferably made of a square wood plate, a low, medium or high density fiber square plate which has higher soundproof properties than any other material available on the market. For example, it can also consist of laminate composite panels 80 (Fig. 5) such as the ones well known to those skilled in the art. Referring to Fig. 5, it will be seen that a composite panel 80 according to a preferred embodiment consists of a first layer 82 which can be made of wood or wood agglomerate and which is disposed on floor surface 56. A second layer 84 is laminated on the first layer 82 and consists of high density fiberboard (HDF) or any other similar material known to one skilled in the art. Finally, a third layer 86 is laminated on the second layer and can consist of a wood coating. Alternative panels made of other materials and shapes can also be used with joints 10, 10a, and 10b to form a panel assembly 50 that covers a substantially flat surface. The panel can consist of wood plates, laminate panels, solid wood panels, derived timber panels, tiles which can be made of ceramic, synthetically produced material, recycled material, porcelain, and the like.
Referring to Fig. 4, it will be seen that each panel 52, 54 has a lower surface 60 and a plurality of abutting sides 64 (only one is shown). Abutting side 64 consists of a lower side wall 66, an upper side wall 68, and a shoulder 70 connecting lower and upper side walls 66, 68. Preferably, lower side wall 66 intersects shoulder 70, forming a concave edge 72 and upper side wall 68 intersects shoulder 70 forming a convex edge 74.
Upper side walls 68 and shoulders 70 of panels 52, 54 mate corresponding engaging portions 32, 34 of joint 10 and lower side walls 66 of panels 52, 54 mate corresponding side walls 18, 20 of joint 10 when joint 10 is engaged between panels 52, 54 adjoining abutting sides 64 thereof. Referring to Fig. 4, it will be seen that longitudinal side walls 18, 20 and side surfaces 26, 28 are vertical respectively to floor surface 58 while upper surfaces 16a, 16b are horizontal respectively to floor surface 56 and are meeting at right angle with longitudinal side walls 18, 20 and side surfaces 26, 28. Thus, mating lower and upper side walls 66, 68 are vertical respectively to floor surface 56 while mating shoulders 70 are horizontal respectively to floor surface 56 and are also meeting at right angle with lower and upper side walls 66, 68.
Referring again to Fig. 4, joint 10 is engaged between two adjoining panels 52, 54 and is compressed laterally inwardly from opposed sides by the adjoining panels 52, 54 such that the laterally deformed joint 10 applies a reactive lateral force on abutting sides 64 of adjoining panels 52, 54. A plurality of abutting sides define the periphery of each panel 52, 54. Usually, a panel 52, 54 comprises four abutting sides 64, opposed pair-by-pair. Each panel 52, 54 is stably secured in place by the reaction forces exerted by joints 10 surrounding the periphery thereof, while being firmly supported on surface 56. A panel can also be secured in place by only two joints engaged to mate with a pair of opposed abutting sides of the panel. An adhesive can be applied under panel 52, 54 or under joint 10, the adhesive allowing a firm adhesion of the panel or the joint on the wall or floor surface.
Referring to Figs. 2 and 6, joint 10a is for use with a panel assembly 100 and is engaged between an abutting side 64 of panel 52 and a surface limitation 102 which can be a wall structure. Surface limitation 102 is usually perpendicular respectively to surface 56 and on which side wall 38 of joint 10a abuts. Joint 10a is disposed on the surface 56 and is pressed laterally by adjoining panel 52 against surface limitation 102. In order to have a substantial fit, the angle between side wall 38 and lower surface 14 the joint 10a must be substantially the same as the one between surface limitation 102 and surface 56. Referring to Fig. 6, it will be seen that surface limitation 102 is substantially perpendicular to surface 56, thus side wall 38 is perpendicular to lower surface 14. Joint 10a is laterally pressed against surface limitation 102 by panel 52 adjacent to surface Umitation 102. Thus, the reaction force produced by the deformation of the joint 10a secures the panel assembly 100 upon the surface 56.
Now referring back to Figs. 4 and 6, joints 10 and 10a have a height from lower surface 14 to the top surface 24 of ridge 22 which is preferably slightly smaller than the thickness of panels 52, 54. Therefore, when joints 10 and 10a are deformed, their height is slightly increased as a result of the lateral force applied thereto, but do not protrude above the surface 58. Alternatively, joint 10a may have a height which is equal to or even greater than the thickness of panel 52 to form a projection line (not shown) surrounding panel assembly 50 along surface limitations 102 ofthe covered surface.
An alternative panel could consist of a first layer made of any suitable material to cover a wall or a floor surface. The first layer is mounted on a second layer made of a rubberlike material. The rubberlike material is disposed on the floor or wall surface to improve the soundproofing properties ofthe assembly. The dimension ofthe first layer is smaller or larger than the dimension of the second layer in a manner such as the assembly of the first and the second layers has at least one abutting side comprising a lower side wall, an upper side wall, and a shoulder connecting lower and upper side walls.
As an example, joint 10 can be dimensioned to have a base member width 9mm and a ridge width 3mm, a total height 7mm and a base member thickness of 3mm. Joint 10a can be dimensioned similarly with one side of the base member 12 being cut off. The joints are usually dimensioned according to the thickness of panels 52, 54. The joints can be manufactured in a relatively large longitudinal dimension and can be cut into sections on site in order to meet installation requirements. For example, some sections of the joints may have a length crossing the entire room and some sections may have a length equal to the length of an abutting side of only one panel 52, 54. It may be desirable to dimension the joints such that a small free space is provided between engaging portions 32, 34 of joints 10, 10a, and 10b and the corresponding upper side wall and shoulder 70 of abutting side 64 of panels 52, 54 to allow for deformation of the base member 12 when the base member 12 is laterally pressed by adjoining panels 52, 54 or surface limitation 102 in the assembled condition. This reduces the total height increase of the assembled joint. Joints 10, 10a and 10b can also be dimensioned to provide a small free space between side walls 18, 20 of the base member 12 and the corresponding lower side wall 66 of abutting side 64 of panels 52, 54. This small free space also reduces the total height increase ofthe joints when assembled. However, with those joint configurations, the reaction force produced by the deformed joints that secures the panel assembly is reduced. In those cases, it might be preferable to apply an adhesive on the floor or wall surface to be covered before disposing the panels and the joints. On the opposite, when the joint compression is sufficient, it is unnecessary to apply an adhesive under the panels and the joints. The compression relationship between the joints and the panels or the surface limitations allows for improved stability ofthe panel assembly without the need of an adhesive for affixing the panels on the on wall or floor surface.
The panel can comprise a plurality of grooves on lower surface 60. The adhesive for affixing the panels on the on wall or floor surface can be applied in these grooves. Modifications and improvements to the above-described embodiments of the present invention may become apparent to those skilled in the art. The foregoing description is intended to be exemplary rather than limiting. The scope of the invention is therefore intended to be limited solely by the scope ofthe appended claims.

Claims

CLATMS
1. A joint for use to tightly assemble panels on a wall or a floor surface, comprising a. a base member having a substantially flat lower surface; and b. a ridge member extending upwardly from the base member, at least one longitudinal surface of the ridge member intersecting with the base member to form a longitudinal edge, thereby defining an engaging portion, and the engaging portion being adapted for mating a corresponding abutting side of a panel.
2. A joint according to claim 1, wherein the ridge member comprises two opposite side surfaces, at least one of the side surface intersecting the base member to form the longitudinal edge.
3. A joint according to claim 2, wherein both side surfaces of the ridge member form a longitudinal edge where one side surface intersects with the base member.
4. A joint according to claim 3, wherein the joint is symmetrical relatively to an axis of symmetry longitudinally and vertically disposed in the middle of the joint.
5. A joint according to claim 3 or 4, wherein the joint has a substantially reversed T-shaped cross-section.
6. A joint according to claim 2, wherein one side surface of the ridge member is contiguous and parallel to a longitudinal side wall extending from one longitudinal side of the lower surface of the base member, the side surface and the side wall forming a contiguous side wall.
7. A joint according to claim 6, wherein the contiguous side wall is perpendicular to the lower surface ofthe base member.
8. A joint according to claim 6 or 7, wherein the joint has a substantially L- shaped cross-section.
9. A joint according to anyone of claims 2 to 8, wherein at least one of the opposite side surfaces is vertical.
10. A joint according to anyone of claims 1 to 9, wherein the base member comprises an upper surface.
11. A joint according to claim 10, wherein the upper surface of the base member is parallel to the lower surface.
12. A joint according to claim 11, wherein the upper surface of the base member is peφendicular and contiguous to a longitudinal side wall extending from one longitudinal side of the lower surface of the base member.
13. A joint according to anyone of claims 2 to 12, wherein the ridge member has a top surface which is contiguous to both opposite side surfaces.
14. A joint according to anyone of claims 1 to 13, wherein the joint is made from a flexible and resilient material that allows deformation when pressure is applied thereon.
15. A joint according to claim 14, wherein the material ofthe joint is rubber.
16. A kit to cover wall and floor surfaces, comprising: a. at least two panels, each having a substantially flat lower surface and at least three abutting sides; and b. at least one joint to tightly assemble the panels on the wall or floor surface to be covered, each joint including: i. a base member having a substantially flat lower surface; and ii. a ridge member extending upwardly from the base member, at least one longitudinal surface of the ridge member intersecting with the base member to form a longitudinal edge, thereby defining an engaging portion, and the engaging portion being adapted for mating a corresponding abutting side of a panel.
17. A kit according to claim 16, wherein the ridge member comprises two opposite side surfaces, at least one of the side surface intersecting the base member to form the longitudinal edge.
18. A kit according to claim 17, wherein both side surfaces of the ridge member form a longitudinal edge where one side surface intersects with the base member.
19. A kit according to claim 18, wherein the joint is symmetrical relatively to an axis of symmetry longitudinally and vertically disposed in the middle of the joint.
20. A kit according to claim 18 or 19, wherein the joint has a substantially reversed T-shaped cross-section.
21. A kit according to claim 17, wherein one side surface of the ridge member is contiguous and parallel to a longitudinal side wall extending from one longitudinal side of the lower surface of the base member, the side surface and the side wall forming a contiguous side wall.
22. A kit according, to claim 21, wherein the contiguous side wall is peφendicular to the lower surface ofthe base member.
23. A kit according to claim 21 or 22, wherein the joint has a substantially L- shaped cross-section.
24. A kit according to claim 17, wherein at least one of the opposite side surfaces of the joint is vertical.
25. A kit according to anyone of claims 16 to 24, wherein the base member comprises an upper surface.
26. A kit according to claim 25, wherein the upper surface of the base member is parallel to the lower surface.
27. A kit according to claim 26, wherein the upper surface is peφendicular and contiguous to a longitudinal side wall extending from one longitudinal side ofthe lower surface ofthe base member.
28. A kit according to anyone of claims 17 to 27, wherein the ridge member has a top surface which is contiguous to both opposite side surfaces.
29. A kit according to anyone of claims 16 to 28, wherein the joint is made from a flexible and resilient material that allows deformation when pressure is applied thereon.
30. A kit according to claim 29, wherein the material ofthe joint is rubber.
31. A kit according to claim 17, wherein the abutting side of the panel comprises at least one portion mating the engaging portion of the joint; the mating portion of the abutting side including an upper side wall intersecting a shoulder to form a longitudinal edge.
32. A kit according to claim 31, wherein the abutting side comprises a lower side wall mating the longitudinal side wall ofthe joint.
33. A kit according to anyone of claims 16 to 32, wherein the panel is selected from the group comprising wood plates, laminate panels, solid wood panels, derived timber panels, tiles which can be in ceramic, synthetically produced material, recycled material, porcelain, and the like.
34. A kit according to anyone of claims 16 to 32, wherein the panel comprises: a. a first layer made of any suitable material to cover a wall or a floor surface; and b. a second layer made of a rubberlike material and having a dimension different than the one of the first panel, the second panel being mounted under the first layer to form an assembly having at least one abutting side.
35. A kit according to anyone of claims 16 to 34, wherein the panel has four abutting sides.
36. A kit according to anyone of claims 16 to 35, wherein the panel comprises at least one groove on the lower surface ofthe panel.
37. A method for covering wall and floor surfaces with panels comprising: a. providing at least two panels, each having a substantially flat lower surface and at least three abutting sides; b. disposing one panel on the wall or floor surface, the lower surface of the panel adjoining the wall or floor surface; c. providing at least one joint to tightly assemble the panels on the wall or floor surface to be covered, each joint including: i. a base member having a substantially flat lower surface; and ii. a ridge member extending upwardly from the base member, at least one longitudinal surface of the ridge member intersecting with the base member to form a longitudinal edge, thereby defining an engaging portion, and the engaging portion being adapted for mating a corresponding abutting side of a panel; d. disposing a joint on the wall or floor surface beside one abutting side ofthe panel, mating the abutting side ofthe panel into the engaging portion of the joint; e. disposing remaining panels and joints side-by-side until the wall or floor surface is covered, the abutting side of a panel mating the engaging portion of the joint to form a tight assembly.
38. A method according to claim 37, comprising applying an adhesive on the wall or floor surface before disposing a panel thereon, the adhesive allowing a firm adhesion ofthe panel on the wall or floor surface.
39. A method according to claim 38, wherein the panel comprises at least one groove on the lower surface of the panel, the adhesive being applied said groove.
40. A method according to anyone of claims 37 to 39, comprising applying an adhesive on the wall or floor surface before disposing a joint thereon, the adliesive allowing a firm adhesion of the joint on the wall or floor surface.
41. A method according to anyone of claims 37 and 40, comprising disposing a joint beside each abutting side of each panel.
42. A method according to anyone of claims 37 and 41, wherein the ridge member comprises two opposite side surfaces, at least one of the side surface intersecting the base member to form the longitudinal edge.
43. A method according to claim 42, wherein the joint has a substantially reversed T-shaped cross-section and comprising disposing the joint between two abutting sides of two adjacent panels, the joint having two longitudinal edges, each longitudinal edge being located where one side surface intersects with the base member.
44. A method according to claim 42 or 43, wherein the joint is symmetrical relatively to an axis of symmetry longitudinally and vertically disposed in the middle ofthe joint.
45. A method according to claim 42, wherein the joint has a substantially L- shaped cross-section and comprising disposing the joint between an abutting side of a panel adjacent and a surface limitation of the wall or floor surface to be covered, the joint having one side surface ofthe ridge member contiguous and parallel to a longitudinal side wall extending from one longitudinal side of the lower surface of the base member, the side surface and the side wall forming a contiguous side wall, the contiguous side wall being disposed on the surface limitation.
46. A method according to claim 45, wherein the contiguous side wall is peφendicular to the lower surface ofthe base member.
47. A method according to anyone of claims 37 to 46, comprising laterally and inwardly compressing the joint on a first panel or a surface limitation with a second panel before disposing the second panel beside the joint, the abutting side of the panel mating the engaging portion of the joint to form a tight assembly.
48. A method according to anyone of claims 37 to 46, comprising disposing a plurality of panels beside a joint, a abutting side of each panel mating the engaging portion ofthe joint to form a tight assembly.
49. A method according to claim 42, wherein at least one ofthe opposite side surfaces of the j oint is vertical.
50. A method according to anyone of claims 37 to 49, wherein the base member comprises an upper surface.
51. A method according to claim 50, wherein the upper surface of the base member is parallel to the lower surface ofthe base member.
52. A method according to claim 51, wherein the upper surface of the joint is peφendicular and contiguous to a longitudinal side wall extending from one longitudinal side ofthe lower surface ofthe base member.
53. A method according to anyone of claims 42 to 52, wherein the ridge member has a top surface which is contiguous to both opposite side surfaces.
54. A method according to anyone of claims 37 to 53, wherein the joint is made from a flexible and resilient material that allows deformation when pressure is applied thereon.
55. A method according to claim 54, wherein the material of the joint is rubber.
56. A method according to claim 37, wherein the abutting side of the panel comprises at least one portion mating the engaging portion of the joint; the mating portion of the abutting side including an upper side wall intersecting a shoulder to form a longitudinal edge.
57. A method according to claim 56, wherein the abutting side comprises one lower side wall mating the longitudinal side wall ofthe joint.
58. A method according to claim 37, wherein the panel is selected from the group comprising wood plates, laminate panels, solid wood panels, derived timber panels, tiles which can be in ceramic, synthetically produced material, recycled material, porcelain, and the like.
59. A method according to anyone of claims 37 to 57, wherein the panel comprises: a. a first layer made of any suitable material to cover a wall or a floor surface; and b. a second layer made of a rubberlike material and having a dimension different than the one of the first panel, the second panel being mounted under the first layer to form an assembly having at least one abutting side.
60. A method according to anyone of claims 37 to 59, wherein the panel has four abutting sides.
61. An assembly that covers a wall or a floor surface with panels, comprising: a. a plurality of panels, each having a substantially flat lower surface and at least three abutting sides, the lower surface of each panel adjoining the wall or floor surface to be covered; b. a plurality of joints that tightly assembles the panels together on the covered wall of floor surface, each joint including i. a base member having a substantially flat lower surface; and ii. a ridge member extending upwardly from the base member, at least one longitudinal surface of the ridge member intersecting with the base member to form a longitudinal edge, thereby defining an engaging portion, and the engaging portion being adapted for mating a corresponding abutting side of a panel.
62. An assembly according to claim 61, wherein an adhesive is applied between the wall or floor surface and a panel disposed thereon, the adhesive allowing a firm adhesion of the panel on the wall or floor surface.
63. An assembly according to claim 62, wherein the panel comprises at least one groove on the lower surface of the panel, the adhesive being applied said groove.
64. An assembly according to anyone of claims 61 to 63, wherein an adhesive is applied between the wall or floor surface and a joint disposed thereon, the adhesive allowing a firm adhesion ofthe joint on the wall or floor surface. .
65. An assembly according to anyone of claims 61 to 64, wherein a joint is disposed beside each abutting side of each panel.
66. An assembly according to anyone of claims 61 to 65, wherein the ridge member comprises two opposite side surfaces, at least one of the side surface intersecting the base member to form the longitudinal edge.
67. An assembly according to claim 66, wherein the joint has a substantially reversed T-shaped cross-section and comprising disposing the joint between two abutting sides of two adjacent panels, the joint having two longitudinal edges, each longitudinal edge being located where one side surface intersects with the base member.
68. An assembly according to claim 66 or . 67, wherein the joint is symmetrical relatively to an axis of symmetry longitudinally and vertically disposed in the middle ofthe joint.
69. An assembly according to claim 66, wherein the joint has a substantially L-shaped cross-section and comprising disposing the joint between an abutting side of a panel adjacent and a surface limitation of the wall or floor surface to be covered, the joint having one side surface ofthe ridge member contiguous and parallel to a longitudinal side wall extending from one longitudinal side of the lower surface of the base member, the side surface and the side wall forming a contiguous side wall, the contiguous side wall adjoining the surface limitation.
70. An assembly according to claim 69, wherein the contiguous side wall is peφendicular to the lower surface ofthe base member.
71. An assembly according to anyone of claims 61 to 70, wherein the joint is laterally and inwardly compressed between a first panel or a surface limitation and a second panel disposed beside the joint, the abutting side ofthe panel mating the engaging portion to form a tight assembly.
72. An assembly according to anyone of claims 61 to 70, wherein a plurality of panels is disposed beside a joint, an abutting side of each panel mating the engaging portion of a joint to form a tight assembly.
73. An assembly according to claim 66, wherein at least one of the opposite side surfaces of the joint is vertical.
74. An assembly according to anyone of claims 61 to 73, wherein the base member comprises an upper surface.
75. An assembly according to claim 74, wherein the upper surface of the base member is parallel to the lower surface ofthe base member.
76. An assembly according to claim 75, wherein the upper surface is peφendicular and contiguous to a longitudinal side wall extending from one longitudinal side ofthe lower surface ofthe base member.
77. An assembly according to anyone of claims 66 to 76, wherein the ridge member has a top surface which is contiguous to both opposite side surfaces.
78. An assembly according to anyone of claims 61 to 77, wherein the joint is made from a flexible and resilient material that allows deformation when pressure is applied thereon.
79. An assembly according to claim 78, wherein the material of the joint is rubber.
80. An assembly according to claim 61, the abutting side of the panel comprises at least one portion mating the engaging portion of the joint; the mating portion of the abutting side including an upper side wall intersecting a shoulder to form a longitudinal edge.
81. An assembly according to claim 80, wherein the abutting side includes one lower side wall mating the longitudinal side wall ofthe joint.
82. An assembly according to claim 61, wherein the panel is selected from the group comprising wood plates, laminate panels, solid wood panels, derived timber panels, tiles which can be in ceramic, synthetically produced material, recycled material, porcelain, and the like.
83. An assembly according to anyone of claims 61 to 82, wherein the panel comprises: a. a first layer made of any suitable material to cover a wall or a floor surface; and b. a second layer made of a rubberlike material and having a dimension different than the one of the first panel, the second panel being mounted under the first layer to form an assembly having at least one abutting side.
84. An assembly according to anyone of claims 61 to 83, wherein the panel has four abutting sides.
PCT/CA2003/001905 2002-12-19 2003-12-09 Panel assembly for wall or floor surfaces WO2004057131A1 (en)

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US60/434,398 2002-12-19

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ES2284320A1 (en) * 2005-04-21 2007-11-01 Forgestal, S.L. System for the formation of a floor
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WO2013117553A3 (en) * 2012-02-06 2013-10-03 Kingfisher Asia Limited Tile
US8910623B2 (en) * 2007-03-13 2014-12-16 Fmi Acquisition, Llc Refractory panels with grout-capturing channels
CN106592860A (en) * 2016-12-16 2017-04-26 俞昱 Combined type energy-saving wallboard

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