FIELD OF THE INVENTION
The present invention relates to a floor panel comprising a top layer and a bottom layer adhered together in an offset relationship such that a marginal end portion of a top surface of the bottom layer and a marginal end portion of a bottom surface of the top layer are exposed wherein at least one of the marginal end portions has an adhesive, and a ratio of a thickness of the top layer to a thickness of the bottom layer is about 5 or greater. The present invention further relates to a floating floor system incorporating the same.
BACKGROUND OF THE INVENTION
Floor panels for use in floating floor systems typically comprise a top layer and a bottom layer adhered together in an offset relationship such that a substantially L-shaped marginal end portion of a top surface of the bottom layer and a substantially L-shaped marginal end portion of a bottom surface of the top layer are exposed. The top layer typically comprises at least one mix layer, a print film, a wear layer, and a top coat. The bottom layer typically comprises at least one mix layer. The bottom layer has a thickness about equal to or greater than the top layer. A ratio of a thickness of the top layer to a thickness of the bottom layer is typically in the range of about 2 or less. For example, the SURFACE SOURCE product sold by Lowe's Home Centers, Inc. has a top layer with a thickness of about 64 mils (about 1.63 millimeters), and a bottom layer with a thickness of about 61 mils (about 1.55 millimeters). Thus, the ratio of the thickness of the top layer to the bottom layer is about 1.05 (64 mils/61 mils=1.05).
In order to assemble the floating floor system, at least one of the marginal end portions of each of the floor panels is provided with an adhesive. The marginal end portion provided with the adhesive is engaged with the marginal end portion of an adjacent floor panel to form the floating floor system. The floor panels may be formed, for example, such that when the floating floor system is assembled on a sub-floor ends of the top layers of the adjacent floor panels substantially abut, while ends of the bottom layers of the adjacent floor panels are spaced apart a desired distance so that a gap is formed there between. Alternatively, the floor panels may be formed, for example, such that when the floating floor system is assembled on the sub-floor the ends of the top layers of the adjacent floor panels substantially abut and the ends of the bottom layers of the adjacent floor panels substantially abut.
Because the thickness of the bottom layer is significantly large (about 98 mils (about 2.5 millimeters)), when the floor panels are assembled such that a gap is formed between the ends of the bottom layers of the adjacent floor panels, the gap can telescope through the floor panels thereby significantly altering the aesthetic and structural characteristics of the top layer. For example, the gaps may cause buckling at a top surface of the top layer. Alternatively, when the floor panels are assembled such that the ends of the bottom layers of the adjacent floor panels substantially abut, unwanted gaps or overlapping can occur between the ends of the bottom layers due to deviations in the size of the marginal end portions and/or errors occurring during installation. These unwanted gaps or overlaps can additionally telescope through the floor panel thereby also significantly altering the aesthetic and structural characteristics of the top layer.
Additionally, the marginal end portions of the top layer of a first row of the floor panels, which are typically positioned adjacent a wall, remain unsupported when the floating floor system is assembled, because the marginal end portions of the top layer of the first row of the floor panels will not engage with an adjacent floor panel. Thus, because the thickness of the bottom layer is significantly large, the gap occurring between the sub-floor and the marginal end portion of the top layer will also negatively impact the aesthetic and structural characteristics of the top layer. For example, buckling at the top surface of the top layer can occur. Also, because the bottom layer and the top layer comprise mix layers, which contain fillers, the bottom layer and the top layer are prone to absorb moisture thereby further affecting the aesthetic and structural characteristics of the floor panels. This is particularly problematic, since the bottom layer is installed directly on a sub-floor.
Still further, because the bottom layer has a thickness greater than the top layer, when the floor panels are stacked, for example, during shipping, a space exists between the marginal end portions of the top layer of the adjacent flooring panels equal to the thickness of the bottom layer. Thus, during shipping, the unsupported marginal end portions of the top layer are prone to bend and/or curl an amount equal to the thickness of the bottom layer. Because of the structural characteristics of the top layer, these bends and/or curls remain in the marginal end portions of the top layer during installation and can thereby significantly alter the aesthetic and structural characteristics of the floor panel. For example, buckling can occur at the top surface of the top layer and/or the bond strength between the marginal end portions of the adjacent floor panels could be negatively affected.
BRIEF SUMMARY OF THE INVENTION
The invention relates to a floor panel comprising a top layer and a bottom layer. The top layer has a top surface and a bottom surface. The top surface has a visible decorative pattern. The bottom layer has a top surface and a bottom surface. The top surface of the bottom layer is adhered to the bottom surface of the top layer such that the bottom layer is offset from the top layer in a direction of length and width and a marginal end portion of the top surface of the bottom layer and a marginal end portion of the bottom surface of the top layer is exposed. At least one of the marginal end portions has an adhesive, and a ratio of a thickness of the top layer to a thickness of the bottom layer is about 5 or greater.
The invention further relates to a floating floor system comprising at least two adjacent floor panels. Each of the floor panels comprises a top layer and a bottom layer. The top layer has a top surface and a bottom surface. The top surface has a visible decorative pattern. The bottom layer has a top surface and a bottom surface. The top surface of the bottom layer is adhered to the bottom surface of the top layer such that the bottom layer is offset from the top layer in a direction of length and width and a marginal end portion of the top surface of the bottom layer and a marginal end portion of the bottom surface of the top layer is exposed. At least one of the marginal end portions has an adhesive, and a ratio of a thickness of the top layer to a thickness of the bottom layer is about 5 or greater. The marginal end portion of the top surface of the bottom layer is engaged with the marginal end portion of the bottom surface of the top layer of the adjacent floor panel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially exploded perspective view of a floor panel according to a first embodiment of the invention.
FIG. 2 is a perspective view of a floating floor system incorporating the floor panel of FIG. 1.
FIG. 3 is a sectional view taken along line 3-3 of FIG. 2.
FIG. 4 is a partially exploded perspective view of a floor panel according to a second embodiment of the invention.
FIG. 5 is a perspective view of a floating floor system incorporating the floor panel of FIG. 4.
FIG. 6 is a sectional view taken along line 6-6 of FIG. 5.
FIG. 7 is a partially exploded perspective view of a floor panel according to a third embodiment of the invention.
FIG. 8 is a perspective view of a floating floor system incorporating the floor panel of FIG. 7.
FIG. 9 is a sectional view taken along line 9-9 of FIG. 8.
DETAILED DESCRIPTION OF THE EMBODIMENT(S)
FIGS. 1-3 show a floor panel 10 according to a first embodiment of the invention. As shown in FIG. 1, the floor panel 10 comprises a top layer 11, a bottom layer 12, and a release member 13. The top layer 11 may be formed, for example, from a substantially flexible sheet material, such as plastic, vinyl, polyvinyl chloride, polyester, or combinations thereof. The top layer 11 has a top surface 14 with a visible decorative pattern 17 and a bottom surface 15. In the illustrated embodiment, the top layer 11 comprises at least one mix layer 16, a print film provided with the visible decorative pattern 17, a wear layer (not shown), and a top coat (not shown), respectively. It will be appreciated by those skilled in the art that although the top layer 11 is shown and described herein as comprising multiple layers that the top layer 11 may alternatively comprise a single layer. Additionally, the types of layers constituting the top layer 11 and the visible decorative pattern 17 could be varied depending on the desired characteristics of the top layer 11.
As shown in FIG. 1, the top layer 11 has a thickness T1 of about 20-200 mils (about 0.508-5.08 millimeters), preferably about 60-180 mils (about 1.524-4.572 millimeters), and more preferably about 80-150 mils (about 2.032-3.810 millimeters). In the illustrated embodiment, the top layer 11 is substantially rectangular in shape and has a length L1 of about 36 inches (about 91.4 centimeters) and a width W1 of about 6 inches (about 15.2 centimeters). However, it will be appreciated by those skilled in the art that the geometrical shape and the length L1 and the width W1 of the top layer 11 may be varied depending on the desired dimension and geometrical configuration of the floor panel 10. For example, the top layer 11 may alternatively have a substantially square shape.
As shown in FIG. 1, the bottom layer 12 has a top surface 18 and a bottom surface 19. The bottom layer 12 may be formed, for example, from a film or tape comprising plastic, vinyl, polyvinyl chloride, polyester, polyolefin, nylon, or combinations thereof. The bottom layer 12 may also include recycle material, such as post industrial or post consumer scrap. The film or tape may be rigid or flexible and is preferably moisture resistant or waterproof. Additionally, the film or tape may be capable of being delivered or shipped in a roll. In the illustrated embodiment, the bottom layer 12 comprises a single layer of rigid black polyvinyl chloride film. Alternatively, the bottom layer 12 could comprise multiple layers, such as two layers of film laminated with a mat, such as a glass mat or polyethylene terephthalate mat, there between. The bottom layer 12 could also be provided with at least one of a continuous or discontinuous ink layer, antimicrobial layer, sound deadening layer, cushioning layer, slide resistant layer, stiffening layer, channeling layer, mechanically embossed texture, or chemical texture.
As shown in FIG. 1, the bottom layer 12 has a thickness T2 less than the thickness T1 of the top layer 11. A ratio of the thickness T1 of the top layer 11 to the thickness T2 of the bottom layer 12 is about 5 or greater, preferably about 10-100, and more preferably about 10-25. The bottom layer 12 has a length L2 and a width W2 the same as the length L1 and the width W1 of the top layer 11. Thus, in the illustrated embodiment, the bottom layer 12 is substantially rectangular in shape and has the length L2 of about 36 inches (about 91.4 centimeters) and the width W2 of about 6 inches (about 15.2 centimeters). However, it will be appreciated by those skilled in the art that the geometrical shape and the length L1 and the width W1 of the bottom layer 12 may be varied depending on the desired dimension and geometrical configuration of the floor panel 10. For example, the bottom layer 12 may alternatively have a substantially square shape.
As shown in FIG. 1, the bottom surface 15 of the top layer 11 is laminated to the top surface 18 of the bottom layer 12 by an adhesive 20. The adhesive 20 may be, for example, any suitable adhesive, such as a hot melt adhesive, a pressure sensitive adhesive, or a structural and/or reactive adhesive. In the illustrated embodiment, the adhesive is a pressure sensitive acrylic adhesive. The adhesive 20 may have, for example, a bond strength of at least 25 force-pounds, and more preferably about 25-30 force-pounds after having been heat aged for about 24 hours at 145 degrees Fahrenheit. In the illustrated embodiment, the adhesive 20 is provided on substantially an entirety of the top surface 18 of the bottom layer 12. The adhesive 20 may be applied to have a thickness, for example, of about 1-2 mils (about 0.0254-0.0508 millimeters). It will be appreciated by those skilled in the art, however, that the thickness of the adhesive 20 may vary depending on the texture of the bottom surface 15 of the top layer 11 and the texture of the top surface 18 of the bottom layer 12 in that a substantially smooth surface would require less of the adhesive 20 due to better adhesion and bond strength.
The top layer 11 is adhered to the bottom layer 12 so that the top layer 11 is offset from the bottom layer 12 in a direction of the length L1, L2 and the width W1, W2. In other words, opposing first ends 21 of the top layer 11 are offset in the direction of the length L1, L2 from opposing first ends 23 of the bottom layer 12 an offset distance D1, D2 and opposing second ends 22 of the top layer 11 are offset in the direction of the width W1, W2 from opposing second ends 24 of the bottom layer 12 an offset distance D3, D4. The offset distances D1, D2, D3, D4 are substantially the same. In the illustrated embodiment, the offset distances D1, D2, D3, D4 are, for example, about 1 inch (about 2.5 centimeters). Because the adhesive 20 is provided on substantially the entirety of the top surface 18 of the bottom layer 12, due to the offset of the top layer 11 relative to the bottom layer 12, a substantially L-shaped marginal end portion of the top surface 18 of the bottom layer 12 remains exposed to form an adhesive surface 25, and a substantially L-shaped marginal end portion of the bottom surface 15 of the top layer 11 remains exposed to form an attachment surface 26.
It will be appreciated by those skilled in the art that the adhesive 20 may also be provided on the marginal end portion of the bottom surface 15 of the top layer 11 instead of or in addition to the top surface 18 of the bottom layer 12 depending on the type and characteristics of the adhesive 20 used to achieve optimum adhesion and bond strength when adhering the adjacent floor panels 10, as described in more detail below with reference to FIGS. 2-3. Further, the adhesive 20 used to adhere the top layer 11 to the bottom layer 12 may be different from the adhesive 20 provided on the marginal end portions of the top layer 11 and and/or the bottom layer 12.
As shown in FIG. 1, the release member 13 is positioned adjacent to the top surface 14 of the top layer 11 and the adhesive surface 25 to cover the adhesive surface 25 during shipping of the floor panel 10 and prior to the installation thereof. In the illustrated embodiment, the release member 13 is a flexible sheet corresponding in size and shape to the bottom layer 12. It will be appreciated by those skilled in the art, however, that the size and shape of the release member 13 may be varied, as long as the release member 13 adequately covers the adhesive surface 25. The release member 13 may be made, for example, from any known suitable release material, such as a poly or silicone coated paper, a plastic sheet, a polymer film, or other material that enables the release member 13 to be quickly and easily removed from the adhesive surface 25 during the installation of the floor panel 10.
FIGS. 2-3 show a floating floor system 27 comprising a plurality of the floor panels 10 installed on a sub-floor 28. As shown in FIG. 2, in order to install the floor panels 10, at least one of the floor panels 10 is arranged on the sub-floor 28 such that the bottom surface 19 of the bottom layer 12 is in contact with the sub-floor 28. Preferably, the installation of the floor panels 10 should start adjacent a wall and/or in a corner of a room (not shown) and proceed outwardly there from. The release member 13 is removed from the floor panel 10 to expose the adhesive surface 25 on the top surface 18 of the bottom layer 12. Another one of the floor panels 10 is then adhered to the adhesive surface 25 by engaging the attachment surface 26 on the bottom surface 15 of the top layer 11 with the adhesive surface 25.
As shown in FIGS. 2-3, the floor panels 10 are installed such that the first ends 21, 23 of the top and bottom layers 11, 12 of the floor panels 10 substantially abut the first ends 21, 23 of the top and bottom layers 11, 12 of the adjacent floor panels 10, and the second ends 22, 24 of the top and bottom layers 11, 12 of the floor panels 10 substantially abut the second ends 22, 24 of the top and bottom layers 11, 12 of the adjacent floor panels 10. The process is repeated until the desired number of the floor panels 10 covers the sub-floor 28. Because the bottom layer 12 is yieldable to surface irregularities of the sub-floor 28, the floor panel 10 will conform to any surface irregularities in the sub-floor 28 and will therefore lie substantially flat on the sub-floor 28. The floor panels 10 can thereby be installed on the sub-floor 28 without any bonding material or adhesive being applied to the sub-floor 28. Additionally, because of the nature of the adhesive 20, particularly when the adhesive is a pressure sensitive adhesive, the floor panels 10 are capable of being easily detached from one another without damaging the floor panels 10 for ease of installation and/or replacement thereof. It will be appreciated by those skilled in the art that the pattern of the floor panels 10 shown in FIG. 2 is just one of numerous possible patterns for installing the floor panels 10 and that the installation of the floor panels 10 is not limited thereto.
Because the thickness T2 of the bottom layer 12 of the floor panels 10 is significantly less than the thickness T1 of the top layer 11, when the adjacent floor panels 10 are engaged, any unwanted gaps or overlapping that may occur between the first and second ends 22, 23 of the bottom layers 12 of the adjacent floor panels 10 due to deviations in the size of the marginal end portions and/or errors occurring during installation will not impact the aesthetic and/or structural characteristics of the top layer 11. Also, the size of any gaps occurring between the sub-floor 28 and the unsupported marginal end portions of the top layer 11 of a first row of the floor panels 10 is reduced. Therefore, by reducing the thickness of the bottom layer 12, buckling at the top surface 18 of the top layer 11 can be prevented. Additionally, because the bottom layer 12 does not comprise a mix layer and is formed of a moisture resistant material, the bottom layer 12 is capable of acting as a moisture barrier between the sub-floor 28 and the floor panel 10. Further, because the thickness T2 of the bottom layer 12 is smaller than the thickness T1 of the top layer 11, when the floor panels 10 are stacked, for example, during shipping, the distance between the unsupported marginal end portions of the adjacent top layers 11 is decreased such that any bending and/or curling of the unsupported marginal end portions of the top layers 11 is reduced.
FIGS. 4-6 show a floor panel 10′ according to a second embodiment of the invention. As shown in FIG. 4, the floor panel 10′ is identical to the floor panel 10 according to the first embodiment of the invention, except the bottom layer 12 has a length L2′ and a width W2′ smaller than the length L1 and the width W2 of the top layer 11. For example, in the illustrated embodiment, the length L2′ of the bottom layer 12 is about 0.125 inches (0.3 centimeters) smaller than the length L1 of the top layer 11, and the width W2′ of the bottom layer 12 is about 0.125 inches (0.3 centimeters) smaller than the width W1 of the top layer 11. It will be appreciated by those skilled in the art, however, that the length L2′ and the width W2′ of the bottom layer 12 may be varied to vary the dimensions of gap 29, as described in more detail below with reference to FIGS. 5-6.
As shown in FIG. 4, the top layer 11 is adhered to the bottom layer 12 so that the top layer 11 is offset from the bottom layer 12 in a direction of the length L1, L2′ and the width W1, W2′. In other words, opposing first ends 21 of the top layer 11 are offset in the direction of the length L1, L2′ from opposing first ends 23 of the bottom layer 12 an offset distance D1, D2′, and opposing second ends 22 of the top layer 11 are offset in the direction of the width W1, W2′ from opposing second ends 24 of the bottom layer 12 an offset distance D3, D4′. In the illustrated embodiment, the offset distances D1, D3, are, for example, about 1 inch (about 2.5 centimeters), and the offset distances D2′, D4′ are, for example, about 1.125 inches (about 2.8 centimeters).
FIGS. 5-6 show a floating floor system 27′ comprising a plurality of the floor panels 10′ installed on the sub-floor 28. The floor panels 10′ are installed in the same way as the floor panels 10 according to the first embodiment of the invention, except the first ends 23 of the bottom layer 12 of the floor panels 10′ are spaced from the first ends 23 of the bottom layer 12 of the adjacent floor panels 10′, and the second ends 24 of the bottom layer 12 of the floor panels 10′ are spaced from the second ends 24 of the bottom layer 12 of the adjacent floor panels 10′ so the gap 29 is formed there between. In the illustrated embodiment, the gap 29 is about 0.125 inches (0.3 centimeters).
Because the thickness T2 of the bottom layer 12 of the floor panels 10′ is smaller than the thickness T1 of the top layer 11, when the gap 29 is provided between the first and second ends 23, 24 of the bottom layers 12 of the adjacent floor panels 10′, the gap 29 will not impact the aesthetic and/or structural characteristics of the top layer 11. Also, the size of any gaps occurring between the sub-floor 28 and the unsupported marginal end portions of the top layer 11 of a first row of the floor panels 10′ is reduced. Therefore, by reducing the thickness of the bottom layer 12, buckling at the top surface 18 of the top layer 11 can be prevented. Additionally, because the bottom layer 12 does not comprise a mix layer and is formed of a moisture resistant material, the bottom layer 12 is capable of acting as a moisture barrier between the sub-floor 28 and the floor panel 10. Further, because the thickness T2 of the bottom layer 12 is smaller than the thickness T1 of the top layer 11, when the floor panels 10′ are stacked, for example, during shipping, the distance between the unsupported marginal end portions of adjacent top layers 11 is decreased such that any bending and/or curling of the unsupported marginal end portions of the top layer 11 is reduced.
FIGS. 7-9 show a floor panel 10″ according to a third embodiment of the invention. As shown in FIG. 7, the floor panel 10″ is identical to the floor panel 10 according to the first embodiment of the invention, except that the bottom layer 12 has a length L2″ and a width W2″ larger than the length L1 and the width W2 of the top layer 11. For example, in the illustrated embodiment, the length L2″ of the bottom layer 12 is about 0.125 inches (0.3 centimeters) larger than the length L1 of the top layer 11, and the width W2″ of the bottom layer 12 is about 0.125 inches (0.3 centimeters) larger than the width W1 of the top layer 11. It will be appreciated by those skilled in the art, however, that the length L2″ and the width W2″ of the bottom layer 12 may be varied to vary the amount of overlap, as described in more detail below with reference to FIGS. 8-9.
As shown in FIG. 7, the top layer 11 is adhered to the bottom layer 12 so that the top layer 11 is offset from the bottom layer 12 in a direction of the length L1, L2″ and the width W1, W2″. In other words, opposing first ends 21 of the top layer 11 are offset in the direction of the length L1, L2″ from opposing first ends 23 of the bottom layer 12 an offset distance D1, D2″, and opposing second ends 22 of the top layer 11 are offset in the direction of the width W1, W2″ from opposing second ends 24 of the bottom layer 12 an offset distance D3, D4″. In the illustrated embodiment, the offset distances D1, D3, are, for example, about 1 inch (about 2.5 centimeters), and the offset distances D2′, D4′ are, for example, about 0.875 inches (about 2.2 centimeters).
FIGS. 8-9 show a floating floor system 27″ comprising a plurality of the floor panels 10″ installed on the sub-floor 28. The floor panels 10″ are installed in the same way as the floor panels 10 according to the first embodiment of the invention, except the first ends 23 of the bottom layer 12 of the floor panels 10″ substantially overlap the first ends 23 of the bottom layer 12 of the adjacent floor panels 10″, and the second ends 24 of the bottom layer 12 of the floor panels 10″ substantially overlap the second ends 24 of the bottom layer 12 of the adjacent floor panels 10″. The first and second ends 23, 24 of the bottom layer 12 overlap, for example, by about 0.125 inches (0.3 centimeters).
Because the thickness T2 of the bottom layer 12 of the floor panels 10″ is smaller than the thickness T1 of the top layer 11, when the first and second ends 23, 24 of the bottom layers 12 of the adjacent floor panels 10″ are overlapped, the overlap will not impact the aesthetic and/or structural characteristics of the top layer 11. Also, the size of any gaps occurring between the sub-floor 28 and the unsupported marginal end portions of the top layer 11 of a first row of the floor panels 10″ is reduced. Therefore, by reducing the thickness of the bottom layer 12, buckling at the top surface 18 of the top layer 11 can be prevented. Additionally, because the first and second ends 23, 24 of the bottom layers 12 are overlapped, the bottom layer 12 is capable of providing a moisture barrier between the sub-floor 28 and the floor panel 10″. Further, because the thickness T2 of the bottom layer 12 is smaller than the thickness T1 of the top layer 11, when the floor panels 10″ are stacked, for example, during shipping, the distance between the unsupported marginal end portions of adjacent top layers 11 is decreased such that any bending and/or curling of the unsupported marginal end portions of the top layer 11 is reduced.
The foregoing illustrates some of the possibilities for practicing the invention. Many other embodiments are possible within the scope and spirit of the invention. It is, therefore, intended that the foregoing description be regarded as illustrative rather than limiting, and that the scope of the invention is given by the appended claims together with their full range of equivalents.
Patent Application
20100247834
