PANEL CONNECTION SYSTEM

Abstract

A panel connection system comprising a fixing plate and a locking member, the fixing plate having a surface with a raised central portion which is flanked by first and second protrusions, wherein the locking member is configured to receive the central portion of the fixing plate. A plurality of panels with shoulder portions have recesses which are cooperatively received by the protrusions such that the shoulder portions of the panels are adjacent the central portion. The locking member has a recess which cooperatively secures with the central portion to secure the panels to the fixing plate.

Description

FIELD OF THE INVENTION

The present invention relates to an assembly of panels in an interconnected and coplanar arrangement, and in particular to a method for the assembly and disassembly of individual panel sections, or small groups of component panel sections, so that they may be constructed or replaced with ease. It has particular application to the laying of floor panels.

BACKGROUND TO THE INVENTION

A flooring system comprises a number of interlocking floor boards or panels composed of hardwood or of a material which is designed to look and feel like hardwood, but which costs only a fraction of the price. This material is typically composed of a resinous substance topped with a printed paper layer that resembles a wood grain and is traditionally used in laminate flooring systems. While most laminate or hardwood flooring systems connect together using a simple tongue and groove mechanism, such as for example the floor panel with a tongue, groove and strip as disclosed in U.S. Pat. No. 7,856,785 (Pervan), some systems consist of panels that are glued together using a wood adhesive. These modern flooring systems therefore have the advantage of easy installation and lasting durability.

The panels of a traditional tongue and groove flooring system, when installed, need to be inserted at an angle to allow adjoining panels to interconnect and lock together. The panels therefore are not smooth and uniform but instead have sides with a tongue portion on one side, and an associated groove on the other as their name suggests. This can provide a problem when panels are required to be shaped around an existing or immovable object such as a door frame, skirting board or toilet bowl. This is not only in terms of cutting the panel so that it is shaped to fit the required area, but also in terms of inserting the shaped panel at the appropriate angle in order to mate and lock with a corresponding panel. In addition, both hardwood and laminate flooring systems are installed as floating floor systems, meaning that the component panels are not attached directly to the subfloor. This can often lead to problems where a floor may have a tendency to provide vertical movement or ‘bounce’ as you walk across it. Unfortunately, it is also very difficult to remove or replace individual panels in a tongue and groove or glued panel flooring system due to the interconnection means of the respective types of panel employed.

In some instances, it is desirable to be able to replace a small number of the panel sections of the floor panel system without having to remove all of the panel sections which are laid down. For example, this could be in order to replace a small damaged section of the floor panel system which may have been affected by gradual wear and tear or by the impact of a sudden accident, such as water damage from a faulty dishwasher or washing machine. It could also be desirable to gain access to the area located immediately underneath the floating floor system for easy access to pipe-work or electrical cabling which may be positioned underneath the floor panels.

There is currently no standard system available which allows for the removal of small sections of laminate or hardwood floor panels without having either a) to remove every single panel in the flooring system to get to the required area, in the case of a tongue and groove flooring system, or b) to physically cut up existing panels in a floor system in the case when a glued panel system is preferred. The process of replacing floor panels can therefore be both time consuming and/or damaging to an existing flooring system.

It would therefore be advantageous to provide a panel connection system which allows a coplanar and interconnected flooring system to be constructed with ease. In addition, it would be desirable to provide a panel connection system which can be securely mounted to a sub-floor to avoid the problems of unwanted bounce as a person walks across the surface of it. It would also be highly advantageous to provide a panel connection system to allow individual panels or small sections of a flooring system to be removed and/or replaced with ease, in a quick and efficient manner, should the need arise.

SUMMARY OF THE INVENTION

Accordingly, a first embodiment of the invention provides a panel connection system comprising a fixing plate and a locking member, the fixing plate having a surface on which a raised central portion and first and second protrusions are located, the first and second protrusions extending away from the fixing plate in a perpendicular direction, the system further comprising first and second panels each having an upper surface, an opposing lower surface, at least one side face and a shoulder portion extending outwards from the side face of the panel in a direction parallel to the lower surface of the panel, the panels further comprising recesses to be received by the first and second protrusions, wherein the locking member engages the central portion of the fixing plate and secures the shoulder portions.

The central portion of the fixing plate preferably extends in a perpendicular direction away from the fixing plate, with the end of the central portion defining a circular cross-section. The central portion is flanked on either side of the surface of the fixing plate with first and second protrusions which extend away from the surface of the fixing plate, and which are shaped and dimensioned to receive and cooperatively secure with associated recesses in panels from a flooring system.

The locking member has a recess formed between a first surface and a second opposing surface. Preferably, the recess formed between the two surfaces of the locking member is shaped and defined to cooperatively engage with the central portion of the fixing plate.

In an embodiment of the invention, the panel connection system is adapted to connect with or be mounted securely to the sub-floor in a flooring panel system. The fixing plate of the panel connection system is configured to receive additional fixing or locking means, which may for example take the form of a screw or adhesive, to allow the fixing plate of the panel connection system to be held securely in place in a flooring system.

An embodiment of the invention provides an interconnected and coplanar flooring panel system having the panel connection system and individual panel components connected and secured thereto. The fixing plate of the panel connection system, which may be secured to the sub-floor of a flooring system, receives a plurality of panels each having an upper surface, an opposing lower surface, at least one side face, a shoulder portion and having recesses which are mounted on cooperatively shaped and dimensioned protrusions of the fixing plate, where the shoulder portions of the panels may be positioned in abutment against the central portion of the fixing plate.

The recess of the locking member is then cooperatively secured with the central portion of the fixing plate such that a first surface of the locking member is adjacent a first panel and the second surface of the locking member is adjacent a second panel. Preferably, the locking member is located entirely in a gap formed between the first and second panels.

It will be apparent to an appropriately skilled person in the art, that panels come in a variety of dimensions, colours and materials. It is therefore anticipated that the locking member of the panel connection system may be suitably coloured or textured to match the finish and size of the panels that are mounted on the fixing plate or, if preferred, to contrast with the panels. It is equally anticipated that although an embodiment of this invention illustrates that the locking member may be located entirely in the recess formed between adjoining panels, the shape of the surface of the locking member on display to a user is not limited to a ‘v’ shape in order to replicate a flash gap typically found in flooring systems. Other designs for the shape of the locking member may include those to reflect a ‘scallop’ or ‘flat and flush’ effect.

In an alternative embodiment of the invention, a plurality of panel components in an interconnected and coplanar flooring panel system may be removed from and/or replaced in the panel connection system. The locking member is removed from the cooperatively formed central portion of the fixing plate, and a panel or plurality of panels may then be removed from the fixing plate and replaced if required.

It will also be appreciated by a person skilled in the art that the panel connection system is not limited to the application of flooring systems. It is envisaged that the panel connection system may also provide methods for the construction and removal or replacement of panels in other areas where you would expect to find panels in an interlocking and coplanar arrangement systems such as walls, ceilings, lofts or roofs. In this specification the terms ‘upper’ and ‘lower’ are used to label the relative positions of parts of the apparatus with reference to their orientation when the system is installed on a horizontal floor. However, the various components may naturally be manufactured, stored or supplied in any orientation and the system may be installed on other surfaces which are not horizontal.

The embodiments of the invention described solve the problem of the removal of small sections of panels in a flooring system without having to remove an entire section of floor panels, or cut and remove a section of the floor, in order to gain access to the selected area. In particular, the panel connection system provides a method to mount and replace a variety of differently sized and shaped panels in a flooring system with ease, as and when required. In addition, the panel connection system provides a method for the vertical insertion of panels, or the removal/replacement of panels in a floor panel system, in order to eliminate the problems associated with the cutting and insertion of scribed floor panels that are required to fit around existing or immovable objects.

Further advantageous embodiments of the invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments and with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Specific embodiments of the invention are described by way of example and with reference to the accompanying drawings in which like numerals are used to indicate like parts and in which:

FIG. 1 is an end view of the panel connection system comprising a fixing plate and a locking member;

FIG. 2 shows in vertical cross-section a panel having a shoulder portion that is employed in the panel connection system;

FIG. 3 shows in vertical cross-section the fixing plate receiving a plurality of panels with shoulder portions, further showing the fixing plate in engagement with the locking member to securely fasten the panels together; and

FIG. 4 shows an alternative embodiment of the invention where an additional recess is created above an upper surface of the central portion when the locking member is engaged with the central portion of the fixing plate, in order to facilitate the removal of the locking member from the fixing plate with a suitable tool.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring now to the drawings, FIG. 1 shows the component parts of the panel connection system generally indicated as 1. The panel connection system 1 forms part of the construction of a flooring system, as described in more detail below.

The panel connection system 1 comprises a fixing plate 2 and a locking member 3. The fixing plate 2 is formed from a rigid material such as metals, woods or plastics. It is anticipated that it could be manufactured by the extrusion of a plastic material, for example polytetrafluoroethylene (PTFE) or other such materials. The fixing plate 2 comprises a horizontal surface 4 which has a central portion 5 projecting away from the surface in a perpendicular direction ending in a circular cross-section 6. The fixing plate 2 is further flanked on either side of the central projection by first and second protrusions 7, 8 which also extend away from the surface 4 in a perpendicular direction. It is understood that when the fixing plate 2 is placed on an external surface, the first and second protrusions 7, 8 will extend away from the horizontal surface 4 of the fixing plate 2 in a vertical direction. Although not shown on the drawing, it will be appreciated by a person skilled in the art that the fixing plate 2 may comprise additional fixing means to secure the fixing plate 2 to a surface such as a sub-floor, for example apertures to receive screws or an adhesive layer.

The locking member 3 is formed from a flexible or yieldable plastic material, which allows the locking member 3 to retain a lateral and longitudinal flexibility. The locking member 3 has a first surface 9 and a second opposing surface 10, and a recess 11 formed between the first 9 and second 10 opposing surfaces. The recess 11 is shaped and dimensioned to cooperatively engage with, and form a secure connection with the circular cross-section 6 of the central portion 5. It should be noted that although FIG. 1 shows the recess 11 of the locking member 3 to cooperatively engage with the circular cross-section 6 of the central portion 5 of the fixing plate 2, any other combination of suitably shaped and dimensioned recess 11 and central portion 5 may also be adopted.

FIG. 2 illustrates a panel 12 that is employed in the panel connection system 1. The panel 12 has an upper surface 17, an opposing lower surface 16, at least one side face 14 and a shoulder portion 15 extending outwards from the side face 14 of the panel 12 in a direction parallel to the lower surface 16 of the panel 12. Each panel 12 further comprises a recess 13 to be received by one of the first 7 and second 8 protrusions of the fixing plate 2.

The panel connection system 1 enables the construction of a coplanar and interconnected arrangement of floor panels 12. FIG. 3 illustrates the way in which the fixing plate 2 receives and mates with the floor panels 12 of FIG. 2, such that the first and second protrusions 7, 8 of the fixing plate 2 interlock with corresponding recesses 13 in the floor panels 12. When the panel 12 is vertically lowered into position on the fixing plate 2 to align the recess 13 of the panel 12 with the protrusion 7, 8 of the fixing plate 2, the shoulder portion 15 of the panel 12 is in abutment with the upwardly projecting central portion 5. It is anticipated that although the material to manufacture the fixing plate 2 will be rigid, the material may still permit a small lateral movement of the central portion 5 such that the panels 12 may still be lowered from a significantly downward vertical direction to avoid the central portion 5, and become attached to the fixing plate 2.

Once the panels 12 are in position, the locking member 3 is applied to secure the panels 12 in the panel connection system 1. The recess 11 of the locking member 3 is engaged with the circular cross-section 6 of the central portion 5 of the fixing plate 2. In engagement, the interlocking action of the recess 11 and central portion 5 aligns the locking member 3 in abutment with the side faces 14 of the panels 12 already attached to the fixing plate 2, such that the first surface 9 of the locking member 3 is in abutment with a side face 14 of a panel 12, and the second surface 10 of the locking member 3 is in abutment with a side face 14 of an adjoining panel 12 in a floor panel system. In addition, the presence of the shoulder portion 15 provides an additional locking means to prevent movement of the panels 12 in an upwardly vertical direction when the panel connection system 1 is in use.

The locking member 3 may be engaged with the central portion 5 either by hand, or by using an appropriate tool (not shown), such as for example a small hammer. It is anticipated that a tool having a roller attachment may be fashioned to allow the locking member 3 to mate with and engage with the central portion 5 of the fixing plate 2 in a fluid movement. The recess 11 of the locking member 3 is engaged with the circular cross-section 6 of the central portion 5 of the fixing plate 2. In engagement, the interlocking action of the recess 11 and central portion 5 aligns the locking member 3 in abutment with the side ends 14 of the panels 12 already attached to the fixing plate 2, such that the first surface 9 of the locking member 3 is in abutment with a side face 14 of a panel 12, and the second surface 10 of the locking member 3 is in abutment with a side face 14 of an adjoining panel 12 in a floor panel system.

The component parts of the panel connection system 1 permit the release and/or replacement of a panel 12 or small group of panels 12 without the need to remove all components of a panel floor system 1. That is to say that it is unnecessary to remove all of the panels 12 and panel connection system 1 apparatus to gain access to a specified area of the sub-floor. A panel 12 or group of panels 12 may be removed in the following manner. In order to release a panel 12 from the panel connection system 1, the recess 11 of the locking member 3 is first disengaged from the central portion 5, to permit access to and release of the panels 12 of interest. The locking member 3 may be removed from the central portion 5 either by hand, or by using an appropriate tool (not shown), such as for example a tool with a simple hook attachment at one end. It is anticipated that such a tool having a hook attachment may be fashioned to engage with and release a first end of the locking member 3. Once released, the remainder of the locking member 3 may be removed from the central portion 5 in a fluid movement. The panels 12 may then be removed from the fixing plate 2 in an upwardly vertical direction by disengaging the first and/or second protrusions 7, 8 from the associated recesses 13 in the panel 12.

In an embodiment of the invention when it is anticipated that the locking member 3 may be a flexible elongate strip and that the fixing plate 2 may also be a rigid elongate strip, one end of the locking member 3 may be unhooked or released from the corresponding end of the central portion 5 of the fixing plate 2 and then further disengaged from successive points along the length of the central portion 5 until the locking member 3 is fully released. The selected panel 12 or panels 12 of interest may then be removed in the manner as previously outlined.

FIG. 4 highlights an alternative embodiment of the invention in which the shape of the recess 11 does not perfectly match the circular cross-section 6 of the central portion 5 but is enlarged to leave a void 18 above an upper surface of the central portion 5 when the arms of the locking member 3 are engaged with the central portion 5 of the fixing plate 2. The void 18 facilitates the removal of the locking member 3 from the fixing plate 2 with a suitable tool (not shown), by allowing the tool to be inserted into the void 18 so that the locking member 3 may be unhooked or released from the corresponding end of the central portion 5 of the fixing plate 2. The locking member 3 is then further disengaged from successive points along the length of the central portion 5 until the locking member 3 is fully released.

The various features and configurations of each of the embodiments described herein, including protrusions 7, 8, associated recesses 13, locking members 3, shoulder portions 15 and the like, may be used in the various combinations other than those illustrated as will be apparent to a skilled person. It will be understood from the foregoing that the embodiments of the invention enable a floor panel system to be constructed and mounted with ease upon a sub-floor, and that individual panels 12 or small sections of panels 12 that are laid down in a flooring system may be removed and/or replaced with the aid of the fixing plate 2 and locking member 3 of the panel connection system 1. The invention is not limited to the embodiments disclosed herein which may be modified or varied without departing from the scope of the invention defined by the claims.

Claims

1. A panel connection system comprising a fixing plate, a locking member and first and second panels, the fixing plate having a surface on which a raised central portion and first and second protrusions are located, the first and second protrusions extending away from the fixing plate in a perpendicular direction, the first and second panels each having an upper surface, an opposing lower surface, at least one side face and a shoulder portion extending outwards from the side face of the panel in a direction parallel to the lower surface of the panel, each panel further comprising a recess to be received by one of the first and second protrusions, wherein the locking member engages the central portion of the fixing plate and secures the shoulder portions of the panels.

2. A panel connection system according to claim 1, wherein the fixing plate comprises additional means for fixing the plate to an external surface.

3. A panel connection system according to claim 1, wherein the central portion extends away from the fixing plate in a perpendicular direction.

4. A panel connection system according to claim 1, wherein the locking member has a first surface and a second opposing surface and a recess located between the first and second opposing surfaces which is shaped and dimensioned to engage with the central portion of the fixing plate.

5. A panel connection system according to claim 1, wherein the locking member is a strip of elongate material.

6. A panel connection system according to claim 5, wherein the strip comprises a flexible material.

7. A panel connection system according to claim 1, wherein the fixing plate is a strip of elongate material.

8. A panel connection system according to claim 7, wherein the fixing plate comprises a rigid material.

9. A panel connection system according to claim 4, wherein the recess of the locking member is configured to receive the central portion of the fixing plate such that the first surface of the locking member is adjacent the first panel and the second surface of the locking member is adjacent the second panel.

10. A panel connection system according to claim 9, wherein the locking member is located entirely in a gap formed between the first and second panels.

11. A method of constructing a panel system comprising:

inserting first and second panels into a panel connection system, the panel connection system comprising a fixing plate and a locking member, the fixing plate having a surface with a raised central portion located between first and second protrusions, the first and second protrusions extending away from the fixing plate in a perpendicular direction, each panel having an upper surface, an opposing lower surface, at least one side face and a shoulder portion extending outwards from the side face of the panel in a direction parallel to the lower surface of the panel, and each panel further comprising a recess to be received by a corresponding one of the first and second protrusions;

and engaging the locking member with the central portion of the fixing plate to secure the shoulder portions.

12. A method of constructing a panel system according to claim 11, wherein a first surface of the locking member is adjacent to the first panel and a second surface of the locking member is adjacent to the second panel.

13. A method of disassembly of a panel system comprising:

removing at least one panel from a panel connection system, the panel connection system comprising a fixing plate and a locking member, the fixing plate having a surface with a raised central portion located between first and second protrusions, the first and second protrusions extending away from the fixing plate in a perpendicular direction, each panel having an upper surface, an opposing lower surface, at least one side face and a shoulder portion extending outwards from the side face of the panel in a direction parallel to the lower surface of the panel, and each panel further comprising a recess to be received by a corresponding one of the first and second protrusions, the method comprising the steps of:

disengaging the locking member from the central portion of the fixing plate to free the shoulder portions;

and detaching at least one panel from the corresponding protrusion of the fixing plate in a perpendicular direction away from the fixing plate.

14. A method of disassembly of a panel system according to claim 13, wherein the locking member is a flexible elongate strip and the step of disengaging the locking member comprises removing the flexible elongate strip from the central portion first at one end of the strip and then successively along the length of the strip.