Interconnecting disengageable flooring system

IS 2 240 290 T3

DESCRIPTION

Interconnectable and detachable floor covering system.

The present invention relates to floor covering surfaces, preferably decorative floor covering surfaces. Furthermore, the present invention relates to a system for manufacturing a floor covering surface, for example a decorative floor surface. More specifically, the present invention relates to thin laminate flooring surfaces comprising a top wear surface, preferably of a decorative nature, a reinforcing substrate material or layer and optionally a backing material or layer. The present invention also relates to components, systems and methods for fabricating a detachable decorative laminate flooring surface from individual floor panels. Furthermore, the present invention relates to decorative laminate products or components for floors, eg panels and elements for connecting the panels.

Various systems have been proposed in an attempt to provide a means of easily fabricating a floor covering surface, however, none have found overwhelming acceptance in the market especially in relation to detachable "laminate" thin laminate surfaces.

It is typical that laminate flooring panel manufacturers have manufactured a product that contains a herringbone and pocket profile within the same flooring panel. The herringbone profile is machined into one side and one end of the panel with the pocket being machined into the opposite side and end of the same panel. This type of fabrication creates a panel that has a directional orientation or "hand guidability" (right or left hand orientation).

In prior art systems a panel is manufactured with a top wear surface. After fabrication the panel is edge machined to remove a portion of the upper wear surface to form a tenon extension for insertion into the corresponding pocket in the adjacent panel. To form the tenon, the upper wear surface has to be machined, thus reducing the amount of marketable square meters. Furthermore, the removal of more upper wear surface accelerates tool wear and thus tools require more maintenance and / or replacement. Consequently the cost and time of manufacture increase. Similarly, in prior art systems, a reinforcing substrate material is fabricated and a portion is then machined apart to form the pocket.

It is typical that, when constructing a floor covering surface using prior art systems with oriented herringbone and pocket panels, the construction begins on one wall and proceeds all the way to the other wall and, it is normal for a The space to be parquet is not of a size that is equally divisible by the size of a floor panel, that is, Panels need to be cut into one end wall on the length or width side to fit. In prior art systems using oriented panels, once a panel has been cut, there is a significant possibility that the remaining portion cannot be used. For example, in the prior art system, using rectangular panels with pins and pockets on opposite edges that intersect, respectively, when a panel is cut lengthwise, two panel pieces are formed with one long edge of each being a spike or a pocket. In the end wall, a portion of a panel with a pocket on the long edge may be needed and inserted. As a result, only one piece of panel with a tenon remains, on the long edge, without an edge with a long pocket.

Many prior art systems, for example the systems in U.S. Patent Nos. 5,706,621 and 5,860,266, require clamping the panel to be joined at an angle relative to a principal plane of a first. panel laid and angled down the new panel so that, mechanically, it becomes interlocked underneath a portion of the first panel. This is repeated until a floor has been built. If it is necessary to change panel number 5, of a sequence of 20 panels, for example, because it is damaged, you have to remove panels 6 to 20 in reverse order to get to panel number 5. This is particularly disadvantageous in large tile systems subject to excessive wear, for example, in a retail space environment.

A number of known proposed systems are studied to provide background for the present invention.

In US Patent No. 3,310,919, entitled "Detachable Floor" a floor is disclosed comprising a plurality of similar panels with straight sides, coupling elements on the sides for a coupling arrangement with the elements. cooperating coupling elements on adjacent panels, and means operatively associated with the coupling elements for interlocking, removably, adjacent panels in a side-to-side contiguous relationship. As illustrated in figure 2 the panels are attached using screws 19 and fixing nails 15.

In US Patent No. 3,657,882, entitled "Tiles" a floor or tile is disclosed comprising either a single piece composed of any of a range of different materials or a plurality of overlapping laminations each composed of of any one of the materials in a range. The tiles are formed with a plurality of identical spikes, projecting laterally, and, on their underside, with an equal number of identical pockets which open at the periphery of the tiles and alternate around the periphery with the spikes. The pins and bags are shaped such that any pin on any one of the tiles is adapted to engage with, and fit within, any bag on any one of the other tiles and, when so engaged, will hold against withdrawal toward the end of the bag, so that when the two tiles are located in a common plane, relative movement between them within the plane is avoided.

In US Patent No. 4,449,346, entitled "Panel Assembly" a panel assembly is disclosed that includes at least two panels and a connector member for mounting the panels to a supporting surface, the panels being positioned edge-to-edge in coplanar relationship with the

ES 2 240 290 T3 respective facing edges thereof separated, and the connecting member between the edges of facing panels and locking the panels together by being fixedly attached to the supporting surface. Each panel has first and second surfaces in first and second parallel planes and each has, at its respective edge, a tenon and a pocket. The tenon and pocket extend along the edge of the panel between the first and second planes and, respectively, project an opening upward and at an angle toward the first plane. The connecting member comprises an elongated body that fills the space between the edges of the confronting panels and has on each side thereof a tenon and a pocket which, respectively, project an opening outwards and at an angle towards the second plane. The spigot and socket on each side are complementary to interlock, with the respective socket and spigot at the respective adjacent facing edges of the panel. The connecting member cooperates with the panels to urge the panels towards each other in a sealing engagement as a result of the compressive force exerted on the member towards the supporting surface when the member has been attached to this supporting surface. It is stated in the patent that the provision of such a connecting member disrupts the hitherto known practice of nailing or screwing the panel edges to secure the panels to the supporting surface, while still providing a locking gear. airtight between the panels. As shown in Figure 2, the connector member is fixedly attached to the support surface using screw 86. Furthermore, "the upper surface 56 of the connector member 14 is coplanar with the planar upper surfaces 16 and 18 of the panels 10 and 12" and therefore forms a part of the upper wear surface, which is easily visible.

In US Patent No. 4,135,339, entitled "Slatted Floor System" a slatted floor system is disclosed which is said to be easy to assemble, provides a firm footing and comfort for confined animals. , resists corrosion, deters the build-up of animal waste, is easy to clean, and can be used to span significantly greater distances than prior art slats. This slatted floor system is said to comprise a plurality of elongated, spaced, generally parallel slats. Each slat has a load bearing top surface with separate opposing outer edges. Each slat also has a bottom surface nearly parallel to the top surface and a pair of side surfaces integral with the top surface and the bottom surface. The side surfaces are joined with the top surfaces along recessed lines of the top edges of the top surface. The side surfaces are said to taper more towards each other at first positions, adjacent to the upper surface, then extend almost parallel to each other and vertically relative to the lower surface of the second portions. This is also said to form, with the upper and lower surfaces, a main compartment, enclosed in a general Y-shape. This patent also discloses that each slat also includes a first pair of projection receiving means extending longitudinally along the first tapered portion of its side surfaces, and a second pair of extending projection receiving means longitudinally along the second portion of the side surfaces. Adjacent slats are disclosed as being connected and interlocked in spaced relationship within a plurality of connectors. Each connector has a pair of projections, with each projection being receivable by one of a first pair of projection receiving means on each of two adjacent slats, and the second pair of projection receiving means receiving media on each of two adjacent slats. . At least one of the first and second pairs of projections on the connectors is adapted to interlock with its corresponding projection-receiving means on adjacent slats. As indicated above, and as shown in Figures 1 and 4, the upper wear surface of the slats is spaced to provide clearance to facilitate the object of the invention, i.e., to discourage build-up of animal waste. Furthermore, as illustrated in the same figures, the projections and the connecting means can be mounted by sliding the edges of the slats and the connectors together when held in a coplanar relationship parallel to each other. And, as shown, the connecting member does not extend the entire length of the slat members.

In US Patent No. 4,461,131, entitled "Panel Interconnection System", a set of rectangular shaped panels, such as a floor, is disclosed, in which the panels comprise top sheets and bottoms grooved with grooves separated by a core, elongated fittings extending along adjacent edges of adjacent panels and with lateral extension receiving means between edge portions of the panel sheets. Each fixture has an upwardly open channel located beyond the edge of the associated panel. Adjacent fittings and adjacent panels are secured together by means of elongated connector strips which have elongated parallel tabs that are received in channels of adjacent fittings. As illustrated in Figure 3, the strips 40 form a portion of the upper wear surface and are thus visibly distinct from the upper surface 10 of the floor panels P.

In US Patent No. 4,796,402, entitled "Step Silencing Parquet Flooring" is disclosed a step silencing parquet flooring, in which the sound of footsteps that could be perceived from a room to room, they are silenced using inhomogeneous fiber decking with surface pressure on the supporting construction layers that are installed under the top wear layer of the parquet decking. This patent discloses that the deck has longitudinal sides and ends formed with a tenon and a pocket by means of which said deck will collaborate with adjacent decks to form a self-silencing parquet floor.

In US Patent No. 5,022,200, entitled "Interlocking Sections for Removable Floors and the Like" an improved interlocking mechanism is alleged and disclosed which includes first and second members which fit together for purposes of interlocking. The second interlocking means has pins mounted within the

ES 2 240 290 T3 itself so that they move along defined paths between the first and second positions, which in the patent are called open and closed positions. In this patent, a means is disclosed for urging the pins into their closed positions in a normal way. The first locking member is noted to have a means for moving the pins to their open positions when the two locking members are moved together and for allowing the pins to return to their closed positions after engagement of the first and second locking members. The first interlocking member has an engaging surface that contacts the pins when force is applied to separate the first and second interlocking members. The shape or inclination of these interlocking surfaces in relation to the defined paths of movement of the pins is such that it causes essential interference of the first interlocking member with the pins, which prevent movement of the pins in the open position, and therefore prevent removal of the locking member. A separate unlocking mechanism is provided to move the pins to the open position and thereby allow disengagement of the mechanism. According to a preferred embodiment, which is disclosed in that patent, the first locking member includes a flange and the second locking member includes means for defining a recess to receive the flange. The pins are generally positioned within the receiving space and the flange includes surfaces, at its outer edge, for moving the pins to the open position, and hook-shaped portions with interlocking surfaces which mesh with the pins in the open position. a closed position. This patent also discloses that it alleges the improvement of the construction of a panel in which the panel is formed in a single molding process which encapsulates a central urethane member, molds the tenon and pocket portions with inlets formed in the same to receive the interlocking members and bond the tough and decorative flooring surfaces.

In US Patent No. 5,157,890, entitled "Floors," a decking system of individual panel assemblies that can be collaboratively intertwined is disclosed. This patent discloses that the periphery of each panel is linked by frame members with two spaced generally parallel flanges and a generally perpendicular weft extending between them. The frame members include, on one side of the frame, between the upper and lower flanges, a rail for receiving a guide block. This guide wedge comprises a generally rectangular base with a guide pin extending therefrom. The base is received by means of a slot within the rail of the adjacent frame member. The frame members can be miter cut to lengths and the corners can be joined by means of a corner clip.

In US Patent No. 5,179,812, entitled "Flooring Product", a decking system is disclosed comprising a wooden panel with an L-shaped frame the base of which is located below the deck panel. wood. This patent discloses the use of a plurality of aluminum reinforcing slats that are connected to the base of the panel. These slats are said to comprise a pocket. In practice, the patent discloses that two decking products, with similar arrangements, are fixed together by placing the base of the rim of each product in the pocket and on the elongated members of the other product. This connection cannot be disengaged unless one of the decking panels is tilted relative to the other.

In US Pat. No. 5,295,341, entitled "Snap-together Decking System", a decking system is disclosed having a base member with an upper side, a lower side and four circumferentially spaced outer edges, a pin connector attached at an outer edge by means of a locking flange and a pocket, a pocket connector attached to another outer edge by means of a locking flange and a pocket, a spike connector with forwardly converging compressible sidewalls terminating at rear interlocking transverse surfaces, the pocket connector having a large inner opening and a small outer opening, the side walls of the spike, in the compressed position, being smaller that said outer opening of the box, so that they pass through the outer opening, and being elastically expandable to be larger than said outer opening to interlock a pin and a pocket. This patent discloses that it is preferable that the connectors are attached to the base members and recesses of the outer edges by means of additional pins and sockets and that they are attached to the base members at the factory during their manufacture.

In US Patent: 5,736,227, entitled "Laminate Wood Parquet and Wood Flooring," a flooring product is disclosed that includes a decorative top layer, an intermediate layer bonded to the top layer, and a base layer bonded to the middle layer. The top, middle and base layers are joined to define an elongated strip of flooring laminate. A tenon and a pocket are formed at the respective side edges of the decking strip. The tenon and pocket extend the full length of the decking strip and interlock adjacent decking strips together side by side to form a mounted wood floor. The base layer has a multiplicity of closely spaced notches cut across the length of the deck strip and along almost the entire length of the deck strip. The notches relieve the load and increase the flexibility of the wood strip so that it adheres much more flexibly to unevenness in the subfloor.

In US Patent No. 3,694,983, entitled "Board or Plastic Tiles for Flooring and Similar Applications", there are disclosed tiles adapted to form, by juxtaposition, a smooth, continuous or diversified carpeting or cladding. made of fabric, plastic or other material. Each tile is attached to a backing of the same measurements but with projections along two adjacent edges of the tile to form an embedded strip. Each strip is equipped with means to allow the intermeshing of fastening means positioned in a fused condition under the edges of two sides of the adjacent tile. The fastening means have a thickness less than that of said backrest so that, in the assembled condition, no extra thickness is produced.

ES 2 240 290 T3 not in relation to the normal thickness of the backrest.

A road construction comprising a plurality of identical invertible polygonal panels is disclosed in US Patent No. 3,859,000, entitled "Construction of roads and panels to make the same". Each panel comprises a plurality of one-piece peripheral frame members that are secured together to define a polygonal configuration and each of the members has an approximately L-shaped projection extending therefrom. This projection is adapted to interlock with an identical projection of an associated member. Each panel also has a pair of load bearing sheets attached to opposite sides of its frame members.

In US Patent No. 5,706,621, entitled "Building Board Joining System", a system is disclosed for mechanically laying and joining building panels, especially hard floating floors and fine. In this patent it is disclosed that the adjacent joining edges of two panels mesh together to provide a mechanical connection that interlocks the joining edges in a first direction perpendicular to the main plane of the panels. This patent indicates that a strip is provided in each joint which is integrated, or integrally formed, with one joining edge and projecting behind the other joining edge. This patent also indicates that the strip has interlocking elements projecting upwards engaging in an interlocking pocket on the rear side of the other joining edge to form a second mechanical connection interlocking the panels in a second direction parallel to the main plane of the panels. panels and at right angles to the joint. Both the first and second mechanical connections allow the mutual displacement of the joined panels in the sense of the joint. The patent indicates that the strip is factory mounted on the underside of the panel and extends across the entire joint edge. This patent discloses that the strip can be made of flexible, elastic aluminum and can be fixed mechanically, by means of glue or any other suitable way. The patent teaches that, alternatively, the strip can be formed integrally with the slat panel. According to this patent, "in any case, the strip 6 must be integrated with the panel, that is, it must not be mounted on the slat panel in connection with the laying".

In US Patent No. 5,860,266, entitled "Method of Joining Building Boards", a method is disclosed for laying and mechanically joining rectangular building panels in parallel rows. This patent discloses the following steps: (a) the placement of a new panel of the adjacent panels on a long edge of a first panel previously laid in a first row and on the short edge of a second panel previously laid on a second adjacent row in such a way that the new panel is in the second row while holding the new panel at an angle relative to a main plane of the first panel, in such a way that the new panel is separated from its final longitudinal position in relation to the second panel and in such a way that the long edge of the new panel is provided with an interlocking pocket which is placed in contact with an interlocking strip in the Adjacent long edge of the first panel, (b) then downward angulation of the new panel to accommodate an interlocking member of the strip of the first panel in an interlocking pocket of the new panel, whereby the new panel and the first panel are mechanically connected to each other in a second sense with respect to the long edges thus connected, where the long edges and the downward angled position of the new panel are meshed with each other and thus , locked together, mechanically, in a first sense too, and (c) the movement of one of the new panels in its longitudinal direction in relation to the first panel towards a final longitudinal position and towards an interlocking element of one of the short edges of the new panel and the second panel remains caught inside. of the interlocking pocket of the other of the short edges, whereby the new panel and the second panel are mechanically connected to each other in both the first and second directions with respect to the connected short edges. This patent teaches that the strip 6 projects horizontally from a panel and is factory mounted on top of the underside of the panel and extends over the entire edge of the panel. This patent indicates that the strip 6 can be made of flexible and elastic aluminum sheets and can be fixed, mechanically, by means of glue or in another appropriate way. This patent indicates that other material can be used for the strip, such as sheets of other metals, as well as aluminum or plastic sections. Alternatively, this patent shows that the strip 6 can be formed integrally with the slat panel. This patent states that "in any case, the strip 6 must be integrated with the slat panel, that is, it must not be mounted on the slat panel in connection with the laying".

In Japanese patent application number 565347, entitled "Procedure to partially recover floor plates" are disclosed floor plates laid on the floor bed with herringbone joints meshed with pocket joints. This patent indicates that a saw is inserted into gap A between both side screed plates of a floor plate to be changed and the tenon joints are cut, thereby cutting the connection between the screed plates and the plate. of soil to be changed. This patent teaches that the tenon joints, left in the pocket joints of the adjacent flooring plates, are then disassembled. The portion where there were previously herringbone joints in the floor plates is cut off and pocket joints are formed again. This patent states that a new floor plate is shown in Figure 4 and that relatively shallow and wide grooves are formed along both sides of the floor plate in relatively deep concave portions. The bottom of the concave portion is indented to hold a foamy synthetic resin. Then the new floor plate is inserted in the position where the removed floor plate was located and in a state where the new floor plate is level with the adjacent floor plate. Foaming resin is cellular and hardened. The hardened foaming resin expands within the pocket joints to form a spigot joint. It should be noted that the new floor plate in contact with the floor bed is fixed by means of an adhesive.

In Japanese patent application number 130691, entitled "Floor plates" are disclosed

ES 2 240 290 T3 floor plates to be laid on a floor floor characterized in that it has a thin decorative laminated wood plate on top of the surface plate of a base material in the form of a sheet. On one side of the base material a meshing projection is formed while a concave meshing portion, to which the anterior meshing projection can be meshed, is formed at the other end thereof. This patent shows that floor plates can include a retaining boss formed on one side of the locking boss and on one side of the concave locking position, and a concave retaining portion, to which the retaining boss engages, it is formed on the other side of the interlocking concave portion.

In German patent number 200949, in Figures 1 and 2, panels for floors with four edges are disclosed in which two edges include an upper pocket for the insertion, below it, of an adjacent panel, while the Two other edges include an extension that includes a tooth formed to insert under the upper pocket portion of an adjacent panel when assembled.

In German patent number 1,534,278 it is indicated in Figures 1 to 3 how two adjacent structures are assembled in which the first structure includes a pocket and a notch to receive the corresponding spike and tooth of an adjacent structure to be connected to the same.

Document 25 02 992 discloses a panel suitable for floors, especially for use in the construction of a temporary floor, as for example in a tent. This flooring panel is noted to have a smooth fiber surface folded back on at least two edges, one of which is given a different profile and the other with a matching counter-profile. This patent shows that it is preferable that those folded sections are on two opposite sides, one having an approximately U-shape with its outer stem and the resulting slot-like opening facing upward and the counter-profile formed by a stem at right angles to the fiber surface. . This patent indicates that such profiles can alternatively be installed on all four panel edges and reveals that the panels can be made of plastic and formed with one-piece corrugated projections, preferably under a softer material. As illustrated in Figure 3, the panels are assembled together using a tenon and pocket arrangement.

In 3041781A1 the internal connection of two panels is disclosed in which the panels include a tenon on one edge and a pocket on the other edge to provide interlocking connections between two panels used, especially, to construct a skating rink or bowling alley. This patent discloses that at the root of the spike there are two parallel sides with facing pieces aligned at right angles to the edge of equal thickness. The patent also discloses that the pocket has two initial side walls against which the pieces of the side faces of the pin come to rest. It is also manifested that this part of the pocket is succeeded by a recess with a semi-trapezoidal shape or a recess with a completely trapezoidal shape. Said patent discloses that the spike may be rounded on the side opposite the lateral face at an acute angle.

Document 35 44 845 A1 discloses a board used for the manufacture of solid wood panels that is formed by glued slats that mesh with complementary profiles. The longitudinal edges of the slats have a joint profile the sections of which extend at an angle to the vertical edge of the slat. This patent application discloses that the joint profile has two upwardly offset, parallel, vertical flanks which are connected at their inner ends by means of straight transverse flanks. The upward and inward flank encloses an acute angle with the slat surface, while the other flank forms an obtuse angle with the associated slat surface. The vertical flanks and the transverse flanks enclose acute angles.

In the European patent application number 0248127, entitled "A table top for a car truck", a table top for a car truck is disclosed consisting of a plurality of plates fixed to at least two joists that are part of the chassis. of the automobile truck. These plates are formed from extruded aluminum and are fixed to the chassis by means of staples with the plates interlocking to secure the plates against relative movement between them.

In 843067 (PCT / SE 83/00423) a means for interlocking adjacent panels is disclosed in which the edges of the panels to be connected include pins and pockets. Furthermore, positioned on either side of the spike and socket joint of two connected panels are recesses formed in said panels to receive a U-shaped clamp means for holding the two panels together at the spike and socket joint.

French application number 2,697,275 discloses the formation of a surface starting from rectangular shaped tiles laid on a flat horizontal surface. This application discloses that the body of the tile has tailored sections on all four sides and the tiles can be joined together by mechanical means via a number of ribs running longitudinally along the tile, which are adapted accordingly. so that they slide into a matching pocket on the adjacent tile. In Fig. 2 it is shown that a member 33 is disclosed for connecting two adjacent tiles. As shown the upper surface of the member 33 forms a portion of the resulting upper wear surface of the soil. This can also be seen in Figure 1 where members 5 and 6 form a portion of the upper wear surface.

Figures 1 to 3 of Japanese application number 54-65528 show a particular pin and socket arrangement for interconnecting two adjacent panels.

French application 2,568,295 discloses a precast decking system consisting of a series of flat panels that are placed directly on the floor. The panels are made, for example, with a resin compound that contains reinforcing elements or that incorporates granules of a resistant material such as quartz or silicon carbide. This patent application also discloses that the panels have interlocking joints on all their edges, made to form projections and recesses, and that the bottom surface of each panel can be covered with a layer of flexible cellular material that does not decompose, which is able to compensate

ES 2 240 290 T3 irregularities in the ground surface.

British patent application number 424,057 discloses a procedure for constructing a parquet floor that comprises the use of reversible rectangular blocks each having projecting flanges that form sphenoidal pockets on each of its four sides, each pocket extending all over the side. in which it is located. The patent shows the pockets on two bordering sides with their mouths facing upwards when the mouths of the other two pockets, on the other two sides, face downwards, whereby with a plurality of such blocks a floor covering can be built wherein each block is nestled on each side that is contiguous with the side of another such block. It is also stated that this procedure comprises the use of connecting members with flanges adapted to mesh under the hanging flanges of two adjacent blocks when a change in the direction of placement is required.

In British patent number 1,237,744, entitled "Improved structure for construction", it is disclosed that it refers to a structure for construction composed of panels joined at their edges by first tenon and pocket connections with elements located in the plane. of the structure for construction as well as by second pin and box connections with elements located perpendicular to said plane.

In Figures 1 and 2 of British Patent No. 1,430,423, entitled "Bonding Structure", a specific pin and socket / notch and tooth bonding structure for interconnecting plastic and metal materials is disclosed.

In British Patent Application No. 2,117,813A, entitled "Pivoting Assembly for Simulated Wall Panels", a joint assembly is disclosed comprising a pair of strips attached to the edges of the respective panels by folding the outer liners of the panels. panels and by means of a dovetail joint joint in the foam insulation material within the panels. This application discloses that the connector strips provide a curved pin and pocket. The pocket strip has a pivotal body shaped in part cylindrical so that one strip can be pivoted relative to the other so that a pin enters the pocket. This application discloses that a connector strip has been installed to slide into the pocket and lock the panels together.

In British Patent Application No. 2,256,023A, entitled "Gasket", a gasket is disclosed between the joining side edges of two similar panels in which one panel has a channel section recess open towards the front face and the other panel has a recess-facing, rear-facing rib to restrict spacing of the panels to provide a predetermined expansion gap between adjacent side edges. This application discloses that the panels can be herringbone and pocket boards for the construction of, for example, a door. In its figures this application discloses a particular tenon and pocket / notch and tooth joint.

In the figures of document number 157871 the connection of two adjacent members is disclosed using a spigot and pocket joint at the edges and in which recesses are included, formed in said panels, separated from the joint, to receive a member in U shape to hold the two panels together at the herringbone and pocket joint.

In Figures 1 to 3 of document number 7114900-9 a means is disclosed for connecting two adjacent members using connecting blocks 2, 5 and 9 in which said blocks form a part of the upper wear surface. This application further discloses a U-shaped member for insertion on the rear side of the panels to hold two panels together at the joint where the joint block exists.

In WO 84/02155, entitled "Device for joining building boards, such as floor boards", a device for joining building boards, such as floor slats, is disclosed from edge surface to surface of edge. This application discloses a system in which the slats comprise a pocket on the back side of each slat, the pocket running along the entire length of the slat parallel to its joining edge, and an almost U-shaped spring device, each of the legs of which is adapted to mesh with the pocket of a slat, and which is prestressed such that, after engagement, the slats are hermetically stapled together edge surface to edge surface.

In Figures 1 to 6 of document 200949, panels are disclosed for joining one to the other in which the panels include herringbone strips that extend on two intersecting edges and pocket strips that extend on the other two edges. intersectors.

In WO 93/13280, entitled "Device for joining floor slats", a device for joining floor slats is disclosed comprising an elongated, flat body with legs adapted to mesh with a longitudinal pocket in each of the floor joint strips. The legs are shaped at a distance from the ends of the plate-shaped body such that the plate-shaped body supports the slats on either side of the pockets.

In US Pat. No. 3,538,665, entitled "Parquet decking", a floating parquet decking is disclosed comprising rectangular-shaped two-layer decking units composed of a parquet layer and a backing layer, the underside being equipped with fringe recesses along the four sides of each unit and a strip of backing layer material being inserted into the space formed by such fringe recesses to bridge the junction between adjacent units. This patent reveals that the material of the backing layer has a modulus of elasticity in tension that does not exceed 5,000 kg / cm².

In 26 16 077 A a connecting frame with a flange for connecting plates lying flat on a supporting substrate is disclosed. This patent application discloses that this arrangement is especially useful for connecting prefabricated parquet flooring elements. This application discloses that it provides a collapsible connection arrangement which replaces rigid connections such as adhesives or nails. This application states that the system has its advantages in that it absorbs expansion and contraction stresses thereby avoiding cracking. It is also noted that the connection pattern prevents overlapping of plate edges on uneven substrates and during

ES 2 240 290 T3 use the connection frame is loaded in tension when the plates expand. In the contraction of the plates, the connection weft brings the plates together and prevents the formation of gaps.

In Figures 1 to 3 of French patent application number 1,293,043 a tile with four edges is disclosed in which one set of intersecting edges includes a tenon extending therefrom and the other two intersecting edges include a pocket open in the direction of the bottom side of the tile. In Figures 4 to 6 are disclosed tiles with four edges in which two intersecting edges include a notch and a pocket open towards the upper side of the panel and the other two intersecting edges have a notch and a pocket open towards the bottom of the panel. panel.

In document 8206934-5 the joining of two panels is disclosed in which a tenon and pocket arrangement is used. The drawings further disclose a U-shaped staple for insertion into the panels on either side of the joint to hold the two panels together at said joint.

In document WO 97/47834, entitled "Floor covering consisting of rough wood panels and processes for manufacturing such floor panels" a floor covering consisting of rough wood panels for floors is disclosed which, at least, on the edges of two opposite sides, they are equipped with mating parts that cooperate with each other. These coupling parts are almost in the form of pins and pockets characterized in that the parts are equipped with integrated mechanical interlocking means. The interlocking means prevents the separation of two coupled floor panels in a direction perpendicular to the related edges and parallel to the underside of the coupled floor panels.

In WO-A-00 20706 a vertically bonded flooring material is disclosed comprising floor slats, which floor slats are provided with edges which are equipped with a pocket, a bottom side and an upper decorative surface. . The floor boards are intended to be joined by means of separate joining profiles. Each of all the edges is equipped with a pocket, the pockets of which are arranged in parallel with their respective edge. The joining profiles are provided with ribs arranged in pairs, the ribs of which are intended to be received by the pocket of a floor board that guides and fixes floor boards in the horizontal direction. The joining profile is equipped with a central cheek section which is comprised of a first and a second elastic cheek independently. Each of these cheeks is equipped so that each of the pins is intended to be received by each of the pockets so that the adjacent floor slats are guided in a vertical direction.

The object of this invention, in view of the prior art, is to provide a more flexible interconnecting decking system, in particular when different panel shapes are combined.

Summary of the invention

This object can be achieved by means of a detachable interconnecting decking system as claimed in independent claim 1. Further enhancements are claimed in the dependent claims.

The present invention is directed to a unique and novel system for easily joining and detaching a floor covering surface, preferably a thin laminate flooring surface (less than 2.54 cm thick) of the "floating" type. This system is designed in such a way that traditional fasteners, such as nails, points, screws, adhesives, thumbtacks, staples, etc., are unnecessary. The system of the present invention accomplishes this task without the need for special tools or experience in laying floors. The system of the present invention achieves its advantages by using, preferably, joining panels which are preferably identical new edges which are preferably identical, making assembly easy and flexible, even for the novice. Furthermore, the system of the present invention provides a simple connection means for use in connection with all novel panel edges, again making assembly and disassembly easy. More importantly, due to the fact that at least two edges of the panels have recesses, formed therein during manufacture, either less reinforcing intermediate substrate material is needed to manufacture the panels and thus save resources. , and / or less decorative top surface material is wasted, that is, it is not necessary to remove as much of the top wear surface portions to provide the interconnect system of this invention.

A further advantage of this invention is that the panels can be oriented in either direction, during installation, without the need to mechanically modify a factory made tenon or pocket profile. These panels can be manufactured in a cost-effective manner (there is no herringbone profile to machine). The amount of material (approximately 0.3175 cm wide) required to create the herringbone profile, by mechanical means, does not have to be machined. The result is a significant cost reduction due to the elimination of the tooling needed to produce the herringbone profile. This also results in a net salable surface area of ​​0.3175 cm. Material that was previously machined to form a herringbone profile (approximately 0.3175 cm thick) is now machined into a pocket profile. Creating a pocket, as opposed to a tenon, provides additional surface area. A larger surface area results in higher revenue because the surface area is made available for sale rather than machining and disposal.

The system of the present invention also eliminates "seam swelling" or "pitting" caused by typical herringbone and pocket systems. When moisture (water) penetrates the seam from above the ground or reaches the seam from the underside of the floorboard panel, the seam profile swells. By way of explanation, the profile of the spike will grow in size and the profile of the pocket will contract in size. This will cause the entire thickness of the paper to change (thickness growth) in the area of ​​the seam. The result is the "chip" directly above the seam area. Since a flanged connector is used in the present invention to make the joint between two panels, the flange is no longer made of a moisture wicking material. Thus, there is no spike that expands after moisture absorption.

ES 2 240 290 T3 whereby "chipping" is no longer a problem when using the system of the present invention.

Brief description of the drawings

The present invention is better understood by reading the description that follows of non-limiting embodiments with reference to the accompanying drawings in which the like parts in each of the various figures are identified with the same reference characters and which are briefly described below. :

Figure 1 illustrates an embodiment of the connector that is not part of the present invention;

Figure 2 illustrates an embodiment of the connector that is not part of the present invention;

Figure 3 illustrates an embodiment of the connector that is not part of the present invention;

Figure 4 illustrates an embodiment of the connector that is not part of the present invention;

Figure 5 illustrates an embodiment of the connector that is not part of the present invention;

Figure 6 illustrates a preferred embodiment of the connector of the present invention;

Figure 7 illustrates one embodiment of the connector of the present invention;

Figure 8 illustrates an embodiment of the connector that is not part of the present invention;

Figure 9 illustrates an embodiment of the connector that is not part of the present invention;

Figure 10 illustrates an embodiment of the connector that is not part of the present invention;

Figure 11 illustrates an embodiment of the connector that is not part of the present invention;

Figure 12 illustrates an embodiment of the connector that is not part of the present invention;

Figure 13 illustrates an embodiment of the connector that is not part of the present invention;

Figure 14 illustrates a preferred embodiment, in particular, of the connector of the present invention (9x scale; 1.00 = 2.54 cm);

Figure 15 illustrates a shaded view of a preferred embodiment of the connector of the present invention;

Figure 16 illustrates one embodiment of the connector of the present invention;

Figure 17 illustrates one embodiment of the connector of the present invention;

Figure 18 illustrates a preferred embodiment of the connector of the present invention and a preferred embodiment of the panels of the present invention;

Figure 19A is a plan view of a panel with truncated pockets in the backing layer;

Figure 19B is a front view of the panel of Figure 19A;

Figure 20A is a plan view of a connector with angled ends;

Figure 20B is a front view of the connector shown in Figure 20A;

Figure 20C is a side view of the connector shown of Figures 20A and 20B;

Figure 21 is an elevational view of a partially assembled section of floor covering comprising square panels and angled end connectors;

Figure 22 is an elevational view of a partially assembled section of floor covering comprising square and triangular panels and angled end connectors;

Fig. 23 is an elevational view of a partially assembled section of floor covering comprising rectangular panels, transverse connectors, and longitudinal connectors;

Figure 24A is a plan view of a cross connector;

Figure 24B is an end view of the cross connector shown in Figure 24A;

Figure 24C is a side view of the cross connector shown in Figures 24A and 24B;

Figure 25 is a side view of an assembled cross connector with two longitudinal connectors showing front views of the longitudinal connectors;

Figure 26A is a plan view of a rectangular panel with complete pockets;

Figure 26B is a front view of the panel shown in Figure 26A; Y

Figure 27 is a plan view of a decking system with hexagonal and triangular shaped panels.

However, it should be noted that the attached drawings only illustrate typical embodiments of this invention and therefore should not be considered as limiting its scope, since this invention may admit other equally effective embodiments.

In a preferred embodiment the present invention is directed to panels, squares, tiles, rectangles, etc., of decorative flooring laminates each having a top wear surface, a middle substrate or reinforcing material below the top surface and, as option, a backing layer surface bonded to the middle substrate material for contact with the existing or supporting soil, or ground surface.

It is preferable that the upper wear surface of the panels of the present invention comprises decorative laminates or laminates prepared by heat and pressure setting. These panels have been manufactured on a commercial scale for a number of years and have found wide acceptance in the construction and furniture industry such as countertop and table tops, kitchen and bathroom work surfaces, wall paneling, partitions, partitions and doors. Such decorative laminates can be described as containing a number of sheets that are consolidated to form a composite or unitary structure bearing a surface decoration which can range from something as simple as a strong color to something as complex as a faux finish. stamped wood grain.

More specifically, a decorative laminate useful in the present invention generally comprises a plurality of layers of synthetic resin impregnated paper sheets consolidated or bonded together within a unitary structure under heat and pressure. In normal practice, this decorative laminate assembly consists, from the bottom up, in a core of one or more sheets impregnated with phenolic resin, above which is a decorative sheet impregnated with melanin resin and / or a Melamine resin impregnated overlay. The core or base member functions to impart rigidity to the laminate and typically comprises a solid substrate which may or may not be formed prior to the initial lamination step. The core sheets are impregnated, prior to stacking, with a solution of alcohol and water with phenol and formaldehyde or a precursor of formaldehyde, dried and partly cured in a

ES 2 240 290 T3 hot air oven and, finally, cut into sheets. Examples of such a base or core member include: (1) a plurality of sheets of kraft paper from 41 to 68 kilos per ream, impregnated all over and bonded with an almost completely cured phenolic resin which has been converted to a state of thermosetting during the initial lamination stage, ( 2) a pre-cured plastic laminate such as glass fiber reinforced thermoset polyester resin laminates or the like, (3) a wood product such as hardwood, wood pulp board, waste wood, plywood or the like, (4) a mineral-based cardboard such as cement and asbestos cardboard, pile of sheets, gypsum cardboard and the like; (5) plastic impregnated cartons, (6) plastic and wood compositions, (7) plastic composites, (8) polyurethane foam with closed cells, e.g. RIM foam, (9) urethane impregnated cartons, (10 ) a combination of these substrates; or (11) any suitable material to perform the desired function in the base or central member.

The decorative sheet, useful in the panels of the present invention, functions to generally give an attractive appearance to the laminate and also to give the panel its surface characteristics (i.e. resistance to chemicals, heat, light, shock and abrasion). Typically, this sheet is made of a high quality, pigmented alpha cellulose paper weighing 22.7 to 68.1 kilos per ream that has been impregnated with a solution of water and alcohol with melanin-formaldehyde resin, partly dried and cured and finally cut into slices. This decorative sheet can be of strong color or it can contain a decorative design or pattern, or a photographic reproduction of natural materials such as wood, marble, leather, etc. As indicated above, the decorative sheet and / or the overlay sheet can be impregnated with melanin resin.

The decorative laminate, useful in the manufacture of the panels of the present invention, can, in general, be obtained, but not limited to it, by placing the core and the decorative sheets, impregnated with resin, between plates covered with steel, plates of steel or stainless steel and subjecting the stack of laminates to temperatures in the range of from about 65.56 ° C to about 260 ° C and to pressures ranging from about 56.25 kg / cm² up to about 112.5 kg / cm² long enough to consolidate the laminate and cure the resins (generally about 25 minutes to an hour). This causes the resin to flow into the paper sheets, cure and consolidate the sheets into a unitary or composite laminate mass referred to in the art as high pressure decorative laminate (HPDL). More than one laminate can be formed at the same time by inserting a plurality of assembled sheets in a stack with each set being separated by means of a release sheet which allows each laminate to be separated after consolidation. Finally, decorative laminates are processed one more time and generally bonded to a reinforcing substrate, such as medium or high-density pulp board, wood-plastic compositions, woods, plywood, wild wood, asbestos cardboard, wood particle board, ceramics, loaded and unloaded plastics, rigid foams with closed cells, or the like. If a cushioning effect is desired, the reinforcing substrate may consist of open cell foam.

Decorative laminate useful in the practice of the present invention can be obtained by placing the core and decorative sheets, impregnated with resin, between coated steel plates, steel plates or stainless steel and subjecting the stack of laminates to temperatures within the range from approximately 65.56 ° C to approximately 260 ° C and at pressures varying below approximately 56.25 kg / cm² up to approximately 112.5 kg / cm² long enough to consolidate the laminate and cure the resins. This causes the resin to flow into the paper sheets, cure and consolidate the sheets into a unitary or composite laminate which is referred to in the art as low pressure decorative laminate (LPDL).

Furthermore, according to one embodiment, the reinforcing substrate of the present invention can be prepared starting from any suitable extrudable thermoplastic, as long as it has the structural and mechanical properties necessary for the end use for which it is desired. In particular, it is preferable that the substrate has a compression fit that is approximately the same or better than conventional medium or high density wood pulp board or fibreboard (in which the compression fit measured according to ASTM F970, as thickness decreases as a function of compressive stress). It is preferable that this decrease in thickness, to 140 kg / cm²It is at most 0.254mm, more preferably at most 0.127mm, and most preferably at most 0.0254mm.

The backing substrate, useful in the practice of the present invention, may comprise one or more members selected from the group consisting of rigid urethanes (eg, RIM foam), poly (acrylonitrile, styrene, and butadiene resins (referred to herein as ABS). below) such as flame retardant ABS resins, fiberglass filled ABS resins, polycarbonate, high impact polyethylene (HIPS), polyethylene, polyphenylene oxide (PPO), and polyvinyl chloride (PVC). It is preferable that the reinforcing substrate is prepared starting from a mixed resin system containing, but not limited to, one or more of the polymers listed above. In addition, these polymers can be filled or unfilled, although from the point of view of impact resistance and physical properties, filled polymers are better. Preferred fillers include calcium carbonate, talc, silicon dioxide, glass fibers, aluminum oxide, and wollastonite, with calcium carbonate and wollastonite being more preferred, and calcium carbonate being most preferred. Non-limiting examples of reinforcing agents include high molecular weight inorganic or organic products, including glass microspheres, glass fibers, asbestos, boron fibers, carbon and graphite fibers, aluminum oxide fibers, oxide fibers. metallic, quartz fibers and aluminum oxide, fused fiber materials and organic fibers. When such conventional ingredients are used, they may generally be present in a range of from about 0.01 to about 50 percent by weight of the total weight of the reinforcing substrate member, with the range of from about 1 to about 50 being preferable.

ES 2 240 290 T3 weight percent of the total weight of the limb.

Additional optional layers may be inserted between the center member and the decorative surface member, on the back of the reinforcing substrate member, or on top of the decorative surface member. It should be understood that the backing layers and / or the decorative layers can be coextruded with the reinforcing substrate member, or they can be applied after the extrusion step by any suitable method.

It is preferable that the panels, according to an embodiment of the present invention, are water repellent and most preferably they are substantially waterproof. As with conventional floor panels, the present panels include a decorative layer, a substrate, and a backing layer. The decorative layer and the backing layer are respectively bonded to the substrate in a conventional manner to form the present panel. According to a preferred embodiment of the present invention, when the reinforcing substrate material is wood pulp cardboard, the backing layer includes, from bottom to top, a hydrophobic impermeable layer and three layers of kraft paper impregnated with phenolic formaldehyde resin. As with the lower resin impregnated layer of the decorative layer, the upper resin impregnated layer of the backing layer is sanded to bond with the substrate. The hydrophobic waterproof layer can be a compound such as DYLARK. DYLARK is a copolymer of styrene and maleic anhydride manufactured by NOVA Chemicals, Inc. DYLARK exhibits remarkable bonding characteristics with phenolic resin impregnated kraft paper. These excellent binding characteristics are believed to be the result of carboxyl groups found in the maleic anhydride of the DYLARK copolymer. The carboxyl groups bind to the phenolic resin to produce a very stable laminate. Although DYLARK is disclosed as the preferred material for the lower backing layer, other functionally and structurally equivalent polymers may be used without departing from the spirit of the present invention. It is desirable not only to prevent moisture from penetrating the backing layer but also to maintain the original moisture content at the time of panel manufacture to prevent sagging of the panel.

Furthermore, although kraft paper impregnated with a phenolic formaldehyde resin is used, in accordance with a preferred embodiment of the present invention, other resin impregnated papers (or similar materials) can be used without deviating from the spirit of the present invention. The resin impregnated layers are kept in the present backing layer to balance the resin impregnated decorative layers which are commonly found in decorative layers used in conjunction with the backing layer. That is, the resin impregnated layers in the decorative layer and the backing layer similarly expand and contract as a result of temperature to maintain the nearly flat configuration of the flooring panel. If the resin impregnated layers were not included, in the backing layer, the decorative panel would expand and contract at a different speed than the backing layer. This would cause the panel to warp in an undesirable manner. As such, those of ordinary skill in this art should appreciate that the phenolic layers can be varied to maintain a balanced relationship between the backing and decorative layers.

As indicated in accordance with one aspect of this invention, the substrate is a poly (acrylonitrile-c-butadiene-c-styrene) (ABS) foam. The construction of the backing layer and the substrate results in a waterproof panel for floors which is not susceptible to being detrimental to the environmental conditions that are common in certain environments. Specifically, the ABS substrate and the styrene-maleic anhydride copolymer layer create a moisture barrier which protects the resin-impregnated layers from the undesirable effects of moisture.

The above-described floor panels are manufactured using methods known in the art. During manufacture the panels can be machined to form the appropriate recesses at the edges or, preferably, they can be manufactured when at least two edges have recesses formed therein during panel manufacture and thus reduce the amount of material needed to make the panel. Furthermore, the panel of the present invention can be manufactured, according to one embodiment, using injection molding techniques in which all edges are formed.

The connector of the present invention includes a number of embodiments however the embodiments shown in Figures 1 to 5, 8 to 13, 23, 24a to 24c and 26a to 26b do not form part of this invention but are useful in understanding the herself. Referring now to Figures 1 to 18, in which the same numbers are used to identify components in the front views of a connector of various embodiments of connector 1 shown, the connector comprises a base 2 and an extension 15 Base 2 is a nearly flat portion to rest on the ground or surface to be covered with mounted panels and connectors. Extension 15 is a projection that has the shape of a "T" with a vertical support 3 and two horizontal flanges 4 and 5. Support 3 is the vertical part of the "T" and flanges 4 and 5 are the portions that they extend vertically at the top of the "T". As shown in many of the exemplary embodiments, the connector 1 has the flanges 6 and 7 that extend vertically from the base 2 near the distal ends of the base distal from the center where the bracket 3 is attached to the base 2. In yet other embodiments the connector 1 has the depressions 8 and 9 in the upper surface of the base 2 immediately adjacent to opposite sides of the bracket 3. In some embodiments, the connector

I has, at the distal ends of flanges 4 and 5 of the T-shaped extension 15, projections 10 and

II that extend vertically. Other embodiments of connector 1 further include notches 13 and 14 which are located on the underside of the proximal ends of flanges 4 and 5 where they are connected to bracket 3. It is preferable that the system of the present invention comprises a connector 1 with a T-shaped extension and ribs 6 and 7 and panels with recesses and channels in such a way that two panels can be interconnected, so that they can be uncoupled, using the connector horizontally and vertically without the use of glue or other adhesives.

It is preferable that the connector has a height of less than 6.096mm.

The connector of the present invention can be manufactured with materials selected from the group forma11

ES 2 240 290 T3 made of loaded and unloaded plastics, rubbers, wood compositions, ceramics, metals and combinations thereof. In the use of preferred laminate panels for flooring it is preferable that the connector of the present invention is made of plastic or metal. The connector, depending on the material and size, can be manufactured using methods known in the art, for example, it is preferable to manufacture the connector with aluminum.

The panels of the present invention include recesses formed therein, shaped to receive a connector such that, when the panels are connected, the upper surface visible to the floorboard consists only of the upper wear surface, that is, it is preferably the decorative layer. The connector projections and panel recesses are formed in such a way that, when two panels are joined together, using a connector of the present invention, the panels are connected to each other vertically, that is, if two panels are connected. at their edges, the edges of the opposing panels do not move up or down (vertically) relative to each other and thus provide a uniform level seam between the two. In a preferred embodiment, for example, once the panels are connected, they are engaged against movement with respect to each other in the direction of a plane extending vertically from and perpendicular to the supporting surface.

The panels, in a particularly preferred embodiment, in addition to the vertical connection, are shaped to provide a horizontal connection between adjacent panels at their edges, that is, if two panels are connected at their edges, the edges cannot move the one horizontally on the other, resulting in a gap between adjacent panels. For example, and according to a preferred embodiment, once connected, the panels are engaged against movement with each other horizontally to and parallel to the support surface.

Various non-limiting embodiments of the connector have been described and, although not shown, the panels of the present invention need to be configured, for example, to correspond to those connectors to obtain the advantages of the present invention, being to understand that the panels can be configured to provide either an exact fit with the connectors or a non-exact fit, as long as the advantages of the present invention are obtained. For example, when it is desired to obtain a permanent structure, an embodiment that allows room for the glue to accumulate between the panels and the connectors may be appropriate. Also when using certain materials for the reinforcing substrate it may be desirable for the panels and connectors to fit exactly together, especially when a temporary structure is desired. For example, some space between certain portions of the connector projections and panel recesses can be tolerated as long as the advantages of the present invention are achieved, especially a resulting floor with only a visible wear surface with uniform seams. leveled.

The panels are constructed in such a way that they connect, so that they can be uncoupled, with the connectors of the present invention, that is, even though the connectors and panels are securely connected to perform the function of a tile surface. , the panels can, if desired, be removed by lifting a panel and separating the panel from the connector, uncoupling the interconnection between panel and connector.

According to one embodiment, the panels of the present invention are constructed in such a way that, when connected to each other using the connector of the present invention, they always form a tight uniform level seam between the panels. The panels, according to a preferred embodiment, are constructed in such a way that the depth of the recess or channel in the lower surface of each panel is always at a certain distance from the upper wear surface. As discussed above, these recesses or channels are shaped to receive a protrusion projecting from the base of a connector (a track is preferred) to interconnect two panels horizontally so that they can be disengaged. Thus, both panels rest on the connector at the point of interconnection. Therefore, even when the supporting structure or the floor of the floor is not uniform or not level, the seam is always tight, uniform and level. Thus, even if the thickness of the panels varies, a uniform level structure is provided when the two panels are interconnected because the depth of the recesses or channels is formed, on the lower surface of each panel, to be at a certain distance from each other. top wear surface. Therefore, the upper wear surface of two adjacent panels will always come to rest at the same level, that is, a certain distance from the protrusions on the base of the connector. It is preferable that the panels of the system of the present invention range in thickness from about 6.096mm to about 8.128mm. According to another embodiment the panels are less than 2.54 cm thick.

The system of the present invention also provides panels in which nearly the entire top wear surface of the fabricated laminate is utilized and thus provides an economic advantage over many prior art systems. With the use of the system of the present invention, the amount of top wear surface that needs to be machined to remove any part of the top wear surface, already manufactured and paid for, is greatly reduced. Almost all of the manufactured upper wear surface is sold to the end user, eliminating the waste experienced in prior art systems. As a result, the salable square meters of decking, manufactured by a factory, increases and costs are reduced.

Furthermore, the connectors of the present invention are not fixed, at the factory, to the panels and, thus, it is not necessary to apply any adhesive, or other means of joining, reducing, again, the material costs, labor costs of work and manufacturing time. In a preferred embodiment the panels are manufactured, with all recesses formed therein, using injection molding techniques. In another preferred embodiment, in which the middle panel reinforcing substrate is extruded, only two edges have to be machined to form recesses therein, since the other two edges running in the machine direction are formed during machining. extrusion. All of the above brings additional savings due to the fact

ES 2 240 290 T3 that the amount of material used for the reinforcing middle substrate is reduced, that is, it is never produced.

The system of the present invention also provides panels that are less susceptible to damage than the pin and pocket systems of the prior art. For example, panel dowels are known to be susceptible to damage during shipping, handling, assembly, and disassembly. If a tenon is broken or deformed almost completely, it will not be able to engage the pocket on the adjacent panel and will therefore be rendered useless. The panels of the present invention do not include tenons, only have recesses or pockets formed therein. It is difficult, if not impossible, to damage a recess or cashier during shipping, handling, assembly and disassembly. Thus, the panels of the present invention are stronger than many prior art panels. This is an important advantage over using the panels for "floating floor" surfaces and for temporary floor constructions which will be disassembled and reassembled many times. The system of the present invention provides connectors (preferably made of metal) that are quite hard, and easy and inexpensive to change, when compared to the cost of a new panel. The systems of the present invention substantially reduce, if not eliminate, the risk of damage to the panel to the point of rendering it inoperable.

The parquet system of the present invention provides a flooring surface that is easy to repair and / or change. The panels of the present invention do not require a unidirectional laying sequence, so a damaged panel can be disassembled and replaced by first removing adjacent panels in either direction. Adjacent panels can be removed in the direction that has the fewest number of panels, in order to simplify the removal and replacement process. The system of the present invention almost completely reduces the time and aggravation of panel removal and replacement. Furthermore, since the floor can be built in multiple directions, more than one person can simultaneously build different portions of a single deck surface. According to a method for mounting, the panels are laid out in a central portion of the floor space and added outwardly from the center. This is especially advantageous in connection with the installation of flooring in large areas, eg retail spaces.

The panels of the system of the present invention also provide substantially more aesthetic flexibility than prior art panels. For example, as the panels are not right- or left-hand, that is, one-way or unidirectional, but instead are multi-directional because all edges are identical, each individual panel can be placed on the floor surface. that it is being built in the most attractive way to the eye Furthermore, the panels of the systems of the present invention allow flexibility in the design and construction of surfaces with parquet-type floors. For example, it is known that, it is usual, that a panel is manufactured with the grain running in the machine direction, however, since the panels of the present invention are multidirectional, the direction of the grain can be easily alternated in the parquet surface, or on a floor of any veined pattern.

The panels of the present invention also reduce waste during floor construction. With the panels of the present invention, each panel is constructed with pockets on all edges so that any portion of the panel that remains after completing the floor to a portion of the end wall can also be used to complete another portion of the floor to the bottom. end wall.

The panels of the system of the present invention are manufactured in such a way that to mount two panels together it is not necessary to hold one panel at an angle relative to the other panel and the new panel can be angled downward to place it in place. The fact that the panels can be interconnected by forcing two panels to come together while they are resting in the same plane is very advantageous in relation to the construction of certain portions of floor surfaces challenged by various physical barriers, for example, the junction between a floor surface and a chimney.

Referring now to Figure 6, the preferred embodiment of the connector 1 of the present invention comprises a base 2, an extension 15, ribs 6 and 7 that are spaced from, and on either side, of the extension 15 and projecting vertically from the base 2. It is preferable that the ribs 6 and 7 are rounded at the top, as shown, and tapered, that is, they decrease in height as we move away from the center of the base 2 towards the end of said base. Thus, the portion of the ribs closest to the center of the base 2 and of the extension 15, extends the greatest distance vertically.

In figure 14 a particularly preferred embodiment of the connector 1 of the system of the present invention is shown. The scale in figure 14 is nine times the actual size. However, it should also be understood that, although not shown, the base 2 of the connector 1 can be constructed in such a way that it does not touch the support structure, that is, when the connector is fully embraced by the two panels that are connect.

Referring to Figures 19A and 19B there are shown top and front views, respectively, of a square panel 20. Panel 20 has a top wear surface 21, a middle substrate 22, and a backing layer surface 23 In the embodiment shown, panel 20 has four pockets 24 in middle substrate 22 on each of the four sides of panel 20. In addition, panel 20 has four channels 25 on the surface of backing layer 23 that run parallel to, and slightly spaced from, each of the four sides of panel 20.

In an alternative embodiment (not shown), two or more channels 25 are formed, in the surface of the backing layer 23, adjacent to each side of the panel 20. Of course, in this embodiment, the connector 1 has two or more ribs. corresponding (6 and 7) on each side of the connector.

Figures 20A to 20C show plan and front views, respectively, of the connector 1 for joining the panels illustrated in Figures 19A and 19B. Connector 1 has a base 2 and an extension 15, as indicated above. Base 2 has two ribs 6 and 7 on the upper surface. Extension 15 has a bracket 3 and two flanges 4 and 5. Extension 15 has a slot 12 in its upper part. The ends of connector 1 are at a 45 degree angle (see Figure 20A) to create the faces

EN 2 240 290 T3 end 16. Since end faces 16, at the same end, are each cut at 45 degrees, a 90 degree angle is formed at each end in the center of connector 1.

As shown in figure 21 a floor mounted section comprises square panels 20 joined together by means of connectors 1. The end faces 16 of two connectors 1 are placed in contact with each other when the connectors are attached to adjacent sides. single panel 20. An advantage of this configuration is that the upper wear surfaces of the panels 20 are fully supported by the connectors 1, even in the corners where the connectors 1 meet.

In an alternative embodiment some of the panels are made in triangular shapes. Triangular shapes increase the decorative possibilities for floor mounted cladding. One possible arrangement of an assembled floor portion is shown in figure 22. Of course, to join the triangular panels, different connectors 1 are needed, which must have end faces cut at 22.5 ° C in some cases and at 45 ° C. ° C in others.

In further embodiments the panels have square, rectangular, triangular, pentagonal, hexagonal, and octagonal geometries. According to the mounting systems of the present invention, it is possible to mount panels having these geometries because the panels and connectors are mounted while the panels are laid on top of the subfloor support. For example, Figure 27 shows a plan view of hexagonal panels 20 in a partially assembled floor system. Although the connectors 1 are used to make the connections between the panels 20, these connectors 1 are not shown for the sake of simplicity. Panel 20b is in position for connection to panels 20f and 20g. Since the panels 20f and 20g are already mounted they are laid flat on top of the subfloor support. Panel 20b is connected by laying this panel 20b flat on top of the subfloor and sliding panel 20b towards panels 20f and 20g. Contact with panels 20f and 20g is made simultaneously and panel 20b is quickly placed in a mating connection with the connectors (not shown) between the panels. Similarly, 20a is shown in position for connection to panels 20c, 20d, and 20e. Panel 20a is placed on the subfloor adjacent to the other panels so that it is in the same plane as the other panels. Panel 20a is then slid towards panels 20c, 20d and 20e until, simultaneously, contact is made with these panels.

A panel and connector assembly is better illustrated in Figure 18. The panels 20 are attached to the connectors 1 "rapidly closing" a flange 4, 5 of a connector 1 within the pocket 24 of a panel 20. By inserting the flange 4, 5 into the pocket 24 the initial contact is made. As the panel 20 and the connector 1 are made to move further towards each other, the rib 6, 7 slides from one side to the other of the surface of the backing layer 23 of the panel. When panel 20 and connector 1 have been fully moved together, flange 4, 5 extends fully into pocket 24 and rib 6, 7 "snaps" into channel 25. During the entire process, the base 2 of the connector 1 and the panel 20 remain almost in the same plane. Since the connector 1 and the panels 20 remain, during assembly, in the same plane, it is possible to simultaneously connect one panel to many other panels. This "snap fit" single plane mounting procedure allows the use of panels with various geometries, as noted above.

Shown, now with reference to Figure 23, is another configuration for the floor covering of the present invention comprising panels shaped to be rectangular. In this embodiment the panels 20 are joined by means of connectors of two independent types: the longitudinal connectors 30 and the transverse connectors 31. In one embodiment of the present invention the longitudinal connectors span multiple panels 20 and are therefore much longer than any given panel 20 in the longitudinal direction. In another embodiment of this invention, the longitudinal connectors 30 are approximately the same length as the panels 20 in the longitudinal direction. The transverse connectors 31 are approximately the same length as the width of the panels 20. The transverse connectors 31 extend at right angles between two parallel and adjacent longitudinal connectors 30. In the configuration shown in Figure 23 each set of panels 20, extending end-to-end in the longitudinal direction, is uneven from each set of adjacent panels running end-to-end in the longitudinal direction. As the panels terminate in different locations on each side of a particular longitudinal connector, the assembly is much stronger as the joints are dispersed more evenly throughout the assembly. If the ends of all the panels were not uneven from one row to the next, weaknesses would occur in the floor in a “four corner” area, where adjacent cross connectors 31 join a single longitudinal connector 30. Also for similar reasons, in some embodiments of this invention, the ends of the longitudinal connectors 30 do not coincide with the longitudinal ends of the panels 20 so that the connectors span at least two consecutive panels 20.

With reference to Figures 24a to 24c, inclusive, they show plan and side views, respectively, of a transverse connector 31. Similar to the connectors described above, this transverse connector 31 has a base 2 and an extension 15 The extension 15 is formed by a support 3 and the flanges 4 and 5. The transverse connector 31 also comprises the ribs 6 and 7 located at opposite ends of the base 2. An important feature of the transverse connector 31 is that the extension 15 is longer than the base 2. Thus, at both ends, the extension 15 extends beyond the base 2. As shown in Figure 24c, the notches 32 and 33 are at both ends of extension 15. The shape and dimensions of notches 32 and 33 are negative images of ribs 6 and 7.

A view of a transverse connector 31 mounted on two longitudinal connectors 30 is shown in Figure 25. The longitudinal connectors 30 are viewed from the end while the transverse connector is viewed from the side. Longitudinal connectors 30 are in parallel while transverse connector 31 is positioned between, and at right angles to, longitudinal connectors 30. A notch 32 of the transverse connector 31 is immediately positioned above the rib 7 of the

ES 2 240 290 T3 right longitudinal connector. As shown in this figure, the notch 33 of the transverse connector 31 is immediately above the rib 6 of the longitudinal connector 30 on the left. As previously indicated, the extension 15 of the transverse connector 31 extends over portions of the bases 2 of the longitudinal connectors 30.

Figures 26a and 26b show plan and front views of a rectangular panel. This panel 20 is, in particular, suitable for mounting with the transverse connectors described in Figures 23 to 25, both inclusive. Similar to the panels described above, this panel has a top wear surface 21, a middle substrate 22, and a backing layer surface 23. Panel 20 also has a pocket 24 to engage flanges 4 and 5 of the connectors. 30 and 31. The pocket 24 extends completely around the perimeter of the panel 20. The panel 20 also has four channels 25 that run parallel to each of the four sides of the panel. Channels 25 are cut or formed in the bottom surface or backing layer 23 of panel 20. Channels 25 extend entirely from side to side of the panel. The channels 25 of the panel 20 are adapted to coincide with the ribs 6 and 7 of the longitudinal and transverse connectors 30 and 31.

Although the particular embodiments of the flooring systems and the components thereof, as shown and discussed in detail herein are fully capable of achieving the objects and advantages outlined above, it is to be understood that they are merely illustrative of the preferred embodiments of this invention and that there is no intentional limitation on the details of interpretation or design shown herein other than those set forth in the appended claims.