Static structures (e.g. – buildings) – Module or panel having discrete edgewise or face-to-face... – Having integral key
Reexamination Certificate
1997-11-25
2001-12-04
Safavi, Michael (Department: 3635)
Static structures (e.g., buildings)
Module or panel having discrete edgewise or face-to-face...
Having integral key
C052S309900, C052S309140
Reexamination Certificate
active
06324809
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an article having interlocking edges and its use in preparing a covering product useful for covering flat surfaces as well as rounded surfaces, particularly useful in preparing a laminate flooring product that is easy to install, easy to repair, essentially glueless in installation and essentially waterproof in use due to the profile and composition of its interlocking edges.
2. Discussion of the Background:
In recent years the use of laminate products in the flooring industry as a replacement or substitute for traditional wood plank flooring has grown tremendously due to the durability and ease of care of the laminate products. However, the laminate flooring products currently available often have several disadvantages.
Many conventional laminate floor products have edges that are machined to fit one into the other. However, the conventional method for preparing such edges provides an interference fit (shown in FIG.
1
). In the interference fit type of edge, any glue that is placed in the cutout portion of the edge must be forced out upon insertion of the corresponding edge on an adjacent piece of laminate. Due to the tight fit, however, the fitting together of the laminate pieces often requires pressure and clamps to hold the pieces together. Additionally when the pieces are joined, and the glue is forced out of the cutout edge, there is no way to control the direction in which the glue will exit. It can exit either in an upwards direction towards the visible surface of the flooring or in a downwards direction to the surface adjacent the subflooring. Either of these options can be detrimental to both the appearance and function of the resulting floor.
In U.S. Pat. No. 5,618,602, an improved laminate floor was provided in which the rib and cutout edges of the laminate floor sections are machined in such a manner as to provide an escape path for glue from the cutout edge up to the visible floor surface while maintaining sufficient glue on the edge surface to bond the adjacent sections together.
However, since essentially no glue is allowed to exit from the bottom of the laminate flooring, the resulting floor can encounter problems due to entry of water into the seam formed by the edges from below. Since the substrate for the laminate flooring described therein is fiberboard based (wood based), the entry of water can cause swelling, ultimately resulting in buckling or other distortions in the floor.
Additionally, most laminate flooring requires the use of glue applied at the interface of each flooring section, and for direct gluedown applications glue is placed on the bottom surface of the flooring section to adhere it to the underfloor. Once the glue sets, the resulting floor can be extremely difficult to repair or replace. Additionally, due to expansion and/or contraction within individual sections of laminate flooring, the resulting floor can undergo various stresses causing distortions, buckling, etc., thus marring the appearance of the floor.
A new type of surface covering edge design, particularly in the laminate flooring arena, is needed to overcome these disadvantages.
SUMMARY OF THE INVENTION
Accordingly, one object of the present invention is to provide a new surface covering product that is easy to install, can be installed without glue if desired, is easy to repair and/or replace and is essentially waterproof
A further object of the present invention is to provide a new surface covering product having an edge design that can be assembled and disassembled in a simple manner without tools or glue.
Another object of the present invention is to provide a surface covering product that has a substantially hydrophobic interior to provide a watertight seam between sections.
Another object of the present invention is to provide a laminate flooring prepared from the surface covering product of the present invention.
Another object of the present invention is to provide a surface covering product that can be used as flooring, wall covering, ceilings and on curved surfaces.
These and other objects of the present invention have been satisfied by the discovery of an article that is suitable for use in surface coverings such as laminate floorings, wherein the article has a planar decorative surface, a lower planar surface and at least one male edge and at least one female edge, with the male and female edges having profiles that provide the ability to interlock adjacent articles by approaching one article to the other at an angle, inserting the male edge into the female edge and causing the lower planar surfaces of the two articles to become coplanar, thus forming a gapless seam between the articles which can be formed, if desired, without glue and which can be, if desired, watertight.
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Aquilino, Welsh & Flaxman
Premark RWP Holdings, INC.
Safavi Michael
LandOfFree
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