WO2012083362A1

WO2012083362A1 - Floor covering system

Info

Publication number: WO2012083362A1
Application number: PCT/AU2011/001651
Authority: WO
Inventors: Gordon Anderson
Original assignee: Unika (Australia) Pty Limited
Priority date: 2010-12-21
Filing date: 2011-12-21
Publication date: 2012-06-28
Also published as: CN102535810A

Abstract

A floor covering system is provided including at least two floor tiles. Each floor tile has a first layer in laminated engagement with a second layer. The system further includes a planar discrete joining member for joining the floor tiles. The joining member and second layer each have at least one complementary locating formation such that upon respective locking engagement between the floor tiles and joining member, an aligned relationship is defined.

Description

FLOOR COVERING SYSTEM FIELD OF THE INVENTION

[0001 ] The present invention relates to floor covering systems.

[0002] The invention has been developed primarily as a floating floor covering system and will be described hereinafter with reference to this application. However, it will be appreciated that the invention is not limited to this particular field of use.

BACKGROUND OF THE INVENTION

[0003] The following discussion of the prior art is intended to place the invention in an appropriate technical context and enable the associated advantages to be fully understood. However, any discussion of the prior art throughout the specification should not be considered as an admission that such art is widely known or forms part of the common general knowledge in the field.

[0004] Flooring systems, which have no part secured to the building structure or subfloor, are known. These types of flooring systems are free to float above the subfloor and are often referred to as "floating floors". Advantageously, floating floors are relatively easy to install and are able to expand and contract with changes in humidity and temperature and as a result, are hard wearing and develop minimal gaps during use.

[0005] Floating floor systems typically include an underlay formed from a resilient and moisture repellent material, and an upper layer in the form of a series of floor planks, which are laid over the underlay and which interconnect to define the flooring surface. In commonly known systems, the floor planks consist of a thin layer of softwood or hardwood bonded to a high-density fibreboard substrate often pre-coated to enhance their wearability (polyurethane is common), but it's possible to coat after installation.

[0006] In an alternate type of floating floor system, the floor planks are formed primarily from polyvinyl chloride (PVC) having a design pattern printed on their upper surface to resemble a desired surface finish, such as marble or hardwood. This alternate type of floating floor has the advantage of being harder wearing than the wood type floating floor as well as being quieter and softer to walk on and better adapted for installation in wet areas. Such a flooring system is disclosed in United States Patent No. 7,155,871 in the name of Tru Woods Limited ("Tru Woods").

[0007] In the Tru Woods system, a laminate tile is formed from two layers of flexible PVC material, with the lower layer performing the underlay function and the top layer performing the floor plank function and having the desired pattern on its upper surface. The two layers are laminated together, prior to sale to the end user, in a laterally offset arrangement to define two marginal portions along the edges of each tile. These marginal portions include an adhesive coating to allow adjacent tiles to be joined in a lap joint formation thereby to progressively build up the floating floor by placing the tiles contiguously in the desired layout.

[0008] However, due to a lack of positive mechanical guiding means, a problem with such a system is that a significant amount of care is required to align adjacent tiles during installation with any slight misalignment being magnified many times over upon completion of the flooring installation. This misalignment may result in the completed floor looking unsightly and gaps potentially appearing at the periphery of the completed floor. Moreover, due to the absence of positive engagement between adjacent tiles, the corners of the tile edges have been known to lift up over time, especially after repeated use or not being laid in perfect alignment.

[0009] It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.

[0010] Moreover, it is an object a preferred form of the invention to provide a floating flooring system that is relatively easy to maintain alignment between components during installation. The assembled floor should preferably be durable and therefore long lasting. DISCLOSURE OF THE INVENTION

[001 1 ] According to a first aspect of the invention, there is provided a floor covering system including:

at least two floor tiles, each floor tile having a first layer and a second layer in laminated engagement; and

a planar discrete joining member for joining the floor tiles,

the joining member and second layer each including at least one generally complementary locating formation such that upon respective locking engagement an aligned relationship is defined between the floor tiles.

[0012] In one embodiment, the joining member includes a plurality of obliquely extending locating protrusions.

[0013] In one embodiment, the plurality of locating protrusions laterally extend from one side of the joining member.

[0014] In one embodiment, the second layer includes a plurality of obliquely extending locating apertures for general complimentary locking engagement with the locating protrusions.

[0015] In one embodiment, the plurality of locating apertures laterally extend from one side of the second layer.

[0016] In one embodiment, each of the obliquely extending locating protrusions and apertures include a straight edge disposed at their lateral peripheries.

[0017] In one embodiment, the complementary locking engagement includes moving the floor tiles together in a direction substantially parallel to the central axis of each locating protrusion such that the locating protrusions engage with the locating apertures. Preferably, upon contact between opposing first layers the locking engagement further includes moving the floor tiles together in a direction parallel to their longitudinal axes thereby locking the floor tiles in the aligned relationship.

[0018] In one embodiment, the joining member is substantially the same thickness as the second layer. [0019] In one embodiment, the floor covering system includes adhesive means for bonding the floor tiles to the joining member. Preferably, the adhesive means includes a peripherally disposed adhesive tape. More preferably, the adhesive tape is peripherally disposed about the underside of the first layer.

[0020] In one embodiment, the first layer has a design pattern on its top surface.

[0021 ] In one embodiment, the floor tiles are sized to substantially correspond to standard ceramic, slate, marble tile or wood plank dimensions.

[0022] In one embodiment, the floor tiles are substantially formed from a resilient plastics material such as polyvinyl chloride.

[0023] In one embodiment, the joining member is substantially formed from a resilient plastics material such as polyvinyl chloride.

[0024] According to a further aspect of the invention, there is provided a floor tile for use in a floor covering system according to the first aspect.

[0025] According to a further aspect of the invention, there is provided a joining member for use in a floor covering system according to the first aspect.

[0026] Reference throughout this specification to "one embodiment", "some embodiments" or "an embodiment" means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases "in one embodiment", "in some embodiments" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0028] Figure 1 a is an underside perspective view of a first layer and a second layer of a floor tile, prior to being laminated, in accordance with the present invention;

[0029] Figure 1 b is an underside perspective view of a complete floor tile and joining member in accordance with the present invention;

[0030] Figure 1 c is a topside and underside perspective view and the floor tile and joining member of Figure 1 b in respective locking engagement;

[0031 ] Figure 2a is a part plan view of two floor tiles and joining member in partial engagement;

[0032] Figure 2b is a part plan view of two floor tiles and joining member in further partial engagement;

[0033] Figure 2c is a part plan view of two floor tiles and joining member in complete engagement; and

[0034] Figure 3 is a perspective view of a plurality of floor tiles in respective aligned engagement.

PREFERRED EMBODIMENT OF THE INVENTION

[0035] Referring to the accompanying drawings, there is provided a floor covering system 10 in accordance with the present invention. Once assembled, the finished floor is of the type typically known as floating floor in that it is not intended to be permanently fixed to, and therefore floats above, a base floor.

[0036] The floor covering system 10 includes at least two floor tiles 12 in an aligned configuration. Referring initially to Figures 1 a, each floor tile includes a first layer 14 in laminating engagement with a second layer 16. It is proposed that this lamination occurs prior to delivery to the end user to define the floor tile 12 as shown on Figure 1 b.

[0037] A planar discrete joining member 18 is provided for joining the floor tiles in an aligned configuration. The joining member 18 and second layer 16 each include at least one generally complementary locating formation 20 such that upon respective locking engagement, an aligned relationship between the floor tiles is defined. For context, Figure 3 shows a plurality of floor tiles after assembly each aligned due engagement between respective locating formations, to define an assembled floor.

[0038] Returning to Figure 1 b, the joining member 18 includes a plurality of locating protrusions 22 each obliquely and laterally extending from one side 24 thereof. These locating protrusions are adapted for general complimentary locking engagement with a plurality of locating apertures 26 laterally and obliquely extending from one side 28 of the floor tile 12.

[0039] The other side of the joining member includes a straight edge 38 which contacts a corresponding straight edge 39 on the other side of the floor tile 12 upon the locking engagement. The joining member 18 also includes further complimentary locking formation in the form of dovetail aperture 32 which is enagageable with a dovetail protrusion 34 at one end of the second layer 16. Further complementary locking formations 36 are provided on the joining member and floor tile to allow complete peripheral locating and locking engagement.

[0040] Without wishing to limit the invention to one geometric configuration, the inventor has found that to allow the locating protrusions 22 to easily and positively engage with the apertures 26, each protrusion and aperture should obliquely extend at an angle of between 22 to 28 degrees with respect to the longitudinal axis of the joining member and floor tile. Each protrusion also has a shape that is generally inwardly tapering so that it is self guiding as it enters the generally outwardly tapering corresponding locating aperture. It will also be noted that each protrusion 22 and aperture 26 includes a minor straight edges 22a and 26a at their extreme lateral peripheries. As described in more detail below, these straight edges assist the longitudinal movement that locks the joining member 18 with respect to the floor tile. [0041 ] It should be noted that the joining member 18 is generally of the same thickness as the second layer so that upon the locking engagement between two floor tiles 12 using the joining member 18, a generally flat under surface is defined. Advantageously, a flat under surface allows the assembled floor to float above the floor base.

[0042] In order to permanently bond the joining member 18 to the floor tile 12, an adhesive means in the form of an adhesive coating 37 is peripherally disposed about the underside of the first layer 14. It is proposed that this coating will be exposed by the removal of a disposable cover strip 40. The adhesive coating 37 may be of the type that reacts when in contact with the joining member such that the bond formed becomes stronger over time. Advantageously, this allows any laying mistakes to be easily corrected.

[0043] Referring to Figure 1 c, each floor tile 12 includes a design pattern 46 printed on the upper surface of the first layer so as to resemble for example, a marble, ceramic or wood textured surface. Alternatively, the design pattern may be printed on a supplementary layer, which is additionally laminated onto first layer.

[0044] In the embodiment depicted, the floor tiles have a generally rectangular shape and therefore would most likely resemble a hardwood floor when completely assembled. However, in other embodiments, the floor tiles could have a square shape so as to for example resemble marble, slate, ceramic or other type of square type floor tile.

[0045] As best shown with reference to Figure 1 a, each floor tile 12 is formed by permanently laminating the first layer 14 to the second layer 16. As mentioned earlier, this laminating occurs in a factory and the floor tiles are supplied to the user in their laminated form. In these respects, it is envisaged that the joining member 18 is formed from the same material as the second layer 16 so as to minimise material cost and maintain a constant thickness when assembled. Moreover, it is proposed that the second layer and joining member be formed of a material consistent with a typical resilient floating floor underlay. In this way, when assembled, the completed floor essentially comprises two continuous layers with the joining member generally incorporated into the second layer 16 substantially without gaps. Advantageously, this provides the prerequisite sound and thermal properties of floating floor systems. It also increases the durability of the completed floor because there are minimal areas of uneven strength, minimal gaps as well as points of possible separation.

[0046] Ideally, the floor tiles 12 and joining member 18 are predominantly formed from a flexible polyvinyl chloride material, otherwise known as PVC or vinyl. The completed floor is therefore hardwearing, easy to walk on and suitable for wet areas. In addition, using a resilient polyvinyl chloride material allows a degree of planar compliance to compensate for surface irregularities in the floor base when laid. Of course, it should be understood that other materials could be used in combination with the PVC such as for example, resins and/or polyurethane, without departing from the scope of the invention. Also, as mentioned earlier, a supplementary layer may be laminated to the upper surface of the first layer to provide the faux design pattern 46.

[0047] The assembly process will now be described in more detail. As shown in Figure 1 b and 1 c, the first stage in the floor assembly process is to engage the joining member 18 with the straight edge 39 of the second layer 16 of either the first or second floor tiles. As can be seen, the dovetail aperture 32 and locking protrusions 36 at the ends engage in this first stage. Once this is completed, the joining member can be slightly longitudinally rotated and the adhesive cover strip 40 peeled away from the side and one end of the underside of the first layer 14. The joining member 18 is then pushed down to contact the adhesive coating thereby bonding it in position with the respective floor tile.

[0048] Referring now to Figure 2a to 2c, the second stage in the assembly process is to introduce a second floor tile to the other side of the joining member 18. It will be appreciated that Figures 2a to 2c illustrate the second stage assembly process from a top plan view whereas Figures 1 a to 1 c illustrate the floor tiles from an underside perspective.

[0049] For the sake of illustration, a first floor tile is designated 42 and a second floor tile is designated 44 and it is the first floor tile 42 that is being introduced to the joining member, which is already engaged and bonded to the second floor tile 44 as described above. As shown in Figure 2a, the second stage first involves engaging the locating protrusions 22 of the joining member with the locating apertures 26 of the second layer of the first floor tile 42 by pushing the floor tiles together in a direction substantially parallel to the central axis of each locating protrusion 22. The protrusions will enter their corresponding apertures until opposing first layers 14 abut as shown in Figure 2b. Upon reaching this position, the second floor tile 44 (and joining member) is moved relative to the first floor tile 42 in a direction parallel to its longitudinal axis (upwardly on Figure 2b) thereby locking the floor tiles in their respective final positions shown on Figure 2c. It should be noted that upon reaching the position shown in Figure 2c the two floor tiles will be automatically locked together in a relative aligned relationship.

[0050] Subsequent to this locking engagement and upon the installer's satisfaction that the desired final position between the first and second floor tiles is achieved, the first floor tile is bonded to the joining member 18 by slightly longitudinally rotating the combined joining member and second floor tile 44 to reveal the adhesive cover strip 40 under the first layer of the first floor tile 42. The cover strip is then peeled away so that the joining member 18 can be bonded to the first floor tile 42.

[0051 ] It should be understood that the first stage engagement will not vary throughout the assembly procedure in that there is only one way for the joining member to engage with either floor tile. However, the second stage may vary by way of the installer's preference and due to selective longitudinal offsetting as shown in Figure 3. More particularly, the locating protrusions 22 do not have to engage with directly corresponding locating apertures 26 and could engage with any aperture on the opposing floor tile. Advantageously, even when longitudinally offset, the floor tiles will be automatically aligned upon engagement.

[0052] As best shown in Figure 3, to assemble a complete floor, a plurality of floor tiles will be required. The assembly process will be essentially the same as it would be for two floor tiles except it is expected that the installer would complete the first stage assembly described above for a number of floor tiles before beginning the second stage assembly.

[0053] As can be seen, one floor tile can be locked to two other floor tiles thereby creating a staggered pattern resembling a normal wooden floor. Specifically and with reference to the above described example, it can be seen that three locating protrusions from one floor tile are engaged with three apertures from the other floor tiles. As mentioned earlier, under these circumstances all three floor tiles are automatically aligned with respect to each other upon engagement.

[0054] A subsequent aspect of the assembly process not described above is the engagement of the longitudinally adjacent floor tile pairs such as those shown on Figure 3. Returning to Figure 1 c to explain further, it can be seen that when joining member 18 is fully engaged with a floor tile, longitudinally opposed offset areas 18a and 14a are defined. Therefore, when the short sides of two floor tiles engage, such as configuration shown in Figure 3, these offset areas make an overlapping engagement. Moreover since the adhesive coating 37 is disposed about the complete periphery of the first layer 14, engagement along the shorter sides of the first tiles creates a further adhesive bond subsequent to the removal of the protective strip 40.

[0055] The floor is built up gradually using the above described process continuing until the floor tiles cover the desired base floor surface. Upon completion, what gaps in the floor surface that remain are covered by combined floor tiles/joining members that are cut to fit, either on site or as supplied. Any locating protrusions 22 that are not required - so that the floor tiles are flush with a wall - can also be simply cut off as required. In addition, an edge trim or moulding may also be provided to seal any smaller peripheral gaps adjacent a wall surface, as in commonly known in the art.

[0056] It will be appreciated that the illustrated floor covering system is relatively easy to install because exact alignment between the adjacent components occurs automatically upon assembly. Advantageously, the complete system is supplied in kit form, which includes both the floor tiles and joining members and assembly may only require a single tool, such as a knife or scissors, to cut the floor tiles or trim any extra protrusions. Consequently, the flooring system of the present invention advantageously does not necessarily require any skilled labour for assembly and is therefore particularly suited to "do-it-yourself" home renovators and/or builders.

[0057] Ideally the components are formed from standard materials, which are well suited to high-speed automated manufacture and, accordingly, are relatively inexpensive to manufacture. [0058] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Claims

1 . A floor covering system including:

a planar discrete joining member for joining said floor tiles,

said joining member and second layer each including at least one generally complementary locating formation such that upon respective locking engagement, an substantially aligned relationship is defined between said floor tiles.

2. A floor covering system according to claim 1 , wherein said joining member includes a plurality of obliquely extending locating protrusions.

3. A floor covering system according to claim 2, wherein said plurality of locating protrusions laterally extends from one side of said joining member.

4. A floor covering system according to claim 2 or claim 3, wherein said second layer includes a plurality of obliquely extending locating apertures for general complimentary locking engagement with said locating protrusions.

5. A floor covering system according to claim 4, wherein said plurality of locating apertures laterally extends from one side of said second layer.

6. A floor covering system according to claim 4 or claim 5, wherein each of said obliquely extending locating protrusions and apertures include a straight edge disposed at their lateral peripheries.

7. A floor covering system according any one of claims 4 to 6, wherein said locking engagement includes moving said floor tiles together in a direction substantially parallel to the central axis of each locating protrusion such that said locating protrusions engage with said locating apertures.

8. A floor covering system according to claim 7, wherein upon contact between opposing said first layers said locking engagement further includes moving said floor tiles together in a direction parallel to their longitudinal axes thereby locking said floor tiles in said aligned relationship.

9. A floor covering system according to any one of the preceding claims, wherein said joining member is substantially the same thickness as said second layer.

10. A floor covering system according to any one of the preceding claims including adhesive means for bonding said floor tiles to said joining member.

1 1 . A floor covering system according to claim 10, wherein said adhesive means includes a peripherally disposed adhesive tape.

12. A floor covering system according to claim 1 1 , wherein said adhesive tape is peripherally disposed about the underside of said first layer.

13. A floor covering system according to any one of the preceding claims wherein said first layer has a design pattern on its top surface.

14. A floor covering system according to any one of the preceding claims, wherein said floor tiles are sized to substantially correspond to standard ceramic, slate, marble tile or wood plank dimensions.

15. A floor covering system according to any one of the preceding claims, wherein said floor tiles are substantially formed from a resilient plastics material such as polyvinyl chloride.

16. A floor covering system according to any one of the preceding claims, wherein said joining member is substantially formed from a resilient plastics material such as polyvinyl chloride.

17. A floor tile for use in a floor covering system according to any one of the preceding claims.

18. A joining member for use in a floor covering system according to any one of the preceding claims.