Patent Application
20080066419
As used throughout the specification and claims, a “laminate” is a multilayered structure, formed from at least a décor layer and an overlay. Laminate flooring is typically a rigid floor covering with a surface layer of one or more thin sheets of a fibrous material (usually paper), impregnated with aminoplastic thermosetting resins (usually melamine). These sheets are generally either pressed as such, for example high-pressure laminate (HPL), compact laminate (CPL) and direct laminate (DL), and in the case of HPL or CPL bonded on a substrate, or in the case of DPL directly pressed on a substrate.
Typically, the décor layer is a monochromatic or patterned paper sheet, impregnated with a melamine-formaldehyde resin. The pattern can be of any image, but is most often a natural wood or stone pattern. However, it is within the scope of the invention to utilize a completely unique “fantasy” pattern derived from a photograph, a drawing, painting or any other image (in analog or digital form), such as described by U.S. Pat. No. 7,003,364, herein incorporated by reference in its entirety. In most embodiments, the décor layer includes a paper sheet, such as Kraft paper, onto which the image/pattern/décor is printed. However, it is within the scope of the invention to combine the décor layer with the core, by, for example, printing the image/pattern/décor directly onto the core itself.
The overlay is conventionally an abrasion resistant sheet formed from alpha-cellulose and impregnated with a thermosetting resin. Preferably, the thermosetting resin is a melamine-formaldehyde resin. In order to provide scratch and/or abrasion resistance, the overlay may be provided with hard particles (i.e., particles having a Moh's hardness of at least approximately 3, preferably at least about 6, such as silicon carbide, alumina, and diamond) having an average particle size between approximately 30-90 μm, and are evenly distributed to a loading of 2-20 g/m2. In order to provide scratch resistance to the product, smaller hard particles, e.g., having an average particle size of between 1-15 μm, and evenly distributed to a loading of 1-15 g/m2, can be used, as described by U.S. Pat. No. 6,106,654, incorporated herein by reference in its entirety. Even greater abrasion/scratch resistance can be achieved by utilizing multiple overlays, such as described by U.S. Pat. No. 4,940,503, incorporated herein by reference in its entirety.
Typically, the laminate is affixed to a core. Typical core materials include metals (such as aluminum, copper, steel, and various alloys) and wood based materials, such as solid wood, wood veneer, oriented strandboard, plywood, fiberboard (e.g., high density fiberboard (HDF) and medium density fiberboard (MDF)); plastics (e.g., extruded or molded, thermoplastic or thermosetting), flaxboard, gypsum, high density reinforced plaster, other cellulosic and structural materials, or composites.
As is known in the art, quarter round moldings and shoe moldings are designed to be utilized above a subfloor 1, in the area where a wall 2 is partly covered by a wall base molding 3. Typically, a layer 4 is placed between the subfloor 1 and a flooring element 5, with a quarter round molding 6 covering the joint between the flooring element 5 and the wall base molding 3. In accordance with the invention, quarter round 6 is provided with means for dissipating water vapor which develops in the area of the wall base.
The quarter round 6 is typically any known quarter round molding, having been modified to include the ventilation of the invention. For example, the quarter round 6 typically has an inner structure, or core which can be formed from one or more of a wood based material, plastics, flaxboard, strandboard, gypsum, high density fiber reinforced plaster, or metal, composites, or other natural or synthetic material such as cork, or any additional material, such as described in U.S. Pat. No. 6,860,074, herein incorporated by reference in its entirety. Preferred plastics include extrudable and/or moldable thermosetting and thermoplastic resins, the latter including high density olefins and polyvinylchloride (PVC). As is known in the art, quarter round moldings generally include a curved outer face, often defining an arc segment of 90°, with adjacent perpendicular faces, such that when the quarter round is installed at a joint between a floor and a wall, the curved outer surface extends from the wall to the floor to aesthetically hide the joint.
The decorative outer face of the quarter round 6 can have a variety of finishes, such as varnishes, lacquers, paints, polyurethane, hard surfaces (optionally containing hard particles, to increase the durability, e.g., abrasion and scratch resistance, of the surface materials), such as laminates (such as taught by U.S. Pat. No. 7,065,931, herein incorporated by reference in its entirety), or hardwood flooring finishes, veneers, foils, stainable papers, or digital printing or other flooring materials, such as vinyl, metal, composites or plastics. It is additionally within the scope of the invention to provide the decorative outer face of quarter round 6 with ceramic or wood tiles, as taught by U.S. Pat. No. 6,860,074. Typical laminates which can be used are those taught by U.S. Pat. No. 6,517,935 (herein incorporated by reference in its entirety), including monochromatic or patterned (including random) décor sheets which may or may not be impregnated with a thermosetting resin, and a cellulosic overlay paper, such as one made from alpha-cellulose, which also may or may not be impregnated with a resin. Other laminates include ones in which the overlay is eliminated, and may be substituted by a polymer containing cellulosic particles, evenly or randomly distributed throughout a (typically otherwise clear) resin. The outer surface may be a conventional laminate, such as a high pressure laminate (HPL), direct laminate (DL), compact laminate (CPL) or a post-formed laminate (PFL) (as described in U.S. application Ser. No. 08/817,391, herein incorporated by reference in its entirety); a foil; a print, such as a photograph or a digitally generated image; or a liquid coating including, for example, aluminum oxide. Thus, in the event natural wood or wood veneer is not selected as the material, the appearance of wood may be simulated by coating the decorative outer surface with a laminate having a decor that simulates wood. Alternatively, the decor can simulate marble, ceramic, terrazzo, stone, brick, inlays, or even fantasy patterns.
In a preferred embodiment, the outer face of quarter round 6 includes a laminate formed from a thermosetting resin, having a decor sheet, optionally an overlay sheet (with or without cellulosic fibers atop or therein) and hard particles therein in order to impart an abrasion resistance thereto, which is affixed or joined to the remainder of the quarter round 6 in a high-pressure laminate process step. Such laminate may be affixed as described by U.S. Pat. No. 6,805,951, herein incorporated by reference in its entirety. The outer face can be other finishing materials such as thermoplastic containing laminates, wood veneers, thermosetting polymers, such as melamine or phenolic resins, thermoplastic polymers such as olefins, foils (such as thermosetting, thermoplastic, paper or metal foils), optionally impregnated with or without hard particles, polyesters, vinyls, liquid coatings, metals (such as sheets or strips), or combinations thereof. For example, the outer face can include multiple elements, as described herein. It is additionally considered within the scope of the invention to affix a material to the outer face during a direct lamination step, as is known in the art.
The specific décor can be selected to enhance the appearance of the surfaces which will be adjacent to quarter round 6 when installed. Such enhancement can be accomplished by matching exactly the visual pattern to that of the adjacent surface, or by contrasting the patterns, for example, such that when installed, a visual pattern extends from a flooring element (wall base or wall) onto and possibly completely across the molding, as described by U.S. application Ser. No. 09/964,838, filed Sep. 28, 2001, herein incorporated by reference in its entirety.
The quarter round 6 typically has durability rating. As defined by the European Producers of Laminate Flooring, such products can have an abrasion resistance rating of anywhere from AC1 to AC5. Typical abrasion resistances are >300 cycles, >400 cycles, >500 cycles, at least 900 cycles (AC1), at least 1800 cycles (AC2), at least 2500 cycles (AC3), at least 4000 cycles (AC4) and at least 6500 cycles (AC5), as measured by European Standard EN 13329 (Annex E). Typical products according to the invention can also have impact resistance ratings of IC1, IC2 or IC3, as measured by European Standard EN 13329.
Moreover, it is possible to provide a texture which enhances the pattern of the underlying paper sheet. Such texturing can be created to be “in register” with, offset from, or to contrast with the image of the paper sheet. Such texturing may be created by physical pressing, e.g., embossing (as taught by U.S. Application Ser. No. 10/440,317 (filed May 19, 2003), U.S. Pat. No. 7,003,364, and WO9731775 and WO9731776, each of which is herein incorporated by reference in its entirety) or chemically created (as taught by U.S. Pat. No. 6,991,830, herein incorporated by reference in its entirety). The texture can be selected to enhance (e.g., match or contrast with) any texture of adjacent surfaces. The texture may also be provided such that features of the texture extend from a flooring element (or wall base or wall) onto and possibly completely across the molding, which texture may, or may not coincide with the underlying décor.
As is shown in
In order to direct the flow of vapor to the quarter round 6, the layer 4 preferably defines channels 4A extending along the lower face of layer 4. Such channels 4A may be formed from circular, rectangular, rhomboid, or other shaped studs 4B, arranged randomly or in a, for example, grid pattern. As an alternative, the lower face of layer 4 may simply be provided with the channels 4A being cut other otherwise formed in the lower face of layer 4A. A preferred layer 4 is PLATON FLOOR, available from Isola AS of Notodden, Norway. Other suitable layers include the underlay sheet described by U.S. Design Pat. No. 508,332. Typical materials for layer 4 include plastics, such as olefins (e.g., high and low density polyethylene), metals (preferably in sheet form, such as aluminum or aluminum alloys), woven and non woven fabrics, or other material which can hinder or prohibit vapors from passing therethrough. Preferably, spacing material 8 is in the form of thin strips or rolls, which are placed vertically into the subfloor 1 and layer 4, resting against the wall base 3 (or wall 2 when a wall base 3 is not used).
As is shown in
The spacing material 8 can be any material which allows water vapor to pass from channels 4A to the room. Typical materials include materials which have physical spaces, e.g., meshes, or materials capable of absorbing water vapor and directing the vapor through the material to the room. Such water absorbing materials preferably direct water vapor by wicking and/or capillary action and may include cotton or other cellulosic substances.
Once the spacing material 8 is positioned, the quarter round 6 is typically placed over the space 9, between flooring element 5 and the wall base 3 (or wall 2), and is installed against spacing material 8 and the wall base 3 (or wall). The quarter round 6 can be secured to the wall base 3 with any known affixing means, e.g., nails, screws, tacks, tracks, clips, fresh glue, pre-applied glue (such as one or two-part microencapsulated systems (as discussed by U.S. Pat. No. 7,029,741, herein incorporated by reference in its entirety)), or any combination thereof.
Due to the configuration of spacing material 8 and the quarter round 6 of the invention, the spacing material 8 creates spaces 7 between the wall base 3 (or wall 2) and the quarter round 6 for water vapor to escape from beneath layer 3 and the subfloor 1.
It is also within the scope of the invention install the assembly of the invention without the spacing material 8. As shown in
When quarter round 6 is formed from a material which can absorb water, the ducts 11A may be coated with a material to prevent such absorption. This material can be a physical sealant, such as paint, or a layer of plastic, or simply a coating, such as wax (such as paraffin), which can reduce or eliminate the passage of water vapor therethrough. If, however, the quarter round 6 is formed from a non-absorbing material, e.g., plastic or metal, such a material is not necessary.
Preferably, ducts 11A terminate, at an upper end at ports 11B. Such ports 11B are preferably regularly spaced across a longitudinal length of quarter round 6. Such a configuration can result in a more aesthetically pleasing surface. Typically, ports 11B can be spaced with about ¼ in. (6.35 mm), about ½ in. (12.7 mm), about 1 in. (25.4 mm), about 2 in. (50.8 mm), and 3 in. (76.2 mm) between. Typically, ports 11B all have the same width and depths, which widths can be about ⅛ in. (3.15 mm), about ¼ in. (6.35 mm), about ½ in. (12.7 mm), and about 1 in. (25.4 mm), and which depths are typically are about ⅛ in. (3.15 mm) or about ¼ in. (6.35 mm).
Although described as being a quarter round molding, the invention can be used with other types of moldings to hide joints between floors and walls. For example,
The shoe moldings 10 can also be provided with a depression 13 which can run the entire length of the shoe molding 10 to assist in dissipation of water vapor and to additionally increase the aesthetics of the shoe molding 10, by, for example, providing a “shadow effect.” Such depression can be substantially straight or can vary in its size and shape, e.g., have a sinusoidal, square wave, stepped, bell-curve or any other regular or irregular pattern along the length.
Depression 13 can also be integrated with ducts 11A and ports 11B, allowing air and water vapor to more easily move from the underside of layer 4 to space above shoe molding 10. As shown in
Although the shoe molding 10 can be joined to the wall 2 or wall base 3 by methods/materials such as glues/adhesives (e.g., fresh and pre-applied), and conventional mechanical fasteners (e.g., nails, screws, and tacks), the shoe molding 10 can be joined with a joining element 16. Such joining element is typically affixed to wall 2 or wall base 3 (by methods/materials such as glues (e.g., fresh and pre-applied), and conventional mechanical fasteners (e.g., nails, screws, and tacks)), and holds shoe molding 10 in its installed position by a tongue and groove joint (
In one embodiment, the shoe molding 10 has a groove or opening 17, preferably having locking edges 17A, sized and shaped to receive a tongue or enlarged portion of the joining element 16.
However, it is within the scope of the invention to relatively “flip” the location of the tongue and groove, by for example, positioning joining element 16 on the hidden face of shoe molding 10, and providing wall 2 or wall base 3 with a groove. The joining element 16 can be attached along the entire length of the wall 2 or wall base 3, or at intervals sufficient to secure the shoe molding 10.
The tongue-groove configuration allows the shoe molding 10 to be snapped against the wall base 3. Typically, the tongue can be bulbous, dove-tailed, half dove-tailed, or straight, with the groove being complimentarily shaped. The joining element 16 and the shoe molding 10 can be joined by snapping the tongue into the groove, such as by any combination of (1) relative horizontal motion in a plane perpendicular or parallel to the axis of the shoe molding 10, (2) relative vertical motion in a plane perpendicular or horizontal to the axis of the shoe molding 10, and (3) relatively rotating the shoe molding 10 in a plane perpendicular to the axis of the shoe molding 10. Optionally, the shoe molding 10 is provided with at least one opening 18, which can also have locking elements 18A to allow for different height configurations for the shoe molding 10, or for additional forces to maintain the shoe molding 10 in place when the joining element has a equal number of tongues. Such opening 18 may also be used as a raceway to house elements, such as wiring (e.g., electrical and audio/visual/telephone), heating elements (e.g., electrical or radiant) and plumbing.
With reference to
Additionally, the invention can be used with an unattached, preferably foam, underlayment 22, alone or in combination with a flat polymeric (preferably polyethylene) sheet, i.e., without the channels 4A. Thus, the invention can be utilized with a ventilated or unventilated underlayment.
Although the moldings of the invention can be joined to the wall 2 by direct mechanical or chemical methods, e.g., nails, screws, and/or glue, one or more clips 23 can be used (
The invention additionally includes an apparatus and method for converting traditional shoe moldings into ventilated shoe moldings 10″. As shown in
The disperser 24 is preferably designed to match the flooring elements. Thus, the disperser 24 can be made from any of the above-identified materials. For example, the disperser 24 can have an upper decorative surface including a foil, sheet or other metal, laminate, paint, print, or other abrasion resistant surface, which decorative surface is positioned on a core, made from, for example, metal, cellulosic materials (such as fiberboard, cork, particleboard, strandboard, etc.), plastic or composite material.
The invention additionally includes packaging to be used by, for example, wholesalers or retailers. In one embodiment, multiple individual pieces, such as shoe molding 10, may be bundled in a single package or kit. In another embodiment, the package or kit includes two, or three, or even up to twenty or more, of each piece packaged therein, which can be all the same or of various different lengths. For example, a single package may include three approximately one-meter (or three foot) sections of each item contained therein, for a total length of about three meters (about nine feet). It is additionally within the scope of the invention to include different sets of items in a single package, for example, one set being about one meter (about three feet) long and an additional set being about two meters (about six feet) long, i.e., 1:2. In one particular embodiment, where three different lengths are included (either of the same or different products), the materials contained in the package have length ratios of 1:2:3 to allow for easy assemblage of the package.
A typical kit in accordance with the invention includes the ventilated molding and other ventilated or conventional pieces. The other pieces can be, e.g., the underlayment, barrier layer, shim, clip, disperser, nail(s), wall base, or glue. A preferable kit includes the ventilated quarter round molding and a wall base, the wall base having a décor which matches a décor of the ventilated quarter round molding.
It should be apparent that embodiments other than those specifically described above may come within the spirit and scope of the present invention. Hence, the present invention is not limited by the above description.
