Flooring system

Abstract

A flooring system comprising a plurality of substantially planar panels 2. The panels comprise a planar square or rectangular body having a knuckle portion 4 along a first edge of the body and a recei

Description

The present invention relates to a system, including apparatus and method of use of the same, for the tongue and groove flooring comprising a number of panels. Although the following description refers to panel constructed primarily from wood or wooden composite materials, the skilled person will recognise that the panel system described herein can work with other materials and is not limited to wood and wooden boards. Tongue and groove panel flooring is known. Systems of this type are a popular for constructing floors, especially wooden floors. The panels allows for a tight, interlocking fit, which enhances stability and reduces gaps. The tongue is a protruding ridge on one edge of the panel and the groove is a corresponding slot on the opposite edge of the panel. The installation process typically involves the preparation of the subfloor and allowing the panels to acclimatise. The first panel is placed with the groove side facing a wall and then the tongue of the panel is inserted into the groove of the adjacent previous panel. The fit is often snug and a tapping block and a mallet can be used to gently tap the panels together, ensuring a tight fit without damaging the tongues or grooves. The rows are then completed usually with staggered joints of the panels in adjacent rows to enhance stability and create a more visually appealing pattern. This can be done by cutting the first panel of the second row to a different length. Often the short ends of the panels are equipped with complimentary tongues and grooves to further enhance stability of the floor. In summary, tongue and groove panels make a floor by interlocking tightly, creating a stable, seamless, and durable surface. This method of flooring installation is effective in ensuring longevity and an aesthetically pleasing finish however there is a problem if one or more of the boards forming the floor needs to be replaced as removing the boards is difficult given the tight and snug fitting using the tongue and groove arrangement. It is therefore an aim of the present invention to provide a flooring system that addresses the abovementioned problems. It is a yet further aim of the present invention to provide a fully accessible tongue and groove flooring system. In a first aspect of the invention there is provided a flooring system comprising a number of substantially planar panels wherein said panels comprise a substantially planar square or rectangular body including a knuckle portion along a first edge of the body and a receiving portion along a second edge of the body, such that at least part of the knuckle portion is received in at least part of the receiving portion of an adjacent panel, wherein the knuckle portion includes; a protruding face or portion wherein said upper part of said protruding face or portion includes a substantially horizontal channel or groove into which is received at least part an overhanging lip or protrusion located on an adjacent panel. Preferably the horizontal channel or groove runs along the length or the knuckle portion. Typically the knuckle portion and / or receiving portion are formed along at least one complete edge of the panel. In one embodiment the knuckle portion and receiving portion are located on opposite sides or edges of the panels. In one embodiment the protruding face or portion is substantially curved. Typically the protruding face or portion is substantially circular in cross section. In a preferred embodiment the protruding face or portion includes one or more substantially planar faces or surfaces. Typically the protruding face or portion includes a substantially vertical face; and at least an upper angled face disposed or located above the substantially vertical face; wherein said upper angled surface includes a substantially horizontal channel or groove into which can be located an overhanging lip or protrusion located on an adjacent panel. Further typically, the protruding face or portion includes upper and lower angled faces disposed or located on either side of the substantially vertical face; wherein said upper angled surface includes a substantially horizontal channel or groove into which can be located an overhanging lip or protrusion located on an adjacent panel. As such, the system provides an interlocking flooring system wherein any panel can be removed and / or replaced with minimal or no disruption to the surrounding panels. Typically the knuckle portion has a prominent portion or distal face from which an upper portion depends back towards the body of the panel, wherein a horizontal channel or groove configured to receive a lip portion is formed along the length of the lip portion. In one embodiment the knuckle portion is a tongue or tongue portion of the panel. In a further embodiment the receiving portion is a groove or groove portion of the panel. In one embodiment the lip or protrusion extends from the top of the receiving portion of the panel. Typically the lip portion of the panel extends a spaced distance from the body. In one embodiment the receiving portion of the panel includes a recess or channel configured to receive at least part of the knuckle portion of an adjacent panel. Typically the top of the recess is at least partially defined by the overhanging lip or protrusion of the panel. In one embodiment the receiving portion includes a bottom lip or stub. Typically the bottom lip or stub at least partially defines the recess or channel. Further typically the bottom lip or stub extends from the panel a shorter distance than the overhanging lip extends from the panel body. In one embodiment the overhanging lip extends from the body 5-6 times larger than the bottom lip extends from the body. Typically the overhanging lip is around 5.5 times larger than the bottom lip or stub. In one embodiment the substantially horizontal channel depth is 4-16 % of the panel thickness. Typically the horizontal channel depth is 7-8% of the thickness of the panel. Further typically the depth of the channel is proportional to the thickness of the board. In one embodiment the receiving portion includes and / or is at least partially constructed or defined by a number of substantially planar surfaces. In one embodiment the receiving portion is defined or at least partially defined by one or more curved surfaces. In one embodiment the panels comprise a number of layers. In one embodiment the panel is laminated. In one embodiment the uppermost surface of the panel comprises a non-wood or noncellulose based material such as porcelain or tile. In one embodiment the panel includes a ferrous or magnetic layer. Typically the magnetic layer is the bottom layer of the panel. In a second aspect of the invention there is provided a method of laying a floor or covering surface using a plurality of substantially planar panels wherein said panels comprise a substantially planar square or rectangular body including a knuckle portion along a first edge of the body and a receiving portion along a second edge of the body, such that at least part of the knuckle portion is received in at least part of the receiving portion of an adjacent panel, wherein the knuckle portion includes; a protruding face or portion wherein said upper part of said protruding face or portion includes a substantially horizontal channel or groove into which is received at least part an overhanging lip or protrusion located on an adjacent panel wherein said method includes the step of inserting at least part of the knuckle portion into the receiving portion. Typically at least part of the overhanging lip is received in at least part of the channel or groove. Typically the panels are arranged in a liner and / or longitudinal arrangement. The panels may also be laid or arranged in a staggered or stepped arrangement. Further embodiments include long planks or panels running in the same direction; a ‘Ladder effect’ with long runner portions with ‘rungs’ in between, substantially at right angles; and ‘herringbone’ patterns and / or the like. In a third aspect of the invention there is provided a panel that forms part of a covering structure in use, said panel comprising a substantially planar square or rectangular body including a knuckle portion along a first edge of the body and a receiving portion along a second edge of the body, such that at least part of the knuckle portion is received in at least part of the receiving portion of an adjacent panel, wherein the knuckle portion includes; a protruding face or portion wherein said upper part of said protruding face or portion includes a substantially horizontal channel or groove into which is received at least part an overhanging lip or protrusion located on an adjacent panel in use. Specific embodiments of the invention are now described with reference to the figures. Figure 1 shows a cross sectional view of the side of a panel in accordance with an embodiment of the invention; Figure 2 shows a cross sectional view of the side of a panel in accordance with an embodiment of the invention; Figure 3 shows a cross sectional view of the side of two panels fitting together in accordance with an embodiment of the invention; and Figure 4 shows a cross sectional view of the side of two panels fitting together in accordance with an embodiment of the invention. Shown in figure 1 is a panel 2 that can be arranged with other panels to make a floor surface. The panel 2 is a rectangular, planar and plank like in form with a tongue or knuckle 4 formed along one edge and a groove or receiving portion 6 formed along an opposing edge. The knuckle 4 in this example is formed from an upper planar surface 8 and a lower planar surface 10. Formed along the length of the upper surface 8 is a horizontal groove or channel 12 which is shaped to receive at least part of the upper lip portion 14 which at least partially defines the receiving portion 6. In this example the receiving portion 6 also includes a lower lip portion 16 which also defines the receiving portion 6 that runs along the edge of the board and receives the knuckle 4 therein. Figure 2 shows another embodiment of the invention where the knuckle 4 and receiving portion 6 are formed from substantially curved surfaces as opposed to the angular planar surfaces defining those features in figure 1. The remaining features of the board 2 however are the same with a knuckle portion 4 having a groove 12 formed in the same into which can fit the upper lip 14 of an adjacent panel when building the floor. Figure 3 shows how the panels fit together and that this configuration has sufficient friction to keep the panels in place, however individual panels can be removed from the flooring system without disturbing adjacent panels or the floor structure as a whole. Figure 4 shows another embodiment of the invention where the knuckle 4 includes a curved surface and receiving portion 6 is substantially formed from flat surface. The remaining features of the board 2 include the knuckle portion 4 being a spaced distance from the top of the board 2 into which can fit the upper lip 14 of an adjacent panel when building the floor. The principal is to enable the Toll in and roll out’ of the board so full access is available with locational elements on at least two edges, including all edges. The underlying goal is still to have full access. This is facilitated in figures 4a and 4b by angling the front 5 surfaces of the upper 14 and lower lips 16 thereby reducing the bottom edge size of the joint in comparison with the upper. By reducing the bottom edge size or profile of the joint, this proves that wider and thicker boards could be accessed mid floor 10 as has been our objective. The result is more location along the length of the board to eliminate lipping, whilst still maintaining full access, and flexibility. As such a novel fully located clip in system has been developed. 15

Claims

1. A flooring system comprising a number of substantially planar panels wherein said panels comprise a substantially planar square or rectangular body including a knuckle portion along a first edge of the body and a receiving portion along a second edge of the body, such that at least part of the knuckle portion is received in at least part of the receiving portion of an adjacent panel, wherein the knuckle portion includes;a protruding face or portion wherein said upper part of said protruding face or portion includes a substantially horizontal channel or groove into which is received at least part an overhanging lip or protrusion located on an adjacent panel.

2. A system according to claim 1 wherein the horizontal channel or groove runs along the length or the knuckle portion.

3. A system according to claim 2 wherein the knuckle portion and / or receiving portion are formed along at least one complete edge of the panel.

4. A system according to claim 3 wherein the knuckle portion and receiving portion are located on opposite sides or edges of the panels.

5. A system according to claim 3 wherein the protruding face or portion is substantially curved.

6. A system according to claim 5 wherein the protruding face or portion is substantially circular in cross section.

7. A system according to any preceding claim wherein the protruding face or portion includes one or more substantially planar faces or surfaces.

8. A system according to claim 7 wherein the protruding face or portion includes a substantially vertical face; and at least an upper angled face disposed or located above the substantially vertical face; wherein said upper angled surface includes a substantially horizontal channel or groove into which can be located an overhanging lip or protrusion located on an adjacent panel.

9. A system according to claim 8 wherein the protruding face or portion includes upper and lower angled faces disposed or located on either side of the substantially vertical face;wherein said upper angled surface includes a substantially horizontal channel or groove into which can be located an overhanging lip or protrusion located on an adjacent panel.

10. A system according to claim 6 or 9 wherein the knuckle portion has a prominent portion or distal face from which an upper portion depends back towards the body of the panel, wherein a horizontal channel or groove configured to receive a lip portion is formed along the length of the lip portion.

11. A system according to claim 10 wherein the knuckle portion is a tongue or tongue portion of the panel and the receiving portion is a groove or groove portion of the panel.

12. A system according to claim 11 wherein the lip or protrusion extends from the top of the receiving portion of the panel and a spaced distance from the body.

13. A system according to claim 12 wherein the receiving portion of the panel includes a recess or channel configured to receive at least part of the knuckle portion of an adjacent panel and is at least partially defined by the overhanging lip or protrusion of the panel.

14. A system according to claim 13 wherein the receiving portion includes a bottom lip or stub and the bottom lip or stub at least partially defines the recess or channel.

15. A system according to claim 14 wherein the bottom lip or stub extends from the panel a shorter distance than the overhanging lip extends from the panel body.

16. A system according to claim 15 wherein the overhanging lip extends from the body 5-6 times more or larger than the bottom lip extends from the body.

17. A system according to claim 16 wherein the overhanging lip is around 5.5 times larger than the bottom lip or stub.

18. A system according to claim 17 wherein the substantially horizontal channel depth is 4-16 % of the panel thickness.

19. A system according to claim 18 wherein the horizontal channel depth is 7-8% of the thickness of the panel.

20. A system according to claim 21 wherein the depth of the channel is proportional to the thickness of the board.

22. A system according to any preceding claim wherein the receiving portion includes and / or is at least partially constructed or defined by a number of substantially planar surfaces.

23. A system according to claim 22 wherein the receiving portion is defined or at least partially defined by one or more curved surfaces.

24. A method of laying a floor or covering surface using a plurality of substantially planar panels wherein said panels comprise a substantially planar square or rectangular body including a knuckle portion along a first edge of the body and a receiving portion along a second edge of the body, such that at least part of the knuckle portion is received in at least part of the receiving portion of an adjacent panel, wherein the knuckle portion includes;a protruding face or portion wherein said upper part of said protruding face or portion includes a substantially horizontal25. A panel that forms part of a covering structure in use, said panel comprising a substantially planar square or rectangular body including a knuckle portion along a first edge of the body and a receiving portion along a second edge of the body, such that at least part of the knuckle portion is received in at least part of the receiving portion of an adjacent panel, wherein the knuckle portion includes;a protruding face or portion wherein said upper part of said protruding face or portion includes a substantially horizontal channel or groove into which is received at least part an overhanging lip or protrusion located on an adjacent panel in use.

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