CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority from U.S. Patent Application Ser. No. 61/103,642, filed Oct. 8, 2008, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION The present invention relates to a flooring panel for a flooring system wherein the flooring panel has a core provided with at least a portion of a locking member, and the core is interposed between opposing first and second decorative surfaces.
BACKGROUND OF THE INVENTION Flooring panels, such as laminate flooring panels, include a core and a top decorative surface with a visible design. Each of the flooring panels therefore has only a single visible design. Since most flooring applications require a large number of flooring panels, it is therefore necessary for manufacturers, distributors and sellers to inventory a large number of flooring panels for each type of visible design. Additionally, it is difficult to mix multiple visible designs in a single flooring application, because separate flooring panels, which may or may not be compatible for installation, need to be purchased.
It is therefore desirable to provide a flooring panel with more than one decorative surface wherein each of the decorative surfaces has a different visible design so that the amount of inventory can be reduced for each type of visible design. It is further desirable to develop a flooring panel with more than one decorative surface wherein each of the decorative surfaces has a different visible design so that multiple visible designs can easily be mixed to achieve a desired floor design. It is still further desirable to develop a locking member for the aforementioned flooring panel so that the flooring panel can easily be installed with either decorative surface being visible.
BRIEF SUMMARY OF THE INVENTION The invention relates to a flooring panel for a flooring system comprising a core interposed between a first decorative surface and a second decorative surface. The core has opposing first and second side surfaces extending substantially perpendicular to the first and second decorative surfaces. The first and second decorative surfaces have different visible designs, and at least the first side surface is provided with at least a portion of a locking member.
The invention further relates to a flooring system comprising at least a first and second flooring panel. The first and second flooring panels each have a core interposed between a first decorative surface and a second decorative surface. The core has opposing first and second side surfaces extending substantially perpendicular to the first and second decorative surfaces. The first side surface of the first flooring panel is positioned adjacent to the second side surface of the second flooring panel. The first and second decorative surfaces have different visible designs. A locking member extends between the first side surface of the first flooring panel and the second side surface of the second flooring panel and locks the first flooring panel to the second flooring panel.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a partial cross sectional view of a first example of a flooring system including flooring panels according to a first embodiment of the invention.
FIG. 2 is partial cross sectional view of a second example of a flooring system including the flooring panels according to the first embodiment of the invention.
FIG. 3 is a cross sectional view of a first alternate embodiment of a locking member of the flooring panels according to the first embodiment of the invention.
FIG. 4 is a cross sectional view of a second alternate embodiment of the locking member of the flooring panels according to the first embodiment of the invention.
FIG. 5 is a cross sectional view of a third alternate embodiment of the locking member of the flooring panels according to the first embodiment of the invention.
FIG. 6 is a cross sectional view of a fourth alternate embodiment of the locking member of the flooring panels according to the first embodiment of the invention.
FIG. 7 is a cross sectional view of a fifth alternate embodiment of the locking member of the flooring panels according to the first embodiment of the invention.
FIG. 8 is a cross sectional view of a sixth alternate embodiment of the locking member of the flooring panels according to the first embodiment of the invention.
FIG. 9 is a cross sectional view of a seventh alternate embodiment of the locking member of the flooring panels according to the first embodiment of the invention.
FIG. 10 is a cross sectional view of the seventh alternate embodiment of the locking member of the flooring panels according to the first embodiment of the invention shown in a mated position.
FIG. 11 is a perspective view of a flexible securing member of the seventh alternate embodiment of the locking member of the flooring panels according to the first embodiment of the invention.
FIG. 12 is a cross sectional view of an eighth alternate embodiment of the locking member of the flooring panels according to the first embodiment of the invention.
FIG. 13 is a cross sectional view of the eighth alternate embodiment of the locking member of the flooring panels according to the first embodiment of the invention shown in a mated position.
FIG. 14 is a perspective view of a flexible securing member of the eighth alternate embodiment of the locking member of the flooring panels according to the first embodiment of the invention.
FIG. 15 is a partial cross sectional view of a flooring system including flooring panels according to a second embodiment of the invention.
FIG. 16 is a cross sectional view of a first alternate embodiment of a locking member of the flooring panels according to the second embodiment of the invention.
FIG. 17 is a cross sectional view of a second alternate embodiment of the locking member of the flooring panels according to the second embodiment of the invention.
FIG. 18 is a cross sectional view of a third alternate embodiment of the locking member of the flooring panels according to the second embodiment of the invention.
FIG. 19 is a cross sectional view of a fourth alternate embodiment of the locking member of the flooring panels according to the second embodiment of the invention.
FIG. 20 is a cross sectional view of a fifth alternate embodiment of the locking member of the flooring panels according to the second embodiment of the invention.
FIG. 21 is a cross sectional view of a sixth alternate embodiment of the locking member of the flooring panels according to the second embodiment of the invention.
FIG. 22 is a cross sectional view of a seventh alternate embodiment of the locking member of the flooring panels according to the second embodiment of the invention shown in a partially mated position.
FIG. 23 is a cross sectional view of the seventh alternate embodiment of the locking member of the flooring panels according to the second embodiment of the invention shown in a mated position.
FIG. 24 is a cross sectional view of an eighth alternate embodiment of the locking member of the flooring panels according to the second embodiment of the invention shown in a partially mated position.
FIG. 25 is a cross sectional view of the eighth alternate embodiment of the locking member of the flooring panels according to the second embodiment of the invention shown in a mated position.
FIG. 26 is a partial cross sectional view of a flooring system including flooring panels according to a third embodiment of the invention shown in a pre-mated position.
FIG. 27 is a cross sectional view of the flooring panels according to the third embodiment of the invention shown in a partially-mated position.
FIG. 28 is a cross-sectional view of the flooring panels according to the third embodiment of the invention shown in a mated position.
DETAILED DESCRIPTION OF THE EMBODIMENT(S) FIG. 1 shows a flooring system 1 including first and second flooring panels 2, 3 according to a first embodiment of the invention. As shown in FIG. 1, the flooring system 1 consists of at least two of the first and second flooring panels 2, 3 mounted on a sub-floor 4. In the illustrated embodiment, the first and second flooring panels 2, 3 are identical and each consists of a core 5, a first decorative surface 6, a second decorative surface 7, and a locking member 10. The core 5 is interposed between the first and second decorative surfaces 6, 7. The core 5 may be, for example, a wood laminate core consisting of one or more layers of high density fiberboard or medium density fiberboard. The core 5 has opposing first and second side surfaces 8, 9 that extend substantially perpendicular to the first and second decorative surfaces 6, 7. The first decorative surface 6 opposes the second decorative surface 7 and extends substantially parallel thereto. The first and second decorative surfaces 6, 7 may consist, for example, of a printed and impregnated cellulosic layer having a desired visible design. The visible design of the first decorative surface 6 is different from the visible design of the second decorative surface 7. It will be appreciated by those skilled in the art, however, that the visible design of the first decorative surface 6 and the visible design of the second decorative surface 7 may be the same. Each of the first and second flooring panels 2, 3 are symmetrical about a central axis 15 extending substantially parallel to the first and second decorative surfaces 6, 7 and substantially perpendicular to the first and second side surfaces 8, 9. The flooring panels 1, 2 can be of various shape, for example, rectangular, square, or any other shape.
The locking member 10 is formed on the first and second side surfaces 8, 9 of the core 5. The locking member 10 consists of a tongue 11 and a groove 12. The tongue 11 extends from the first side surface 8 of the core 5 substantially from a center thereof. The tongue 11 may be materially formed in one piece with the core 5. The tongue 11 has opposing lateral surfaces provided with indentations 13. The tongue 11 has a mating surface 16 extending substantially perpendicular to the first and second decorative surfaces 6, 7. The mating surface 16 may be beveled to facilitate insertion of the tongue 11 into the groove 12. The groove 12 is formed in the second side surface 9 of the core 5 in a substantial center thereof. The groove 12 has a size and configuration corresponding to the size and configuration of the tongue 11. The groove 12 has an abutment surface 17 extending substantially perpendicular to the first and second decorative surfaces 6, 7. The groove 12 has opposing lateral surfaces provided with projections 14 corresponding to the indentations 13 of the tongue 11. The projections 14 may be materially formed in one piece with the core 5. The tongue 11 and the groove 12 are formed such that when the first side surface 8 of the first flooring panel 2 opposes the second side surface 9 of the second flooring panel 3, the tongue 11 is capable of mating with the groove 12 and locking therewith. Although the tongue 11 is shown and described herein as having the indentations 13 and the groove 12 is shown and described herein as having the projections 14, it will be appreciated by those skilled in the art that alternatively the tongue 11 may be formed to have the projections 14 and the groove 12 may be formed to have the indentations 13. Further, it is not necessary that the number of the projections 14 and the number of the indentations 13 be the same or be limited to two, the number of the projections 14 and the number of the indentations 13 may be varied to achieve a desired result.
As shown in FIG. 1, when the first and second flooring panels 2, 3 are mounted on the sub-floor 4, the first and second flooring panels 2, 3 are arranged such that the second decorative surfaces 7 of both of the first and second flooring panels 2, 3 are arranged adjacent to the sub-floor 4. The first side surface 8 of the first flooring panel 2 opposes the second side surface 9 of the second flooring panel 3. The tongue 11 of the first flooring panel 2 is inserted into the groove 12 of the second flooring panel 3 so that the projections 14 engage with the indentations 13 to lock the first flooring panel 2 to the second flooring panel 3. When the first flooring panel 2 is locked to the second flooring panel 3, the first and second flooring panels 2, 3 are prevented from moving in a direction substantially perpendicular to the first and second decorative surfaces 6, 7 and in a direction substantially perpendicular to the first and second side surfaces 8, 9. It will be appreciated by those skilled in the art, however, that the first and second flooring panels 2, 3 may also be arranged such that the first decorative surfaces 6 of both of the first and second flooring panels 2, 3 are arranged adjacent to the sub-floor 4. Thus, because the first and second flooring panels 2, 3 are reversible, the visible design of the first decorative surface 6 or the visible design of the second decorative surface 7 may be made visible depending on the desired floor design.
FIG. 2 shows a second example of the flooring system 1 including the first and second flooring panels 2, 3 according to the first embodiment of the invention. As shown in FIG. 2, when the first and second flooring panels 2, 3 are mounted on the sub-floor 4, the first and second flooring panels 2, 3 are arranged such that the first decorative surface 6 of the first flooring panel 2 and the second decorative surface 7 of the second flooring panel 3 are arranged adjacent to the sub-floor 4. The first side surface 8 of the first flooring panel 2 opposes the second side surface 9 of the second flooring panel 3. The tongue 11 of the first flooring panel 2 is inserted into the groove 12 of the second flooring panel 3 so that the projections 14 engage with the indentations 13 to lock the first flooring panel 2 to the second flooring panel 3. When the first flooring panel 2 is locked to the second flooring panel 3, the first and second flooring panels 2, 3 are prevented from moving in a direction substantially perpendicular to the first and second decorative surfaces 6, 7 and in a direction substantially perpendicular to the first and second side surfaces 8, 9. Thus, because the first and second flooring panels 2, 3 are not only reversible, but also the locking member 10 is configured to be reversible, the visible design of the first decorative surface 6 and the visible design of the second decorative surface 7 may be caused to alternate depending on the desired floor design.
FIG. 3 shows a first alternate embodiment of the locking member 10 of the first and second flooring panels 2, 3 according to the first embodiment of the invention. As shown in FIG. 3, the locking member 10 consists of the tongue 11 and the groove 12. The mating surface 16 of the tongue 11 is provided with a hook material 20. The abutment surface 17 of the groove 12 is provided with a loop material 21. The tongue 11 of the first flooring panel 2 is inserted into the groove 12 of the second flooring panel 3 so that the hook material 20 engages with the loop material 21 to lock the first flooring panel 2 to the second flooring panel 3. Although the tongue 11 is shown and described herein as having the hook material 20 and the groove 12 is shown and described herein as having the loop material 21, it will be appreciated by those skilled in the art that alternatively the tongue 11 may be formed to have the loop material 21 and the groove 12 may be formed to have the hook material 20.
FIG. 4 shows a second alternate embodiment of the locking member 10 of the first and second flooring panels 2, 3 according to the first embodiment of the invention. As shown in FIG. 4, the locking member 10 consists of the tongue 11 and the groove 12. The abutment surface 17 of the groove 12 is provided with an adhesive 22. The adhesive 22 may be, for example, a pressure sensitive adhesive or a microsphere encapsulated adhesive. The tongue 11 of the first flooring panel 2 is inserted into the groove 12 of the second flooring panel 3 so that the mating surface 16 engages the adhesive 22 to lock the first flooring panel 2 to the second flooring panel 3. Although the abutment surface 17 of the groove 12 is shown and described herein as being provided with the adhesive 22, it will be appreciated by those skilled in the art that alternatively the mating surface 16 of the tongue 11 may be provided with the adhesive 22. Additionally, the adhesive 22 may be a two part adhesive wherein a first part of the adhesive is applied to the mating surface 16 and a second part of the adhesive is applied to the abutment surface 17 or vice versa.
FIG. 5 shows a third alternate embodiment of the locking member 10 of the first and second flooring panels 2, 3 according to the first embodiment of the invention. As shown in FIG. 5, the locking member 10 consists of the tongue 11 and the groove 12. The opposing lateral surfaces of the tongue 11 and the opposing lateral surfaces of the groove 12 are provided with roughened surfaces at 23, 24, respectively. The tongue 11 of the first flooring panel 2 is inserted into the groove 12 of the second flooring panel 3 so that the roughened surfaces 23, 24 engage to frictionally lock the first flooring panel 2 to the second flooring panel 3.
FIG. 6 shows a fourth alternate embodiment of the locking member 10 of the first and second flooring panels 2, 3 according to the first embodiment of the invention. As shown in FIG. 6, the locking member 10 consists of the tongue 11 and the groove 12. The opposing lateral surfaces of the tongue 11 and the groove 12 have corresponding curved profiles 25, 26, respectively. Each of the curved profiles 25, 26 is substantially S-shaped. The tongue 11 of the first flooring panel 2 is inserted into the groove 12 of the second flooring panel 3 so that the curved profiles 25 of the tongue 11 engage with the curved profiles 26 of the groove 12 to lock the first flooring panel 2 to the second flooring panel 3.
FIG. 7 shows a fifth alternate embodiment of the locking member 10 of the first and second flooring panels 2, 3 according to the first embodiment of the invention. As shown in FIG. 7, the locking member 10 consists of the tongue 11 and the groove 12. The mating surface 16 is provided with an indentation 27 formed in a substantial center thereof. The indentation 27 has a substantially rectangular cross-section. The abutment surface 17 is provided with a projection 28 extending from a substantial center thereof. The projection 28 may be materially formed in one piece with the core 5. The projection 28 is configured substantially in the shape of an arrow in that the projection 28 consists of a shaft with a distal end having opposing inclined surfaces that converge at a central point. The tongue 11, of the first flooring panel 2 is inserted into the groove 12 of the second flooring panel 3 so that the projection 28 engages with the indentation 27 to lock the first flooring panel 2 to the second flooring panel 3. Although the tongue 11 is shown and described herein as having the indentation 27 and the groove 12 is shown and described herein as having the projection 28, it will be appreciated by those skilled in the art that alternatively the tongue 11 may be formed to have the projection 28 and the groove 12 may be formed to have the indentation 27.
FIG. 8 shows a sixth alternate embodiment of the locking member 10 of the first and second flooring panels 2, 3 according to the first embodiment of the invention. As shown in FIG. 8, the locking member 10 consists of the tongue 11 and the groove 12. The mating surface 16 is provided with an indentation 29 formed in a substantial center thereof. The indentation 29 has a distal portion having a smaller cross-section than a proximal portion thereof. The abutment surface 17 is provided with a projection 30 extending from a substantial center thereof. The projection 28 may be materially formed in one piece with the core 5. The projection 30 is configured substantially in the shape of a wedge and has a distal portion having a greater cross-section than a proximal portion thereof. The tongue 11 of the first flooring panel 2 is inserted into the groove 12 of the second flooring panel 3 so that the projection 30 engages with the indentation 29 to lock the first flooring panel 2 to the second flooring panel 3. Although the tongue 11 is shown and described herein as having the indentation 29 and the groove 12 is shown and described herein as having the projection 30, it will be appreciated by those skilled in the art that alternatively the tongue 11 may be formed to have the projection 30 and the groove 12 may be formed to have the indentation 29.
FIGS. 9-10 show a seventh alternate embodiment of the locking member 10 of the first and second flooring panels 2, 3 according to the first embodiment of the invention. As shown in FIG. 9, the locking member 10 consists of the tongue 11, the groove 12, and a flexible securing member 33. One of the opposing lateral surfaces of the tongue 11 is provided with an indentation 31 having a substantially rectangular cross section and an inclined bottom surface. The opposing lateral surfaces of the groove 12 are provided with securing member receiving indentations 32 corresponding to the indentation 31 of the tongue 11. A flexible securing member 33 is arranged in at least one of the securing member receiving indentations 32. As shown in FIG. 11, the flexible securing member 33 is separate from the first and second flooring panels 2, 3 and is a substantially elongated strip having an end section with a protrusion 34. The protrusion 34 of the flexible securing member 33 is configured to project from the securing member receiving indentation 32 when the flexible securing member 33 is received in the securing member receiving indentation 32. The flexible securing member 33 may be made, for example, by molding, preferably injection molding, any type of polymer material, such as nylon, polyethylene terphthlate, polyethylene, or polypropylene.
As shown in FIG. 9, as the tongue 11 of the first flooring panel 2 is inserted into the groove 12 of the second flooring panel 3, the tongue 11 engages the protrusion 34 of the flexible securing member 33 and pushes the protrusion 34 into the securing member receiving indentation 32 in one of the opposing lateral surfaces of the groove 12. As shown in FIG. 10, when the tongue 11 is fully received in the groove 12, the protrusion 34 of the flexible securing member 33 is caused to project into the indentation 31 in the tongue 3 to lock the first flooring panel 2 to the second flooring panel 3.
FIGS. 12-13 show an eighth alternate embodiment of the locking member 10 of the first and second flooring panels 2, 3 according to the first embodiment of the invention. As shown in FIG. 12, the locking member 10 consists of the tongue 11, the groove 12, and a flexible securing member 37. The opposing lateral surfaces of the tongue 11 are provided with indentations 35 having a substantially rectangular cross section and an inclined bottom surface. The opposing lateral surfaces of the groove 12 are provided with securing member receiving indentations 36 corresponding to the indentations 35 of the tongue 11. A flexible securing member 37 is arranged in each of the securing member receiving indentations 36. As shown in FIG. 14, the flexible securing member 37 is separate from the first and second flooring panels 2, 3 and is a substantially elongated strip having a substantial V-shape and an end section with a protrusion 38. The protrusion 38 of the flexible securing member 37 is configured to project from the securing member receiving indentation 36 when the flexible securing member 37 is received in the securing member receiving indentation 36. The flexible securing member 37 may be made, for example, by molding, preferably injection molding, any type of polymer material, such as nylon, polyethylene terphthlate, polyethylene, or polypropylene.
As shown in FIG. 12, as the tongue 11 of the first flooring panel 2 is inserted into the groove 12 of the second flooring panel 3, the tongue 11 engages the protrusions 38 of the flexible securing members 37 and pushes the protrusions 38 into the securing member receiving indentations 36 in the opposing lateral surfaces of the groove 12. As shown in FIG. 13, when the tongue 11 is fully received in the groove 12, the protrusions 38 of the flexible securing members 37 are caused to project into the indentations 35 in the tongue 3 to lock the first flooring panel 2 to the second flooring panel 3.
FIG. 15 shows a flooring system 40 including first and second flooring panels 41, 42 according to a second embodiment of the invention. As shown in FIG. 15, the flooring system 40 consists of at least two of the first and second flooring panels 41, 42 mounted on a sub-floor 43. In the illustrated embodiment, the first and second flooring panels 41, 42 are identical and each consists of a core 44, a first decorative surface 45, a second decorative surface 46, and a locking member 50. The core 44 is interposed between the first and second decorative surfaces 45, 46. The core 44 may be, for example, a wood laminate core consisting of one or more layers of high density fiberboard or medium density fiberboard. The core 44 has opposing first and second side surfaces 47, 48 that extend substantially perpendicular to the first and second decorative surfaces 45, 46. The first decorative surface 45 opposes the second decorative surface 46 and extends substantially parallel thereto. The first and second decorative surfaces 45, 46 may consist, for example, of a printed and impregnated cellulosic layer having a desired visible design. The visible design of the first decorative surface 45 is different from the visible design of the second decorative surface 46. It will be appreciated by those skilled in the art, however, that the visible design of the first decorative surface 45 and the visible design of the second decorative surface 46 may be the same. The flooring panels 41, 42 can be of various shape, for example, rectangular, square, or any other shape.
The locking member 50 is formed on the first and second side surfaces 47, 48 of the core 44. The locking member 50 consists of a first locking extension 51 and a second locking extension 52. The first locking extension 51 extends from the first side surface 47 of the core 44 on a side proximate the second decorative surface 46. The first locking extension 51 is substantially L-shaped and includes a mating projection 53 and a mating recess 54. The mating projection 53 has a mating surface 55 extending substantially parallel to the first and second decorative surfaces 45, 46. The mating projection 53 has opposing lateral surfaces provided with indentations 77. The mating recess 54 has an abutment surface 56 extending substantially parallel to the first and second decorative surfaces 45, 46. The mating recess 54 has opposing lateral surfaces provided with projections 76. The projections 76 may be materially formed in one piece with the first locking extension 51. The first locking extension 51 may be materially formed in one piece with the core 44.
The second locking extension 52 extends from the second side surface 48 of the core 44 on a side proximate the first decorative surface 45. The second locking extension 52 is substantially L-shaped and includes a mating projection 57 and a mating recess 58. The mating projection 57 has a mating surface 59 extending substantially parallel to the first and second decorative surfaces 45, 46. The mating projection 57 has opposing lateral surfaces provided with indentations 77 corresponding to the projections 76 of the first locking extension 51. The mating recess 58 has an abutment surface 60 extending substantially parallel to the first and second decorative surfaces 45, 46. The mating recess 58 has opposing lateral surfaces provided with projections 76 corresponding to the indentations 77 of the first locking extension 51. The projections 76 may be materially formed in one piece with the second locking extension 52. The second locking extension 52 may be materially formed in one piece with the core 44. The second locking extension 52 has a size and configuration corresponding to the size and configuration of the first locking extension 51. The first locking extension 51 and the second locking extension 52 are formed such that when the first side surface 47 of the first flooring panel 41 opposes the second side surface 48 of the second flooring panel 42, the first locking extension 51 is capable of mating with the second locking extension 52 and locking therewith.
As shown in FIG. 15, when the first and second flooring panels 41, 42 are mounted on the sub-floor 43, the first and second flooring panels 41, 42 are arranged such that the second decorative surfaces 46 of both of the first and second flooring panels 41, 42 are arranged adjacent to the sub-floor 43. The first side surface 47 of the first flooring panel 41 opposes the second side surface 48 of the second flooring panel 42. The first locking extension 51 of the first flooring panel 41 is mated with the second locking extension 52 of the second flooring panel 42 so that the projections 76 engage the indentations 77 to lock the first flooring panel 41 to the second flooring panel 42. When the first flooring panel 41 is locked to the second flooring panel 42, the first and second flooring panels 41, 42 are prevented from moving in a direction substantially perpendicular to the first and second decorative surfaces 45, 46 and in a direction substantially perpendicular to the first and second side surfaces 47, 48. It will be appreciated by those skilled in the art, however, that the first and second flooring panels 41, 42 may also be arranged such that the first decorative surfaces 45 of both of the first and second flooring panels 41, 42 are arranged adjacent to the sub-floor 43. Thus, because the first and second flooring panels 41, 42 are reversible, the visible design of the first decorative surface 45 or the visible design of the second decorative surface 46 may be made visible depending on the desired floor design.
FIG. 16 shows a first alternate embodiment of the locking member 50 of the first and second flooring panels 41, 42 according to the second embodiment of the invention. As shown in FIG. 16, the locking member 50 consists of the first locking extension 51 and the second locking extension 52. The mating surfaces 55, 59 of each of the mating projections 53, 57 of the first and second locking extension 51, 52 are provided with a loop material 62. The abutment surfaces 56, 60 of each of the mating recesses 54, 58 of the first and second locking extension 51, 52 are provided with a hook material 61. The mating projection 53 of the first flooring panel 41 is inserted into the mating recess 58 of the second flooring panel 42 so that the hook material 61 engages with the loop material 62, and the mating projection 57 of the second flooring panel 42 is inserted into the mating recess 54 of the first flooring panel 41 so that the hook material 61 engages with the loop material 62 to lock the first flooring panel 41 to the second flooring panel 42. Although the mating projections 53, 57 are shown and described herein as having the loop material 62 and the mating recesses 54, 58 are shown and described herein as having the hook material 61, it will be appreciated by those skilled in the art that alternatively the mating projections 53, 57 may be formed to have the hook material 61 and the mating recesses 54, 58 may be formed to have the loop material 62 or any other combination thereof.
FIG. 17 shows a second alternate embodiment of the locking member 50 of the first and second flooring panels 41, 42 according to the second embodiment of the invention. As shown in FIG. 17, the locking member 50 consists of the first locking extension 51 and the second locking extension 52. The abutment surfaces 56, 60 of the mating recesses 54, 58 are provided with an adhesive 63. The adhesive 63 may be, for example, a pressure sensitive adhesive or a microsphere encapsulated adhesive. The mating projection 53 of the first flooring panel 41 is inserted into the mating recess 58 of the second flooring panel 42 so that the mating surface 55 engages the adhesive 63 and the mating projection 57 of the second flooring panel 42 is inserted into the mating recess 54 of the first flooring panel 41 so that the mating surface 59 engages the adhesive 63 to lock the first flooring panel 41 to the second flooring panel 42. Although the abutment surfaces 56, 60 of mating recesses 54, 58 are shown and described herein as being provided with the adhesive 63, it will be appreciated by those skilled in the art that alternatively the mating surfaces 55, 59 of the mating projections 53, 57 may be provided with the adhesive 63. Additionally, the adhesive 63 may be a two part adhesive wherein a first part of the adhesive is applied to the mating surfaces 55, 59 and a second part of the adhesive is applied to the abutment surfaces 56, 60 or vice versa.
FIG. 18 shows a third alternate embodiment of the locking member 50 of the first and second flooring panels 41, 42 according to the second embodiment of the invention. As shown in FIG. 18, the locking member 50 consists of the first locking extension 51 and the second locking extension 52. Opposing lateral surfaces of the mating projections 53, 57 and opposing lateral surfaces of the mating recesses 54, 58 are provided with roughened surfaces at 64, 65, respectively. The mating projection 53 of the first flooring panel 41 is inserted into the mating recess 58 of the second flooring panel 42 and the mating projection 57 of the second flooring panel 42 is inserted into the mating recess 54 of the first flooring panel 41 so that the roughened surfaces 64, 65 engage to frictionally lock the first flooring panel 41 to the second flooring panel 42.
FIG. 19 shows a fourth alternate embodiment of the locking member 50 of the first and second flooring panels 41, 42 according to the second embodiment of the invention. As shown in FIG. 19, the locking member 50 consists of the first locking extension 51 and the second locking extension 52. The opposing lateral surfaces of the mating projections 53, 57 and the mating recesses 54, 58 have corresponding curved profiles 66, 67, respectively. Each of the curved profiles 66, 67 is substantially S-shaped. The mating projection 53 of the first flooring panel 41 is inserted into the mating recess 58 of the second flooring panel 42 and the mating projection 57 of the second flooring panel 42 is inserted into the mating recess 54 of the first flooring panel 41 so that the curved profiles 66 of the mating projections 53, 57 engage with the curved profiles 67 of the mating recesses 54, 58 to lock the first flooring panel 41 to the second flooring panel 42.
FIG. 20 shows a fifth alternate embodiment of the locking member 50 of the first and second flooring panels 41, 42 according to the second embodiment of the invention. As shown in FIG. 20, the locking member 50 consists of the first locking extension 51 and the second locking extension 52. The mating surfaces 55, 59 are provided with an indentation 68 formed in a substantial center thereof. The indentation 68 has a substantially rectangular cross-section. The abutment surfaces 56, 60 are provided with a projection 69 extending from a substantial center thereof. The projection 69 may be materially formed in one piece with the core 44. The projection 69 is configured substantially in the shape of an arrow in that the projection 69 consists of a shaft with a distal end having opposing inclined surfaces that converge at a central point. The mating projection 53 of the first flooring panel 41 is inserted into the mating recess 58 of the second flooring panel 42 and the mating projection 57 of the second flooring panel 42 is inserted into the mating recess 54 of the first flooring panel 41 so that the projections 68 engage with the indentations 68 to lock the first flooring panel 41 to the second flooring panel 42. Although the mating projections 53, 57 are shown and described herein as having the indentations 68 and the mating recesses 54, 58 are shown and described herein as having the projection 69, it will be appreciated by those skilled in the art that alternatively the mating recesses 54, 58 may be formed to have the projections 69 and the mating projections 53, 57 may be formed to have the indentations 68 or any other combination thereof.
FIG. 21 shows a sixth alternate embodiment of the locking member 50 of the first and second flooring panels 41, 42 according to the second embodiment of the invention. As shown in FIG. 21, the locking member 50 consists of the first locking extension 51 and the second locking extension 52. The mating surfaces 55, 59 are each provided with an indentation 70 formed in a substantial center thereof. The indentation 70 has a distal portion having a smaller cross-section than a proximal portion thereof. The abutment surfaces 56, 60 are each provided with a projection 71 extending from a substantial center thereof. The projection 71 may be materially formed in one piece with the core 44. The projection 71 is configured substantially in the shape of a wedge and has a distal portion having a greater cross-section than a proximal portion thereof. The mating projection 53 of the first flooring panel 41 is inserted into the mating recess 58 of the second flooring panel 42 and the mating projection 57 of the second flooring panel 42 is inserted into the mating recess 54 of the first flooring panel 41 so that the projections 71 engage with the indentations 70 to lock the first flooring panel 41 to the second flooring panel 42. Although the mating projections 53, 57 are shown and described herein as having the projections 71 and the mating recesses 54, 58 are shown and described herein as having the indentations 70, it will be appreciated by those skilled in the art that alternatively the mating recesses 54, 58 may be formed to have the projections 69 and the mating projections 53, 57 may be formed to have the indentations 68 or any other combination thereof.
FIGS. 22-23 show a seventh alternate embodiment of the locking member 50 of the first and second flooring panels 41, 42 according to the second embodiment of the invention. As shown in FIG. 22, the locking member 50 consists of the first locking extension 51, the second locking extension 52, and the flexible securing member 33. A distal lateral surface of each of the mating projections 53, 57 is provided with an indentation 72 having a substantially rectangular cross section and an inclined bottom surface. The first side surface 47 of the first flooring panel 41 and the second side surface 48 of the second flooring panel 42 are each provided with securing member receiving indentations 73 corresponding to the indentations 72 of the mating projections 53, 57. The flexible securing member 33 is arranged in each of the securing member receiving indentations 73. As shown in FIG. 11 and previously discussed herein, the flexible securing member 33 is a substantially elongated strip having an end section with the protrusion 34. The protrusion 34 of the flexible securing member 33 is configured to project from the securing member receiving indentation 73 when the flexible securing member 33 is received in the securing member receiving indentation 73.
As shown in FIG. 22, as the mating projection 53 of the first flooring panel 41 is inserted into the mating recess 58 of the second flooring panel 42 and the mating projection 57 of the second flooring panel 42 is inserted into the mating recess 54 of the first flooring panel 41, the mating projections 53, 57 engage the protrusions 34 of the flexible securing members 33 and push the protrusions 34 into the securing member receiving indentations 73. As shown in FIG. 23, when the mating projections 53, 57 are fully received in the mating recesses 54, 58, the protrusions 34 of the flexible securing members 33 are caused to project into the indentations 72 in the mating projections 53, 57 to lock the first flooring panel 41 to the second flooring panel 42.
FIGS. 24-25 show an eighth alternate embodiment of the locking member 50 of the first and second flooring panels 41, 42 according to the second embodiment of the invention. As shown in FIG. 24, the locking member 50 consists of the first locking extension 51, the second locking extension 52, and the flexible securing member 37. A distal lateral surface of each of the mating projections 53, 57 is provided with an indentation 75 having a substantially rectangular cross section and an inclined bottom surface. The first side surface 47 of the first flooring panel 41 and the second side surface 48 of the second flooring panel 42 are each provided with securing member receiving indentations 75 corresponding to the indentations 74 of the mating projections 53, 57. The flexible securing member 37 is arranged in each of the securing member receiving indentations 75. As shown in FIG. 14 and previously discussed herein, the flexible securing member 37 is a substantially elongated strip having a substantial V-shape and an end section with a protrusion 38. The protrusion 38 of the flexible securing member 37 is configured to project from the securing member receiving indentation 75 when the flexible securing member 37 is received in the securing member receiving indentation 75.
As shown in FIG. 24, as the mating projection 53 of the first flooring panel 41 is inserted into the mating recess 58 of the second flooring panel 42 and the mating projection 57 of the second flooring panel 42 is inserted into the mating recess 54 of the first flooring panel 41, the mating projections 53, 57 engage the protrusions 38 of the flexible securing members 37 and push the protrusions 38 into the securing member receiving indentations 75. As shown in FIG. 25, when the mating projections 53, 57 are fully received in the mating recesses 54, 58, the protrusions 38 of the flexible securing members 37 are caused to project into the indentations 74 in the mating projections 53, 57 to lock the first flooring panel 41 to the second flooring panel 42.
FIG. 26 shows a flooring system 80 including first and second flooring panels 81, 82 according to a third embodiment of the invention. As shown in FIG. 26, the flooring system 80 consists of at least two of the first and second flooring panels 81, 82 mounted on a sub-floor 83. In the illustrated embodiment, the first and second flooring panels 81, 82 are identical and each consists of a core 84, a first decorative surface 85, a second decorative surface 86, and a locking member 90. The core 84 is interposed between the first and second decorative surfaces 85, 86. The core 84 may be, for example, a wood laminate core consisting of one or more layers of high density fiberboard or medium density fiberboard. The core 84 has opposing first and second side surfaces 87, 88 that extend substantially perpendicular to the first and second decorative surfaces 85, 86. The first decorative surface 85 opposes the second decorative surface 86 and extends substantially parallel thereto. The first and second decorative surfaces 85, 86 may consist, for example, of a printed and impregnated cellulosic layer having a desired visible design. The visible design of the first decorative surface 85 is different from the visible design of the second decorative surface 86. It will be appreciated by those skilled in the art, however, that the visible design of the first decorative surface 85 and the visible design of the second decorative surface 86 may be the same. Each of the first and second flooring panels 81, 82 are symmetrical about a central axis 89 extending substantially parallel to the first and second decorative surfaces 85, 86 and substantially perpendicular to the first and second side surfaces 87, 88. The flooring panels 81, 82 can be of various shape, for example, rectangular, square, or any other shape.
The locking member 90 consists of a pair of opposing grooves 91, 92 and a flexible securing member 93. The grooves 91, 92 are formed in the first and second side surfaces 87, 88, respectively, in a substantial center thereof. The grooves 91, 92 have a size and configuration corresponding to the size and configuration of the flexible securing member 93. The grooves 91, 92 have opposing lateral surfaces provided with projections 94. The projections 94 are arranged proximate an opening into the grooves 91, 92. The projections 94 may be materially formed in one piece with the core 5. The flexible securing member 93 is separate from the first and second flooring panels 81, 82 and is a substantially elongated strip having a substantially C-shape and end sections with protrusions 95. The flexible securing member 93 may be made, for example, by molding, preferably injection molding, any type of polymer material, such as nylon, polyethylene terphthlate, polyethylene, or polypropylene.
As shown in FIG. 26, when the first and second flooring panels 81, 82 are mounted on the sub-floor 83, the first and second flooring panels 81, 82 are arranged such that the second decorative surfaces 86 of both of the first and second flooring panels 81, 82 are arranged adjacent to the sub-floor 83. The first side surface 87 of the first flooring panel 81 opposes the second side surface 88 of the second flooring panel 82. The flexible securing member 93 is inserted into the groove 91 of the first flooring panel 81 until the protrusion 95 rides over the projection 94 and locks behind the projection 94. As shown in FIG. 27, the flexible securing member 93 is inserted into the groove 92 of the second flooring panel 82 until the protrusion 95 rides over the projection 94 and locks behind the projection 94. The protrusions 95 therefore engage with the projections 94 to lock the first flooring panel 81 to the second flooring panel 82, as shown in FIG. 28. When the first flooring panel 81 is locked to the second flooring panel 82, the first and second flooring panels 81, 82 are prevented from moving in a direction substantially perpendicular to the first and second decorative surfaces 85, 86 and in a direction substantially perpendicular to the first and second side surfaces 87, 88. It will be appreciated by those skilled in the art, however, that the first and second flooring panels 81, 82 may also be arranged such that the first decorative surfaces 85 of both of the first and second flooring panels 81, 82 are arranged adjacent to the sub-floor 83. Thus, because the first and second flooring panels 81, 82 are reversible, the visible design of the first decorative surface 85 or the visible design of the second decorative surface 86 may be made visible depending on the desired floor design. Additionally, because the locking member 10 is configured to be reversible, the visible design of the first decorative surface 85 and the visible design of the second decorative surface 86 may be caused to alternate depending on the desired floor design.
The foregoing illustrates some of the possibilities for practicing the invention. Many other embodiments are possible within the scope and spirit of the invention. For example, the locking member is not limited to the locking members 10, 50, 80 shown and described herein. It will be appreciated by those skilled in the art that other locking members may be use to lock or otherwise secure the first flooring panels 2, 41, 81 to the second flooring panel 3, 42, 82 including but not limited to, other known mechanical locking members that are formed integral with and/or separate from the first and second flooring panels 2, 3, 41, 42, 81, 82 or adhesives. Additionally, although the first and second flooring panels 2, 3, 41, 42, 81, 82 are shown and described herein as being identical, it will be appreciated by those skilled in the art that the first and second flooring panels 2, 3, 41, 42, 81, 82 may have other configurations and still be capable of locking together and performing the functions shown and described herein. It is, therefore, intended that the foregoing description be regarded as illustrative rather than limiting, and that the scope of the invention is given by the appended claims together with their full range of equivalents.
