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.