Flooring system

Abstract

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. 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.

Description

[0001]Flooring SystemThe present invention relates to a system, including apparatus andmethod of use of the same, for the tongue and groove flooringcomprising a number of panels.Although the following description refers to panel constructedprimarily from wood or wooden composite materials, the skilledperson will recognise that the panel system described herein canwork with other materials and is not limited to wood and woodenboards.Tongue and groove panel flooring is known. Systems of this typeare a popular for constructing floors, especially wooden floors.The panels allows for a tight, interlocking fit, which enhancesstability and reduces gaps. The tongue is a protruding ridge onone edge of the panel and the groove is a corresponding slot onthe opposite edge of the panel.The installation process typically involves the preparation of thesubfloor and allowing the panels to acclimatise. The first panelis placed with the groove side facing a wall and then the tongueof the panel is inserted into the groove of the adjacent previouspanel. The fit is often snug and a tapping block and a mallet canbe used to gently tap the panels together, ensuring a tight fitwithout damaging the tongues or grooves.The rows are then completed usually with staggered joints of thepanels in adjacent rows to enhance stability and create a morevisually appealing pattern. This can be done by cutting the firstpanel of the second row to a different length. Often the shortends of the panels are equipped with complimentary tongues andgrooves to further enhance stability of the floor.In summary, tongue and groove panels make a floor byinterlocking tightly, creating a stable, seamless, and durablesurface. This method of flooring installation is effective inensuring longevity and an aesthetically pleasing finish howeverthere is a problem if one or more of the boards forming the floorneeds to be replaced as removing the boards is difficult given thetight and snug fitting using the tongue and groove arrangement.It is therefore an aim of the present invention to provide aflooring system that addresses the abovementioned problems.It is a yet further aim of the present invention to provide a fullyaccessible tongue and groove flooring system.In a first aspect of the invention there is provided a flooringsystem comprising a number of substantially planar panelswherein said panels comprise a substantially planar square orrectangular body including a knuckle portion along a first edge ofthe 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 leastpart of the receiving portion of an adjacent panel, wherein theknuckle portion includes;a protruding face or portion wherein said upper part of saidprotruding face or portion includes a substantially horizontalchannel or groove into which is received at least part anoverhanging lip or protrusion located on an adjacent panel.Preferably the horizontal channel or groove runs along the lengthor the knuckle portion. Typically the knuckle portion and / orreceiving portion are formed along at least one complete edge ofthe panel.In one embodiment the knuckle portion and receiving portion arelocated on opposite sides or edges of the panels.In one embodiment the protruding face or portion is substantiallycurved. Typically the protruding face or portion is substantiallycircular in cross section.In a preferred embodiment the protruding face or portionincludes one or more substantially planar faces or surfaces.Typically the protruding face or portion includes a substantiallyvertical face; and at least an upper angled face disposed or locatedabove the substantially vertical face; wherein said upper angledsurface includes a substantially horizontal channel or groove intowhich can be located an overhanging lip or protrusion located onan adjacent panel.Further typically, the protruding face or portion includes upperand lower angled faces disposed or located on either side of thesubstantially vertical face;wherein said upper angled surface includes a substantiallyhorizontal channel or groove into which can be located anoverhanging lip or protrusion located on an adjacent panel.As such, the system provides an interlocking flooring systemwherein any panel can be removed and / or replaced with minimalor no disruption to the surrounding panels.Typically the knuckle portion has a prominent portion or distalface from which an upper portion depends back towards the bodyof the panel, wherein a horizontal channel or groove configuredto receive a lip portion is formed along the length of the lipportion.In one embodiment the knuckle portion is a tongue or tongueportion of the panel. In a further embodiment the receivingportion is a groove or groove portion of the panel.In one embodiment the lip or protrusion extends from the top ofthe receiving portion of the panel. Typically the lip portion ofthe panel extends a spaced distance from the body.In one embodiment the receiving portion of the panel includes arecess or channel configured to receive at least part of the knuckleportion of an adjacent panel. Typically the top of the recess is atleast partially defined by the overhanging lip or protrusion of thepanel.In one embodiment the receiving portion includes a bottom lipor stub. Typically the bottom lip or stub at least partially definesthe recess or channel. Further typically the bottom lip or stubextends from the panel a shorter distance than the overhanginglip 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 thebottom lip or stub.In one embodiment the substantially horizontal channel depth is4-16 % of the panel thickness. Typically the horizontal channeldepth is 7-8% of the thickness of the panel. Further typically thedepth of the channel is proportional to the thickness of the board.In one embodiment the receiving portion includes and / or is atleast partially constructed or defined by a number of substantiallyplanar surfaces.In one embodiment the receiving portion is defined or at leastpartially defined by one or more curved surfaces.In one embodiment the panels comprise a number of layers. Inone embodiment the panel is laminated. In one embodiment theuppermost surface of the panel comprises a non-wood or non-cellulose 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 oflaying a floor or covering surface using a plurality of substantiallyplanar panels wherein said panels comprise a substantially planarsquare or rectangular body including a knuckle portion along afirst edge of the body and a receiving portion along a second edgeof the body, such that at least part of the knuckle portion isreceived in at least part of the receiving portion of an adjacentpanel, wherein the knuckle portion includes;a protruding face or portion wherein said upper part of saidprotruding face or portion includes a substantially horizontalchannel or groove into which is received at least part anoverhanging lip or protrusion located on an adjacent panelwherein said method includes the step of inserting at least part ofthe knuckle portion into the receiving portion.Typically at least part of the overhanging lip is received in at leastpart of the channel or groove.Typically the panels are arranged in a liner and / or longitudinalarrangement. The panels may also be laid or arranged in astaggered or stepped arrangement. Further embodiments includelong planks or panels running in the same direction; a ‘Laddereffect’ with long runner portions with ‘rungs’ in between,substantially at right angles; and ‘herringbone’ patterns and / orthe like.In a third aspect of the invention there is provided a panel thatforms part of a covering structure in use, said panel comprising asubstantially planar square or rectangular body including aknuckle portion along a first edge of the body and a receivingportion along a second edge of the body, such that at least partof the knuckle portion is received in at least part of the receivingportion of an adjacent panel, wherein the knuckle portionincludes; aprotruding face or portion wherein said upper part of saidprotruding face or portion includes a substantially horizontalchannel or groove into which is received at least part anoverhanging lip or protrusion located on an adjacent panel in use.Specific embodiments of the invention are now described withreference to the figures.Figure 1 shows a cross sectional view of the side of a panel inaccordance with an embodiment of the invention;Figure 2 shows a cross sectional view of the side of a panel inaccordance with an embodiment of the invention;Figure 3 shows a cross sectional view of the side of two panelsfitting together in accordance with an embodiment of theinvention; andFigure 4 shows a cross sectional view of the side of two panelsfitting together in accordance with an embodiment of theinvention.Shown in figure 1 is a panel 2 that can be arranged with otherpanels to make a floor surface. The panel 2 is a rectangular,planar and plank like in form with a tongue or knuckle 4 formedalong one edge and a groove or receiving portion 6 formed alongan opposing edge. The knuckle 4 in this example is formed froman upper planar surface 8 and a lower planar surface 10. Formedalong the length of the upper surface 8 is a horizontal groove orchannel 12 which is shaped to receive at least part of the upperlip portion 14 which at least partially defines the receiving portion6.In this example the receiving portion 6 also includes a lower lipportion 16 which also defines the receiving portion 6 that runsalong the edge of the board and receives the knuckle 4 therein.Figure 2 shows another embodiment of the invention where theknuckle 4 and receiving portion 6 are formed from substantiallycurved surfaces as opposed to the angular planar surfaces definingthose features in figure 1. The remaining features of the board 2however are the same with a knuckle portion 4 having a groove12 formed in the same into which can fit the upper lip 14 of anadjacent panel when building the floor.Figure 3 shows how the panels fit together and that thisconfiguration has sufficient friction to keep the panels in place,however individual panels can be removed from the flooringsystem without disturbing adjacent panels or the floor structureas a whole.Figure 4 shows another embodiment of the invention where theknuckle 4 includes a curved surface and receiving portion 6 issubstantially formed from flat surface. The remaining features ofthe board 2 include the knuckle portion 4 being a spaced distancefrom the top of the board 2 into which can fit the upper lip 14 ofan adjacent panel when building the floor.The principal is to enable the ‘roll in and roll out’ of the board sofull access is available with locational elements on at least twoedges, including all edges. The underlying goal is stil l to have fullaccess.This is facilitated in figures 4a and 4b by angling the frontsurfaces of the upper 14 and lower lips 16 thereby reducing thebottom edge size of the joint in comparison with the upper.By reducing the bottom edge size or profile of the joint, thisproves that wider and thicker boards could be accessed mid flooras has been our objective. The result is more location along thelength of the board to eliminate lipping, whilst still maintainingfull access, and flexibility. As such a novel fully located clip insystem has been developed.

Claims

Claims1. A flooring system comprising a number of substantially planarpanels wherein said panels comprise a substantially planar squareor rectangular body including a knuckle portion along a first edgeof the body and a receiving portion along a second edge of thebody, such that at least part of the knuckle portion is received inat least part of the receiving portion of an adjacent panel, whereinthe knuckle portion includes;a protruding face or portion wherein said upper part of saidprotruding face or portion includes a substantially horizontalchannel or groove into which is received at least part anoverhanging lip or protrusion located on an adjacent panel.

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

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

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

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

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

7. A system according to any preceding claim wherein theprotruding face or portion includes one or more substantiallyplanar faces or surfaces.

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

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

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

11. A system according to claim 10 wherein the knuckle portionis a tongue or tongue portion of the panel.

12. A system according to claim 11 wherein the receiving portionis a groove or groove portion of the panel.

13. A system according to claim 12 wherein the lip or protrusionextends from the top of the receiving portion of the panel.

14. A system according to claim 13 wherein the lip portion of thepanel extends a spaced distance from the body.

15. A system according to claim 14 wherein the receiving portionof the panel includes a recess or channel configured to receive atleast part of the knuckle portion of an adjacent panel.

16. A system according to claim 15 wherein the top of the recessis at least partially defined by the overhanging lip or protrusionof the panel.

17. A system according to claim 16 wherein the receiving portionincludes a bottom lip or stub.

18. A system according to claim 17 wherein the bottom lip orstub at least partially defines the recess or channel.

19. A system according to claim 18 wherein the bottom lip orstub extends from the panel a shorter distance than theoverhanging lip extends from the panel body.

20. A system according to claim 19 wherein the overhanging lipextends from the body 5-6 times more or larger than the bottomlip extends from the body.

21. A system according to claim 20 wherein the overhanging lipis around 5.5 times larger than the bottom lip or stub.

22. A system according to claim 21 wherein the substantiallyhorizontal channel depth is 4-16 % of the panel thickness.

23. A system according to claim 22 wherein the horizontalchannel depth is 7-8% of the thickness of the panel.

24. A system according to claim 23 wherein the depth of thechannel is proportional to the thickness of the board.

25. A system according to any preceding claim wherein thereceiving portion includes and / or is at least partially constructedor defined by a number of substantially planar surfaces.

26. A system according to claim 25 wherein the receiving portionis defined or at least partially defined by one or more curvedsurfaces.

27. A system according to claim 26 wherein the panels comprisea number of layers.

28. A system according to claim 27 wherein the panel islaminated.

29. A system according to claim 28 wherein the uppermostsurface of the panel comprises a non-wood or non-cellulose basedmaterial.

30. A system according to claim 29 wherein the panel includes aferrous or magnetic layer.

31. A system according to claim 30 wherein the magnetic layer isthe bottom layer of the panel.

32. A method of laying a floor or covering surface using aplurality of substantially planar panels wherein said panelscomprise a substantially planar square or rectangular bodyincluding a knuckle portion along a first edge of the body and areceiving portion along a second edge of the body, such that atleast part of the knuckle portion is received in at least part of thereceiving portion of an adjacent panel, wherein the knuckleportion includes;a protruding face or portion wherein said upper part of saidprotruding face or portion includes a substantially horizontal33. A panel that forms part of a covering structure in use, saidpanel comprising a substantially planar square or rectangular bodyincluding a knuckle portion along a first edge of the body and areceiving portion along a second edge of the body, such that atleast part of the knuckle portion is received in at least part of thereceiving portion of an adjacent panel, wherein the knuckleportion includes;a protruding face or portion wherein said upper part of saidprotruding face or portion includes a substantially horizontalchannel or groove into which is received at least part anoverhanging lip or protrusion located on an adjacent panel in use.

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