Patent Application
20130232898
The present disclosure relates to flooring panels configured for being supported by a sub-floor, and kits including such flooring panels.
A finished floor typically consists of a sub-floor and a flooring surface, supported by the sub-floor. The nature of a sub-floor will vary depending on the flooring surface it needs to support and the environment in which it must function. For example, the linoleum tile or carpet on a main floor of a house, the sub-floor may simply consist of sheets of plywood. For a ceramic tile floor a cement layer will typically also be required.
Basement flooring presents additional challenges, one of which is the possibility of moisture being present and another which is to insulate the floor from what could be a very cold underlying surface of poured concrete. Additionally, noise dampening, in some instances, may also be a desirable characteristic.
In one aspect, there is provided a flooring panel configured for being supported by a sub-floor. The flooring panel defines a sub-floor-opposing surface, and includes a flooring material, a moisture barrier, and an insulator. The flooring material includes a flooring surface configured for receiving human traffic when the flooring panel is being supported on the sub-floor. The moisture barrier is co-operatively disposed relative to the flooring material such that, when the flooring panel is being supported on the sub-floor, the moisture barrier is disposed between the sub-floor and the flooring material. The sub-floor opposing surface is configured for co-operating with the sub-floor, when the flooring panel is being supported on the sub-floor, to define a space between the sub-floor opposing surface and the sub-floor for providing a fluid passage for receiving flow of water disposed between the sub-floor opposing surface and the sub-floor. The insulator is interposed between, and connected to both of the flooring material and the moisture barrier.
In another aspect, there is provided a flooring surface kit including a plurality of flooring panels. Each of the flooring panels defines a sub-floor opposing surface, and includes a flooring material, a moisture barrier, a sub-floor opposing surface, and an insulator. The flooring material includes a flooring surface configured for receiving human traffic when the flooring panel is being supported on a sub-floor. The moisture barrier is co-operatively disposed relative to the flooring material such that, when the flooring panel is being supported on the sub-floor, the moisture barrier is disposed between the sub-floor and the flooring material. The sub-floor opposing surface is configured for co-operating with the sub-floor, when the flooring panel is being supported on the sub-floor, to define a space between the sub-floor opposing surface and the sub-floor for providing a fluid passage for receiving flow of water disposed between the sub-floor opposing surface and the sub-floor. The insulator is interposed between, and connected to each of the flooring material and the moisture barrier. Each of the flooring panels is further configured for alignment with at least another one of the flooring panels such that the flooring materials of the aligned flooring panels are disposed in an abutting relationship with one another.
Reference will now be made to the drawings, which show by way of example, embodiments of the present disclosure, and in which:
In one aspect, and referring to
The flooring panel 100 defines a sub-floor opposing surface 108, and includes a flooring material 104, a moisture barrier 106, and an insulator 110.
The flooring material 104 includes a flooring surface 112 configured for receiving human traffic when the flooring panel 100 is being supported on the sub-floor 102. Exemplary flooring material 104 include any of the following: wood, wood parquet, composites, such as high density fiberboard or medium density fibreboard, veneers, laminates, polyvinyl chloride, polymeric resins, rubber, linoleum, reinforced resin, carpet, stone, and ceramic, or combinations thereof. The flooring material 104 can take any shape or size. In some embodiments, for example, the flooring surface is substantially planar.
In some embodiments, for example, the sub-floor 102 is poured concrete, concrete planks, or plywood.
The moisture barrier 106 is co-operatively disposed relative to the flooring material 104 such that, when the flooring panel 100 is being supported on the sub-floor 102, the moisture barrier 106 is disposed between the sub-floor 102 and the flooring material 104. Amongst other things, the moisture barrier 106 functions to interfere with transport of water vapour from the space between the flooring panel 100 and the sub-floor 102 and to the flooring material 104. In some embodiments, for example, the moisture barrier 106 includes (and, in some embodiments, is defined by) material characterized by a water permeability that is less than 0.2 grams/day/100 square inches at 100 degrees Fahrenheit (° F.) and 90% relative humidity as measured according to ASTM F1249-01. ASTM F1249-01 is a Standard Test Method for water vapor transmission rate through plastic film and sheeting using a modulated infrared sensor.
In some embodiments, for example, the material of the moisture barrier 106 is waterproof. In some embodiments, for example, the material of the moisture barrier 106 includes polymeric material. In some embodiments, for example, the material of the moisture barrier 106 is plastic material. In some of these embodiments, for example, the moisture barrier 106 is a high density polyethylene or polypropylene. In some embodiments, for example, the moisture barrier 106 is extruded in sheets, and then cut to size. In other embodiments, for example, the moisture barrier 106 is injection molded. In some embodiments, for example, the minimum thickness of the moisture barrier 106 is 30/1000 of an inch. In some embodiments, for example, the maximum thickness of the moisture barrier 106 is 40/1000 of an inch.
The sub-floor opposing surface 108 is configured for co-operating with the sub-floor 102, when the flooring panel 100 is being supported on the sub-floor 102, to define a space between the sub-floor opposing surface 108 and the sub-floor 102 for defining a fluid passage 114 for receiving flow of water disposed between the sub-floor opposing surface 108 and the sub-floor 102. In some embodiments, for example, the defined fluid passage 114 includes a cross-sectional area of at least 0.015625 square inches. In some embodiments, for example, the defined fluid passage 114 includes a vertical height above the sub-floor of at least ⅛ of an inch. In some embodiments, for example, upon installation of the flooring panel 100 upon a sub-floor 102 that is co-operatively sloped to facilitate transport of water, by the influence of gravity, towards a drain operatively provided within an interruption in the sub-floor 102, the provided fluid passage 114 provides space to facilitate such transport.
In some embodiments, for example, the sub-floor opposing surface 108 defines a plurality of channels which function as the fluid passages 114 when the flooring panel 100 is being supported on the sub-floor 102. In some embodiments, for example, the sub-floor opposing surface 108 defines a plurality of projections 116, and the spaces between the projections 116 function as the fluid passages 114 when the flooring panel 100 is being supported on the sub-floor 102. In some embodiments, for example, the projections 116 are aligned in rows and columns to enable the flooring panels 100 to be cut between the projections 116 without leaving any half-cut projections.
In some embodiments, for example, the sub-floor opposing surface 108 is defined by the moisture barrier 106.
The insulator 110 is interposed between, and connected to both of the flooring material 104 and the moisture barrier 106. Amongst other things, the insulator 110 functions to dampen noise created by human traffic across the flooring surface 112 of the flooring panel 100. In some embodiments, for example, the insulator 110 includes sufficient impact sound transmission dampening characteristics. In this respect, in some embodiments, for example, the insulator 110 is characterized by an Impact Insulation Class (“IIC”) of at least 50. In some embodiments, for example, the insulator 110 functions to sufficiently reduce airborne sounds. In this respect, in some embodiments, for example, the insulator 110 is characterized by a Sound Transmission Class (“STC”) of at least 50. In some embodiments, for example, the insulator 110 also functions as a heat insulator. In this respect, in some embodiments, for example, the insulator 110 is characterized by an R-value of at least 0.3. In some embodiments, for example, the insulator functions 110 as a cushioning agent. In some embodiments, for example, the minimum thickness of the insulator 110 is 3/32 of an inch. In some embodiments, for example, the maximum thickness of the insulator 110 is 0.5 inches.
In some embodiments, for example, the material of the insulator 110 is a flooring underlayment. In some embodiments, for example, the insulator 110 is EASYMAT™ available from Custom Building Products of Seal Beach, Calif. In some embodiments, for example, the insulator material includes polymeric material, such as a polymeric foam, an example of which is polypropylene foam.
In some embodiments, for example, the flooring material 104 is attached to the insulator 110. In some of these embodiments, for example, the flooring material 104 is attached to the insulator 110 with an adhesive. Exemplary adhesives include pressure sensitive adhesives.
In some embodiments, for example, the moisture barrier 106 is attached to the insulator 110. In some of these embodiments, for example, the moisture barrier 106 is attached to the insulator 110 with an adhesive. Exemplary adhesives include pressure sensitive adhesives.
In some embodiments, for example, and specifically referring to
In some embodiments, for example, the flooring panel 100 is a first flooring panel 100, and a second flooring panel 200 is also provided, wherein the second flooring panel 200 includes: a flooring material 204 including a flooring surface 212 configured for receiving human traffic when the flooring panel 200 is being supported on the sub-floor 102, a moisture barrier 206 co-operatively disposed relative to the flooring material 204 such that, when the flooring panel 200 is being supported on the sub-floor 102, the moisture barrier 206 is disposed between the sub-floor 102 and the flooring material 204, and an insulator 210 interposed between, and connected to each of the flooring material 204 and the moisture barrier 206. The first flooring panel 100 is further configured for alignment with the second flooring panel 200 such that the flooring materials 104, 204 of the flooring panels 100, 200 are disposed in an abutting relationship with each other. In some embodiments, for example, the alignment is such that the flooring surfaces 112, 212 of the flooring panels 100, 200 are disposed in a co-planar relationship with one another. The first flooring panel 100 is also further configured such that, upon effecting the alignment of the flooring panels 100, 200, the insulator 110 or 210 of one of the aligned flooring panels 100, 200 is disposed in abutting relationship with the insulator 110 or 210 of the other one of the aligned flooring panels 100, 200. In some embodiments, for example, the first flooring panel 100 is further configured such that the effecting of the alignment of the flooring panels 100, 200 effects elastic deformation of at least a portion of the insulator 110, 210 of at least one of the flooring panels 100, 200 while effecting the abutting relationship between the insulators 110, 210. In some of these embodiments, for example, the at least a portion of each insulator 110, 210, whose elastic deformation is effected by the alignment of the flooring panels 100, 200 includes elastically deformable material. In some embodiments, for example, the first flooring panel 100 is further configured such that, upon effecting the alignment of the flooring panels 100, 200, the moisture barrier 106 or 206 of one of the aligned flooring panels 100, 200 is disposed in abutting relationship with the moisture barrier 106 or 206 of the other one of the aligned flooring panels 100, 200.
In some embodiments, for example, the flooring panel 100 is a first flooring panel 100, and a second flooring panel 200 is also provided, wherein the second flooring panel 200 includes: a flooring material 204 including a flooring surface 212 configured for receiving human traffic when the flooring panel 200 is being supported on the sub-floor 102, and a moisture barrier 206 co-operatively disposed relative to the flooring material 204 such that, when the flooring panel 200 is being supported on the sub-floor 102, the moisture barrier 206 is disposed between the sub-floor 102 and the flooring material 204. The first flooring panel 100 is further configured for alignment with the second flooring panel 200 such that the flooring materials 104, 204 of the flooring panels 100, 200 are disposed in an abutting relationship with one another. In some embodiments, for example, the alignment is such that the flooring surfaces 112, 212 of the flooring panels 100, 200 are disposed in a co-planar relationship with one another. The first flooring panel 100 is also further configured such that, upon effecting the alignment of the flooring panels 100, 200, the moisture barrier 106 or 206 of one of the aligned flooring panels 100, 200 is disposed in abutting relationship with the moisture barrier 106 or 206 of the other one of the aligned flooring panels 100, 200.
In some of these embodiments, for example, the second flooring panel 200 also defines a sub-floor opposing surface 208. The sub-floor opposing surface 208 is configured for co-operating with the sub-floor 102 when the flooring panel 200 is being supported on the sub-floor 102 to define a space between the sub-floor opposing surface 208 and the sub-floor 102 for providing a fluid passage 214 for receiving flow of water disposed between the sub-floor opposing surface 208 and the sub-floor 102.
In another aspect, and referring to
Each of the flooring panels 300 (or 400) is further configured for alignment with at least another one of the flooring panels 400 (or 300) such that the flooring materials 304, 404 of the aligned flooring panels 300, 400 are disposed in an abutting relationship with one another. In some embodiments, for example, the alignment is such that the flooring surfaces 312, 412 of the aligned flooring panels 300, 400 are disposed in a co-planar relationship with one another.
For each of the flooring panels 300 (400), exemplary flooring materials 304 (404) include any of the following: wood, wood parquet, composites, such as high density fibreboard or medium density fibreboard, veneers, laminates, polyvinyl chloride, polymeric resins, rubber, linoleum, reinforced resin, carpet, stone, and ceramic, or combinations thereof. The flooring material 304 (404) can take any shape or size. In some embodiments, for example, the flooring surface is 312, (412) substantially planar.
In some embodiments, for example, the sub-floor 102 is poured concrete, concrete planks, or plywood.
For each of the flooring panels 300 (400), amongst other things, the moisture barrier 306, (406) functions to interfere with transport of water vapour from the space between the flooring panel 300 (400) and the sub-floor 102 and to the flooring material 304 (404). In some embodiments, for example, the moisture barrier 306 (406) includes material characterized by a water permeability that is less than 0.2 grams/day/100 square inches at 100° F. and 90% relative humidity as measured according to ASTM F1249-01.
In some embodiments, for example, for each of the flooring panels 300, (400), the material of the moisture barrier 306 (406) is waterproof. In some embodiments, for example, the material of the moisture barrier 306 (406) includes polymeric material. In some embodiments, for example, the material of the moisture barrier 306 (406) is plastic material. In some of these embodiments, for example, the moisture barrier 306 (406) is a high density polyethylene or polypropylene. In some embodiments, for example, the moisture barrier 306 (406) is extruded in sheets, and then cut to size. In other embodiments, for example, the moisture barrier 306 (406) is injection molded. In some embodiments, for example, the minimum thickness of the moisture barrier 306 (406) is 30/1000 of an inch. In some embodiments, for example, the maximum thickness of the moisture barrier 306 (406) is 40/1000 of an inch.
In some embodiments, for example, for each of the flooring panels 300 (400), when the flooring panel 300 (400) is being supported on the sub-floor 102, the defined fluid passage 314 (414) includes a cross-sectional area of at least 0.015625 square inches. In some embodiments, for example, the defined fluid passage 314 (414) includes a vertical height above the sub-floor 102 of at least ⅛ of an inch. In some embodiments, for example, upon installation of any of the flooring panels 300 (400) upon a sub-floor 102 that is co-operatively sloped to facilitate transport of water, by the influence of gravity, towards a drain operatively provided within an interruption in the sub-floor, the provided fluid passage 314 (414) provides space to facilitate such transport.
In some embodiments, for example, for each of the flooring panels 300 (400), the sub-floor opposing surface 308 (408) defines a plurality of channels which function as the fluid passages 314 (414) when the flooring panel 300 (400) is being supported on the sub-floor 102. In some embodiments, for example, the sub-floor opposing surface 308 (408) defines a plurality of projections 316 (416), and the spaces between the projections define the fluid passages 314 (414) when the flooring panel 100 (200) is being supported on the sub-floor 102. In some embodiments, for example, the projections 316 (416) are aligned in rows and columns to enable the flooring panels 300 (400) to be cut between the projections without leaving any half-cut projections.
In some embodiments, for example, for each of the flooring panels 300 (400), the sub-floor opposing surface 308 (408) is defined by the moisture barrier 306 (406).
For each of the flooring panels 300 (400), amongst other things, the insulator 310 (410) functions to dampen noise created by human traffic across the flooring surface 312 (412) of the flooring panel 300 (400). In some embodiments, for example, the insulator 310 (410) includes sufficient impact sound transmission dampening characteristics. In this respect, in some embodiments, for example, the insulator 310 (410) is characterized by an Impact Insulation Class (“IIC”) of at least 50. In some embodiments, for example, the insulator 310 (410) functions to sufficiently reduce airborne sounds. In this respect, in some embodiments, for example, the insulator 310 (410) is characterized by a Sound Transmission Class (“STC”) of at least 50. In some embodiments, for example, the insulator 310 (410) also functions as a heat insulator. In this respect, in some embodiments, for example, the insulator 310 (410) is characterized by an R-value of at least 0.3. In some embodiments, for example, the insulator 310 (410) functions as a cushioning agent. In some embodiments, for example, the minimum thickness of the insulator 310 (410) is at least 3/32 of an inch. In some embodiments, for example, the maximum thickness of the insulator 310 (410) is 0.5 inches.
In some embodiments, for example, the method of the insulator 310 (410) is a flooring underlayment. In some embodiments, for example, the insulator is EASYMAT™ available from Custom Building Products of Seal Beach, Calif.
In some embodiments, for example, the flooring material 304 (404) is attached to the insulator 310 (410). In some of these embodiments, for example, the flooring material 304 (404) is attached to the insulator 310 (410) with an adhesive. Exemplary adhesives include pressure sensitive adhesives.
In some embodiments, for example, the moisture barrier 306 (406) is attached to the insulator 310 (410). In some of these embodiments, for example, the moisture barrier 306 (406) is attached to the insulator 310 (410) with an adhesive. Exemplary adhesives include pressure sensitive adhesives.
In some embodiments, for example, the kit further includes instructions for effecting the alignment and coupling of the flooring panels 300, 400.
In some embodiments, for example, the configuration of each one of the flooring panels 300, 400 for the alignment with at least another one of the flooring panels is such that at least one pair of alignable flooring panels 300, 400 is defined, and for each one of the one or more pairs of alignable flooring panels 300, 400 the alignment of the flooring panels 300, 400 of the alignable flooring panel pair is effected by coupling of the flooring panels 300, 400 to one another, such that the coupling at least effects limiting of movement of the coupled flooring panels 300, 400 relative to one another in a direction normal to the flooring surface 312, 412 of either of the coupled flooring panels 300, 400. In this respect, in some of these embodiments, the kit includes instructions for effecting the coupling of the flooring panels 300, 400. In some embodiments, for example, the coupling of the flooring panels is effected by an interlocking assembly 600. In this respect, in some embodiments, for example, the kit includes instructions for effecting the coupling with the interlocking assembly 600. In some of these embodiments, for example, the interlocking assembly 600 includes a respective interlocking assembly portion 320, 420 of each of the flooring panels 300, 400. In some of these embodiments, for example, a profile is cut into “blanks” of the pre-cursor flooring material to thereby define the respective interlocking portion 320, 420 of each of the flooring panels 300, 400. In some of these embodiments, for example, the respective interlocking assembly portions 320, 420 are configured to co-operate to effect the coupling of the flooring panels 300, 400. In some of these embodiments, for example, the respective interlocking assembly portion 320, 420 of one of the flooring panels 300, 400 is at least one groove 322 and the respective interlocking assembly portion 420 of the other one of the flooring panels is at least one tongue 424. In some of these embodiments, for example, for each one of the one or more pairs of alignable flooring panels 300, 400, each of the flooring panels 300, 400 of the alignable flooring panel pair is further configured such that, upon the effecting of the coupling of the flooring panels 300, 400, the insulator 310 or 410 of one of the coupled flooring panels 300, 400 is disposed in abutting relationship with the insulator 310 or 410 of the other one of the coupled flooring panels 300, 400. In some of these embodiments, for example, for each one of the one or more pairs of alignable flooring panels each of the flooring panels 300, 400 of the alignable flooring panel pair is further configured such that the effecting of the coupling of the flooring panels 300, 400 effects elastic deformation of at least a portion of the insulator 310, 410 of at least one of the flooring panels 300, 400 while effecting the abutting relationship between the insulators 310, 410 of both of the flooring panels 300, 400. In some embodiments, for example, the at least a portion of each insulator 310, 410, whose elastic deformation is effected by the effecting of the coupling of the flooring panels 300, 400, includes elastically deformable material. In some embodiments, for example, for each one of the one or more pairs of alignable flooring panels, each of the flooring panels 300, 400 of the alignable flooring panel pair is further configured such that, upon the effecting of the coupling of the flooring panels 300, 400, the moisture barrier 306 or 406 of one of the coupled flooring panels 300, 400 is disposed in abutting relationship with the moisture barrier 306 or 406 of the other one of the coupled flooring panels 300, 400. In some embodiments, for example, a hydrophobic material, such as wax, is applied to the side edges of each flooring panel so as to increase impermeability to vapour once one flooring panel is coupled to another flooring panel.
In some embodiments, for example, the configuration of each one of the flooring panels 300 (400) for the alignment with at least another one of the flooring panels 400 (300) is such that at least one pair of alignable flooring panels is defined, and for each one of the one or more pairs of alignable flooring panels, each of the flooring panels 300, 400 of the alignable flooring panel pair is further configured such that, upon effecting the alignment of the flooring panels 300, 400, the insulator 310 or 410 of one of the aligned flooring panels 300, 400 is disposed in abutting relationship with the insulator 310 or 410 of the other one of the aligned flooring panels 300, 400. In some of these embodiments, for example, for each one of the one or more pairs of alignable flooring panels, each of the flooring panels 300, 400 of the alignable flooring panel pair is further configured such that the effecting of the alignment of the flooring panels 300, 400 effects elastic deformation of at least a portion of the insulator 310, 410 of at least one of the flooring panels 300, 400 while effecting the abutting relationship between the insulators 310, 410 of both of the flooring panels 300, 400. In some embodiments, for example, the at least a portion of each insulator 310, 410, whose elastic deformation is effected by the effecting of the abutting relationship of the flooring panels 300, 400, includes elastically deformable material. In some embodiments, for example, for each one of the one or more pairs of alignable flooring panels, each of the flooring panels 300, 400 of the alignable flooring panel pair is further configured such that, upon the effecting of the alignment of the flooring panels 300, 400, the moisture barrier 306 or 406 of one of the aligned flooring panels 300, 400 is disposed in abutting relationship with the moisture barrier 306 or 406 of the other one of the aligned flooring panels 300, 400.
In some embodiments, for example, the configuration of each one of the flooring panels 300 (400) for the alignment with at least another one of the flooring panels 400 (300) is such that at least one pair of alignable flooring panels is defined, and for each one of the one or more pairs of alignable flooring panels 300, 400, each of the flooring panels 300, 400 of the alignable flooring panel pair is further configured such that, upon effecting the alignment of the flooring panels 300, 400, the moisture barrier 306 or 406 of one of the aligned flooring panels 300, 400 is disposed in abutting relationship with the moisture barrier 306 or 406 of the other one of the aligned flooring panels 300, 400.
While this invention has been described with reference to illustrative embodiments and examples, the description is not intended to be construed in a limiting sense. Thus, various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modifications or embodiments. Further, all of the claims are hereby incorporated by reference into the description of the preferred embodiments.
