Patent Grant
12098559
This disclosure is directed to panel components having tongue and groove portions.
Ceramic tile constitute a majority of wall coverings used in residential showers. Ceramic tiles are durable and low-cost and therefore suitable for vertical installation in wet areas. However, one of the main disadvantages of ceramic tiles is the complex installation that requires a skilled installer. Poor installation can lead to cracking over time and/or leaks that can cause mold or structural damage to the residence.
Various products have been developed for wet surfaces such as vertical shower wall panels or coverings that do not require the need for professional installation and can be installed via the general population of do-it-yourself (DIY) individuals. For example, U.S. Pat. No. 6,397,547 to Mårtensson and U.S. Patent Publication No. 2020/0131783 to Liu et al. attempt to provide leak-free panels. However, these panels are subject to major water leaking concerns where corners of adjacent panels meet due to features that are consistent with conventional tongue and groove panels.
Referring to
Referring also to
Accordingly, referring also to the example scenario shown in
For these reasons, conventional tongue and groove panels are not suitable for surfaces that are exposed to moisture such as shower wall panels.
To avoid leaking at the corners, some shower wall panels are provided with dimensions of 2 feet by 8 feet or 4 feet by 8 feet so that the panels span the entire height of the shower wall and do not form unions that allow water therethrough. However, these panels do not provide the visually attractive tile format that many individuals prefer.
Silicone sealants can be used to seal edges of conventional panel systems. However, for various reasons, silicone is not always desirable to use or to rely on as the primary element for inhibiting water breach.
Accordingly, it is desirable to have a system of panels with interlocking tongue and groove connections that inhibit water from permeating through the system.
The drawings illustrate only example embodiments and are therefore not to be considered limiting of the scope of the disclosure, as the present disclosure may admit to other equally effective embodiments. The elements and features shown in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the example embodiments. Additionally, certain dimensions or positions may be exaggerated to help visually convey such principles.
The disclosed system and method may be understood more readily by reference to the following detailed description of particular embodiments and the examples included therein and to the Figures and their previous and following description.
It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the present disclosure which will be limited only by the appended claims.
It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Thus, for example, reference to “a tongue” includes one or more of such tongues, and so forth.
“Optional” or “optionally” means that the subsequently described event, circumstance, or material may or may not occur or be present, and that the description includes instances where the event, circumstance, or material occurs or is present and instances where it does not occur or is not present.
Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, also specifically contemplated and considered disclosed is the range from the one particular value and/or to the other particular value unless the context specifically indicates otherwise. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another, specifically contemplated embodiment that should be considered disclosed unless the context specifically indicates otherwise. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint unless the context specifically indicates otherwise. Finally, it should be understood that all of the individual values and sub-ranges of values contained within an explicitly disclosed range are also specifically contemplated and should be considered disclosed unless the context specifically indicates otherwise. The foregoing applies regardless of whether in particular cases some or all of these embodiments are explicitly disclosed.
Optionally, in some aspects, when values are approximated by use of the antecedents “about,” “substantially,” or “generally,” it is contemplated that values within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particularly stated value or characteristic can be included within the scope of those aspects.
Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of skill in the art to which the disclosed apparatus, system, and method belong. Although any apparatus, systems, and methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present apparatus, system, and method, the particularly useful methods, devices, systems, and materials are as described.
Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other additives, components, integers or steps. In particular, in methods stated as comprising one or more steps or operations it is specifically contemplated that each step comprises what is listed (unless that step includes a limiting term such as “consisting of”), meaning that each step is not intended to exclude, for example, other additives, components, integers or steps that are not listed in the step.
It is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of aspects described in the specification. Thus, words denoting order, such as “first” or “next,” should be interpreted as optional aspects unless plain meaning or logic dictates otherwise.
In conventional panels 10, the first and second tongues join or intersect at one end thereof as shown in corner 1 of
In the panel 100 of the present disclosure, similar to the conventional panels 10, the first and second tongues can join at one end thereof, and the first and second back legs can join at one end thereof. However, in the panel 100 of the present disclosure, the longitudinal dimension (or length) of one or more of the first tongue, the second tongue, the first back leg, or the second back leg can be extended such that they can form an overlap with the tongues and/or back legs of another adjacent panel substantially near the corners thereof when the panels are coupled or interlocked. The overlap can create a water-tight seal or minimizes penetration/leak of water therethrough at the corners even when the interlocked panels are not perfectly aligned (e.g., with respective face portions abutting). In particular, the opposite ends of one or more of the first tongue, second tongue, the first back leg, and the second back leg can extend towards the fourth edge, second edge, third edge, and first edge respectively (will be described below in greater detail in association with
Disclosed herein, with reference to
A first side 114 can extend between the first edge 104 of face surface 102 and the back surface 112. The first side 114 can comprise at least one projection (e.g., a first tongue 116).
A second side 118 can extend between the second edge 106 of the face surface 102 and the back surface 112. The second side 118 can comprise at least one projection (e.g., a first front leg 120 and a first back leg 122 that cooperate to define a first groove 124 therebetween).
A third side 126 can extend between the third edge 108 of the face surface 102 and the back surface 112. The third side 126 can comprise at least one projection (e.g., a second tongue 128).
A fourth side 130 can extend between the fourth edge 110 of the face surface 102 and the back surface 112. The fourth side 130 can comprise at least one projection (e.g., a second front leg 132 and a second back leg 134 that cooperate to define a second groove 136 therebetween).
In some aspects, a body 101 of the panel 100 can define the face surface 102, the back surface 112, the first side 114, the second side 118, the third side 126, and the fourth side 130.
In the example embodiment illustrated in
As defined herein, the first tongue 116 can be defined as any portion of the panel 100 that extends beyond a first plane 96 (shown in
It is contemplated that in some example embodiments a portion of the panel can define portions of both the first tongue 116 and the second tongue 128 (at their intersection). Likewise, it is contemplated that a portion of the panel can define portions of both the first back leg 122 and the second back leg 134. Further, in some optional aspects, as illustrated in
Thus, in certain aspects, the first and second tongues 116, 128 and first and second back legs 122, 134 need not have a consistent thickness along their respective longitudinal dimensions. Rather, the first tab 150 (at an intersection between the first tongue 116 and the second back leg 134) can have a first tab thickness. Similarly, the second tab (at the intersection between the second tongue 128 and the first back leg 122) can have a second tab thickness. The first tab thickness and the second tab thickness can optionally be between 0.1 mm and 5 mm (e.g., between 0.2 mm and 5 mm, or between 0.2 mm and 1 mm, or between 0.2 mm and 0.5 mm). In various aspects, for embodiments having first and second tabs 150, 152, the respective tab thicknesses of the first and second tabs can be the same or different. It is contemplated that, for many materials, a small thickness can lead to breaking. Thus, a thickness of much lower than 0.1 mm or 0.2 mm be too breakable for certain material. However, in further optional aspects, for certain materials that are resistant to breaking, the thickness can be less than 0.1 mm. It is further contemplated that the tab must be receivable into a groove of an adjacent panel. As will be apparent, the first and second tabs can be the thinnest portion of the respective tongue. Therefore, the thickness of the groove can be limited by the maximum thickness of the tongue. Moreover, because of the overlap of the respective tongues and back legs of adjacent tiles at the tab(s) (e.g., the first tab 150 and the second tab 152), a large tab thickness can force misalignment between adjacent panels relative to the third axis 94. Accordingly, a minimum thickness that is sufficient to resist breaking can be desirable.
Thus, referring to
Similarly, in further aspects and with reference to
It is contemplated that the main body portions 151,155 of the first and second tongues 116,128 can have the same respective lengths as tongues of conventional tongue and groove panels. Likewise, the main body portions 157,153 of the first and second back legs 122,134 can have the same respective dimensions as back legs of conventional tongue and groove panels.
Referring to
In various aspects, at least one of the first tongue 116 or the first back leg 122 has a longitudinal dimension along the first axis 90 that is greater than the length of the face surface, and at least one of the second tongue 128 or the second back leg 134 has a longitudinal dimension along the second axis 92 that is greater than the width of the face surface.
Referring to
Conventionally, the forward and rear surfaces 166, 168 of the second tongue 128 and respective forward and rear surfaces 160,162 of the first tongue 116 are equally spaced from the face surface 102 relative to the third axis 94 (e.g., coplanar with each other) (e.g., in conventional panel 10). Likewise, conventionally, the rear surface 164 of the first front leg 120 and the rear surface 170 of the second front leg 132 are equally spaced from the face surface 102 relative to the third axis 94; and the forward surface 165 of the first back leg 122 and forward surface 172 of the second back leg 134 are conventionally equally spaced from the face surface 102 relative to the third axis 94. In order to provide the tab(s) (e.g., tabs 150, 152, etc.) that partially defines the tongue(s) and/or back leg(s) that are longer than their respective edges of the face surface 102 along which they extend, at least one of the forward or rear surfaces of the first tongue 116 can be offset from at least one of the forward or rear surfaces of the second tongue 128 relative to the third axis 94. In further optional aspects, the forward surface of the first back leg 122 can be offset from the forward surface of the second back leg 134 relative to the third axis 94. In still further aspects, the rear surface of the first front leg 120 can be offset from the rear surface of the second front leg 132 relative to the third axis 94.
For example,
Referring to
In various aspects, the sides of the panel 100 can be formed via milling. Accordingly, dimensions of the milling tools (relative to the third axis 94) and the respective positions of the milling tools relative to the third axis 94 as they move along the respective edges can determine the positions of the forward surfaces (e.g., upper surfaces for a flooring application) and rear surfaces (e.g., lower surfaces for a flooring application) of the tongues, front legs, and back legs, as further described herein. As can be understood, the respective forward and rear surfaces of each tongue and corresponding groove on opposing sides of the panel can have similar positions relative to the third axis 94 to enable mating of adjacent panels.
Referring to
Referring to
Referring to
One way to form the fourth embodiment of the panel is to offset each of the forward surface 166 and rear surface 168 of the second tongue 128, the rear surface 170 of the second front leg 132, and the forward surface 172 of the second back leg 134 from their conventional positions by a tab thickness. That is, the forward surface 166 of the second tongue 128 can be spaced from the forward surface 160 of the first tongue 116 along the third axis 94 by a tab thickness in a direction toward the face surface 102 (shown as the spacing from the conventional position 166′ of the forward surface). The rear surface 168 of the second tongue 128 can be spaced from the rear surface 162 of the first tongue 116 along the third axis 94 by the tab thickness in a direction toward the face surface 102 (shown as the spacing from the conventional position 168′ of the rear surface). The rear surface 170 of the second front leg 132 can be spaced from the rear surface 164 of the first front leg 120 along the third axis 94 by the tab thickness in the direction toward the face surface 102 (shown as the spacing from the conventional position 164′ of the rear surface). The forward surface 172 of the second back leg 134 can be spaced from the forward surface 165 of the first back leg 122 along the third axis 94 by the tab thickness in the direction toward the face surface 102 (shown as the spacing from the conventional position 165′ of the forward surface). In some example embodiments, the forward surface 166 and rear surface 168 of the second tongue 128, the rear surface 170 of the second front leg 132, and the forward surface 172 of the second back leg 134 may be offset from their conventional positions either by different thicknesses or a single thickness.
Referring to
One way to form the fifth embodiment of the panel is to offset each of rear surface 168 of the second tongue 128 and the forward surface 172 of the second back leg 134. That is, the rear surface 168 of the second tongue 128 can be spaced from the rear surface 162 of the first tongue 116 along the third axis 94 by a tab thickness in a direction away from the face surface 102 (shown as the spacing from the conventional position 162′ of the rear surface), and the forward surface 172 of the second back leg 134 is spaced from the forward surface 165 of the first back leg 122 along the third axis 94 by the tab thickness in the direction away from the face surface 102 (shown as the spacing from the conventional position 172′ of the forward surface).
According to various aspects, the first tongue 116 and the second tongue 128 are joint at one end 174 such that the first tongue 116 extends past the third edge 108 by a distance of the second tongue width w3 at said one end thereof and the second tongue extends past the first edge 102 by a distance of the first tongue width w1 at said one end 174 thereof. In further aspects, the first back leg 122 and the second back leg 134 are joint at one end 175 such that the first back leg extends past the fourth edge 110 by a distance of a portion of the second back leg width w2 that extends beyond the second front leg at said one end thereof and the second back leg extends past the second edge 106 by a distance of a portion of the first back leg width w4 that extends beyond the first front leg at said one end 175 thereof.
In some aspects, and as shown in
Even though it is not shown in the figures or different embodiments described herein, the opposite ends of the first and second tongues 116, 128 and the first and second back legs 122, 134 of the panel 100 may not extend all the way to the edges (110, 106, 108, 104), respectively, but may still be longer than the respective faces (104, 108, 106, 110) from which they protrude out. In said example, there may be gaps between the edges (110, 106, 108, 104) and tongues (116, 128) and back legs (122, 134), respectively. Said gaps may be covered by the extensions of the tongues (116, 128) and/or back legs (122, 134) of adjacent interlocked panels 100.
Referring to
Referring to
In various aspects, the material of the disclosed panels can be waterproof or water resistant. For example, the panels can comprise polymer (e.g., polyvinylchloride, polyethylene terephthalate, acrylonitrile butadiene styrene, polypropylene, or polyurethane). In further aspects, the panel can comprise wood-based materials such as plywood, solid wood or HDF. In still further aspects, the panel 100 can comprise fibercement, magnesium oxide (mineral core panels), chalk, or talc. In still further aspects, the panel can comprise one or more ceramic materials. In some aspects, and with reference to
In exemplary aspects, and with reference to
Referring to
Referring to
In some aspects, the panels 100 of the system 200 can have grout deposited therebetween. Optionally, one or more (optionally, all) of the first edge 104, the second edge 106, the third edge 108, and the fourth edge 110 of the face surface 102 can be beveled.
Embodiments disclosed herein can form surface coverings that inhibit water permeation without a need for silicone sealants. Although described herein as an option for use as a vertical wall covering in showers, embodiments disclosed herein can be used in various applications for any walls, floors, ceilings, or any suitable surface. The panels can be used for wet or dry surfaces and can be used to inhibit permeation of fluids other than water (e.g., oil). The panels can be provided in any orientation (horizontal, vertical, or diagonal). The panels can be inexpensively installed and can be effective when installed by inexperienced (e.g., DIY) users. The panels can allow for tolerance in subsurface flatness or roughness while still forming a surface covering that inhibits water permeation.
Because panel thicknesses are constrained by features such as weight and volume, the thickness of the tabs (e.g., the first tab 150 or the second tab 152) can be similarly constrained. It is contemplated that conventional panels avoid thin portions that might be subject to breaking during manufacturing, transportation, or installation. Accordingly, the panels as disclosed herein, which maintain the entire panel thickness while also thin extensions that do not easily break or chip off during transportation and installation, are a nonobvious deviation from conventional panels.
In view of the described products, systems, and methods and variations thereof, herein below are described certain more particularly described aspects of the invention. These particularly recited aspects should not however be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular” aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.
Aspect 1: A panel comprising: a face surface having: a first edge and a second edge that extend along a first axis and are spaced by a width along a second axis that is perpendicular to the first axis, and a third edge and a fourth edge that extend along the second axis and are spaced by a length along the first axis; a back surface spaced from the face surface along a third axis that is perpendicular to the first and second axes; a first side that extends between the first edge of the face surface and the back surface, wherein the first side comprises a first tongue; a second side that extends between the second edge of the face surface and the back surface, wherein the second side comprises a first front leg and a first back leg that cooperate to define a first groove therebetween; a third side that extends between the third edge of the face surface and the back surface, wherein the third side comprises a second tongue; and a fourth side that extends between the fourth edge of the face surface and the back surface, wherein the fourth side comprises a second front leg and a second back leg that cooperate to define a second groove, wherein: at least one of the first tongue or the first back leg has a longitudinal dimension along the first axis that is greater than the length of the face surface; or at least one of the second tongue or the second back leg has a longitudinal dimension along the second axis that is greater than the width of the face surface.
Aspect 2: The panel of aspect 1, wherein at least one of the first tongue or the first back leg has a longitudinal dimension along the first axis that is greater than the length of the face surface, and at least one of second tongue or the second back leg has a longitudinal dimension along the second axis that is less than the width of the face surface.
Aspect 3: The panel of aspect 1 or aspect 2, wherein: at least one of the first tongue or the first back leg has a longitudinal dimension along the first axis that is greater than the length of the face surface by at least 0.2 mm, or at least one of the second tongue or the second back leg has a longitudinal dimension along the second axis that is greater than the width of the face surface by at least 0.2 mm.
Aspect 4: The panel of any one of aspects 1-4, wherein the first tongue extends away from the first edge of the face surface by a select distance along the second axis, wherein the second back leg extends beyond the first edge of the face surface in a direction away from the second edge of the face surface by the select distance.
Aspect 5: The panel of aspect 4, wherein the first tongue has a forward surface and a rear surface, wherein the second tongue has a forward surface and a rear surface, wherein the rear surface of the second tongue is spaced from the rear surface of the first tongue along the third axis by a tab thickness in a direction toward the face surface, and wherein each of the first back leg and the second back leg has a forward surface and a rear surface, wherein the forward surface of the second back leg is spaced from the forward surface of the first back leg along the third axis by the tab thickness in a direction toward the face surface.
Aspect 6: The panel of any one of aspects 1-5, wherein the first tongue extends at least to a plane that is perpendicular to the first axis and includes the fourth edge of the face surface.
Aspect 7: The panel of aspect 6, wherein each of the first and second front legs defines a rear surface that is spaced from the face surface along the third axis, wherein the rear surface of the second front leg is spaced from the rear surface of the first front leg relative to the third axis by a tab thickness in a direction toward the face surface.
Aspect 8: The panel of aspect 6 or aspect 7, wherein the second tongue extends at least to a plane that is perpendicular to the second axis and includes the fourth edge of the face surface.
Aspect 9: The panel of aspect 8, wherein each of the first and second front legs defines a rear surface that is spaced from the face surface along the third axis, wherein the rear surface of the second front leg is spaced from the rear surface of the first front leg along the third axis by a tab thickness in a direction toward the face surface, and wherein each of the first tongue and the second tongue has a forward surface and a rear surface, wherein the forward surface of the second tongue is spaced from the forward surface of the first tongue along the third axis by the tab thickness in a direction toward the face surface.
Aspect 10: The panel of aspect 4, wherein the second tongue extends at least to a plane that is perpendicular to the second axis and includes the second edge of the face surface.
Aspect 11: The panel of aspect 10, wherein each of the first tongue and the second tongue has a forward surface and a rear surface, wherein the forward surface of the second tongue is spaced from the forward surface of the first tongue along the third axis in a direction toward the face surface, wherein the rear surface of the second tongue is spaced from the rear surface of the first tongue along the third axis by a tab thickness in a direction toward the face surface, wherein each of the first and second front legs defines a rear surface that is spaced from the face surface relative to the third axis, wherein the rear surface of the second front leg is spaced from the rear surface of the first front leg along the third axis by the tab thickness in the direction toward the face surface, and wherein each of the first back leg and the second back leg has a forward surface and a rear surface that is spaced from the forward surface along the third axis, wherein the forward surface of the second back leg is spaced from the forward surface of the first back leg along the third axis by the tab thickness in the direction toward the face surface.
Aspect 12: The panel of any one of the preceding aspects, wherein the second tongue extends away from the third edge of the face surface by a select distance along the first axis, wherein the first back leg extends beyond the third edge of the face surface in a direction away from the fourth edge of the face surface by the select distance.
Aspect 13: The panel of aspect 12, wherein each of the first tongue and the second tongue has a forward surface and a rear surface, wherein the rear surface of the second tongue is spaced from the rear surface of the first tongue along the third axis in a direction away from the face surface, and wherein each of the first back leg and the second back leg has a forward surface and a rear surface that is spaced from the forward surface along the third axis, wherein the forward surface of the second back leg is spaced from the forward surface of the first back leg along the third axis by the tab thickness in the direction away from the face surface.
Aspect 14: The panel of any one of the preceding aspects, wherein the tab thickness is between 0.2 mm and 5 mm.
Aspect 15: The panel of any one of the preceding aspects, wherein each of the first front leg and the first back leg has a width relative to the second dimension, wherein the width of the first back leg is greater than the width of the first front leg.
Aspect 16: The panel of any one of the preceding aspects, wherein each of the second front leg and the second back leg has a width relative to the second dimension, wherein the width of the second back leg is greater than the width of the second front leg.
Aspect 17: The panel of any one of the preceding aspects, wherein the first tongue and second back leg intersect at a first tab, wherein the first tongue has a rear surface, wherein the second back leg has a forward surface, wherein the first tab is at least partially defined by the rear surface of the first tongue and the forward surface of the second back leg.
Aspect 18: The panel of aspect 17, wherein the rear surface of the first tongue and the forward surface of the second back leg are offset by a first tab thickness of between 0.2 mm and 5 mm.
Aspect 19: The panel of any one of the preceding aspects, wherein the second tongue and first back leg intersect at a second tab, wherein the second tongue has a rear surface, wherein the first back leg has a forward surface, wherein the second tab is at least partially defined by the rear surface of the second tongue and the forward surface of the first back leg.
Aspect 20: The panel of aspect 19, wherein the rear surface of the first tongue and a forward surface of the second back leg are offset by a second tab thickness of between 0.2 mm and 5 mm.
Aspect 21: The panel of any one of the preceding aspects, wherein at least one of the first, second, third, or fourth edges of the face surface is beveled.
Aspect 22: The panel of any one of the preceding aspects, wherein each of the first back leg and the second back leg has a planar forward surface, wherein each of the first tongue and the second tongue has a planar rear surface, wherein the forward surface of the first back leg is oriented at an acute angle with respect to the rear surface of the first tongue, and wherein the forward surface of the second back leg is oriented at an acute angle with respect to the rear surface of the second tongue.
Aspect 23: A surface covering comprising: at least a first and second panels as recited in any one of the preceding aspects, wherein at least one of the first tongue or the second tongue of the first panel overlaps a respective first tongue or second tongue of the second panel so that an axis that is parallel to the third axes of the first and second panels extends through both overlapping tongues of the first and second panels.
Aspect 24: The surface covering of aspect 23, further comprising grout between the first panel and the second panel.
Aspect 25: A panel comprising: a face portion defining a face surface of the panel; and a back portion connected to the face portion and defining a back surface of the panel, wherein the face portion and the back portion cooperate to define: opposing first and second sides of the panel that extend along a first axis and are spaced apart along a second axis that is perpendicular to the first axis; and opposing third and fourth sides of the panel that extend between the first and second sides along the second axis and are spaced apart along the first axis, wherein the face surface has: a first edge and a second edge that extend along the first axis and are spaced by a width along the second axis; and a third edge and a fourth edge that extend along the second axis and are spaced by a length along the first axis, wherein the back surface is spaced from the face surface along a third axis that is perpendicular to the first and second axes, wherein the face portion has a consistent peripheral profile extending between the face surface and the back portion such that the length and width of the face surface respectively correspond to a length and a width of the face portion, wherein the back portion has a variable profile along the third axis that defines: a projection of the first side or the second side that has a longitudinal dimension along the first axis that is greater than the length of the face portion; or a projection of the third side or the fourth side that has a longitudinal dimension along the second axis that is greater than the width of the face portion.
Aspect 26: The panel of aspect 25, wherein the back portion defines a tongue on the first side of the panel that is greater than the length of the face portion.
Aspect 27: The panel of aspect 25 or aspect 26, wherein the back portion defines a leg that defines a portion of a groove on the second side of the panel that is greater than the length of the face portion.
Aspect 28: The panel of any one of aspects 25-27, wherein the back portion defines a tongue on the third side of the panel that is greater than the width of the face portion.
Aspect 29: The panel of any one of aspects 25-28, wherein the back portion defines a leg that defines a portion of a groove on the fourth side of the panel that is greater than the width of the face portion.
Aspect 30: A surface covering comprising: at least a first and second panels as recited in any one of aspects 25-29, wherein at least one projection of the first panel overlaps a respective projection of the second panel so that an axis that is parallel to the third axes of the first and second panels extends through both overlapping projections of the first and second panels.
Aspect 31: A panel comprising: a body portion having a length, a width, and a thickness, the body comprising: a first face; a second face disposed opposite to the first face and spaced apart by the thickness; a first side extending from a first edge of the first face to a first edge of the second face; a second side disposed opposite to the first side and extending from a second edge of the first face to a second edge of the second face, the second side and the first side spaced apart by the width along a first axis; a third side extending from a third edge of the first face to a third edge of the second face; and a fourth side disposed opposite to the third side and extending from a fourth edge of the first face to a fourth edge of the second face, the third side and the fourth side spaced apart by the length along a second axis that is perpendicular to the first axis; a first tongue disposed at the first side and extending away from the second side, the first tongue having a first tongue length and the first tongue width; a first groove defined by a pair of first front leg and first back leg disposed at the second side and extending away from the first side, the first back leg having a first back leg length and a first back leg width; a second tongue disposed at the third side and extending away from the fourth side, the second tongue having a second tongue length and a second tongue width; and a second groove defined by a pair of second front leg and second back leg disposed at the fourth side and extending away from the third side, the second back leg having a second back leg length and a second back leg width, wherein: at least one of the first tongue length of the first tongue and the first back leg length of the first back leg extend along the second axis and is greater than the length of the body portion; or at least one of the second tongue length of the second tongue and the second back leg length of the second back leg extend along the first axis and is greater than the width of the body portion.
Aspect 32: The panel of aspect 31, wherein the first tongue and the second tongue are joint at one end such that the first tongue extends past the third side by a distance of the second tongue width at said one end thereof and the second tongue extends past the first side by a distance of the first tongue width at said one end thereof; and the first back leg and the second back leg are joint at one end such that the first back leg extends past the fourth side by a distance of the second back leg width at said one end thereof and the second back leg extends past the second side by a distance of the first back leg width at said one end thereof.
Aspect 33: The panel of aspect 31, wherein an opposite end of one of the first tongue, the second tongue, the first back leg, and the second back leg extends till the fourth side, the second side, third side, and the first side respectively.
Aspect 34: The panel of aspect 31, wherein an opposite end of one of the first tongue, the second tongue, the first back leg, and the second back leg extends past the fourth side, the second side, third side, and the first side respectively and by a distance less than the second back leg width, the first back leg width, the second tongue width, and the first tongue width respectively.
Aspect 35: The panel of aspect 31, wherein an opposite end of one of the first tongue, the second tongue, the first back leg, and the second back leg extends past the fourth side, the second side, third side, and the first side respectively and by a distance equal to the second back leg width, the first back leg width, the second tongue width, and the first tongue width respectively.
Aspect 36: The panel of aspect 31, wherein an opposite end of at least one of the first tongue, the second tongue, the first back leg, and the second back leg extends till the fourth side, the second side, third side, and the first side respectively.
Aspect 37: The panel of aspect 31, wherein an opposite end of at least one of the first tongue, the second tongue, the first back leg, and the second back leg extends past the fourth side, the second side, third side, and the first side respectively and by a distance less than the second back leg width, the first back leg width, the second tongue width, and the first tongue width respectively.
Aspect 38: The panel of aspect 31, wherein an opposite end of at least one of the first tongue, the second tongue, the first back leg, and the second back leg extends past the fourth side, the second side, third side, and the first side respectively and by a distance equal to the second back leg width, the first back leg width, the second tongue width, and the first tongue width respectively.
Aspect 39: The panel of aspect 31, wherein the first tongue has a first tongue thickness and the second tongue has a second tongue thickness, and wherein the first back leg has a first back leg thickness, the first front leg has a first front leg thickness, the second back leg has a second back leg thickness, and the second front leg has a second front leg thickness.
Aspect 40: The panel of aspect 39, wherein an opposite end of the second back leg extends past the first side and an opposite end of the first tongue extends past the fourth side such the second back leg and the first tongue join at a corner defined by the first side and the fourth side, wherein the second back leg is configured such that the second back leg thickness is greater than the first back leg thickness of the first back leg by a first tab thickness, and wherein the second tongue is configured such that the second tongue thickness is lesser than the first tongue thickness.
Although several embodiments of the invention have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other embodiments of the invention will come to mind to which the invention pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the invention is not limited to the specific embodiments disclosed herein, and that many modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims which follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention, nor the claims which follow.
This application is a continuation of U.S. patent application Ser. No. 17/489,166, filed Sep. 29, 2021, now U.S. Pat. No. 11,708,698, which claims priority to and the benefit of the filing date of U.S. Provisional Patent Application No. 63/085,715, filed Sep. 30, 2020, the entirety of each of which is hereby incorporated by reference herein.
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| Number | Date | Country | |
|---|---|---|---|
| 20230313539 A1 | Oct 2023 | US |
| Number | Date | Country | |
|---|---|---|---|
| 63085715 | Sep 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17489166 | Sep 2021 | US |
| Child | 18328228 | US |
