Static structures (e.g. – buildings) – Module or panel having discrete edgewise or face-to-face... – Having integral key
Reexamination Certificate
2001-01-22
2004-07-27
Friedman, Carl D. (Department: 3635)
Static structures (e.g., buildings)
Module or panel having discrete edgewise or face-to-face...
Having integral key
C052S282100, C052S582100, C052S586100, C052S591100, C052S592200, C403S364000, C403S381000, C144S364000, C144S380000
Reexamination Certificate
active
06766622
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a floor panel for use in making floor coverings, as well as a method for making the floor panel.
2. Related Art
More particularly, the invention relates to a floor panel which, at least at its edges, includes tongue-and-groove connection parts, which are made in one piece with the floor panel and shaped in such a manner that when coupled together along mutual edges by the tongue and groove coupling parts the floor panels are locked glue-free in a direction parallel to the plane of the panels and transverse to the edge connection, as well as in a direction perpendicular to this plane. Such floor covering panels are described in U.S. Pat. No. 6,006,486.
The floor panels can be joined together very fast by means of clicking and/or turning and are connected firmly without the necessity of using glue. It is also possible to disconnect these floor panels, after which they can be used again at another location.
When the floor covering is stepped on, it may occur that two adjacent panels undergo a minimal bending and, thus, carry out a movement in respect to each other. This movement is not unusual, as the floor panels are normally installed over an insulating and somewhat resilient underlay material.
This movement between the floor panels may result in a creaking noise, due to the friction which is created at the surfaces which are in contact with each other, because the coupling has locking surfaces associated with the tongue and groove parts between two panels which extend in a direction other than the horizontal direction (parallel to the principal plane of the panels).
It was noted that this phenomenon occurs with floor panels which are made of a material having a glued fibre-like wood based material, more particularly MDF or HDF.
In spite of the fact that by the use of tongue-and-groove connections made from MDF or HDF a rather smooth surface is obtained, as a result of which the aforementioned clicking and/or turning into each other takes place in a particularly easy manner, over the long term wear and tear may result from the mutual movement of the floor panels, as a result of which the trouble-free fitting of the floor panels can be influenced disadvantageously.
This invention in first instance has as an objective a floor covering panel in which the aforementioned and other disadvantages are avoided and, when being stepped upon, the creaking between the floor panels is avoided whereas over the long term the wear and tear of the tongue-and-groove connection also is limited.
According to the invention, this object is achieved in that a non-metallic sliding agent is applied on at least one of the panels at least at the location where the floor panels cooperate with each other, generally at the tongue-and-groove connection. The sliding agent is applied in the factory, for example, subsequent to the fabrication of the floor panels.
Due to the presence of this sliding agent, the floor panels, with the coupling parts of their tongue-and-groove connected, can slide over each other without thereby creating a perceptible sound. Due to the presence of the sliding agent, the friction, moreover, is reduced, as a result of which there is less wear and tear. If the sliding agent is provided at well-defined locations, this, as will be explained hereafter, also results in the floor panels being more easily joined, as the sliding agent reduces resistance during joining.
Preferably, a sliding agent is applied in the form of a layer which lies at least partially on top of the surface of one or both edges involved. By working with a layer on top of the surface, a good lubricating and sliding function is obtained.
According to a first possibility, the sliding agent is applied substantially over the entire surface of the edge of at least one of the floor panels.
According to a second embodiment, however, the sliding agent is applied in the form of one or more local strips extending in the longitudinal direction at the tongue-and-groove connection. Due to the provision of the sliding agent in the form of strips, it can easily be applied in a continuous process. Moreover, by applying such a strip locally, it is possible to avoid, due to the deformation of the sliding agent, that the latter is pushed beyond the tongue-and-groove connection, as a result of which a soiling at the upper side of the floor covering is avoided. Moreover, by local application in the form of a strip, the sliding agent can be applied efficiently at the location where it is desired, as a result of which the applied quantity can be kept limited.
The local application has also as an advantage that the strip may consist of a relatively thick layer of this sliding agent without creating any disadvantage.
More particularly, it is preferred that precisely one strip is applied.
Each respective strip in original, undeformed condition preferably has a maximum width of 4 mm.
The strip does not have to be continuous and may, for example, also consist of a succession of line portions, dots, and so on.
Preferably, the sliding agent is kept away from the upper edge of the floor panel, with the advantage that the sliding agent, when deformed, can not appear at the upper side of the floor covering. In first instance, this is of importance when a strip of some thickness is applied.
Specifically, it is preferred that between the upper edge and the strip of sliding agent that has been applied on a top area which is situated closest to the upper edge when seen along the contour of the surface, a receiving space is provided, as a result of which possible surplus sliding agent which is pressed aside can be taken up, so that the sliding agent cannot move up to the upper side. Such an intermediate receiving space may also be provided in the direction towards the lower edge.
As already becomes clear from the foregoing, preferably a deformable material is applied as a sliding agent.
More particularly, this sliding agent preferably is plastically deformable and, for example, meltable, but sets at room temperature, such that, during the manufacturing of the floor panels, it may be sprayed or be applied by means of a supply nozzle, in liquid form.
Suitable sliding agents are, amongst others, wax, in particular, paraffin.
It is noted that impregnating a tongue-and-groove of floor panels with paraffin is known but that this is performed to render the tongue-and-groove connection more resistive against the penetration of water. Hereby, the paraffin is applied over the entire surface of the tongue-and-groove and this in such a way that the paraffin completely penetrates into the surface. As a result thereof, this paraffin can not remedy the aforementioned problems arising with a tongue-and-groove connection engaged under a certain tension.
According to the invention, the sliding agent, more particularly, the paraffin, is applied in such a manner that a lubricating and/or sliding effect and, even better, a lubricating film is obtained. The necessary quantity of sliding agent depends on the material of the floor panels, the shape of the coupling and, eventually, when there is a tension between the floor parts, the value of this tension. This necessary quantity can be determined by tests.
In the case of a layer “lying on top”, the thickness with which the sliding agent is provided, preferably is at least such that, at least with a glossy-looking sliding agent, a glossy surface remains visible after the application. More particularly, it is preferred that the layer of sliding agent in such case has an average thickness in the order of magnitude of 0.05 mm or more, although smaller thicknesses in principle are not excluded.
According to the invention, the tongue and/or groove can also be treated with a surface treatment product for sealing and/or hardening the surface, in which case the sliding agent is applied on top of this product, as a result of which the additional advantage is obtained that the sliding agent will not penetrate into the floor panels until after a certain period of
Bacon & Thomas PLLC
Friedman Carl D.
Horton Yvonne M.
Unilin Beheer B.V.
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