FIELD OF THE INVENTION
[0001] The present invention relates to a vertical joint system for substrates enabling
the substrates to be jointed together side by side. Non-limiting examples of such
substrates include wooden boards or panels which may be used as floor, wall or ceiling
covering. The present invention also relates to a surface covering system utilising
substrates which incorporate the joint system.
BACKGROUND ART
[0002] "Click" type floor coverings comprise a plurality of substrates, each provided with
like joint systems to facilitate coupling of adjacent substrates. These joint systems
often comprise first and second joints running along two opposite sides of the substrate.
The joints are configured so that the first joint on one substrate is able to engage
the second joint on an adjacent substrate. The joints rely on specific configurations
of tongues, grooves, protrusions, recesses and barbs to effect interlocking engagement.
[0003] Joint systems for flooring may be generally categorised as horizontal (or "lay down")
joint systems or vertical joint systems. Horizontal joint systems require motion in
a plane substantially parallel to a plane containing a major surface of the flooring
substrate (i.e. a horizontal plane) in order to effect the engagement of joints on
adjacent substrates. Vertical joint systems on the other hand require motion and/or
force in a plane perpendicular to a major surface of the substrates to effect engagement
of the joints. Thus it should be understood that the expression "vertical" in the
context of the present type of joint system, and as used in this specification, does
not mean absolutely vertical but rather perpendicular to a major surface of a substrate.
When the substrate is laid on a horizontal surface then "vertical" in this context
is also absolute vertical. But as those skilled in the art will understand substrates
can be laid on surfaces of other dispositions for example on vertical surfaces such
as a vertical wall; or, inclined surfaces such as on a pitched ceiling. In such situations
the vertical joint system holds it's meaning as a joint system that operates/engages
by way of motion and/or force in a plane perpendicular to a major surface of the substrates
[0004] There are also "quasi" vertical joint systems which, while their manufacturer may
claim to be a vertical system, initially require engagement of joints of adjacent
panels by a lateral insertion of one joint into another followed by a rotation of
one panel relative to another so that their respective major surfaces are coplanar.
[0005] The above references to the background art do not constitute an admission that the
art forms a part of the common general knowledge of a person of ordinary skill in
the art. The above references are also not intended to limit the application of the
joint system as disclosed herein.
SUMMARY OF THE INVENTION
[0006] Aspects of the present invention provide vertical joint systems for substrates. The
vertical joint systems facilitate the provision of surface covering system that allow
for very easy installation and more particularly repair. To this end repair can be
achieved by vertical lifting of damaged panels without the need to pull up excess
flooring from the closest wall to the damaged panels.
[0007] Other aspects of the present invention a provide vertical joint systems for substrates
wherein engaged substrates can rotate or pivot relative to each other in either positive
or negative (i.e. clockwise or anticlockwise) while maintain engagement
[0008] In one aspect there is provided vertical joint system for a substrate having an opposed
major first and second surfaces, the joint system comprising:
first and second non-symmetrical joints extending along opposite sides of the substrate,
the first and second joints configured to enable two substrates with like joint systems
to engage each other in response to a force applied in an engagement direction which
is perpendicular to the major surfaces;
the first and second joints each provided with two laterally spaced transversely extending
surfaces configured to enable the first joint of one substrate to engage the second
joint of a second substrate with the two transversely extending surfaces of the first
joint located relative to the two transversely extending surfaces of the second joint
to form respective first and second locking planes on an innermost and an outermost
side of each joint, each locking plane lying parallel to the engagement direction
and wherein the transversely extending surfaces associated with each locking plane
extend laterally toward each other from opposite sides of the locking plane with the
transversely extending surfaces of the second joint overhanging the transversely extending
surfaces of the first joint to inhibit separation if the engaged joints, wherein in
at least one of the transversely extending surfaces associated with each locking plane
has a curved profile.
[0009] In one embodiment the transversely extending surfaces are configured to enable relative
rotation of two engaged substrates by up to 3° while maintaining engagement of the
two substrates.
[0010] In one embodiment the transversely extending surfaces are configured to enable relative
rotation of one of the engaged substrates relative to the other by an angle of between
7° to 10° in a direction into a surface of which the substrates are laid while maintaining
engagement of the two substrates. In one embodiment a void is created on at least
one side of each locking plane by virtue of the non-symmetrical configuration of the
first and second joints.
[0011] In one embodiment at least one of the transversely extending surfaces associated
with at least one of the locking planes has a profile of a continuous convex curve.
[0012] In one embodiment at least one of the locking planes one of the transversely extending
surface has a profile of a continuous convex curve and the other has a profile comprising
one or more straight lines.
[0013] In one embodiment each of the transversely extending surfaces has a profile of a
continuous convex curve.
[0014] In one embodiment two or more of the transversely extending surfaces have profiles
of different continuous convex curves.
[0015] In one embodiment each joint comprises a protrusion extending in the engagement direction
and an adjacent recess formed along a respective side of the substrate; and the transversely
extending surfaces are formed on an outermost surface of each protrusion and an inner
most surface of each recess.
[0016] In one embodiment the protrusion of the first joint has a bulbous profile with a
neck of reduced width wherein a portion of the transversely extending surface on the
protrusion of the first joint is adjacent an outermost side of the neck.
[0017] In one embodiment the recess of the second joint has a bulbous profile with a neck
of reduced width wherein a portion of the transversely extending surface on the recess
of the second joint is adjacent an outermost side of the neck.
[0018] In one embodiment a plane containing a line of shortest distance across the or each
neck of is inclined relative to the major surfaces.
[0019] In one embodiment a plane containing a line of shortest distance across the or each
neck lies in a plane inclined relative to the major surfaces.
[0020] In one embodiment the respective lines of shortest distance across each neck are
parallel to each other.
[0021] In one embodiment the lines of shortest distance across each neck are collinear.
[0022] In one embodiment each transversely extending surface constitutes a portion of a
respective inflexion surface.
[0023] In one embodiment each of the first and second joints is formed with a third transversely
extending surface located between the two transversely extending surfaces of that
joint, the third transversely extending surfaces relatively located to form a third
locking plane disposed intermediate the first and second locking planes and wherein
the third transversely extending surfaces associated with the third locking plane
extend laterally toward each other from opposites of the third locking plane with
the third transversely extending surface of the second joint in alignment with or
overhanging the third transversely extending surface of the first joint.
[0024] In one embodiment the first and second joints are relatively configured to engage
each other about a third locking plane inhibiting separation of the engaged joints
in a direction parallel to the engagement direction, the third locking plane being
disposed parallel to and between the first and second locking planes.
[0025] In one embodiment each of the first and second joints comprise a third transversely
extending surface wherein the third transversely extending surfaces extend to opposite
sides of the third locking plane when in the engaged joint.
[0026] In a second aspect there is provided vertical joint system for a substrate having
an opposed major first and second surfaces, the joint system comprising:
first and second non-symmetrical joints extending along opposite sides of the substrate,
the first and second joints configured to enable two substrates with like joint systems
to engage each other in response to a force applied in an engagement direction which
is perpendicular to the major surfaces;
the first and second joints each provided with two laterally spaced inflexion surfaces
configured to enable the first joint of one substrate to engage the second joint of
a second substrate with the two inflexion surfaces of the first joint engaging the
two inflexion surfaces of the second joint on inner most and outer most sides of each
joint to form respective first and second locking planes each of which independently
inhibit separation of the engaged joints in a direction parallel to the engagement
direction each locking plane lying parallel to the engagement direction and wherein
the inflexion surfaces associated with each locking plane lie on both sides of that
locking plane.
[0027] In one embodiment the inflexion surfaces are configured to enable relative rotation
of two engaged substrates by up to 3° while maintaining engagement of the two substrates.
[0028] In one embodiment the inflexion surfaces are configured to enable relative rotation
of one of the engaged substrates relative to the other by an angle of between 7° to
10° in a direction into a surface of which the substrates are laid while maintaining
engagement of the two substrates.
[0029] In one embodiment each joint comprises a third inflexion surface and the respective
third inflexion surfaces are relatively configured to engage each other to form a
third locking plane disposed between the first and second locking planes.
[0030] In one embodiment a void is created on at least one side of each locking plane by
virtue of the non-symmetrical configuration of the first and second joints.
[0031] In one embodiment at least one of the inflexion surfaces associated with each locking
plane has a profile of a continuous curve.
[0032] In one embodiment one inflexion surface associated with one locking plane has a profile
of a continuous curve and the other inflexion of that locking plane has a profile
comprising one or more straight lines. In one embodiment each of the inflexion surfaces
has a profile of a continuous curve.
[0033] In one embodiment each joint comprises a protrusion extending in the engagement direction
and an adjacent recess formed along a respective side of the substrate; and the inflexion
surfaces associated with the first and second locking planes are formed on an outermost
surface of each protrusion and an inner most surface of each recess.
[0034] In one embodiment the protrusion of the first joint has a bulbous profile having
a neck of reduced width wherein a portion of the inflexion surface on the protrusion
of the first joint is formed along an outermost side of the neck.
[0035] In one embodiment the recess of the second joint has a bulbous profile having a neck
of reduced width wherein a portion of the inflexion surface on the recess of the second
joint is formed along an outermost side of the neck.
[0036] In one embodiment a plane containing a line of shortest distance across the or each
neck of is inclined relative to the major surfaces.
[0037] In one embodiment a plane contain a line of shortest distance across the or each
neck lies in a plane inclined relative to the major surfaces.
[0038] In one embodiment the respective lines of shortest distance across each neck are
parallel to each other.
[0039] In one embodiment the lines of shortest distance across each neck are collinear.
[0040] In a third aspect there is provided a vertical joint system for a substrate having
an opposed major first and second surfaces, the joint system comprising:
non-symmetrical male and female joints extending along opposite sides of the substrate,
the male and female joints configured to enable two substrates with like joint systems
to engage each other in response to a force applied in an engagement direction which
is perpendicular to the major surfaces;
the male joint comprising a male protrusion extending generally perpendicular from
the first major surface toward the second major surface and a male recess formed inboard
of the male protrusion; the female joint comprising a female protrusion extending
generally perpendicular from the second major surface toward the first major surface
and a female recess formed inboard of the female protrusion; the male joint having
a first male locking surface formed on a side of its male protrusion most distant
from its female recess, a second male locking surface formed on a side of its female
recess most distant from its male protrusion and a third male locking surface being
a surface common to the male protrusion and male recess; the female joint having a
first female locking surface formed on a side of its female recess most distant from
its male protrusion, a second female locking surface formed on a side of its male
protrusion most distant from its female recess, and a third female locking surface
being a surface common to the female protrusion and female recess; the locking surfaces
being configured so that when a male and female joint of two substrates are engaged,
the first male and first female locking surfaces engage to form a first locking plane,
the second male and second female locking surfaces engage to form a second locking
plane, and the third male and third female locking surfaces engage to form a third
locking plane located between the first and second locking planes each locking plane
inhibiting separation of the engaged joints in a direction parallel to the engagement
direction.
[0041] In one embodiment the locking surfaces are configured to enable relative rotation
of two engaged substrates by up to 3° while maintaining engagement of the two substrates.
[0042] In one embodiment the locking surfaces are configured to enable relative rotation
of one of the engaged substrates relative to the other by an angle of between 7° to
10° in a direction into a surface of which the substrates are laid while maintaining
engagement of the two substrates.
[0043] In one embodiment: at least one of the first male locking surface and the first female
locking surface is provided with a smoothly curved transversely extending portion;
and at least one of the second male locking surface and the second female locking
surface is provided with a smoothly curved transversely extending portion.
[0044] In one embodiment the other of the first male locking surface and the first female
locking surface is provided with a transversely extending portion comprising at least
one planar surface.
[0045] In one embodiment the other of the second male locking surface and the second female
locking surface is provided with a transversely extending portion comprising at least
one planar surface.
[0046] In one embodiment each of first and second male and female locking surfaces comprises
a smoothly curved transversely extending portion.
[0047] In one embodiment each of the first male locking surface, first female locking surface,
second male locking surface and second female locking surface is formed with an inflexion;
wherein the inflexions engage each other about the first and second locking planes.
[0048] In one embodiment at least one of the third male locking surface and the third female
locking surface is formed with an inflexion.
[0049] In a fourth aspect there is provided a vertical joint system for a substrate having
an opposed major first and second surfaces, the joint system comprising:
first and second non-symmetrical joints extending along opposite sides of the substrate,
the first and second joints configured to enable two or more substrates with like
joint systems to engage each other in response to a force applied in an engagement
direction which is perpendicular to the major surfaces and to enable engaged substrates
to be disengaged by lifting a first substrate in a direction opposite the engagement
direction to facilitate rotation of adjacent engaged substrates along opposite sides
of the first substrate to lie in planes declined from the first substrate and subsequently
applying a force in the engagement direction to the second joints of the engaged substrates.
[0050] In one embodiment the first and second joints are each provided with two laterally
spaced transversely extending surface portions configured to enable the first joint
of one substrate to engage the second joint of a second substrate with the two transversely
extending surfaces of the first joint located relative to the two transversely extending
surfaces of the second joint to form respective first and second locking planes on
an innermost and an outermost side of each joint, each locking plane lying parallel
to the engagement direction and wherein the transversely extending portions associated
with each locking plane extend laterally toward each other from opposites of the locking
plane with the transversely extending portions of the second joint overhanging the
transversely extending portions of the first joint.
[0051] In one embodiment at least one of the transversely extending surfaces associated
with at least one of the locking planes has a profile of a continuous convex curve.
[0052] In one embodiment the first and second joints are each provided with two laterally
spaced inflexion surfaces configured to enable the first joint of one substrate to
engage the second joint of a second substrate with the two inflexion surfaces of the
first joint engaging the two inflexion surfaces of the second joint on inner and outer
most sides of each joint to form respective first and second locking planes each of
which independently inhibit separation of the engaged joints in a direction parallel
to the engagement direction each locking plane lying parallel to the engagement direction
and wherein the inflexion surfaces associated with each locking plane lie on both
sides of that locking plane.
[0053] In one embodiment the first joint is a male joint and the second joint is a female
joint, the male joint comprising a male protrusion extending generally perpendicular
from the first major surface toward the second major surface and a male recess formed
inboard of the male protrusion; the female joint comprising a female protrusion extending
generally perpendicular from the second major surface toward the first major surface
and a female recess formed inboard of the female protrusion; the male joint having
a first male locking surface formed on a side of its male protrusion most distant
from its female recess, a second male locking surface formed on a side of its female
recess most distant from its male protrusion and a third male locking surface being
a surface common to the male protrusion and male recess; the female joint having a
first female locking surface formed on a side of its female recess most distant from
its male protrusion, a second female locking surface formed on a side of its male
protrusion most distant from its female recess, and a third female locking surface
being a surface common to the female protrusion and female recess; the locking surfaces
being configured so that when a male and female joint of two substrates are engaged,
the first male and first female locking surfaces engage to form a first locking plane,
the second male and second female locking surfaces engage to form a second locking
plane, and the third male and third female locking surfaces engage to form a third
locking plane located between the first and second locking planes each locking plane
inhibiting separation of the engaged joints in a direction parallel to the engagement
direction.
[0054] In one embodiment the first and second joints are configured to create three locking
planes when mutually engaged, each locking plane lying parallel to the engagement
direction and inhibiting separation of engaged joints in a direction opposite the
engagement direction.
[0055] In one embodiment when the substrate is in the configuration of a planar rectangular
or square substrate having four sides, the first joint extends for two adjacent sides
and the second joint extends for the remaining two adjacent sides.
[0056] In a fifth aspect there is provided a surface covering system comprising a plurality
of substrates where in each substrate is provided with a vertical joint system in
accordance with any one of the first to fourth and tenth aspects.
[0057] In a sixth aspect there is provided a semi-floating surface covering system comprising:
a plurality of substrates each substrate having a vertical joint system in accordance
with any one of the first to fourth and tenth aspects;
a quantity of re-stickable adhesive bonded to the first major surface;
and, one or more release strips covering the re-stickable adhesive.
[0058] In one embodiment the quantity of re-stickable adhesive is applied it two or more
spaced apart lines extending in a longitudinal direction of the substrate.
[0059] In one embodiment the quantity of re-stickable adhesive is applied as a continuous
strip or bead in at least one of the spaced apart lines.
[0060] In one embodiment the re-stickable adhesive is applied in a plurality of lines which
are evenly spaced from each other and symmetrically disposed about a longitudinal
centre line of the substrate.
[0061] In one embodiment the re-stickable adhesive has a thickness measured perpendicular
to the first major surface of between 1 - 6mm.
[0062] In one embodiment the re-stickable glue has a thickness of between 2 - 4mm.
[0063] In one embodiment the quantity of adhesive comprises a quantity of joint adhesive
bonded to the substrate and covered with a release strip, the joint adhesive located
in a position wherein when the joint system of one substrate is coupled to the joint
system of another substrate with the cover strip removed, the joint adhesive on the
one substrate adheres to the joint of the other substrate.
[0064] In one embodiment the substrate is made from a material selected from the group consisting
of; solid timber, engineered timber, laminate, Bamboo, plastics, and vinyl.
[0065] In a seventh aspect there is provided a method of manufacturing a semi-floating surface
covering substrate comprising:
providing a surface covering system in accordance with the fifth aspect;
bonding a quantity of a re-stickable adhesive to the first major surface; and, covering
the adhesive with a release strip.
[0066] In one embodiment bonding the adhesive comprises applying the adhesive in two or
more spaced apart lines extending in a longitudinal direction of the substrate.
[0067] In one embodiment the bonding comprises applying the adhesive as a continuous strip
or bead in at least one of the spaced apart lines onto the first major surface.
[0068] In one embodiment the method comprises applying the adhesive with a uniform thickness
of between 1 - 6 mm measured in a direction perpendicular to the major surfaces.
[0069] In one embodiment the method comprises applying the adhesive with uniform thickness
of between 2 - 4 mm.
[0070] In one embodiment the method comprises bonding a quantity of re-stickable adhesive
to at least a portion of the joint and covering the adhesive in the joints with a
release strip, the re-stickable adhesive being applied at a location on a first substrate
wherein when the vertical joint systems of the first and a second substrate are coupled
together with a release strip covering the adhesive in the joint of the first substrate
being removed, the adhesive adheres to the joint of the second substrate.
[0071] In an eighth aspect there is provided a surface covering system comprising a plurality
of substrates, each substrate having: opposite first and second major surfaces wherein
the first major surface is arranged to face an underlying support to be covered by
the system; and a vertical joint system, the vertical joint system comprising:
first and second non-symmetrical joints extending along opposite sides of a substrate,
the first and second joints configured to enable two or more substrates to engage
each other in response to a force applied in an engagement direction which is perpendicular
to the major surfaces and to enable engaged substrates to be disengaged by: (a) lifting
a first substrate in a direction opposite to the engagement direction to facilitate
rotation of adjacent engaged substrates along opposite sides of the first substrate
to lie in planes declined from the first substrate; and (b) subsequently applying
a force in the engagement direction to the second joints of the engaged substrates.
[0072] In one embodiment the surface covering system comprises at least one a jack demountably
attachable to the first substrate the jack comprising a shaft arranged to pass through
a hole formed in the first substrate to bear on the underlying support, the jack being
operable to extend the shaft through the hole to thereby lift the first substrate
form the underlying support. In one embodiment of the surface covering system the
vertical joint system is in accordance with any one of the first to fourth and tenth
aspects.
[0073] In one embodiment the surface covering system comprises a quantity of re- stickable
adhesive bonded to the first major surface; and, one or more release strips covering
the re-stickable adhesive.
[0074] In one embodiment the surface covering system comprises a quantity of re- stickable
adhesive bonded to one or both of the first and second joints and respective release
strips overlying the re-stickable adhesive bonded on the joints.
[0075] In one embodiment the vertical joint system comprises a quantity of re-stickable
adhesive bonded to one or both of the first and second joints and respective release
strips overlying the re-stickable adhesive bonded on the joints.
[0076] In a ninth aspect there is provided a substrate for a surface covering system, the
substrate comprising a vertical joint system according to any one of of the first
to fourth and tenth aspects.
[0077] In one embodiment the substrate comprises a quantity of re-stickable adhesive bonded
to one or both of the first and second joints and respective release strips overlying
the re-stickable adhesive bonded on the joints.
[0078] In one embodiment of the substrate each joint provided with the bonded re-stickable
adhesive is provide with a recess for seating the bonded re-stickable adhesive.
[0079] In one embodiment the substrate comprises a quantity of re-stickable adhesive bonded
to the first major surface; and, one or more release strips covering the re-stickable
adhesive on the first major surface.
[0080] In one embodiment the vertical joint system comprises a layer of wax being provide
on surfaces of the joint which when engaged with a like joint engage to form the first
and second locking planes.
[0081] In one embodiment of vertical joint system each recess of one substrate is provided
with the joint system is configured to elastically open to enable a corresponding
protrusion of a second substrate with a like joint system to like to enter and engage
the recess.
[0082] In a tenth aspect there is provided a vertical joint system for a substrate having
an opposed major first and second surfaces, the joint system comprising:
first and second non-symmetrical joints extending along opposite sides of the substrate,
the first and second joints configured to enable two substrates with like joint systems
to engage each other in response to a force applied in an engagement direction which
is perpendicular to the major surfaces;
the first and second joints being configured to enable relative rotation of two engaged
substrates by up to 3° while maintaining engagement of the two substrates. In one
embodiment of the tenth aspect the first and second joints are each provided with
two laterally spaced generally convex surfaces configured to enable the first joint
of one substrate to engage the second joint of a second substrate with the two generally
convex surfaces of the first joint located relative to the two generally convex surfaces
of the second joint to form respective first and second locking planes on an innermost
and an outermost side of each joint, each locking plane lying parallel to the engagement
direction and wherein the generally convex surfaces associated with each locking plane
extend laterally toward each other from opposite sides of the locking plane with the
generally convex surfaces of the second joint overhanging the generally convex surfaces
of the first joint to inhibit separation if the engaged joints, wherein in at least
one of the generally convex associated with each locking plane has a curved profile.
[0083] In one embodiment of the tenth aspect each joint comprises a protrusion extending
in the engagement direction and an adjacent recess formed along a respective side
of the substrate; and the transversely extending surfaces are formed on an outermost
surface of each protrusion and an inner most surface of each recess.
[0084] In one embodiment of the tenth aspect each recess configured to elastically open
to enable a protrusion of a substrate with a like joint system to like to enter and
engage the recess.
[0085] In one embodiment of the tenth aspect the first and second joints are configured
to form a third locking plane intermediate the first and second locking planes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0086] Notwithstanding any of forms which may fall within the scope of the joint system
as set forth in the Summary, specific embodiments will now be described, by way of
example only, with reference to the accompanying drawings in which:
Figure 1 a is a section view of a panel incorporating an embodiment of the vertical
joint system;
Figure 1 b is a cross section view of a portion of two panels incorporating the vertical
joint system in an engaged state;
Figure 2 is an isometric view of a portion of two panels incorporating the vertical
joint system when in a disengaged state;
Figure 3a illustrates the ability of engaged panels incorporating the vertical joint
system to rotate in a first direction relative to each other;
Figure 3b illustrates the ability of engaged panels incorporating the vertical joint
system to rotate in a second opposite direction relative to each;
Figure 4a illustrates the effect of lateral bowing of a substrate overlying a depression
or hollow in a supporting surface;
Figure 4b is an enlarged view of detail A marked on Figure 4a; Figure 4c illustrates
the effect of lateral bowing of a panel when overlying a hump or rise in an underlying
surface;
Figure 4d is an enlarged view of detail B marked on Figure 4c;
Figure 4e is a schematic representation providing a comparison in the ability to accommodate
surface a hump or rise between prior art joint systems and vertical joint systems
in accordance with embodiments of the present invention;
Figure 4f is an enlarged view of detail C marked on Figure 4e;
Figure 4g is a schematic representation providing a comparison in the ability to accommodate
surface a hollow or dip between prior art joint systems and vertical joint systems
in accordance with embodiments of the present invention;
Figure 4h is an enlarged view of detail D marked on Figure 4g;
Figure 5a is a representation of the relative juxtaposition of panels incorporating
the present vertical joint system being ready for engagement;
Figures 5b - 5e depict sequentially the engagement of panels incorporating embodiments
of the vertical joint system from a point of initial contact in Figure 5b to complete
engagement in Figure 5e;
Figures 5f - 5k depict in sequence a self aligning feature of embodiments of the vertical
joint system;
Figures 5l - 5u provides a schematic comparison between the effect of the self aligning
feature enabled by embodiments of the present invention and the prior art;
Figure 6a is an elevation view of an area covered by substrates joined together with
embodiments of the present vertical joint system and identifying a panel to be removed;
Figure 6b is a view of section A-A from Figure 6a;
Figure 6c is a top elevation of a panel fitted with jacks enabling the removal of
the panel;
Figure 6d - 6s depict in sequence steps for the removal and replacement of the highlighted
panel in Figure 6a;
Figure 7a is a side elevation of the jack depicted in Figure 6c;
Figure 7b is a top elevation of the jack shown in Figure 6c;
Figure 8a is a side elevation of a wedge used in conjunction with the jack for extracting
an engaged panel;
Figure 8b is an elevation view of the wedge shown in Figure 8a;
Figures 9a - 9f depict in sequence the disengagement of joined panels from an initial
fully engaged state depicted in Figure 9a to a fully disengaged state shown in Figure
9f;
Figure 10a depicts a panel incorporating a second embodiment of the vertical joint
system; Figure 10b illustrates the engagement of two panels incorporating the second
embodiment of the vertical joint system;
Figure 11a depicts a panel incorporating a third embodiment of the vertical joint
system;
Figure 11b illustrates the engagement of two panels incorporating the third embodiment
of the vertical joint system;
Figure 11c illustrates the ability of engaged panels incorporating the joint system
of the third embodiment to rotate in a first direction relative to each other;
Figure 11d illustrates the ability of engaged panels incorporating the joint system
of the third embodiment to rotate in a second opposite direction relative to each;
Figure 12a depicts a panel incorporating a fourth embodiment of the vertical joint
system;
Figure 12b illustrates the engagement of two panels incorporating the fourth embodiment
of the vertical joint system;
Figure 13a depicts a panel incorporating a fifth embodiment of the vertical joint
system;
Figure 13b illustrates the engagement of two panels incorporating the fifth embodiment
of the vertical joint system;
Figure 14a depicts a panel incorporating a sixth embodiment of the vertical joint
system;
Figure 14b illustrates the engagement of two panels incorporating the sixth embodiment
of the vertical joint system;
Figure 15a depicts a panel incorporating a seventh embodiment of the vertical joint
system;
Figure 15b illustrates the engagement of two panels incorporating the seventh embodiment
of the vertical joint system;
Figure 16a depicts a panel incorporating a eighth embodiment of the vertical joint
system;
Figure 16b illustrates the engagement of two panels incorporating the eighth embodiment
of the vertical joint system;
Figure 17a depicts a panel incorporating a ninth embodiment of the vertical joint
system;
Figure 17b illustrates the engagement of two panels incorporating the ninth embodiment
of the vertical joint system;
Figure 17c schematically illustrates panels of different thickness incorporating the
ninth embodiment of the vertical joint system;
Figure 17d illustrates the engagement of two panels shown in Figure 17c; Figure 17e
provides a series of representations of illustrating the engagement of separate pair
of panels of varying thickness the incorporating the ninth embodiment of the vertical
joint system
Figure 18a depicts a panel incorporating a tenth embodiment of the vertical joint
system;
Figure 18b illustrates the engagement of two panels incorporating the tenth embodiment
of the vertical joint system;
Figure 19a depicts a panel incorporating a eleventh embodiment of the joint system;
Figure 19b illustrates the engagement of two panels incorporating the eleventh embodiment
of the vertical joint system;
Figure 20a depicts a panel incorporating a twelfth embodiment of the vertical joint
system;
Figure 20b illustrates the engagement of two panels incorporating the twelfth embodiment
of the vertical joint system;
Figure 21 a depicts a panel incorporating a thirteenth embodiment of the vertical
joint system;
Figure 21 b illustrates the engagement of two panels incorporating the thirteenth
embodiment of the vertical joint system;
Figure 22 illustrates the engagement of two panels incorporating a fifteenth embodiment
of the vertical joint system;
Figure 23a depicts a panel incorporating a fourteenth embodiment of the vertical joint
system;
Figure 23b illustrates the engagement of two panels incorporating the fourteenth embodiment
of the vertical joint system;
Figures 23c - 23i depict in sequence the engagement and disengagement of the fourteenth
embodiment of the vertical joint system when incorporating a re-stickable adhesive.
Figure 24a depicts a panel provided with incorporating any embodiment of the vertical
joint system with the addition of a re-stickable adhesive laid as strips;
Figure 24b is a view of section AA of the panel shown in Figure 24a;
Figure 24c shows the panel of Figures 24a and 24b when adhered to an underlying supporting
surface;
Figure 25a depicts a panel provided with any embodiment of the vertical joint system
with the addition of a re-stickable adhesive laid as beads;
Figure 25b shows the panel of Figure 25a when adhered to an underlying supporting
surface; Figures 26a-26e depict in sequence the removal of a panel of the type shown
in Figures 25a and 25b which is adhered to an underlying supporting;
and,
Figures 27a and 27b depicts a method of laying a floor using jointed panels.
DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS
[0087] Figures 1 a - 2 illustrate a first embodiment of a vertical joint system 10 (hereinafter
referred to as "joint system 10") for a substrate. The substrate is shown in cross
section view and in this embodiment is in the form of an elongated rectangular panel
12. The substrate or panel 12 has opposed major first and second surfaces 14 and 16
respectively. Each of the surfaces 14 and 16 are planar surfaces and lie parallel
to each other. In one orientation the surface 14 is an exposed surface of the panel
12 while the surface 16 bears against a support surface or structure such as but not
limited to a concrete, timber, tile or vinyl floor or timber battens. Joint system
10 comprises a first joint Jm and a non-symmetrical second joint Jf. The first joint
Jm can be notionally considered to be a male joint while the second joint Jf can be
notionally considered to be a female joint. This designation of the joints will be
explained shortly.
[0088] Assuming the substrate to be in the shape of a quadrilateral the joint Jm extends
along two adjacent sides and Jf extend along the remaining two adjacent sides. For
example when the substrate is an elongated rectangular floor board as shown in Figures
1 b and 1 c the joint Jm extends along one longitudinal side and an adjacent transverse
side, while the joint Jf extends along the other (i.e. opposite) longitudinal side
and the other (i.e. opposite) adjacent transverse side.
[0089] Figure 1 b illustrates a first joint Jm of a first panel 12a engaged with a second
joint Jf of a second panel 12b having an identical joint system 10. For ease of description
the panels 12a and 12b will be referred to in general as "panels 12".
[0090] As will be explained in greater detail shortly, the first and second joints Jm and
Jf are configured to enable two panels 12 (i.e. panels 12a and 12b) to engage each
other in response to a pressure or force F (see Figure 5) applied in an engagement
direction D which is perpendicular to the major surfaces 14 and 16. When the panels
12 are floor panels the direction D lies in the vertical plane and more particularly
is directed downwardly toward a surface on which the panels are laid. This is equivalent
to the joints Jm and Jf engaging by virtue of motion of one joint (or substrate) relative
to another in a direction perpendicular to a plane containing the major surfaces.
[0091] The joint Jm comprises a male protrusion Pm and a male recess Rm, while the joint
Jf comprises a female protrusion Pf and a female recess Rf. The first joint Jm is
notionally designated as the male joint by virtue of its protrusion Pm depending from
the upper surface 14. The second joint Jf is notionally designated as the female joint
by virtue of its recess Rf being configured to receive the protrusion Pm.
[0092] When describing features or characteristic common to all protrusions the protrusions
will be referred to in general in this specification in the singular as "protrusion
P", and in the plural as "protrusions P". When describing features or characteristic
common to all recesses the recesses will be referred to in general in this specification
in the singular as "recess R", and in the plural as "recesses R". When describing
features or characteristic common to all joints the joints will be referred to in
general in this specification in the singular as "joint J", and in the plural as "joints
J".
[0093] The male joint Jm has first, second and third male locking surfaces ML1 , ML2 and
ML3 respectively (referred to in general as "male locking surfaces ML"). Each of the
male locking surfaces ML extends continuously in the general direction perpendicular
to the major surfaces. Similarly the female joint Jf has first, second and third female
locking surfaces FL1 , FL2 and FL3 respectively, (referred to in general as "female
locking surfaces FL"). The male and female locking surfaces collectively and generally
are referred to locking surfaces L.
[0094] Each of the locking surfaces L extends continuously in the general direction perpendicular
to the major surfaces. The expression "extend continuously in the general direction
perpendicular to the major surfaces" in the context of the male and female locking
surfaces is intended to denote that the surfaces extend generally between the opposite
major surfaces but continuously so that it extends in one direction only , i.e. always
in the direction of the surface 14 to the surface 16 or vice versa and thus does not
return upon itself as would be the case for example if the surface included a barb
or hook like structure.
[0095] The male locking surface ML1 extends from an edge of the major surface 14 adjacent
the protrusion Pm and down the adjacent side of the protrusion Pm to appoint prior
to the surface of the protrusion Pm turning through greater than 45° from the perpendicular
to the major surface 14. It will be noted that the locking surface ML1 extends continuously
in the general direction perpendicular to the major surface 14, without returning
upon itself. Thus every point on the surface ML1 lies on a different horizontal plane.
In contrast, in the event that a hook or barb like structure were provided then the
corresponding surface would turn upon itself and a plane parallel to the major surface
14 would insect the surface at three different locations.
[0096] The male locking surface ML2 extends from the second major surface 16 up along an
adjacent side of the recess Rm to a point prior to the deepest portion of the recess
Rm turning through more than 45° toward the protrusion Pm. Finally, the third male
surface ML3 extends along a shared or common surface between a protrusion Pm and Rm
and denoted by end points prior to the surface turning through more than 45° to the
perpendicular at the deepest portion of the recess Rm, or the most distant portion
of the protrusion Pm. As will be explained shortly, the first and second male and
female locking surfaces engage about respective locking planes inhibiting vertical
separation of engaged joints Jm and Jf. The third male and female locking planes ML3
and FL3 may also be configured to form a third locking plane. Also, the locking surfaces
L in various embodiments comprise inflexion surfaces which in turn may comprise transverse
outward extending surfaces which may take the form of convex or cam surfaces, or bulges.
The relationship between the locking surfaces L, inflexion surfaces and transverse
outward extending surfaces will be apparent in the following description.
[0097] Looking at the configuration of the first and second joints Jm and Jf (referred to
in general as "joints J") more closely, it will be seen that each of these joints
is provided with two laterally spaced apart transversely outward extending surfaces
or bulges. The transversely extending surfaces bulges may also be considered and termed
as "cam surfaces" as they move across and in contact with each other and at times
often with a rolling or pivoting action. The transversely extending surfaces are designated
as Cm 1 and Cm2 on the first joint Jm and Cf 1 and Cf2 on the joint Jf. In many embodiments
transversely extending surfaces are smoothly curved convex surfaces. However as will
be apparent from the following description is some embodiments the transversely extending
surfaces are of other configurations. For example a transversely extending surface
may be generally convex in that the surface is not continuously or smoothly curved
for its entire length but is composed of one or more straight/planar surfaces. For
ease of reference the transversely extending surfaces on the male joint Jm will be
referred to "surface Cmi" where i = 1 ,2,3 and similarly the transversely extending
surfaces on the female joint Jf will be referred to "surface Cfi" where i = 1 ,2,3.
[0098] The surface Cm1 is formed on a protrusion Pm of a first joint Jm while the surface
Cm2 is formed in a recess Rm of joint Jm. Similarly the surface Cf2 is formed on a
protrusion Pf on the joint Jf while the surface Cf1 is formed in a recess Rf of the
second joint Jf. (For ease of description the surfaces Cm2 and Cm 1 will be referred
to in general as " surface Cm"; surfaces Cf 1 and Cf2 will be referred to in general
as " surface Cf"; and collectively the surfaces Cm2, Cm1 , Cf1 and Cf2 will be referred
to in general as " surfaces C").
[0099] Figure 1 b depicts the joints J in an engaged state. As is evident when the joints
J are engaged their respective transversely extending surfaces are located relative
to each other to form respective first and second locking planes 18 and 20 which inhibit
the separation of the engaged joints in a direction opposite the engagement direction
D.
[0100] Each locking plane 18, 20 lies parallel to the engagement direction D. The transversely
extending surfaces Cm 1 , Cf 1 , Cm2, Cf2 associated with each locking plane extend
laterally toward each other from opposite sides of the locking plane with the transversely
extending surfaces of the second or female joint (i.e. Cf 1 and Cf2) overhanging the
transversely extending surfaces of the first or male joint (i.e. Cm 1 and Cm2). This
inhibits separation of the engaged joints Jm and Jf. It will also be noted that at
least one of the transversely extending surfaces associated with each locking plane
has a curved profile. In this instance the surface Cf 1 associated with locking plane
18, and both surfaces Cf2 and Cm2 associated with locking plane 20 have curved profiles.
[0101] During the engagement of the joints Jm and Jf the surfaces Cm 1 and Cm2 pass and
snap over the surfaces Cf 1 and Cf2. This action is enabled by one or both of resilient
compression of the protrusions Pm and Pf and resilient tension in the recesses Rm
and Rf as the surfaces Cm pass the surfaces Cf in response to application of the force
F. Whether there is one or both of resilient compression of the protrusions Pm and
Pf and resilient tension in the recesses Rm and Rf is dependent on the material from
which the panel 12 is made. For example in the case of a panel made from a very stiff
or hard material such as strand bamboo there would be very little compression of the
protrusions P but tension in the recess R which results in its opening or widening
would allow for the engagement. The ability for the protrusions P to enter the recesses
R is assisted by the provision of a lubricant such as wax on the joints Jm and Jf.
The provision of the lubricant and in particular wax also substantially eliminates
joint noise and aids in the ability of adjacent engaged joints J to rotate relative
to each other. This rotation motion is describe later in the specification.
[0102] Horizontal separation between engaged joints Jm and Jf is inhibited by the seating
of the protrusions P in the respective recesses R. The joints Jm and Jf are also provided
with respective planar abutment surfaces 24 and 26. The surfaces 24 and 26 extend
from opposite edges of and perpendicular to the major surface 14. The respective surfaces
Cm and Cf are configured to create lateral compression forces between the surfaces
24 and 26 maintaining them in contact thus preventing the creation of a gap between
joined panels 12a and 12b.
[0103] Accordingly as described above, the surfaces Cm and Cf co-operate to provide both
vertical and horizontal arrestment of panels 12a and 12b when the respective joints
Jm and Jf are engaged. However in addition to this the surfaces Cm and Cf enable limited
relative rotation between panels 12a and 12b while maintaining engagement of the panels
12. This is depicted in Figures 3a and 3b.
[0104] Figure 3a shows the panel 12a being rotated by +3° (3° in an anticlockwise direction)
relative to the panel 12b. The rotation is facilitated by pivoting at an upper corner
of surface 24 on surface 26. This rotates the protrusion Pm within recess Rf and causes
the surface cam Cm2 to ride or roll up, but not past the apex of, the surface Cf2.
The projection Pf is now effectively pinched between the surfaces Cm2 and Cm3. In
this configuration vertical separation between the substrates 12a and 12b is inhibited
by this pinching effect as well as due to the surface Cm 1 remaining below surface
Cf1 . Horizontal arrestment is maintained by virtue of the projections Pm and Pf remaining
within respective recesses Rm and Rf.
[0105] With reference to Figure 3b, the panel 12a is rotated by -3° (3° in a clockwise direction)
relative to panel 12b. This is facilitated by the surface Cm2 rolling down and acting
as a pivot or fulcrum point against the side of Joint Jf containing the surface Cm2.
This causes separation of the surfaces 24 and 26 creating a gap at the upper major
surfaces 14. Nevertheless the panels 12a and 12b remain vertically and horizontally
engaged. Vertical arrestment between the substrates is maintained by engagement of
the surfaces Cm2 and Cf2; and surfaces Cm1 and Cf1. Horizontal arrestment is provided
by the projections Pm and Pf being maintained in their recess Rf and Rm.
[0106] The relative rotation between the panel 12a and 12b is of great assistance in the
installation of the substrates particularly on uneven surfaces such as an undulating
concrete floor. This is of great importance to the "do-it-yourself" user although
benefits also flow through to the professional layer. Consider for example an uneven
undulating surface on which it is desired to lay a click type floor covering having
say a prior art joint system where the tongue is inserted laterally or at an inclined
angle into a groove or recess. The undulation may be in the form of a concave recess
or shallow in a portion of the surface having a width several times greater than the
width of the panels. Depending on the degree or slope of the concavity it may be extremely
difficult if not impossible to insert a tongue of a "to be" installed panel into the
groove of a previously laid panel. This arises because the two panels do not and will
not lie in the same plane, but rather are angled relative to each other due to the
concavity.
[0107] Additionally, when installing floor boards of a length of about 1 m or longer on
an uneven surface, banana-ing or lateral bowing occurs of the previously installed
floor board by virtue of an installer kneeling on it when trying to lay the next floor
board. The kneeled on board will bow under the weight of the installer due to the
uneven underlying surface. This effect is depicted in Figures 4a to 4d. Figures 4a
and 4b show lateral bowing of a panel 12x outwardly when the uneven surface is a fall
or hollow. Figures 4c and 4d show lateral inward bowing of a panel 12x when the uneven
surface is a hump. It will be appreciated that this bowing makes it very difficult
to get full longitudinal engagement with an adjacent panel without gapping. In these
circumstances, even professional installers have difficulty in laying the floor and
will need to rely on substantial physical exertion and experience. The do-it- yourself
installer will often give up and either returns the flooring to the retailer on the
basis that it does not "click" together or end up paying for a profession installer.
[0108] To provide perspective of the effect of the relative rotation capabilities of the
joint system 10 in comparison to the prior art reference made to Figures 4e to 4h.
Conventional flooring systems are able to accommodate a concavity or a hump in an
underlying substrate for example a concrete floor of 3 - 5mm over a length of 1 m,
being the industry standard. Undulations greater than this either prohibit the use
of many prior art systems or at least make them very difficult to install. Assuming
that they can be installed the undulation can subsequently cause prior art joint systems
to disengage horizontally and thus gap excessively. Specifically in the event that
the undulation is in the form of a hump or undulation there is the possibility of
either total horizontal separation between the adjacent panels and/or splitting or
shearing of the joints. In the event that the undulation is a concavity prior art
joints are liable to shear or break due to excessive tensile force being applied to
the joints.
[0109] In Figures 4e to 4h (which are schematic only and not drawn to scale) the 3 - 5mm
surface undulation which can be accommodated by the prior art system is shown as shaded
area 30. Figures 4e and 4f represent an undulation in the form of a rise or hump of
3-5mm, whereas Figures 4g and 4h represent an undulation in the form of a fall or
hollow of 3-5mm. In comparison the + or - 3° rotation available by embodiments of
the joint system 10 over a 1 m length provide a total possible displacement of 52mm.
The +3° rotation is illustrated in Figures 4e and 4f, while the - 3° rotation is illustrated
in Figures 4g and 4h.This enables substrates utilising embodiments of the joint system
10 to be successfully laid on floors without horizontal disengagement or separation
where the floor may have for example a concave undulation which over a distance of
one metre drops by 52mm below adjacent planar surface portion of the floor. Maintaining
horizontal engagement maintains the structural integrity of the floor. This is beneficial
in terms of the appearance of the floor which in turn can add value to an associated
house.
[0110] It will be recognised by those skilled in the art that this enables the laying of
a flooring system incorporating the embodiments of the current joint system on substrates
that fall outside of 3 - 5mm undulation over a length of 1 m dictated by the world
industry standards. This has significant practical and commercial benefits. The practical
benefits are that the flooring will be able to be successfully and easily laid by
do-it -yourself installers and professional installer on substrates that hitherto
were unsuitable for conventional click type flooring. The commercial benefit is that
because the flooring systems can be laid they are not returned to the point of sale
by disgruntled and frustrated installers requesting a refund for a system that, in
their eye, does not work. The conventional systems will work if the substrate is within
the narrow band prescribed as the world industry standard. But the installer is usually
unaware of the standard and in any event has not idea as to whether or not their substrate
complies. This is not an issue with embodiments of the present invention as it is
able to be installed without separation on substrates that fall outside of the world
industry standards.
[0111] Returning to Figures 1 and 2, it can be seen that the surfaces Cm and Cf constitute
portions of respective inflexion surfaces, which in turn form portions of respective
locking surfaces L. Specifically, the surface Cm1 constitutes a part of an inflexion
surface Im 1 (indicated by a phantom line) which in turn forms part of first male
locking surface ML1 (indicated by broken dot line) of the protrusion Pm. The inflexion
surface Im 1 extends generally in the direction D from the abutment surface 24.
[0112] Similarly surface Cm2 constitutes a portion of inflexion surface Im2 (indicated by
a phantom line) which in turn forms part of second male locking surface ML2 (indicated
by broken dot line). Surface ML2 is formed on the surface of recess Rm and depends
generally in the direction D from near a root 32 of the recess Rm.
[0113] The surface Cf2 constitutes part of an inflexion surface If2 (indicated by a phantom
line) which in turn forms part of second female locking surface FL2 (indicated by
broken dot line) formed on an outer most side of the projection Pf and extending generally
in the direction parallel to the direction D.
[0114] The surface Cf1 constitutes part of the inflexion surface If 1 (indicated by a phantom
line) which in turn forms part of first female locking surface FL1 (indicated by broken
dot line). Surface FL1 depends from abutment surface 26 and in a direction generally
parallel to direction D and toward a root 34 of the recess Rf.
[0115] Looking at Figure 1 b, it will be seen that the surfaces Cm1 ,Im 1 and ML1 engage
the surfaces Cf1 , If 1 and FL1 respectively; and the surfaces Cm2, Im2 and ML2 engage
the surfaces Cf2, If2 and FL2 when the joints Jm and Jf are engaged. The engagement
of these surfaces forms or create the first and second locking planes 18, 20. Different
portions of the locking L, inflexion I and transversely extending surfaces C operate
as arresting and rolling surfaces during various stages of engaging and disengaging
of the joints Jm and Jf.
[0116] To provide the rolling action between adjacent engaged substrates at least one of
the surfaces C and indeed one of inflexion surfaces I in each pair of engaged or related
surfaces is formed with a profile of a continuous or smooth curve. For example consider
the surfaces Cm1 and Cf 1 and corresponding inflexion surfaces Im1 and Iff . When
the joints Jm and Jf are engaged, surfaces Cm1 and Cf1 are located about or adjacent
the first locking plane 18; as are corresponding inflexion surfaces Im1 and Iff. In
this instance the surface Cf1 and the corresponding inflexion surface If 1 has a profile
of a continuous or smooth curve. However the surface Cm1 and corresponding inflexion
surface Im 1 has a profile which comprises a straight line 36. The straight line is
relatively short and forms a small ridge or peak 38 on the surface Cm 1 and inflexion
surfaces Im 1 . The ridge 38 presents a relatively small contact area against the
inflexion surface If 1 minimising the friction between the surfaces and the possibility
of sticking during relative rotational motion.
[0117] In contrast, the surfaces Cm2 and Cf2; and corresponding inflexion surfaces Im2 and
If2 which are located about and form the second locking plane 20 each have a profile
of a continuous curve. However other embodiments will be described later in which
one of the surfaces Cm2/lm2 or Cf2/lf2 has a profile comprising one or more straight
lines. The first and second male locking surfaces ML1 and ML2, and indeed the associated
surfaces Cm 1 and Cm2 and corresponding inflexion surfaces Im 1 and Im2 constitute
the extreme (i.e. inner most and outer most) transversely extending and inflexion
surfaces of the first (male) joint Jm. The first and second female locking surfaces
FL1 and FL2, and indeed the associated surfaces Cf1 and Cf2 and inflexion surfaces
If 1 and If2 constitute the extreme transversely extending and inflexion surfaces
of the second (female) joint Jf. These extreme transversely extending and inflexion
surfaces form respective surface pairs which create the extreme (i.e. inner most and
outer most) locking planes 18 and 20 in mutually engaged joints Jm and Jf. This is
clearly evident from Figure 1 b.
[0118] Specifically the surface pairs are in this embodiment: Im 1 and If1 , or Cm 1 and
Cf1 ; and, Im2 and If2, or Cm2 and Cf2. The above described relative rotation between
panels incorporating embodiments of the joint system 10 is facilitated by forming
one surface in each of the surface pairs as a smoothly or continuously curved surface.
[0119] The surfaces Cm1 and Im 1 form part of an outer peripheral surface 40 of the protrusion
Pm. The protrusion Pm has a generally ball like or bulbous profile which depends in
the direction D from major surface 14. The outer surface 40 after the inflexion surface
Im 1 curves toward the recess m. The surface 40 is provided with a recess 42 at a
location most distant the major surface 14. As shown in Figure 1 b, when the joints
Jm and Jf are engaged the recess 42 forms a reservoir 44 against a lower most portion
of surface 46 of the recess Rf. Save for the recess 42 the end of the protrusion Pm
facing the bottom of recess Rf1 is rounded or curved. The first male locking surface
ML1 comprises the combination of surface 24 and the inflexion surface Im 1.
[0120] The recess 42 and corresponding reservoir 44 may be used for various different purposes.
These include but are not limited to receiving adhesive and/or sealing compound; acting
as a reservoir for debris which may have fallen into the recess Rf during installation,
or both.. In this regard the recess 42 faces a lowest part of the surface 46 in the
recess Rf. It is expected that most debris falling into the recess Rf will collect
at the lowest point on the surface 46. As the joints Jm and Jf are engaged by a vertical
motion a substantial proportion of any debris is likely to be captured in the subsequently
created reservoir 44. In the absence of such a feature, it may be necessary to clean
the recess Rf for example by blowing with compressed air, use of a vacuum or a broom
to remove debris which may otherwise interfere with the engagement process. The recess
42/reservoir 44 can also accommodate expansion and contraction in the joints J.
[0121] The surface 40 after the recess 42 curves around to the recess Rm and incorporates
a further inflexion surface Im3. The inflexion surface Im3 is a "shared" surface between
the protrusion Pm and recess Rm and includes a surface Cm3. The surface Cm3 transitions
the surface 40 from a generally horizontal disposition to a generally vertical disposition.
The third male locking surface ML3 is substantially co-extensive with the inflexion
surface Im3.
[0122] It will be noted that the protrusion Pm is formed with a neck 48 having a reduced
width in comparison to other portions of the protrusion Pm. It will be seen that the
surface Cm 1 is adjacent an outer most side of the neck 48. Moreover, a portion of
the inflexion surface Im 1 adjacent the abutment surface 24 forms the outer most side
of the neck 48. Further, a portion of the inflexion surface Im3 forms the opposite
side of neck 48. In this embodiment a line 50 of shortest distance across the neck
48 is inclined relative to the major surface 14.
[0123] The inflexion surface Im3 leads to surface 52 formed in the root 32 of the recess
Rm. The surface 52 curves around to meet with and join inflexion surface Im2. The
surface Im2 extends generally in the direction D leading to a surface 54 which extends
perpendicular to the major surfaces 14 and 16 and subsequently to a bevelled surface
56 which leads to the major surface 16. The second male locking surface extends from
above the inflexion surface Im2 and along the bevelled surface 56 to the major surface
16.
[0124] Looking at the configuration of the joint Jf on an opposite side of panel 12, it
can be seen that the surface Cf1 and corresponding inflexion surface If 1 extend generally
in the direction D from the abutment surface 26. The first female locking surface
FL1 comprises the combination of surfaces 26 and If 1. The inflexion surface If 1
leads to the surface 46 at the root 34 of recess Rf. The surface 46 forms a vertical
arrestment surface for the protrusion Pm. Moreover the surface 46 includes a centrally
located substantially horizontal land 58 which faces the recess 42 when the joint
Jm is inserted in the joint Jf. The land 58 lies substantially parallel to the major
surfaces 14 and 16. Moving in a direction toward the protrusion Pf, the surface 46
leads to and incorporates a further inflexion surface If3 and corresponding co-extensive
third female locking surface FL3. The surfaces If3 and FL3 are shared surfaces between
recess Rf and protrusion Pf and extends in a direction generally opposite the direction
D.
[0125] The inflexion surface If 3 leads to an upper arcuate surface portion 60 of the projection
Pf which in turn leads to the surface Cf2 and inflexion surface If2. The inflexion
surface If2 leads to the planar surface 62 that extends perpendicular to the major
surfaces 14 and 16. This surface in turn leads to inclined surface 64 in turn leads
to the major surface 16. The second female locking surface comprises the combination
of surfaces If2, 62 and 64.
[0126] The recess Rf is configured to receive the protrusion Pm. Moreover, the recess Rf
is formed with a neck 66. The neck forms a restricted opening into the recess Rf.
A line 68 of shortest distance across the neck 66 is in this embodiment inclined relative
to the major surfaces 14 and 16. More particularly, the line 66 is inclined at substantially
the same angle as the line 50. The protrusion Pf like protrusion Pm is of a ball like
or bulbous configuration.
[0127] Further, similar to the protrusion Pm, the protrusion Pf is formed with a neck 70
of reduced width. A line 72 of shortest distance across the neck 70 is inclined to
the major surfaces 14 and 16. However in this embodiment the line 70 is inclined at
a different angle to the lines 50 and 68.
[0128] With reference again to Figure 1 b, it is also seen that the shared locking and inflexion
surfaces ML3 and FL3; and Im3 and If3 respectively, and indeed their corresponding
surfaces Cm3 and Cf3 are located relative to each other to form a third locking plane
74 along which separation of the engaged joints J is inhibited. The third locking
plane 74 is parallel with and between the inner and outer most locking planes 18 and
20.
[0129] The joints Jm and Jf are based in part on anatomical joints of the human body and
in particular the hip joint and shoulder joint. These joints Jm and Jf are designed
to provide horizontal and vertical strength and allow relative rotational motion to
a limited extent without disengagement. In effect the joints Jm and Jf can be considered
as ball and socket type joints. The comparison with anatomical joints is enhanced
in some embodiments described hereinafter which include a re-stickable flexible, elastic
and non curing or non-solidifying adhesive acting between the joints Jm and JF. In
such embodiments the adhesive acts in a manner akin to both a tendon allowing relative
motion but maintaining connection, and as cartilage providing a cushioning effect.
Also when wax is provided on the joints can act as a fluid in the joint providing
lubrication.
[0130] It is further evident from Figure 1 b that due to their non-symmetrical nature the
joints Jm and Jf are relatively configured so that when they are engaged several spaces
or gaps are formed between the engaged joints. A space 76 is formed immediately below
the abutment surfaces 24 and 26 and opposite the surface Cf1 . The space 76 may also
be described as being a space formed between respective upper portions of the inflexion
surfaces Im 1 and If 1. Space 78 is formed between lower parts of inflexion surfaces
Im1 and If 1. A generally vertically extending space 80 is formed between the shared
inflexion surfaces Im3 and If3; and a generally horizontal space 82 is formed between
the root 32 of recess Rm and arcuate surface portion 60 of the projection Pf. The
spaces allow thermal expansion and contraction of the panels 12 without dislocation
or fracturing of the joints Jm and Jf as well as assisting in the relative rotation
of the panels 12.
[0131] The engagement and disengagement of the joints Jm and Jf will now be described in
detail with reference to Figures 5a - 9f.
[0132] Figure 5a depicts a first panel 12a which has already been laid and a second panel
12b which is in the process of being laid. The panels 12a and 12b are supported on
an underlying horizontal surface 90. Panel 12a has a joint Jf which is open and ready
for connection with the joint Jm of panel 12b. Panel 12b is laid adjacent panel 12a
with the joint Jm resting on the joint Jf. The edge of panel 12b provided with the
joint Jf is simply resting on the surface 90 so that there is a small angle of approximately
1 °-3° between the panels 12a and 12b.
[0133] From Figure 5b it will be seen that in this position surfaces Cm1 and Cm3 rest on
the surfaces Cf1 and Cf3 respectively while the surfaces Cm2 and Cf2 are vertically
separated. In this configuration upper portions of the surfaces Cf 1 and Cf3 may be
considered as cam arresters in that they prohibit the entry of the projection Pm into
the recess Rf.
[0134] In order to commence engagement of the surfaces Jm and Jf a downward pressure or
force F is applied in the direction perpendicular to the major surfaces 14 and directed
toward the underlying surface 90. This pressure or force applies compression to the
protrusion Pm and tension the recess Rf which depending on the material from which
the panels 12 are made will result in one or both of the protrusion Pm compressing
and the recess Rf opening or widening so that the surfaces Cm 1 and Cm3 can slide
past the surfaces Cf1 and Cf3. Again the provision of wax on the joints Jm and Jf
assist this sliding action. This results in the protrusion Pm sliding through the
neck 66 into recess Rf. The opening the recesses Rm and Rf generates stress in the
joints shown by lines T in Figure 5c. This stress is about the curvature at opposite
ends of the root of each recess Rf and Rm. The stress is released as the protrusions
Pm and Pf pass through the necks of the recesses Rf and Rm providing a spring action
closing the recesses onto the protrusions and drawing the protrusions into the recesses.
Thus the recesses are able to elastically open and subsequently self close. This action
occurs with the other embodiments of the joint system described later in the specification.
[0135] The joints in this embodiment are configured so that the respective surfaces Cm and
Cf which pass each other do so at slightly different times. In this particular embodiment
the surface Cm1 passes the surface Cf1 marginally before the surface Cm3 passes the
surface Cf3. Once the surfaces Cm1 , Cm3 pass surfaces Cf 1 , Cf3 the remainder of
protrusion Pm is drawn into the recess Rf by an over centre or snap action. This is
due to the relative configuration of the inflexion surfaces and the release of compression
in the protrusion Pm after the surfaces Cm1 and Cm3 pass through the surfaces Cf1
and Cf3. In effect the respective necks 48 and 66 lay one within the other.
[0136] Simultaneously with this action occurring, a similar action is occurring in relation
to the protrusion Pf and the recess Rm. The surface Cm2 passes the surface Cf2 marginally
after passing of the surfaces Cm3 and Cf3. This is depicted in Figure 5c. As the recess
Rm is pushed onto the protrusion Pf , by action of the downward pressure or force
F, the protrusion Pf is compressed between the surfaces Cf3 and Cf2. After these surfaces
pass the surfaces Cm3 and Cm2 the recess Rf is drawn onto the protrusion Pf by an
over centre or snap action. While the joints J are engage by application of pressure
or force in a vertical direction (i.e. perpendicular the major surfaces 14, 16) the
relative motion between the joints J is not solely vertical. Rather there is a combined
vertical motion with lateral displacement. With reference to Figures 5b-5e and the
joint Jm, this lateral motion is motion of the joint Jm is to the left and is highlighted
by the closing in the horizontal gap or separation G of the surface 24 and 26 during
the engagement process. The horizontal gap G reduces from a maximum gap G1 in Figure
5b to progressively smaller gaps G2 and G3 and finally to a zero gap G4 in figure
5e in which case there is face to face contact between surfaces 24 and 26, when the
joints Jm and Jf are fully engaged. Which of the joints Jm and Jf laterally move is
just dependant on which one is least constrained from lateral motion. Indeed both
could move laterally toward each other to equal or different degree. This lateral
motion is symptomatic of the vertical stability of the engaged joint system
[0137] Figure 5d illustrates the joints Jm and Jf marginally before full engagement. Here
it can be seen that there is a small gap between the bottom of projection Pm and the
recess Rf and that the major surface 14 of panel 12b is marginally raised relative
to the major surface 14 on the panel 12a. The relative downward motion of the panel
12b is halted and the joint fully engaged when the projection Pm hits the arrestment
surface 58 on the recess Rf, as shown in Figure 5e. In this configuration the reservoir
46 is formed between the recess 42 and the arrestment surface 58. In this configuration
the surfaces Cm 1 , Cm2, Cm3 on the male joint Jm lay underneath the corresponding
surfaces Cf 1 , Cf2, Cf3 on the female joint.
[0138] The aforementioned mentioned ability for the joints Jm and Jf to enable both positive
and negative relative rotation without disengagement is able to accommodate for uneven
surfaces. Additionally the joints Jm and Jf facilitate self alignment of adjacent
panels 12. These features substantially simplify the installation to the extent that
a very average home handyperson can easily install panel incorporating embodiments
of the joint system 10.
[0139] The self aligning aspect of the system 10 arises from the shape and configuration
of the joints Jf and Jm and is explained with reference to Figures 5b, and 5f - 5k.
[0140] Figure 5f shows a panel 12b being roughly positioned for subsequent engagement with
panel 12a and prior to the application of any downward force or pressure to engage
the panels. The panels 12a and 12b are skewed relative to each other. At one end 85
the protrusion Pm sits on top of recess Rf. The corresponding view in cross section
is as shown in Figures 5b and 5j with the joint Jm of panel 12b lying on top of the
recess Rf of panel 12a. At the opposite end 87 the joints are laterally spaced apart.
In between, the degree of separation between joints Jm and Jf varies linearly. So
at location AA joints Jm and Jf are in contact but protrusion Pm partially rests on
protrusion Pf and partially overlies recess Rf and the panels separated by a distance
X1 shown in Figure 5i. While at a further location BB along the panels the protrusion
Pm lies directly above and on protrusion Pf and the panels are separated by a larger
distance X2 shown in Figure 5h.
[0141] Now a downward pressure or force F is applied at a location between locations 85
and BB to commence engaging the joints and panels. This force is transmitted between
the panels for the length along which they are in contact, i.e. essentially between
locations 85 and BB. At most points along this length the protrusion Pf is to the
left of the apex of protrusion Pf and at least partially overhanging the recess f.
Also it will be recognised that due to the curvature of surfaces Cm3 and Cf3 there
will be a natural tendency for the protrusion Pf to be drawn into the recess Rf.
[0142] Consequently the force F when transmitted to the contacting surfaces of joints Jm
and Jf will initially resolve into components which include a lateral (transverse)
component acting to urge the joint Jf into the recess and thus the panel 12b toward
the panel 12a. Accordingly the distance between the panels at end 87 closes. As the
location of the application of the force is advanced along the panel 12b toward end
87 the this closing effect continues until the at end 87 the protrusion Pm sits above
the recess Rf as shown in Figure 5j and the panels are fully aligned as shown in Figure
5k. Thus the panels self align under application of the downward engaging force. Naturally
if the force F is sufficient then in addition to the self alignment, the joints Jm
and Jf will also fully engage as shown in Figure 5k. The self aligning effect combined
with the engagement of the joints Jm and Jf produces a zipper like effect akin to
a snap lock bag.
[0143] It should also be understood that floors are often under dynamic tensile and compressive
load due to variations in temperature and humidity. They are also under static load
from furniture or other household items. Should the tensile load exceed the load carrying
capacity of the joints one or both of the protrusions Pm and Pf may fracture or shear.
This has several effects. It will release tension in the immediate vicinity of the
floor. In addition it will result in a horizontal separation along the fractured panel
producing a visible gap. Further depending on the prevailing conditions and circumstance
there may also be a vertical displacement of one of the adjacent panels resulting
in a height difference.
[0144] Once this tension has been released it can be extremely difficult if not virtually
impossible to reconnect the disengaged panel or fully connect a new panel. This is
because the panels on opposite sides of the fracture, which are still under tension,
are being pulled and will move away from each other. To reinstate the floor to its
original state one must pull the two sides together. If one merely places a new panel
in the space of the previous panel then the gap will remain. This leaves the home
owner with the only option of using unsightly filler to make good the gap caused by
the separation. This in turn is likely to have a negative impact on the value of the
home. The self aligning aspect of the joint system 10 also facilities the self re-tensioning
of say a floor upon replacement of damaged panels as described below. The release
in tension, subsequent movement of panels and self re-tensioning is described in greater
detail in Figures 51 - 5u. Figure 51 illustrates a floor composed of plurality of
panels 12. Two of the panels 12a and 12b are being removed and replaced. Assume that
there is tension between the panels 12 as described in the preceding paragraph. Once
the two panels 12a and 12b are removed leaving a gap 31 there is naturally a release
of tension in the floor in the area of the gap 31. Consequently, panels 12 adjacent
the gap will shift away from each other as shown by the arrows 33 in Figure 5m. The
effect of this is to produce a widening of the gap 31. This widening is illustrated
in Figure 5n, and in enlarged view in Figure 5o, and occurs as an additional longitudinal
band 35 along a line of abutment which previously existed between panels 12a and 12b
prior to their removal. This widening does not only occur within the gap 31 here will
also be a separation or at least an increase in tension between remaining adjacent
panels along a continuation of the band 35 as there are now fewer panels to accommodate
the tension. Figure 5p and corresponding enlarged view of Figure 5q illustrate the
effect of replacing the panels with panels having conventional lay down or horizontal
locking systems. New panels 12a1 and 12b1 are inserted into the gap 31 and engaged
with adjacent panels on either side. However due to the widening of the gap 31 , the
new installed panels 12a1 and 12b1 cannot be fully engaged with each other. The widening
may only be in the order of 0.5 to 2mm but this is sufficient to be easily visible
on a floor.
[0145] Ordinarily, in the case for example of a tongue and groove type locking system, the
tongue will have been sawn off so that there is no mechanical joining between the
panels 12a1 and 12b1. A filler will be used to fill the band 35 between the panels
12a1 and 12b1 . Significantly the filler is unable to transfer tension across the
panels 12a1 and 12b1 .
[0146] Consequently, it is not possible to reinstate the tension within the floor as a whole.
Now tension within the floor will act on opposite sides of the filler and the band
35. In time this is likely to lead to the fracturing of the filler and the creation
of a new gap 37 shown in Figure 5r and corresponding enlarged view Figure 5s between
the panels 12a1 and 12b1 .
[0147] Figure 5t and enlarged view Figure 5u shows the result in using panels or substrates
incorporating joint systems in accordance with embodiments of the present invention.
That is assume all of the panels 12 in Figs 5l-5s are provided with say joint system
10. When panels 12a and 12b are removed there is still a widening of gap 31 by creation
of band 35. New panel 12a1 is installed and engaged with panels 12c and 12d. Now panel
12b1 is inserted with say its female joint Jf beneath the male joint Jm of panel 12a1
and the male joint Jm of panel 12b1 lying on top of the female joint Jf of adjacent
panels 12e and 12f.
[0148] Applying downward pressure on the male joint of panel 12a1 where it overlies joint
Jf of panel 12b1 . This results in these joints and corresponding panels engaging.
This will cause a slight motion of the panel 12b1 away from panels 12e and 12f. However
this motion does not cause a separation greater than the distance X2 shown in Figure
5h. By now applying downward pressure on the male joint Jm of panel 12b1 , the panels
12b1 and 12e and 12f are pulled toward each other. Moreover the panels on either side
of an interface 39 between panels 12a1 and 12b1 are pulled inwardly toward each other
as shown by the arrows 33 in Figures 5t and 5u. Further the joints Jm and Jf of panels
12b1 ; and, 12e and 12f are engaged and the entirety of the floor thus re-tensioned
and structural integrity reinstated.
[0149] The above describes the situation where the floor is under tension. But equally problems
arise in prior art systems when a floor in under compression in which case there can
be a closing in the gap 31 . With the prior art systems one must cut the panels to
reduce their width to fit in the closed gap. Consequently there will be no full mechanical
joint between the newly installed panels and the existing panels. The structural integrity
is lost. Embodiments of the present invention can operate in essentially the same
manner as described above with reference to Figures 5l-5u but in "reverse" to push
the gap open and mechanically engage all adjacent panels 12 to reinstate full structural
integrity. Again this will be effective for gap of up to about the lateral extend
of surface Cf 1 which may range to about 2mm.
[0150] The above self aligning and "zipper" effects also apply when a panel is warped or
twisted about its length.. Embodiments of the joint system enable a warped panel to
be aligned and pulled in having the effect of flattening the warp or twist in the
panel provided the panel to which it is being engaged is flat and not itself warped
or twisted.
[0151] When engaging the joints Jm and Jf downward pressure can be applied by a person of
a weight of about 70 kilograms or more traversing the joints Jm a small hopping or
one legged jumping or small stomping motion. In this way joining of adjacent panels
12 can be achieved without the need to constantly kneel and stand as is required with
prior art systems. The engagement of joint Jm into joint Jf may also be aided by light
tapping with a rubber mallet M. The ease of installation not only widely expands the
range of do-it-yourself installers by reducing the skill and strength level required
it also has significant benefits to all installer including professionals by way of
minimising physical stress and exertion. For an employer or installation company this
reduces injury and sick leave to workers.
[0152] Consequently, workers are able to work longer and have increased income and insurance
premiums for and compensation claims against the employer can be reduced.
[0153] When panels12 with the joint system 10 are used in large area such as for example
in commercial premises a modified compactor can be used to apply the force or pressure
to engage the joints Jm and Jf. The compactor is envisaged as being in the form similar
to those used for compacting sand prior to laying pavers, but having a soft smooth
non scratch base lining. The lining may comprise but is not limited to a rubber, foam,
felt, or cardboard sheet. The process of removal of a damaged panel will now be described
with particular reference to Figures 6a - 9f. As will become evident from the following
description the removal process of a damaged panel relies on the relative rotation
enabled between the joined panels by virtue of the configuration of the joint system
10. Figures 6a - 6s depict in sequence various steps in the removal and replacement
of a damaged panel. The removal and replacement is facilitated by use of an extraction
system which comprises in combination a jack 92 shown in Figures 7a and 7b and a wedge
tool 94 shown in Figures 8a and 8b.
[0154] The jack 92 is a simple hand screw jack which is applied to a panel being removed.
The screw jack 92 is provided with an elongated threaded shaft 96 provided at one
end with a cross bar handle 98. The thread of the shank 96 is engaged within a threaded
boss 100 formed on a clamp plate 102. The plate 102 is of a square shape with the
boss 100 located centrally in the plate 102. The boss 100 overlies a through hole
in the plate 102 through which the shaft 96 can extend. Distributed about the plate
102 are four through holes 104 for receiving respective fastening screws 106.
[0155] The wedge tool 94 comprises a wedging block 108 coupled at one end to a handle 1
10. The wedging block 108 is formed with a base surface 1 12 which in use will bear
against a surface on which the panels 12 are installed, and an opposite surface 1
14 which lies beneath and contacts a major surface 16 of the panel 12 adjacent the
panel being removed. The surface 1 14 includes the relatively inclined portion 1 16
and a parallel land 1 18. The inclined portion 1 16 extends from a leading edge 120
of the wedge block 108 toward the handle 1 10. The surface 1 16 is inclined relative
to the surface 1 12, while land 1 18 lies parallel to the surface 1 12 and is formed
contiguously with the surface 1 16. The handle 1 10 is bent so that a free end 122
of the handle 1 10 lies parallel with but laterally displaced from a distal end 124
which is connected with the wedge block108.
[0156] Figure 6a depicts an area of flooring including a damaged panel 12b which is connected
along each side with adjacent panels 12. For the purpose of describing the method
of replacing the damaged panel 12b reference will be made only to two of the connected
panels 12a and 12c which engage along opposite longitudinal sides of the panel 12b.
The three side by side interlocked panels 12a, 12b and 12c are each provided with
an embodiment of the joint system 10 and cover a surface 90 as shown in Figure 6b.
The central panel 12b has a major surface 14 which is damaged by virtue of a scratch,
gash or water damage 126. It should also be understood that unless one of panels 12a
or 12c is immediately adjacent a wall then other panels 12 will be interlocked with
each of panels 12a and 12c.
[0157] In order to replace the damaged panel 12b, a drill 130 (see Figure 6d) is used to
drill a hole 128 through the panel 12b for each jack 92 used in the extraction process.
The hole 128 is formed of a diameter sufficient to enable the passage of shank 96.
The length of the panel 12b being removed dictates the number of jacks 92 that may
be required. Thus in some instances, extraction can be effected by the use of one
jack 92 whereas others may require two or more jacks. In this particular instance
two jacks 92 are used as shown in Figure 6c, but for ease of description the extraction
process refers to only one of the jacks 92.
[0158] Upon completion of the hole 128, the clamp plate 102 is placed on the panel 12b with
its boss 100 overlying the hole 128hole as shown in Figure 6e. The plate 102 is fixed
to the panel 12b by way of the four self tapping screws 106 that pass through corresponding
holes 104. This is illustrated in Figure 6f. The screws may be screwed in by a DIY
battery operated screw driver or using a manual screwdriver.
[0159] The next stage in the removal process is shown in Figures 6g and 6h involves engaging
the shank 96 with the threaded boss 100 and then screwing down the shaft 96 by use
of the handle 98 to lift the panel 12b above the surface 90. It should be immediately
recognised that this action requires the relative rotation of the joints Jm and Jf
of panel 12b while maintaining their engagement with the joints of adjacent panels
12a and 12c. This rotation is a relative negative rotation as will be explained shortly.
However simultaneously there is also a positive rotation of the joints between the
panels engaged on either side of panels 12a and 12c opposite the panel 12b.
[0160] The jack 92 is operated to lift the damaged panel 12b vertically upward by a distance
sufficient to effect a negative rotation between the damaged panel 12b and the adjacent
adjoining panels 12a and 12c. The negative rotation is in the order of 7° - 10°. This
is explained with particular reference to Figure 6h which shows an angle Θ1 between
the major surfaces 14 of panels 12a and 12b; and an angle 02 between major surfaces
14 of panels 12b and 12c. Prior to lifting of the panel 12d, it should be understood
that the angles 01 and 02 will be 180° assuming that the surface 90 is flat. Formation
of a negative angle between adjoined panels 12 is indicative of the angle 01 exceeding
180°. The amount by which the angles 01 and 02 exceed 180° during the disengagement
is equated to the negative rotation of the panels during this process. For example
if angle 01 is say 187° then the relative negative rotation between panels 12a and
12b is 7°.
[0161] It will be understood by those skilled in the art that vertically raising of any
prior art system having a lateral projection (e.g. a tongue) that seats in a groove
or recess of an adjacent panel is virtually impossible without breaking the tongue
or fracturing the panel with the groove. Thus this action if attempted with a prior
art system is very likely to result in the damaging of one more panels which were
not previously damaged or in need of replacement.
[0162] The ability for the panels incorporating embodiments of the present joint system
to be removed by vertical lifting is a direct result and consequence of the joint
system. This provides a lay-down disengagement process of panels being directly opposite
to the prior art which requires a lay-up disengagement process. As a consequence of
the joint system and the ability to disengage without damaging adjacent panels by
vertical lifting, repair of a floor can be achieved in a world's best practice manner
fully reinstating the integrity of the floor without the need to peel back the entire
floor from one wall to the damaged area, and/or engaging a professional installer.
[0163] The jack 92 mechanically lifts and self supports the panel 12b, panels 12a, 12c and
panels adjacent to panels 12a and 12c. Thus the installer does not need to rely on
their own strength to lift and hold the panels. In contrast some prior art systems
use suction cups for example as used by glaziers to hold glass sheets to grip a panel
to be removed. The installer must then use their strength to lift the panel. While
this is difficult enough it becomes impossible if the panel is also glued to the surface
90. The jack 92 which provides a mechanical advantage is able to operate in these
circumstances. In addition as the jack self supports the panels 12 the installer is
free to use both hands in the repair process and indeed is free to walk away from
the immediate vicinity of the panel12b.
[0164] The jack 92 is operated to lift the panel 12b vertically upwards to a location where
the negative rotation between the panel 12b and adjacent panels 12a and 12c is in
the order of 7° to 10°. This is the position shown in Figure 6h and 9d. In this position,
there is partial dislocation of the joints Jm and Jf between panels 12a and 12b. This
partial dislocation arises from the surface Cm 1 rolling over surface Cf 1 with the
surface 38 snapping past the apex of surface Cf 1 and is denoted by an audible "clunk".
Notwithstanding this dislocation the panels remain engaged due to the pinching of
protrusion Pf between surfaces Cm2 and Cm3.
[0165] The jack 92 can be provided with a scale to give an installer an indication of the
when the negative rotation is in the order of 7° to 10°. The scale could comprise
for example a coloured band on the shank 96 which becomes visible above the boss 100
when shank has been screwed down to lift the panel sufficiently to create the above
mentioned negative rotation. Several bands could be provided on the shank for panels
of different thickness.
[0166] In order disengage panel 12b one must first disengage whichever of the panels 12a
or 12c has its female joint Jf engaged with panel 12b. In this instance this is panel
12a. Working above the panels 12 an installer will not immediately know that it is
panel 12a. But this can be easily determined by either: lightly tapping on both panels
12a and 12c; or, applying light hand pressure and feeling for joint movement. Due
to the orientation of the joints this tapping will result in panel 12a fully disengaging
in the vicinity of the tapping. Thereafter as shown in Figure 6i, applying a downward
force or pressure on the panel 12a at other locations along its length will result
in a total disengagement of joints Jm and Jf on the panels 12a and 12b.
[0167] The interaction between the respective surfaces on the joints Jm and Jf on the panels
12a and 12b from the position where the panels are fully engaged and lie on the same
plane as shown in Figure 6f to the point of disengagement shown in Figure 6h will
be described in more detail with reference to Figures 9a - 9e.
[0168] Figure 9a illustrates the panels 12a and 12b prior to operation of the jack 92. This
equates the relative juxtaposition of the panels shown in Figures 6a, 6b, and 6d-6g.
As the jack 92 is operated to progressively lift the panel 12b from the surface 90,
there is a gradual rotation between the respective joints Jm and Jf. Figure 9b illustrates
the joint Jm of panel 12b and joint Jf of panel 12a at relative rotation of approximately
-2°. Here the abutment surfaces 24 and 26 commence to separate with the surface Cm
1 and in particular the ridge 38 commencing to ride up the surface Cf1. Simultaneously
the surface 40 of projection Pm commences to lift from the surface 46 of recess f.
There is also now a slight increase in the separation between upper portions of inflexion
surfaces and Im3 and If3. Finally, the surface Cm2 rides down the surface Cf2.
[0169] Figure 9c shows the effect of continued lifting of the panel 9b to a position where
the relative negative rotation between the panels 12a and 12b is about 5°. Here the
separation between abutment surfaces 24 and 26 is more pronounced and the surface
Cm 1 and in particular ridge 38 reside higher on the surface Cf 1 but not yet disengaged
from the surface Cf 1. There is an increase in the separation between the surfaces
40 and 46 and the surface Cm2 is now seated firmly in a deepest portion of the concavity
in inflexion surface If2. This is increasing pressure /force exerted by: surface Cm2
on the neck of protrusion Pf; and, surface Cm 1 on surface Cf 1.
[0170] Continued operation of the jack 92 further increases the angle between the panels
12a and 12b to approximately -7° as shown in Figure 9d. At this point, the surface
Cm 1 and ridge 38 have now moved past the surface Cf 1 and lie outside of the neck
66 of recess Rf. This would ordinarily be indicated to the installer by an audible
"clunk". However the surface Cm3 is engaged by and below the surface Cf3; and the
surface Cm2 resides below the surface Cf2. More particularly, the protrusion Pf is
now being compressed or pinched on opposite sides by the surfaces Cm3 and Cm2. Thus
while at this -7° disposition, the joints Jm and Jf are still partially engaged and
in the absence of any external force, maintain vertical and horizontal locking of
the panels 12a and 12b. Further, during the rotation of the joints Jm and Jf up to
the -7° rotation the surface Cm2 operates as a fulcrum lifting the projection Pm from
the recess Rf.
[0171] The application of a downward pressure or force on the panel 12a results in one or
both of: compressing the projection Pf; or, opening the neck of recess Rm formed by
the surfaces Cm3 and Cm2, to enable the projection Pf to escape the recess Rm. Wax
in the joint will reduce friction and now assist in the disengagement of the joints.
Now the panel 12a is free to fall back to the surface 90 as shown in Figure 9f and
Figure 6i. Thus at this point in time the panels 12a and 12b are fully disengaged.
However removal of the panel 12b also requires disengagement of the joint Jf of panel
12b from the joint Jm of panel 12c. This process is shown in Figures 6j to 61.
[0172] Immediately after disengagement of panels 12a and 12b, the panel 12b is held above
surface 90 by the jack 92. To continue the replacement process the panel 12b is lowered
back to the surface 90 by unscrewing shaft 96 from the boss 100 of the clamp plate
102. An installer next grips and lifts the joint Jm of panel 12b to insert the wedge
tool 94 between the disengaged joints of the panels 12a and 12b and push it to a position
where the land 1 18 of surface 1 14 is in contact with the major surface 16 of panel
12c and inside of the joints Jm and Jf. This is shown in Figure 6j. Disengagement
of the panel 12b from the panel 12c is now effected by initially rotating the panel
12b by about -7° to -10° to effect a disengagement of the surface Cm 1 of panel 12c
from the surface Cf 1 in the joint Jf of panel 12b. The wedge tool 94 is configured
to assists the installer in achieving this rotation. This is also depicted in Figure
6j. Moreover when the wedge block 108 is under the under panel 12c slightly inboard
of its joint Jm, and the panel 12b is rotated in the anticlockwise direction toward
the handle 1 10, the panel 12b will rotate or pivot by 7° to 10° prior to or by the
time it abuts the handle 1 10. The reaching of this position is ordinarily denoted
by an audible "clunk" as the surface Cm 1 passes from below to above surface Cf1 .
This juxtaposition of the joints Jm and Jf is as shown in Figure 9d.
[0173] Subsequent application of downward pressure or force for example by way of rubber
mallet M as shown in Figure 6k will result in total disengagement of the joints Jf
and Jm of panels 12b and 12c respectively as shown in Figure 61. Now the damaged panel
12b is totally disengaged from both adjacent panels 12a and 12c and can be removed.
[0174] To replace the damaged panel 12b with a new panel 12b1 an installer now removes the
wedge tool 94, lifts the edge of panel 12c by hand and slides a new panel 12b1 beneath
the raised panel 12c so that the joint Jm lies above the joint Jf. The opposite side
of panel 12b1 rests on panel 12a. This sequence of events is shown in Figures 6m-6p.
[0175] The installer now lowers the panel 12c onto the panel 12b1 . When this occurs, the
male joint Jm of panel 12c rests on the neck 48 of female joint Jf of panel 12bi;
and the joint Jm of panel 12b1 will rest on the neck 48 of the joint Jf of previously
laid panel 12a. This is shown in Figure 6q.
[0176] To fully engage the panel 12b1 downward force or pressure is applied on the male
joints Jm of panels 12c and 12b1 . This can be done in either order, i.e. panel 12c
then panel 12b1 or panel 12b1 then panel 12c. Figure 6q shows the configuration when
joint Jm of panel 12c is first engaged with joint Jf of panel 12b1 . Figure 6r depicts
the joint Jm of panel 12b1 now engaged with joint Jf of panel 12a, reinstating the
floor as shown in Figure 6s. The self aligning properties of the joint system as described
above with reference to Figures 5f-5k will operate during this process if the panels
are initially misaligned. The ability to easily remove and replace only the panels
12 which are damaged instead of peeling back the entire floor has enormous practical,
commercial and environmental benefits. These are summarised as follows:
The panels can be easily replaced by handypersons of limited skill and with very rudimentary
and low cost equipment. This avoid the need for hiring professional installers
[0177] The repair is also relatively clean as there is no need to chisel or cut out panels
or parts thereof.
[0178] As only the damaged panels need be replaced there is no need to move furniture which
in itself is often difficult and inconvenient
[0179] From the view point of the retailer there is initial benefit in that the retailer
should encourage the purchaser to purchase slightly more panels that required to cover
a given area to provide spare panels in the event of damage. For example the retailer
would explain the benefits in purchasing say an additional one to three square meters
of panels. This is much the same as when say a new house in build and the builder
leave extra floor and roof tiles or paint for the purposes of repair. A major issue
with repair of damaged flooring it the difficultly is sourcing identical panels several
years after installation. If identical panel cannot be sourced it may be that an entire
level of flooring will need to be replaced when only a small number (e.g. two or three)
panels are damaged. For example say the ground floor of a house has three bed rooms
a hallway, kitchen and family room all cover by wooden floor panels of the same appearance
forming a continuous floor. The entire housing furniture selection and decor is often
selected to match with the floor. In such instances when matching replacement panels
are not available the entire ground level floors may need to be replaced. Indeed this
occurred on a large scale flooring a freak storm in Perth, Western Australia in March
2010. A much more common trigger for this is the spilling overtime of water from refrigerators
with water dispensers. Having a small supply of replacement panel at hand avoids the
need for full scale floor replacement. A new and growing market for wooden flooring
is that uses a relative cheap and plentiful material for the panel and using a bubble
jet printer to print a pattern for example the wood grain of exotic trees on the upper
major surface 12. It will be appreciated that these patterns can be very complex and
trying to rectify a scratch by use of an ink pen is virtually impossible. Again a
small supply of additional panels made with the initial purchase of the flooring can
potentially save thousands of dollars. A similar situation applies with wooden flooring
is that use a relative cheap and plentiful material and are stained on their major
surface to mimic the appearance of a more exotic and expensive timber.
[0180] The commercial consequence of full floor replacements as described above should not
be underestimated. Often this is at the expense of insurance companies. This naturally
has a knock effect with insurance premiums increasing and shareholder dividends reducing.
Also there are timing issue where insurance companies may not be able to have damage
assessed and therefore rectified for months.
[0181] Now consider the environmental aspects. Typically wooden floor panel are coated with
polyurethane or other sealants. Also they may bear adhesives and glues. This often
prevents destruction of the damaged boards by incineration due to generation of toxic
gases. Consequently they must go to land fill.
[0182] The joint 10 depicted in Figures 1-9f is representative of one of a large number
of possible embodiments. A small selection of other possible embodiments will now
be described. In describing these embodiments the same referencing system will be
used as for the joint 10 however each specific embodiment of a joint will be demarcated
by the addition of the alphabetical suffix e.g. "a, b, c,
[0183] Figures 10a and 10b depict a second embodiment of a joint system 10a incorporated
into a substrate 12. The joint system 10a comprises a male joint Jm and female joint
Jf along opposite sides. It can be seen that the joint system 10a is of the same general
configuration as the joint system 10 shown in Figures 1 and 2. In particular the male
joint Jm comprises male locking surfaces ML1 , ML2, ML3; inflexion surfaces Im1 ,
Im2, and Im3; as well as surfaces Cm 1 , Cm2, and Cm3. Likewise the female joint Jf
is provided with female locking surfaces FL1 , FL2, FL3; inflexion surfaces If 1 ,
If2, If3 and surfaces Cf 1 , Cf2 and Cf3. The relative locations of the locking surfaces,
inflexion surfaces and surfaces for the joint system 10a are generally the same as
for the joint system 10. However, there are subtle differences in the specific shape
and depth of the surfaces. In particular the surface Cm 1 in the joint 10a is continuously
curved rather than being provided with the ridge 38 of the joint system 10. In addition
the mating inflexion surfaces Im 1 and If 1 are shallower so that the spaces 76 and
78 about the locking plane 18 are smaller than that for the joint system 10. This
can be seen by comparison between Figures 10b and Figure 1 b. Further, there is a
lessening in the depth of the inflexion surfaces Im3 and If3 to the extent that there
is no space equivalent to the space 80 of the joint system 10. It can also be seen
that the inflexion surfaces Im2 and If2 in the joint system 10a are shallower than
the corresponding surfaces in the joint system 10 resulting in a smaller overlap in
the surfaces Cf2 and Cm2 when the joints Jm and Jf of adjacent panels 12 are engaged.
[0184] The joint system 10a may be used in the same circumstances and with the same materials
with the system 10. However due to the slightly shallower depth of the inflexion surfaces
I, the joint system 10a is suited to more rigid substrates such as but not limited
to bamboo where the compressibility of the projections Pm and Pf2 when passing through
the necks of the corresponding recesses Rm and Rf may be limited.
[0185] Figures 1 1 a to 1 1 d depict a further embodiment of the joint system 10b provided
on opposite sides of the substrate 12. The substantive differences between the joint
systems 10b and 10 lie in: (a) the configuration of the immediate inflexion surfaces
Im3 and If3; and, (b) the removal of the concave recess 42 from the projection Pm
and the formation of a similar recess 42f on the surface 58 of recess f.
[0186] In general, the inflexion surfaces Im3 and If3 are "angularised" in that they are
not smoothly or continuously curved for their entire length. Specifically the surface
Cm3 (which is part of the inflexion surface Im3) is provided with a narrow ridge 140
similar to the ridge 38 depicted on the protrusion Pm of joint system 10. In addition
the inflexion surface Im3 is provided with a "V" shaped gear tooth 142 extending toward
the root 52 of the recess R. On the female joint Jf the surface Cf3 is sharpened to
form a narrow ridge 144. As depicted in Figure 1 1 b, the apex 145 of gear tooth 142
bears against surface Cf3 below the ridge 144 when joints Jm and Jf are engaged.
[0187] The purpose and effect of the variation in configuration of the inflexion surfaces
Im3 and If3, and in particular the provision of the gear 142 and variations in the
configuration of the surfaces Cf3 and Cm3 is to allow greater relative rotation of
up to 5° to 10°or more of between joined while maintaining engagement to assist in
installation on undulating surfaces. This is shown in Figures 1 1 c and 1 1 d. The
ability to increase the degree of rotation is most pronounced in the positive or upward
direction of the male jointed panel 12b relative to panel 12a. This is facilitated
by the surface Cm3 bearing against the surface of protrusion Pf in the recess Rf after
the apex 145 of gear tooth 142 has passed over the ridge 144. As a consequence the
protrusion Pf remains pinched between the surfaces Cm3 and Cm2 thus maintaining horizontal
and vertical engagement. The joint system 10b enables a panel to ramp up relative
to an adjacent horizontal panel to say a raised cross-over or floor trim piece.
[0188] Figures 12a and 12b depict a further embodiment of joint system 10c incorporated
in a substrate 12. The joint systems 10c and 10 differ in substance in relation to
their aspect ratios. Joint system 10c may be used for substrates of smaller thickness
than for joint system 10. As there is less thickness or depth in the substrate 12
the male and female joints Jm and Jf of joint system 10c are shallower but broader.
This is most notable by a visual comparison between the protrusion Pm and recess Rf
of the joint systems 10c and 10. In joint 10c the protrusion Pm is broader and provided
with a flatter bottom surface 42 as is the recess Rf. The broadening of the protrusion
Pm also is the effect of sharpening the profile of the Cm3. However, the method of
operation and effect of the joint system 10c is the same as for joint system 10. In
particular the remains three vertical locking planes 18, 20 and 74 and respective
substrates 12 are able to rotate by up to 3 degrees in opposite directions relative
to each other.
[0189] Figures 13a and 13b depict a further embodiment of the joint system 10d applied to
a substrate 12. The substantive differences between the joint system 10d and 10 lies
in the depth and relative disposition of the intermediate inflexion surfaces Im3 and
If3; and the width of the protrusions P and recesses R. In the joint system 10d, the
inflexion surfaces Im3 and If3 are shallower and are inclined more towards the horizontal
i.e. toward a plane containing major surfaces 14 and 16. As a consequence, when the
male and female joints Jm and Jf are engaged only inner and outer locking planes 18
and 20 are created; the third locking plane 74 which arises with the earlier embodiments
of the joint system being absent. In the joint system 10d, there is no point on the
inflexion surface Im3 which is vertically below and laterally inside of a point on
the inflexion surface If3. Also the protrusions P and recesses R are broader in the
joint system 10d. This provides greater horizontal shear strength along shear planes
S1 and S2 which pass through the protrusions Pm and Pf parallel to the major surfaces
14 and 16. This is beneficial with panels of smaller thickness (e.g. say 7mm-3mm)
which are otherwise susceptible to shearing along planes S1 and S2. Notwithstanding
this, the joint system 10d operates in substantially the same manner as the joint
systems 10-10c in that it is a vertical system and adjoining substrates 12 can to
rotate by 3 degrees relative to each other without disengagement.
[0190] Figures 14a and 14b illustrate a further embodiment of the joint system 10e applied
to a substrate 12. The joint system 10e embodies the same basic concepts as the joint
system 10 and in particular has extreme (or inner and outermost) locking, inflexion
and transversely extending surfaces which form respective locking planes 18 and 20
and enable relative rotation between the male and female joints Jf and Jm of joined
substrates 12. Also as with all of the embodiments the joint system 10e is a vertical
system where joints are engaged by the application of a force or pressure in a direction
perpendicular to the major surfaces 14 and 16. However as it is readily apparent from
a comparison between the joint system 10e and the joint system 10 there are numerous
differences in the specific configuration of the projections P and recesses R on the
male or female joints Jf and Jr.
[0191] Starting with the male joint Jm, in the system 10e, there is a bevelled surface 146
between the major surface 14 and the side surface 24. In addition, between the side
surface 24 and the inflexion Im1 the joint system 10e comprises a right angle rebate
148. The protrusion Pm is more symmetrical than in joint system 10 and is provided
with a central slot 150 which extends in a direction perpendicular to the major surfaces
14 and 16. Additionally surface 40 of the protrusion Pm is flat rather than arcuate.
The slot 150 provides the protrusion Pm with a degree of resilience. This resilience
is not in order to effect engagement of the protrusion Pm with recess Rf but rather
provides resilience to assist in the rotation of the protrusion Pm within the recess
Rf.
[0192] The protrusion Pf is more rounded than the corresponding protrusion Pf in system
10 and is also provided with a central slot 152 which extends parallel to the slot
150. Slot 152 also provides resilience to the protrusion Pf to assist in its rotation
within the socket Rm. Surface 58 at the root 34 of recess Rf is flat and lies parallel
with the major surfaces 14 and 16 and also parallel with the surface 40. A square
shoulder 154 is formed between the inflexion surface If 1 and side surface 26 on the
female joint Jf. Shoulder 154 engages the rebate 148 when the joints Jf and Jm are
engaged as shown in Figure 14b. A further difference in the configuration of joint
system 10e is the provision of an inclined surface 156 between the inflexion surface
Im2 and the bevelled surface 56 at the joint Jm.
[0193] It will be seen from Figure 14b that the joint system 10e has three vertical locking
planes 18, 20 and 74 as in the joint system 10. A space 158 is created between the
surfaces 40 and 58 when the male joint Jm is engaged with a female joint Jf. This
space may be used in the same manner as the void 44 shown in Figure 1 b for the collection
of debris.
[0194] Figures 15a and 15b depict a further embodiment of a joint system 10f incorporated
on a substrate 12. In the joint system 10f, the male and female joints Jm and Jf are
shallower and squarer than that in the system 10. Male joint Jm comprises an inflexion
surface If 1 and corresponding surface Cm1 on an outermost surface and an inflexion
surface Im2 and corresponding surface Cm2 on an innermost surface. There is also an
intermediate surface Cm3 but no intermediate inflexion surface Im3. The female joint
Jf is formed with: surfaces Cf 1 and Cf2 on inner and outermost surfaces of the joint
respectively; and, an inflexion surfaces If2. However, the joint system 10f does not
include an intermediate inflexion surface If3 nor an inflexion surface If2 on the
outermost surface of the female joint.
[0195] Projections P and recesses R in the joint system 10f are squatter than those in the
joint system 10. This provides improved shear strength as in the joint system 10d.
When substrates 12 incorporated in the joint system 10f are engaged with each other
two locking planes 18 and 20 are created by the surface Cf 1 and Cm 1 ; and Cf2 and
Cm2 respectively. A "quasi" intermediate locking plane is formed by the provision
of planar surfaces 25 and 27 on protrusions Pm and Pf respectively. The surfaces 25
and 27 are perpendicular to the major surface 14. When the joints Jm and Jf are engaged
the surfaces 25 and 27 abut each other. This provides frictional locking against relative
motion between the joints Jm and Jf in the vertical plane. This provides an effect
similar to but to less degree than the locking plane 74 in the joint system 10f. Vertical
arrestment between the joined substrates 12 is created by the abutment of the surface
40 of projection Pm with the surface 58 in the recess Rf.
[0196] A further difference in the configuration between the joint systems 10f and 10 is
the omission in the joint system 10f of bevelled surfaces 56 and 64 which lead from
the surfaces 50 and 62 respectively to the major surface 16. Thus, in the joint system
10f, the surfaces 54 and 66 extend directly from the respective surfaces Cm2 and Cf2
to the major surface 16.
[0197] Figures 16a and 16b depict a further joint system 10g which is suited to panels made
of plastics materials such a vinyl or other relatively soft/flexible materials. In
the joint system 10g various inflexion surfaces or transversely extending surfaces
are formed comprising one or more planar surfaces. However, on each of the extreme
locking planes 18 and 20, there remains at least one arcuate transversely outward
extending surface to facilitate a rolling motion enabling rotation between the joint
panels 12. More specifically it can be seen that the projection Pm in the joint system
10f comprises a first locking surface ML1 and having abutment surface 24 and contiguous
inflexion surface Im1. The inflexion surface Im 1 includes a planar and inwardly sloping
surface 160 depending from the surface 24, and an additional planar surface 162 which
extends parallel to the surface 24 and is contiguous with the surface 160. Thereafter,
the inflexion surface Im1 incorporates an arcuate or a smoothly curved surface Cm
1 . The surface Cm 1 leads to a planar bottom surface 40 of the projection Pm which
lies in a plane parallel to the major surfaces 14 and 16. The surface 40 is contiguous
with an intermediate and smoothly curved surface Cm3. However the concave recess 42
of earlier embodiments has been replaced with a slot 163 which lies perpendicular
to the major surface 14. The slot 163 provides the projection Pm with an increased
ability to compress within recess m to facilitate rotation during within the recess
Rm.
[0198] Extending from the surface Cm3 is an inclined planar surface 164 which leads to a
planar surface 52 of the recess Rm. The surface 52 lies parallel to the major surfaces
14. The planar surface 164 and the surface Cm3 together form intermediate inflexion
surface Im3 and third male locking surface ML3. This is provided with a sharp corner
where the surface 164 meets the surface Cm3. The innermost surface ML2 of the male
joint Jm includes an angular inflexion surface Im2 and planar surface 56. The inflexion
surface Im2 comprises contiguous planar surfaces 166 and 168 which are inclined relative
to each other to form a generally concave but angular or sharp corner in the recess
Rm. The inflexion surface Im2 further comprises another planar surface 170 which extends
perpendicular to the major surfaces 14 and 16. This surface then joins bevelled surface
56 leading to the major surface 16.
[0199] The female joint Jf has first female locking surface FL1 comprising abutment surface
26 which extends perpendicular to major surface 14 and contiguous inflexion surface
If 1. Inflexion surface If 1 is composed of planar surfacel 72 which slopes toward
the recess Rf, planar surface 174 which is parallel to surface 26 and a smoothly curved
concave surface 176 which leads to the surface 58 at the root of recess Rf. The surfaces
172, 174 and upper portion of surface 176 together form a transversely extending surface
in the form of a generally convex cam Cf1. Surface 58 at the root 34 of recess Rf
is planar and parallel to the major surface 14. Thereafter, the female joint Jf comprises
an intermediate surface If3 which may be considered to be in inverted form of the
inflexion surface Im3. To this end the inflexion surface If 3 comprises a planar surface
180 which is inclined in a direction toward major surface 14, and a contiguous smoothly
curved surface Cf3. The surface Cf3 joins with a planar surface 60 parallel to the
major surface 14. The outermost side of the female joint Jf in system 10f is formed
with a second female locking surface FL2 having smoothly curved surface Cf2 which
leads to a planar surface 62 and subsequently to inwardly bevelled surface 64 leading
to the major surface 16.
[0200] The joints Jm and Jf are engaged by application of a force or pressure in a direction
perpendicular to the major surfaces 14 and 16. As is evident from Figure 16d, that
joint system 10f results in the provision of three locking planes 18, 20 and 74 as
a result of the relative juxtaposition of the surfaces Cf1 and Cm1 ; Cm1 and Cm2;
and Cm3 and Cf3.
[0201] Further, in the engaged joint, the surfaces Cm1 and Cm3 reside in the angular corners
of the recess f while smoothly curved surfaces Cf2 and Cf3 reside in the angular corners
formed in the recess Rm. In this embodiment it will be noted that there remains on
each of the inner and outermost locking planes, an arcuate or smoothly curved surfaces
C. Specifically, on locking plane 18, the smoothly curved surface Cm 1 is able to
roll against the surface of the joint Jf while on the locking plane 20, the arcuate
surface Cf2 is able to roll on the surface of the male joint Jm. Also due to the non-symmetrical
configuration of the joints Jm and Jf voids or spaces are created between the engaged
surface to further assist in the relative rotation between joints and allow for expansion.
[0202] Figures 17a and 17b depict a further joint system 10h which is based on and very
similar to the joint system 10f. In particular, the system 10h is of the same general
shape and configuration of the system 10g with the substantive differences being the
omission of the slot 163 and a reduced length in the bevelled surfaces 56 and 64.
This reduced length is a function of the thickness of the substrate 12h which is less
than that of the substrate 12g. In a non-limiting example, the substrate 12g incorporating
the joint system 10g may have a thickness in the order of 5.2mm, while the substrate
12h incorporating the joint system 10h may have a thickness in the order of 3.5mm.
[0203] In all other respects, the joint system 10h is the same in configuration and function
as the joint system 10g.
[0204] Figures 17c to 17e illustrate a further feature of embodiments of the joint system
relating to the ability to manufacture the system and panels of varying thickness
using a single set of tools. Figure 17a and 17b illustrate the joint system 10h formed
in panels 12 of a nominal thickness of say 3mm. In Figure 17c and 17d the nominal
thickness of 3mm is marked as the innermost horizontal lines 14a and 16a. These lines
indicate the major surfaces 14 and 16 of a panel 12. The next adjacent pair of lines
14b and 16b illustrates the major surfaces of the panel 12 if it were made to a thickness
of 3.5mm. Continuing in an outward direction line pairs 14c and 16c; 14d and 16d;
14e and 16e; and 14f and 16f; illustrate the major surfaces 14 and 16 for panels 12
made to thicknesses of 4mm, 5mm, 6mm and 7mm respectively. Figure 17e provides perspective
for panels 12 made to these different thicknesses. As explained in greater detail
hereinafter the ability to manufacture joint systems on panels of varying thickness
with a single set of cutting tools provides benefits over the prior art. A further
feature of this is that notwithstanding the variation in thickness of the panels 12
it will be seen that the physical size of the joints Jm and Jf and the interlocking
surfaces remains constant. Thus the strength of the engagement between panels is not
compromised by a variation in the thickness of the panels.
[0205] Figures 18a and 18b depict a further embodiment of the joint system 10i. The joint
system 10i may be viewed as a hybrid combining various features of earlier described
joint systems. Both the male and female joints Jf and Jm comprise ball or bulbous
like protrusions P, and recesses R having smoothly or continuously curved surfaces.
The respective surfaces C of the male and female joints Jf and Jm are arranged to
provide three locking planes 18, 20 and 74 when mutually engaged as depicted in Figure
18b. The male and female joints comprise complimentary planar stepped surfaces 148
and 154 which lie parallel to the major surface 14 similar to the joint system 10e.
Indeed the joint system 10i may be viewed as a modification of the joint system 10e
but with the following differences: broadening of the respective protrusions P and
recesses R; a marginal inclining of the surfaces 24 and 26 from the perpendicular
of major surface 14; a flattening of a portion of the inflexion surface If 1 between
an upper end of surface Cf1 and surface 154; and extension of the bevelled surface
56 so as to extend directly from the Cm2 to the major surface 16. It will be further
noted from a comparison between Figures 18b and 14b that a space 82 now exists between
the planar surfaces 40 and 52, and there is a space between the surfaces 154 and 148
in the engaged joints Jm and Jf. The joint system 10i operates in the same way as
the previously described joint systems in terms of engagement and disengagement and
the rolling action between the joints.
[0206] Figures 19a and 19b depict a further embodiment of the joint system 10j. The protrusions
Pm and Pf are each provided with respective slots 163 and 152 similar to that of the
joint system 10e. In the joint system 10j the surfaces Cm1 , Cm2, Cm3, Cf 1 and Cf3
are each smoothly curved. However the surface Cf2 on the female joint Jf is angular,
being composed of a plurality of contiguous planar surfaces. Nevertheless, as shown
in Figure 19b, when the joints Jm and Jf are engaged the locking surfaces ML1 and
FL1 ; ML2 and FL2; and ML3 and FL3 create three locking planes 18, 20 and 74 as herein
before described. In each of the outermost locking planes 18 and 20, one of the two
respective engaged surfaces is continuously curved. Specifically in locking planes
18 and 20 surfaces Cm 1 and Cm2 are continuously curved. This maintains the ability
of the joints to roll provided the positive and negative relative rotation and the
ability to disengage and thus move and replace a damaged substrate in an identical
manner as described in relation to the earlier embodiments. The joint system 10j further
includes surfaces 146 and 154 similar to the subsystem 10e but in this instance these
surfaces are inclined at an acute internal angle relative to the major surface 14.
Further the projection Pm and recess Rf are relatively configured to form a relatively
large void or space 190 between surfaces 40 and 58. The slots 152, 163 provide an
internal suspension system enabling compression of the protrusions Pm and Pf to assist
in the rolling motion.
[0207] Figures 20a and 20b depict a further embodiment of the joint system 10k. The protrusion
Pm is formed with continuously curved surfaces Cm1 , Cm2 and Cm3. On the female side
the protrusion Pf is formed with angular surfaces Cf2 and Cf3, surface Cf 1 comprises
contiguous planar surfaces 191 , 192 and 193. Surface Cf3 comprises contiguous planar
surfaces 194, 195 and 196. The surfaces 191 and 194 each lead to the surface 60 of
protrusion Pf which lies parallel with major surface 14. Both surfaces 192 and 195
extend perpendicular to the major surface 14 while surfaces 193 and 196 are inclined
toward each other surface 193 leads to an oppositely inclined surface 162 which in
turn leads to bevelled surface 64 which is cut inwardly but substantially parallel
to surface 193. The surface 64 leads to the major surface 16. The route 34 of the
recess Rf is formed with planar surface 46 which lies parallel to major surface 14,
and to oppositely and outwardly inclined surfaces 197 and 198. Surface 198 leads to
an inwardly inclined surface 199 which in turn is formed contiguously with planar
surface 200. Surface 200 lies perpendicular to the major surface 14 and joins with
surface 154. The combination of surfaces 196 and 197; and surfaces 198 and 199 form
respective concave recesses for seating the surfaces Cm1 and Cm3 as shown clearly
in Figure 20b.
[0208] Looking at the male joint Jm, it will be seen that opposite ends of the surface 52
in the recess Rm lead to contiguous outwardly inclined surfaces 201 and 202. Surface
201 then leads to a planar surface 203 which leads to the surface Cm2. On the opposite
side the surface 202 is formed contiguously with a further planar surface 204 which
then leads to the surface Cm3. Surfaces 203 and 204 lie perpendicular to the major
surface 14. In combination the surfaces 201 , 203 and part of the surfaces Cm2 form
a concave recess for the surface Cf2. Similarly, the combination of the surfaces 202,
204 and part of the surface Cm3 forms a further concave recess for seating the surface
Cf3.
[0209] The protrusion Pm is also formed with a planar surface 205 that lies perpendicular
to the major surface 14 and extends between the surface Cm1 and the surface 148. When
the joints Jm and Jf are engaged, the surfaces 205 and 204 are spaced apart while
the respective surfaces 148 and 154; and 26 and 24 are in abutment.
[0210] Figures 21 a and 21 b depict a further embodiment of the joint system 101. The protrusion
Pm has a male locking surface ML1 which, starting from the major surface 14 is initially
provided with a small bevelled surface 146 similar to that shown in the joints 10e
and 10i and extends downwardly ending in a smoothly curved surface Cm 1 . The first
male locking surface ML1 also comprises an inflexion surface Im1 which includes a
planar portion 220 and extends from the bevelled surface 146 toward the surface Cm1.
[0211] Protrusion Pm also includes a slot 158 similar to that of the joint system 10e. The
protrusion Pm is formed with a curved distal surface 40 and is of a generally symmetrical
configuration about a centreline passing through the slot 158. To this end the line
of shortest distance 50 across the neck 48 of the protrusion Pm lies on a plane parallel
to the major surface 14. The slot 158 in the protrusion Pm is outwardly flared near
the surface 40 so as to create in effect two prongs or a bifurcation with generally
rounded or curved extremities 221.
[0212] The third inflexion surface Im3 and corresponding third male locking plane ML3 on
a side of protrusion Pm opposite the inflexion surface IM1 is smoothly curved and
leads to a planar surface 52 in the root 32 of recess m. The surface 52 lies parallel
to the major surface 14. On an opposite side of the recess Rm the joint Jm is formed
with a second male locking surface ML2 which comprises a smoothly curved inflexion
surface IM2 which subsequently leads to bevelled surface 56.
[0213] The first female locking surface FL1 in the joint Jf comprises a short bevelled surface
155 commencing from the major surface 14 followed by a planar surface portion 222
which extends perpendicular to the major surface 14. Surface 222 leads to inflexion
surface If 1 which is smoothly curved and extends toward a root 34 of recess Rf. The
root 34 is provided with a planar surface 46 that extends parallel to the major surface
14. The surface 46 in turn leads to third inflexion surface If3 which is smoothly
curved and corresponds with the third female locking surface FL3. Distal surface 60
of female protrusion Pf extends between the second and third female locking surfaces
FL2 and FL3 and lies in a plane parallel to major surface 14. The second female locking
surface FL2 extends continuously toward the major surface 16 beyond the inflection
surface IF2 in a smoothly curved manner and subsequently leads to bevelled surface
64.
[0214] It will be seen from Figure 21 b that each of the respective male and female locking
surfaces and the corresponding inflexion surfaces engage about respective locking
planes 18 , 20 and 74.
[0215] In a further variation of the joint system 101 embodiment a bead B (shown in phantom
line) of adhesive of the type described in detail shortly can be accommodated in the
mouth of the slot 158. This provides additional vertical locking between engaged panels
as well as cushioning.
[0216] Figure 22 depicts a further embodiment of the joint system 10m with joints Jf and
Jm depicted on separate but engaged panels 12a and 12b. The joint system 10m is similar
to the joint system 10 depicted in Figures 1 a - 2 with the main differences residing
in the configuration of the surfaces Cm3 and If3 on the male protrusion Pf. In the
joint system 10m the surface Cf3 extends further in the transverse outward direction
so as to hook under the surface Cf3 when the joints Jm and Jf are engaged. This provides
greater resistance to vertical separation along the intermediate plane 74 in comparison
to that of the joint system 10. Further, the surface Cf3 is provided with small ridge
or peak 38' similar in configuration and effect to the peak 38 on the surface Cm1
. Due to the configuration of the surface Cf3 there is an increased grab or pinching
of the protrusion Pf between the surfaces Cm3 and Cm2 during the rotation of the joint
Jm in a negative sense relative to the joint Jf. The joint Jm is particularly well,
but not exclusively, suited for use with panels or substrates made of softer material.
[0217] Figure 23a and 23b depict a further embodiment of the joint system 10n. The joint
system 10m differs from the joint system 10 depicted in Figures 1 - 3b by the provision
of additional of three concave recesses, namely concave recesses 42b, which is formed
in the root of the recess f; concave recess 42c which is formed in the root of the
recess Rm; and concave recess 42d formed in the protrusion Pf. The recess 42d is located
so that when joints Jm and Jf are engaged the recesses 42 and 42b face each other
to form a substantially cylindrical or elliptical void 230. Similarly, the concave
recesses 42c and 42d are located to face each other when the joints Jm and Jf are
engaged to form a further substantially cylindrical void 232. The void 230 may be
used as a dam or void to collect dirt and other debris generated during the laying
of substrates 12 provided with the joint system Jm.
[0218] Alternately, one of the recesses 42 and 42b may be provided with a pre-laid re- stickable
flexible adhesive and configured to extend into the other of the recess 42 and 42b.
The expression "re-stickable adhesive" throughout the specification and claims is
intended to mean adhesive which is capable of being able to be removed and re-adhered,
does not set or cure to a solid rigid mass and maintains long term (e.g. many years)
characteristics of flexibility, elasticity and stickiness. The characteristic of being
re-stickable is intended to mean that the adhesive when applied to a second surface
can be subsequently removed by application of a pulling or shearing force and can
subsequently be reapplied (for example up to ten times) without substantive reduction
in the strength of the subsequent adhesive bond. Thus the adhesive provides a removable
or non-permanent fixing. The characteristics of flexibility and elasticity require
that the adhesive does not solidify, harden or cure but rather maintains a degree
of flexibility, resilience and elasticity. Such adhesives are generally known as fugitive
or "booger" glues and pressure sensitive hot melt glues. Examples of commercially
available adhesives which may be incorporated in embodiments of the present invention
includes, but are not limited to: SCOTCH-WELD
™ Low Melt Gummy Glue; and GLUE DOTS
™ from Glue Dots International of Wisconsin.
[0219] It is noted that manufacturers of re-stickable glue/adhesive may advise that the
adhesive is not suitable for particular materials for example wood. However when the
joint system is incorporated in wooden or wood based panels this is does not preclude
the use of such adhesives. This is because wooden or wood based panels are usually,
and if not can be, coated with a polymer sealant or other coating. Thus provided the
adhesive is recommended for use with polymer surfaces can be used on polymer coated
wooded or wood based panels. Alternately, both recesses 42 and 42b may be provided
with the re-stickable adhesive so as to engage each other when the joints Jm and Jf
are engaged.
[0220] In a similar manner, one or both of the concave recesses 42c and 42d may be provided
with a bead of re-stickable adhesive of the type described hereinafter. When only
one of the two recesses 42c and 42d is provided with the adhesive the adhesive is
configured in a bead so as to extend into the other of the recesses 42c and 42d. However
when both are provided with adhesive, the adhesive material while still in the form
of a bead may be formed of a smaller thickness or depth.
[0221] Provision of the adhesive material has multiple effects. Firstly, it acts to assist
in minimising the possibility of vertical or horizontal separation during the normal
service life of the substrates 12. In addition the adhesive may act as a seal against
moisture passing either from the major surfaces 14 through a joint to the major surface
16, or in a reverse direction in the event of moisture seeping up through a surface
in which the substrates 12 are laid. The provision of the re-stickable adhesive however
does not interfere with the ability to remove and replace one or more damaged substrates
12 due to the unique removal system described herein above. As the adhesive is re-stickable
and in particular does not set or cure, the removal system remains effective for the
removal of one or more panels 12 without damage to the joint of adjoining adjacent
panels 12 which are not removed.
[0222] One further feature of the joint system 10n is that the locking surfaces ML3 and
FL3 are each provided with planar surfaces 210 and 212 which lie parallel to the locking
plane 74. There surfaces are pressed together when the joints Jm and Jf are engaged.
Provided no wax is placed on these surfaces they will in effect provide a frictional
intermediate locking plane 74. Such frictional intermediate locking planes can be
incorporated in other of the above described
[0223] In one embodiment as shown in Figures 23c-23i adhesive is applied to both of the
recesses in the male joint Jm only and not in the female joint Jf. In such an embodiment,
due to the nature of the re-stickable adhesive, when a substrate 12 is removed from
adjacent adjoining substrates, the adhesive remains in the recesses 42 and 42c of
the removed substrates. Moreover, the nature of the adhesive is such that it remains
in the recess in which it is originally provided. This is depicted in Figures 23c-23i
which progressively show the disengagement of joints Jm and Jf of the joint system
10n
[0224] Figure 23c shown joints Jm and Jf prior to engagement. Recesses 42 and 42c are each
provided with respective beads B1 and B2 of re-stickable adhesive 300 covered with
release strips R1 and R2. There is no adhesive in the recesses 42b and 42d. Figure
23d shows the joints Jm and Jf fully engaged with the release strips R1 and R2 removed
so that the re-stickable adhesive 300 in beads B1 and B2 adhere to the surface of
the recesses 42b and 42d.
[0225] Figures 23e -23i show the typical disengagement process of joints Jm and Jf in embodiments
of any joints system with initially the joint Jm being rotated in a negative (clockwise)
direction relative to joint Jf to release protrusion Pm from recess Rf, and the subsequent
application of downward pressure on the female joint Jf. The re-stickable adhesive
is able to flex and move during the separation process to allow the rotation and subsequently
is pulled from the recesses 42b and 42d to remain in recesses 42 and 42c.
[0226] The adhesive beads B bonded to a joint J may also act to absorb debris that lies
in a recess into which the bead B is to be adhered. For example a bead B bonded in
recess 42 can absorb debris in the recess 42b into which the bead B is adhered. The
debris will initially adhere to the outside surface of the bead B. As the panels 12
move in normal use there will also be some movement and rolling of the bead B. It
is believed that this will have the effect of drawing the debris into the adhesive
so that the adhesive envelops the debris and provides a fresh adhesive surface to
stick to the recess 42b.
[0227] One or more adhesive beads can be provided in each of the previously described embodiments
to provide added vertical and horizontal locking strength while still allowing the
full operation and benefits of the embodiments. This may be achieved for example by
the provision of one or more recesses 42 in one of the joints Jm or Jf to seat a bead
of the re- stickable adhesive. Depending on the thickness of the bead a receiving
recess may or may not be required on the other joints Jm and Jf. The provision of
the re-stickable adhesive can be seen as providing an additional locking plane to
the joint system.
[0228] Typically, as in the above example, the adhesive is laid in only one of two mutually
facing recesses 42. The bond when the adhesive is initially placed in that recess
is stronger than the bond when that adhesive contacts a surface of the opposed recess
in another substrate. Thus when a substrate is removed, the adhesive originally applied
to that substrate remains with that substrate.
[0229] In all of the above described the embodiments of the joint system 10, it will be
noted that the protrusions Pm and Pf are not of the same configuration, i.e. cannot
be transposed over each other. Similarly the recesses Rm and Rf are not of the same
configuration, i.e. cannot be transposed over each other. More particularly the respective
engaging protrusions and recesses are not of a complementary configuration. Thus the
protrusions Pm and Pf; the recesses Rm and Rf ; and joints Jm and Jf are asymmetrical.
As a consequence when a protrusion P is engaged in a recess R gaps or spaces are created
between the male and female locking surfaces ML1 , FL1 and ML2, FL2 at the inner and
outer locking planes 18 and 20. This assists in providing the ability of embodiments
of the joint system to roll or rotate in opposite directions by up to 3°by providing
space into which the protrusion can roll without disengaging. In turn this aids in
the ability of the joint system to be used easily and with success on undulating floors.
This will be recognised by those in the art as filling a need particularly in the
do it yourself market for flooring system which hitherto has endured systems that
require high quality underlying surfaces for successful installation.
[0230] As a result of the specific configuration of the joint systems in accordance with
embodiments of the present invention, and in particular as they are true vertical
systems it is possible for manufacturers to manufacture panels with a wide range of
thickness with a single set of cutting tools. For example for manufactured or natural
wood substrates a single set of cutting tool can produce joint systems on panel ranging
from 20mm to 8mm with the only adjustment required being a simple one of cutting depth.
Similarly with plastics panels such LVT a single set of cutting tool can produce joint
systems on panel ranging from 7mm to 3mm as shown and previously described with reference
to Figures 17c-17e. This is of significant commercial benefit giving rise to reduced
production costs which can be passed on to the consumer.
[0231] The range in cost for set of cutting tools for cutting a joint system is typically
between US$30,000 to US$50,000. Usually a set of cutting tools used for prior art
joints can be used for two different thicknesses. For example one set is used for
joints on panels of thickness of 7mm-6mm; and a second set for thickness of 5mm-4mm.
It also takes about 3 hours to replace a set of cutting tools then several additional
hours to set up the cutting machine with the new set of tool. Subsequently several
test runs are made and products evaluated to fine tune the tool and machine setting
before full scale production can recommence. If the only adjustment required is to
change the depth of cut then there is no cost for new cutting tools and the downtime
is reduced to a total of about 1 hour. A further benefit of this is that relative
small manufactures and able to afford to produce relative small production runs of
at low coast and thus compete with larger manufactures. This may increase competition
and thus in turn benefit the consumer.
[0232] With reference to Figures 24a-26e a semi floating/semi direct stick surface covering
system may be provided by a plurality of substrates 12 incorporating any one of the
joints systems 10 as hereinbefore described and further incorporating a quantity of
the re-stickable adhesive 300 bonded to the first major surface 16. The re-stickable
adhesive 300 is used in conjunction with a sealant or sealing membrane (not shown)
which is applied to an underlying surface onto which the adhesive 300 is to be bonded.
Many sealants are commercially available which may perform this function. Such sealants
may include for example BONDCRETE
™ or, CROMMELIN
™ concrete sealer. The type of sealant used is simply dependent on the type of surface
onto which the semi-floating surface covering system is to be used. The purpose is
to prevent the generation of dust which may otherwise interfere with the bonding strength
of the blue adhesive 300. Others have in the past used glues to adhere substrates
to floors. In particular adhesives have been used to glue wooden floor boards to an
underlying surface. However to the best of the inventor's knowledge, all such systems
use glues which are specifically designed to set or cure to a solid unyielding bonded
layer. In the art of timber or wooden flooring, this is known as "direct stick" flooring.
Some have proposed to utilize adhesives which take up to an hour or two to set or
cure to enable installers to move the flooring panels during installation to ensure
correct alignment. Indeed others propose using adhesives which may take up to 28 days
to fully cure or harden.
[0233] Some consumers prefer direct stick flooring to floating flooring as it provides a
harder more solid feel and significantly does not provide bounce when being walked
on and does not generate noise such as creaking or squeaking. A disadvantage however
of the direct stick flooring is that it is very messy to apply, and once the adhesive
has cured, which it is specifically designed to do, removal and/or repair of one or
more damaged panels is problematic. The removal of a direct stick panel generally
requires the use of power tools to initially cut through a section of the panel, and
then much hard labour in scraping the remainder of the plank and adhesive from the
underlying subsurface. This generates substantial dust and noise and of course usually
comes at substantial expense due to the associated time required.
[0234] Use of the re-stickable adhesive as described hereinabove with substrates 12 incorporating
the joint system 10 provides a semi-floating surface covering system having the benefits
of both traditional floating surface coverings and direct stick coverings but without
the substantial disadvantages of direct stick surface coverings. Specifically, the
use of the re-stickable adhesive 300 eliminates bounce and noise often found with
conventional floating flooring, but still provides a degree of cushioning due to the
flexible and elastic characteristics of the adhesive which does not set or cure. Further
the characteristics of the adhesive also enable movement of substrates/panels 12 due
to changes in environmental condition such as temperature and humidity. This is not
possible with direct stick flooring. Indeed recently, the world market has been having
problems with direct sticking of compressed bamboo substrates due to the completely
rigid and inflexible bond created by the traditional adhesives. Accordingly, should
the compressed bamboo need to move or expand due to variations in environmental conditions
it is restricted from doing so by the direct stick adhesive. Consequently it has been
suggested by multiple flooring associations around the world that compressed bamboo
should not be direct stuck to substrates but limited to application in floating floor
systems which enable it to move in response to dynamic seasonal changes.
[0235] The provision of the re-stickable adhesive also enables for the take up of undulations
or variations in the underlying surface to which it is applied. This is facilitated
by providing the adhesive 300 in beads or strips of a thickness measured perpendicular
to the major surfaces 14, 16 of between 1 - 6mm and more particularly 2 - 4mm. In
addition to taking up variations in the underlying surface, the adhesive as mentioned
above also provides acoustic benefits in: (a) eliminating noise and squeak which may
otherwise arise from the bounce or deflection in traditional floating floors; (b)
dampening vibrations (i.e. noise) transmission between adjacent panels; and (c) dampening
vibrations (i.e. noise) transmission in multi-storey buildings from an upper level
to an immediately adjacent lower level. This again is to be contrast with direct stick
glues which due to their curing into a rigid bond, do not in any way dampen vibration
or noise transmission.
[0236] The benefits and advantages of the use of re-stickable adhesive as herein before
described in their own right give rise to a floor covering systems comprising substrates
which may be tessellated and on which the adhesive is applied. Such systems do not
necessarily require vertical joints systems of the type described hereinabove and
may also be used with other types of joints systems. Indeed in certain circumstances,
it is believed that the re- stickable adhesive concept gives rise to a surface covering
system with joint-less substrates. Thus in one embodiment there would be provided
a semi-floating surface covering system which comprises a plurality of substrates
each substrate having first and second opposite major surfaces, the first major surface
arranged to lie parallel to and face a surface to be covered; a quantity of re-stickable
adhesive as herein before described bonded to the first major surface; and one or
more release strips covering the removal adhesive.
[0237] It is envisaged in one embodiment that the adhesive 300 will be applied at the time
of manufacture of the substrate 12. Thus in this embodiment a commercial product would
comprise for example boxes of substrates 12 provided with one or more lines of adhesive
material 300 covered with release strips 302. Installers are then able to simply install
a surface covering by applying, if it does not already exist, a sealing coat or membrane
to the surface 304, removing the release strip 302 and pressing the substrate 12 onto
an underlying surface 304. In the event that the substrate also includes a joint system
such as, but not limited to, the joint systems 10 et al as described herein above,
then the installer would engage joints of adjacent panels during the installation
process.
[0238] In one example it is envisaged that the adhesive material 302 may be applied by rolling
a strip or bead of hot melt pressure sensitive adhesive onto the major surface 16.
Figures 24a-24c illustrate the adhesive 300 applied as strips of adhesive, while Figures
25a and 25b illustrate the adhesive 300 applied as beads B of adhesive. In embodiments
where the re-stickable adhesive is provided by say GLUE DOTS
™ adhesive dots, the dots can be applied by machine16.
[0239] In the present embodiments the quantity of re-stickable adhesive 300 is applied in
three spaced apart lines extending in a longitudinal direction L of a panel 12. However
as will be explained in greater detail below, the adhesive material 300 may be applied
in different configurations. The re-stickable adhesive material 300 is covered by
one or more release strips 302. In the depicted embodiment a separate release strip
302 is applied individually to each individual line of adhesive material 300. However
in an alternate embodiment, a single release strip having dimensions substantially
the same as dimensions of the major surface 16 may be applied to the quantity of re-stickable
adhesive 300. In that instance, when using the substrate 12, an installer need peel
off only one release strip 302 rather than a number of separate release strips.
[0240] Figures 24c and 25b depict the use of the adhesive based surface covering systems
on an underlying surface 304 which may, for example, be a concrete pad. In order to
apply the panel 12 the release strips 302 are removed and the panel 12 is applied
with surface 16 directed toward or facing the surface 304. By contacting the adhesive
material 300 to the surface 304 and applying downward pressure, the panel 12 is adhered
to the surface 304. Additional panel 12 can be likewise adhered to a surface 304 and
tessellated to form a surface covering. The adhesive material 300 is sufficiently
tacky and strong to adhere to the surface 304 with sufficient force to prevent lifting
or separation between the panel 12 and surface 304 under normal use conditions. It
is believed that providing the adhesive in the form of beads B (Figures 25a and 25b)
may provide greater horizontal movement which typically occurs with changes in environmental
conditions (e.g.temperature and humidity). This stems from the rounded nature of the
beads B which may facilitate an easier rolling or shear rolling effect than the strips
of adhesive.
[0241] Removal of a damaged panel (either with no joint system or with joint system of a
type described herein above, i.e. a vertical joint system) can be performed in the
same manner as described herein above in relation to Figures 6a-6s. That is, a damaged
panel is removed vertically by use of one or more jacks 92. Figures 26a - 26e depict
in part the removal of a damaged panel 12b of a semi-floating surface covering system
which includes adjoined panels 12a and 12c. Each of the panels in the semi-floating
floor system is formed with a joint system 10 which may be in accordance with any
one of the embodiments of the joint system described above. In addition beads B of
adhesive material 300 adhere the panels 12 to the underlying surface 90. In this particular
embodiment there are no beads of adhesive material in between the joints Jm and Jf
of the joint system 10. However in alternate embodiments such adhesive material may
be provided. In terms of the process for removal of the panel 12b the provision of
additional adhesive between the joints Jm and Jf is of no consequence. That is, the
removal process remains the same as irrespective of whether or not adhesive material
exists between the joints Jm and Jf.
[0242] Figures 26b - 26e show sequentially the steps of attaching a jack 92 to the damaged
board 12b and subsequently operating the jack to lift the panel 12b from the surface
90. The sequence of steps and the method of their performance are identical to that
described herein above in relation to Figures 6d - 6h. However in this instance due
to the provision of the beads B of adhesive 300 the operation of the jack 92 to vertically
lift the panel 12b also has the effect of initially flexing and stretching the beads
B and subsequently causing the beads B to detach and lift from the underlying surface
90. This will occur generally in sequence as a jack is operated to lift the panel
12b from a region in the vicinity of the jack 92 outwardly to lower lying regions.
Thus the first beads B to detach form surface 90 will be those on either side of or
otherwise closest to the shaft 96 of the jack 92. As the jack 92 progressively lifts
the panel 12b the beads B of adhesive 300 nearest the most recently detached beads
will now lift off the surface 90 and so on.
[0243] Generally, the entirety of the bead B will lift from the surface 90 and thus remain
bonded to the substrate 12. In some instances, very small portions of the adhesive
300 may remain on the underlying surface 90. Once the jack 92 has been operated to
the extent to lift the panel 12b so that all of the adhesive beads B have been detached,
the remainder of the normal removal process as described in relation to Figures 6g
- 6i; and indeed the entirety of the replacement processes shown and described in
relation to Figures 6j - 6o is be employed to reinsert a fresh undamaged panel.
[0244] It will be noted that some of the beads B of adhesive 300 have separated from the
adjacent panels 12a and 12c. During the reinstatement process, these beads which remain
on the panels 12a and 12c will re-adhere to the underlying surface 90. In addition,
of course when a fresh panel is joined to the panels 12a and 12c, the adhesive 300
on that fresh panel will now also adhesively bond to the surface 90.
[0245] As will be understood by those skilled in the art, this represents a huge advantage
over direct stick flooring systems in terms of the ability to properly repair a damaged
floor. The accepted industry standard for optimal repair of a damaged floor is to
peel back all of the panels from the closest wall to the damaged panel or panels.
With direct stick systems, this is such a difficult task, that generally repairers
take shortcuts and simply attempt to remove and replace only the damaged panels. This
makes it impossible to reconnect mechanical joints between panels. In the event of
any dimensional variation in the panels either due to environmental expansion or contraction,
or simply due to the inability to source dimensionally equivalent fresh panels, installation
will generally also require the use of fillers to make good any gap between the existing
panels and the newly instated panel.
[0246] A further feature of substrates incorporating having embodiments of the joint system
10 is the ability to reverse lay. Reverse laying has two meanings in the art. One
meaning refers to the ability to lay form both sided of a panel. For example consider
a first panel approximately midway between parallel walls in a room. The ability to
reverse lay enables two installers (or two teams of installers) to lie in opposite
directions away from the first panel. This naturally greatly reduces the installation
time. This is used with direct stick panels and has the benefit of enabling run out
to be amortised between opposing walls of a room to provide a superior visual appeal.
Reverse laying with direct stick is possible because a layer can fix with glue a first
panel in an optimum position in or near the middle of the room to minimise run out
near the walls. Additional panels can be stuck down form opposite side of the first
panel. This cannot be done with floating floors because a first panel placed in an
optimum position is not fixed, it floats, and thus cannot be used as a base to lay
in opposite directions.
[0247] The other meaning of reverse lay refers to the ability to engage panels 12 which
extend perpendicular (or some orientation other than parallel) to each other. This
enables for example the ability to lay in say a herring bone pattern.
[0248] Current prior art, even with direct stick, makes it reasonably difficult to reverse
lay flooring because traditionally one must lay from the female joint away. This is
because in the prior art lay down process the male joint is traditionally 50+% shorter
than the female joint thus creating a less extreme angle needed or not needed to engage
the male portion into the female portion into a locked horizontal plane. As the present
joint system 10 is vertical, there is no lay down process. Rather the vertical nature
of the joint system 10 makes it exceptionally easy to engage panels from either side,
either placing a male joint on an exposed female joint, in order to lay in one direction,
or sliding the female joint under a male joint of a previously laid panel in order
to lay in the reverse direction.
[0249] Figures 27a and 27b illustrate the above aspects or meaning of reverse laying pictorially.
Figure 27a shows a floor plan 400 of a building in which a floor comprising a plurality
of panels 12 is laid. Figure 27b illustrates in enlarged view detail A of Figure 27a
encompassing a portion of a passageway of the building. Consider the laying a traditional
floating floor in the building. The layer would choose a wall for example wall 402
in a room 403 as a starting wall against which a first panel 12a is laid. It is well
known that walls in buildings are never perfectly parallel or square to each other
and may be out of alignment by up to 100mm or more. In the current floor plan, wall
404 runs generally but not exactly parallel to a wall 402 and may be out of alignment
by a length of say 100mm between opposite ends of the walls 402 and 404. Thus as the
layer lays additional panels 12b, 12c, etc up to panel 12p the misalignment or divergence
between the walls 404 and 402 becomes apparent as the edge of panel 12p does not abut
the wall 404. Rather, there is a divergence between the edge of panel 12p and wall
404 requiring the provision of obliquely cut panels 12q laid end to end to make up
the gap between the panels 12p and wall 404. (It should be explained that it would
be unusual for a single panel to be of a length sufficient to extend for the full
length of the room 403. Thus reference to panels 12a, 12b etc is made solely for the
purposes of ease of description. Ordinarily for example panels 12a, 12b etc shown
in room 403 would comprise a plurality of panels joined end to end.)
[0250] The substantial misalignment between the walls 402 and 404 is highlighted by the
obliquely cut panel 12q. It will be also seen in Figure 27a that there are openings
406 and 408 for example as doorways in wall 404 into room 410 and hallway 412. The
panels laid in room 410 and 412 follow the same direction and alignment with the panels
12 in the room 403. This then continues on the degree of misalignment between the
panels and the walls of the house.
[0251] It will also be seen however that in other areas for example rooms 414, 416, and
hallway 418 the panels 12 are laid generally perpendicular to the panels laid in the
other rooms. This is provided as an illustration of the second form or type of reverse
laying.
[0252] With the use of the semi-floating semi-direct stick floor system as described above
in relation to Figures 24a - 25b, a layer can now utilise a centre line 420 of say
room 401 as a starting point for the laying of the first panel and then reverse lay
in opposite directions. By doing so the misalignment between the walls 402 and 404
from a visual perspective can be minimised by amortising the run out in the panels
12 immediately adjacent the walls 402 and 404. This can be seen by the center line
420 passing obliquely through the panels 12i and 12j which are shown in positions
provided by traditional laying practice for floating floors.
[0253] Now that embodiments of the vertical joint system and surface covering system have
been described in detail it will be apparent to those skilled in the art that numerous
modifications and variations can be made without departing from the basic inventive
concepts. For example embodiments are decided in relation to wooden flooring panels.
However the systems are applicable to many different materials and may also be applied
to surfaces or structures other than floors. For example panels incorporating the
joint system may be made from plastics material to treat the LVT ("luxury vinyl tile")
market or may be provided on base substrates made of plastics materials to which are
attached face panels of other material such as carpet or ceramic tiles. In this embodiment
the resultant panel has a laminate type structure where the base includes embodiments
of the joint system and the face panel is provides a consumer with the desired finish.
It will also be apparent many of the features of different embodiments are interchangeable
or can be additionally applied. For example the recess 42 can be applied to each and
every embodiment of the joint system. As can: an opposing recess of the type shown
as recess 42b in Figure 22a; or indeed additional recesses 42b, 42c and 42d. Further
the re-stickable adhesive 300 may be applied to such recesses. Also the jack 92 is
described as a screw jack. However other types of jacks or lifting system can be used
such as lever jack or pneumatic or hydraulic operated systems. Further the joint systems
10 are largely described in application to elongated rectangular panels. However they
can be applied to panels of any shape that can tessellate. For example the joint system
may be applied to square, hexagonal or triangular panels. Also there is no need for
the panels to be of identical shape and/or size.
[0254] All such modifications and variations together with others that would be obvious
to persons of ordinary skill in the art are deemed to be within the scope of the present
invention the nature of which is to be determined form the above description and the
appended claims.
ITEMS
[0255] Item 1. A vertical joint system for a substrate having an opposed major first and
second surfaces, the joint system comprising:
first and second non-symmetrical joints extending along opposite sides of the substrate,
the first and second joints configured to enable two substrates with like joint systems
to engage each other in response to a force applied in an engagement direction which
is perpendicular to the major surfaces;
the first and second joints each provided with two laterally spaced transversely extending
surfaces configured to enable the first joint of one substrate to engage the second
joint of a second substrate with the two transversely extending surfaces of the first
joint located relative to the two transversely extending surfaces of the second joint
to form respective first and second locking planes on an innermost and an outermost
side of each joint, each locking plane lying parallel to the engagement direction
and wherein the transversely extending surfaces associated with each locking plane
extend laterally toward each other from opposite sides of the locking plane with the
transversely extending surfaces of the second joint overhanging the transversely extending
surfaces of the first joint to inhibit separation if the engaged joints, wherein in
at least one of the transversely extending surfaces associated with each locking plane
has a curved profile.
[0256] Item 2. The vertical joint system according to item 1 wherein the transversely extending
surfaces are configured to enable relative rotation of two engaged substrates by up
to 3° while maintaining engagement of the two substrates.
[0257] Item 3. The vertical joint system according to item 1 or 2 wherein the transversely
extending surfaces are configured to enable relative rotation of one of the engaged
substrates relative to the other by an angle of between 7° to 10° in a direction into
a surface of which the substrates are laid while maintaining engagement of the two
substrates.
[0258] Item 4. The vertical joint system according to any one of items 1 to 3 wherein a
void is created on at least one side of each locking plane by virtue of the non-symmetrical
configuration of the first and second joints.
[0259] Item 5. The vertical joint system according to any one of items 1 to 4 wherein in
at least one of the transversely extending surfaces associated with at least one of
the locking planes has a profile of a continuous convex curve.
[0260] Item 6. The vertical joint system according to any one of items 1 to 4 wherein in
at least one of the locking planes one of the transversely extending surface has a
profile of a continuous convex curve and the other has a profile comprising one or
more straight lines.
[0261] Item 7. The vertical joint system according to any one of items 1 to 4 wherein each
of the transversely extending surfaces has a profile of a continuous convex curve.
[0262] Item 8. The vertical joint system according to item 7 wherein two or more of the
transversely extending surfaces have profiles of different continuous convex curves.
[0263] Item 9. The vertical joint system according to any one of items 1 to 8 wherein each
joint comprises a protrusion extending in the engagement direction and an adjacent
recess formed along a respective side of the substrate; and the transversely extending
surfaces are formed on an outermost surface of each protrusion and an inner most surface
of each recess.
[0264] Item 10. The vertical joint system according to item 9 wherein the protrusion of
the first joint has a bulbous profile with a neck of reduced width wherein a portion
of the transversely extending surface on the protrusion of the first joint is adjacent
an outermost side of the neck.
[0265] Item 11. The vertical joint system according to item 9 or 10 wherein the recess of
the second joint has a bulbous profile with a neck of reduced width wherein a portion
of the transversely extending surface on the recess of the second joint is adjacent
an outermost side of the neck.
[0266] Item 12. The vertical joint system according to item 10 or 1 1 wherein a plane containing
a line of shortest distance across the or each neck of is inclined relative to the
major surfaces.
[0267] Item 13. The vertical joint system according to item 1 1 or 12 wherein a plane containing
a line of shortest distance across the or each neck lies in a plane inclined relative
to the major surfaces.
[0268] Item 14. The vertical joint system according to item 13 wherein the respective lines
of shortest distance across each neck are parallel to each other.
[0269] Item 15. The joint system according to item 13 wherein the lines of shortest distance
across each neck are collinear.
[0270] Item 16. The vertical joint system according to any one of items 1 to 15 wherein
each transversely extending surface constitutes a portion of a respective inflexion
surface.
[0271] Item 17. A vertical joint system according to any one of items 1 - 16 wherein each
of the first and second joints is formed with a third transversely extending surface
located between the two transversely extending surfaces of that joint, the third transversely
extending surfaces relatively located to form a third locking plane disposed intermediate
the first and second locking planes and wherein the third transversely extending surfaces
associated with the third locking plane extend laterally toward each other from opposites
of the third locking plane with the third transversely extending surface of the second
joint in alignment with or overhanging the third transversely extending surface of
the first joint.
[0272] Item 18. The vertical joint system according to any one of items 1 to 16 wherein
the first and second joints are relatively configured to engage each other about a
third locking plane inhibiting separation of the engaged joints in a direction parallel
to the engagement direction, the third locking plane being disposed parallel to and
between the first and second locking planes.
[0273] Item 19. The vertical joint system according to item 18 wherein each of the first
and second joints comprise a third transversely extending surface wherein the third
transversely extending surfaces extend to opposite sides of the third locking plane
when in the engaged joint.
[0274] Item 20. A vertical joint system for a substrate having an opposed major first and
second surfaces, the joint system comprising:
first and second non-symmetrical joints extending along opposite sides of the substrate,
the first and second joints configured to enable two substrates with like joint systems
to engage each other in response to a force applied in an engagement direction which
is perpendicular to the major surfaces;
the first and second joints each provided with two laterally spaced inflexion surfaces
configured to enable the first joint of one substrate to engage the second joint of
a second substrate with the two inflexion surfaces of the first joint engaging the
two inflexion surfaces of the second joint on inner most and outer most sides of each
joint to form respective first and second locking planes each of which independently
inhibit separation of the engaged joints in a direction parallel to the engagement
direction each locking plane lying parallel to the engagement direction and wherein
the inflexion surfaces associated with each locking plane lie on both sides of that
locking plane.
[0275] Item 21. The vertical joint system according to item 20 wherein the inflexion surfaces
are configured to enable relative rotation of two engaged substrates by up to 3° while
maintaining engagement of the two substrates.
[0276] Item 22. The vertical joint system according to item 20 or 21 wherein the inflexion
surfaces are configured to enable relative rotation of one of the engaged substrates
relative to the other by an angle of between 7° to 10° in a direction into a surface
of which the substrates are laid while maintaining engagement of the two substrates.
[0277] Item 23. The vertical joint system according to any one of items 20 to 22 wherein
each joint comprises a third inflexion surface and the respective third inflexion
surfaces are relatively configured to engage each other to form a third locking plane
disposed between the first and second locking planes..
[0278] Item 24. The vertical joint system according to any one of items 20 to 23 wherein
a void is created on at least one side of each locking plane by virtue of the non-symmetrical
configuration of the first and second joints.
[0279] Item 25. The vertical joint system according to any one of items 20 to 24 wherein
at least one of the inflexion surfaces associated with each locking plane has a profile
of a continuous curve.
[0280] Item 26. The vertical joint system according to any one of items 20 to 24 wherein
in one inflexion surface associated with one locking plane has a profile of a continuous
curve and the other inflexion of that locking plane has a profile comprising one or
more straight lines.
[0281] Item 27. The vertical joint system according to any one of items 20 to 24 wherein
each of the inflexion surfaces has a profile of a continuous curve.
[0282] Item 28. The vertical joint system according to any one of items 20 to 27 wherein
each joint comprises a protrusion extending in the engagement direction and an adjacent
recess formed along a respective side of the substrate; and the inflexion surfaces
associated with the first and second locking planes are formed on an outermost surface
of each protrusion and an inner most surface of each recess.
[0283] Item 29. The vertical joint system according to item 28 wherein the protrusion of
the first joint has a bulbous profile having a neck of reduced width wherein a portion
of the inflexion surface on the protrusion of the first joint is formed along an outermost
side of the neck.
[0284] Item 30. The vertical joint system according to item 28 or 29 wherein the recess
of the second joint has a bulbous profile having a neck of reduced width wherein a
portion of the inflexion surface on the recess of the second joint is formed along
an outermost side of the neck.
[0285] Item 31. The vertical joint system according to item 29 or 30 wherein a plane containing
a line of shortest distance across the or each neck of is inclined relative to the
major surfaces.
[0286] Item 32. The vertical joint system according to item 29 or 30 wherein a plane contain
a line of shortest distance across the or each neck lies in a plane inclined relative
to the major surfaces.
[0287] Item 33. The vertical joint system according to item 32 wherein the respective lines
of shortest distance across each neck are parallel to each other.
[0288] Item 34. The joint system according to item 32 wherein the lines of shortest distance
across each neck are collinear.
[0289] Item 35. A vertical joint system for a substrate having an opposed major first and
second surfaces, the joint system comprising:
non-symmetrical male and female joints extending along opposite sides of the substrate,
the male and female joints configured to enable two substrates with like joint systems
to engage each other in response to a force applied in an engagement direction which
is perpendicular to the major surfaces; the male joint comprising a male protrusion
extending generally perpendicular from the first major surface toward the second major
surface and a male recess formed inboard of the male protrusion; the female joint
comprising a female protrusion extending generally perpendicular from the second major
surface toward the first major surface and a female recess formed inboard of the female
protrusion; the male joint having a first male locking surface formed on a side of
its male protrusion most distant from its female recess, a second male locking surface
formed on a side of its female recess most distant from its male protrusion and a
third male locking surface being a surface common to the male protrusion and male
recess; the female joint having a first female locking surface formed on a side of
its female recess most distant from its male protrusion, a second female locking surface
formed on a side of its male protrusion most distant from its female recess, and a
third female locking surface being a surface common to the female protrusion and female
recess; the locking surfaces being configured so that when a male and female joint
of two substrates are engaged, the first male and first female locking surfaces engage
to form a first locking plane, the second male and second
female locking surfaces engage to form a second locking plane, and the third male
and third female locking surfaces engage to form a third locking plane located between
the first and second locking planes each locking plane inhibiting separation of the
engaged joints in a direction parallel to the engagement direction.
[0290] Item 36. The joint system according to item 35 wherein the locking surfaces are configured
to enable relative rotation of two engaged substrates by up to 3° while maintaining
engagement of the two substrates.
[0291] Item 37. The vertical joint system according to item 35 or 36 wherein the locking
surfaces are configured to enable relative rotation of one of the engaged substrates
relative to the other by an angle of between 7° to 10° in a direction into a surface
of which the substrates are laid while maintaining engagement of the two substrates
[0292] Item 38. The vertical joint system according to any one of items 35 to 37 wherein:
at least one of the first male locking surface and the first female locking surface
is provided with a smoothly curved transversely extending portion; and at least one
of the second male locking surface and the second female locking surface is provided
with a smoothly curved transversely extending portion.
[0293] Item 39. The vertical joint system according to item 38 wherein in the other of the
first male locking surface and the first female locking surface is provided with a
transversely extending portion comprising at least one planar surface.
[0294] Item 40. The vertical joint system according to item 38 or 39 wherein the other of
the second male locking surface and the second female locking surface is provided
with a transversely extending portion comprising at least one planar surface.
[0295] Item 41. The vertical joint system according to any one of items 35 to 37 wherein
each of first and second male and female locking surfaces comprises a smoothly curved
transversely extending portion.
[0296] Item 42. The vertical joint system according to any one of items 35 to 41 wherein
each of the first male locking surface, first female locking surface, second male
locking surface and second female locking surface is formed with an inflexion; wherein
the inflexions engage each other about the first and second locking planes.
[0297] Item 43. The vertical joint system according to any one of items 35 to 42 wherein
at least one of the third male locking surface and the third female locking surface
is formed with an inflexion.
[0298] Item 44. A vertical joint system for a substrate having an opposed major first and
second surfaces, the joint system comprising:
first and second non-symmetrical joints extending along opposite sides of the substrate,
the first and second joints configured to enable two or more substrates with like
joint systems to engage each other in response to a force applied in an engagement
direction which is perpendicular to the major surfaces and to enable engaged substrates
to be disengaged by lifting a first substrate in a direction opposite the engagement
direction to facilitate rotation of adjacent engaged substrates along opposite sides
of the first substrate to lie in planes declined from the first substrate and subsequently
applying a force in the engagement direction to the second joints of the engaged substrates.
[0299] Item 45. The vertical joint system according to item 44 wherein the first and second
joints are further configured to enable the adjacent engaged substrates to rotate
by up to 7° to 10° downward from the first substrate without disengaging.
[0300] Item 46. The vertical joint system according to item 44 or 45 wherein the first and
second joints are configured to enable adjacent engaged substrates to rotate by up
to 3° in planes inclined relative to the first substrate.
[0301] Item 47. The vertical joint system according to any one of items 44 to 46 wherein
the first and second joints are each provided with two laterally spaced transversely
extending surface portions configured to enable the first joint of one substrate to
engage the second joint of a second substrate with the two transversely extending
surfaces of the first joint located relative to the two transversely extending surfaces
of the second joint to form respective first and second locking planes on an innermost
and an outermost side of each joint, each locking plane lying parallel to the engagement
direction and wherein the transversely extending portions associated with each locking
plane extend laterally toward each other from opposites of the locking plane with
the transversely extending portions of the second joint overhanging the transversely
extending portions of the first joint.
[0302] Item 48. The vertical joint system according to item 47 wherein at least one of the
transversely extending surfaces associated with at least one of the locking planes
has a profile of a continuous convex curve.
[0303] Item 49. The vertical joint system according to any one of items 44 to 47 wherein
the first and second joints are each provided with two laterally spaced inflexion
surfaces configured to enable the first joint of one substrate to engage the second
joint of a second substrate with the two inflexion surfaces of the first joint engaging
the two inflexion surfaces of the second joint on inner and outer most sides of each
joint to form respective first and second locking planes each of which independently
inhibit separation of the engaged joints in a direction parallel to the engagement
direction each locking plane lying parallel to the engagement direction and wherein
the inflexion surfaces associated with each locking plane lie on both sides of that
locking plane.
[0304] Item 50. The vertical joint system according to any one of items 44 to 47 wherein
the first joint is a male joint and the second joint is a female joint, the male joint
comprising a male protrusion extending generally perpendicular from the first major
surface toward the second major surface and a male recess formed inboard of the male
protrusion; the female joint comprising a female protrusion extending generally perpendicular
from the second major surface toward the first major surface and a female recess formed
inboard of the female protrusion; the male joint having a first male locking surface
formed on a side of its male protrusion most distant from its female recess, a second
male locking surface formed on a side of its female recess most distant from its male
protrusion and a third male locking surface being a surface common to the male protrusion
and male recess; the female joint having a first female locking surface formed on
a side of its female recess most distant from its male protrusion, a second female
locking surface formed on a side of its male protrusion most distant from its female
recess, and a third female locking surface being a surface common to the female protrusion
and female recess; the locking surfaces being configured so that when a male and female
joint of two substrates are engaged, the first male and first female locking surfaces
engage to form a first locking plane, the second male and second female locking surfaces
engage to form a second locking plane, and the third male and third female locking
surfaces engage to form a third locking plane located between the first and second
locking planes each locking plane inhibiting separation of the engaged joints in a
direction parallel to the engagement direction.
[0305] Item 51. The vertical joint system according to any one of items 44 to 47 wherein
the first and second joints are configured to created three locking planes when mutually
engaged, each locking plane lying parallel to the engagement direction and inhibiting
separation of engaged joints in a direction opposite the engagement direction.
[0306] Item 52. The vertical joint system according to any one of items 1 to 51 wherein
when the substrate is in the configuration of a planar rectangular or square substrate
having four sides, the first joint extends for two adjacent sides and the second joint
extends for the remaining two adjacent sides.
[0307] Item 53. A surface covering system comprising a plurality of substrates where in
each substrate is provided with a vertical joint system in accordance with any one
of items 1 -52.
[0308] Item 54. A semi-floating surface covering system comprising:
a plurality of substrates each substrate having a vertical joint system in accordance
with any one of items 1 -52;
a quantity of re-stickable adhesive bonded to the first major surface; and,
one or more release strips covering the re-stickable adhesive.
[0309] Item 55. The surface covering system according to item 54 wherein the quantity of
re-stickable adhesive is applied it two or more spaced apart lines extending in a
longitudinal direction of the substrate.
[0310] Item 56. The surface covering system according to item 55 wherein the quantity of
re-stickable adhesive is applied as a continuous strip or bead in at least one of
the spaced apart lines.
[0311] Item 57. The surface covering system according to any one of items 54 - 56 wherein
the re-stickable adhesive is applied in a plurality of lines which are evenly spaced
from each other and symmetrically disposed about a longitudinal centre line of the
substrate.
[0312] Item 58. The surface covering according to any one of items 54 - 57 wherein the re-stickable
adhesive has a thickness measured perpendicular to the first major surface of between
1 -6mm.
[0313] Item 59. The surface covering system according to item 58 wherein the re-stickable
glue has a thickness of between 2 - 4mm.
[0314] Item 60. The surface covering system according to any one of items 54 - 59 wherein
the quantity of adhesive comprises a quantity of joint adhesive bonded to the substrate
and covered with a release strip, the joint adhesive located in a position wherein
when the joint system of one substrate is coupled to the joint system of another substrate
with the cover strip removed, the joint adhesive on the one substrate adheres to the
joint of the other substrate.
[0315] Item 61. The system according to any one of items 54-60 wherein the substrate is
made from a material selected from the group consisting of; solid timber, engineered
timber, laminate, Bamboo, plastics, and vinyl.
[0316] Item 62. A method of manufacturing a semi-floating surface covering substrate comprising:
providing a surface covering system in accordance with item 53;
bonding a quantity of a re-stickable adhesive to the first major surface; and, covering
the adhesive with a release strip.
[0317] Item 63. The method according to item 62 wherein bonding the adhesive comprises applying
the adhesive in two or more spaced apart lines extending in a longitudinal direction
of the substrate.
[0318] Item 64. The method according to item 63 wherein the bonding comprises applying the
adhesive as a continuous strip or bead in at least one of the spaced apart lines onto
the first major surface.
[0319] Item 65. The method according to any one of items 62 - 64 comprising applying the
adhesive with a uniform thickness of between 1 - 6 mm measured in a direction perpendicular
to the major surfaces.
[0320] Item 66. The method according to item 65 comprising applying the adhesive with uniform
thickness of between 2 - 4 mm.
[0321] Item 67. 67. The method according to any one of items 62-66 comprising bonding a
quantity of re-stickable adhesive to at least a portion of the joint and covering
the adhesive in the joints with a release strip, the re-stickable adhesive being applied
at a location on a first substrate wherein when the vertical joint systems of the
first and a second substrate are coupled together with a release strip covering the
adhesive in the joint of the first substrate being removed, the adhesive adheres to
the joint of the second substrate.
[0322] Item 68. A surface covering system comprising a plurality of substrates, each substrate
having: opposite first and second major surfaces wherein the first major surface is
arranged to face an underlying support to be covered by the system; and a vertical
joint system, the vertical joint system comprising:
first and second non-symmetrical joints extending along opposite sides of a substrate,
the first and second joints configured to enable two or more substrates to engage
each other in response to a force applied in an engagement direction which is perpendicular
to the major surfaces and to enable engaged substrates to be disengaged by: (a) lifting
a first substrate in a direction opposite to the engagement direction to facilitate
rotation of adjacent engaged substrates along opposite sides of the first substrate
to lie in planes declined from the first substrate; and (b) subsequently applying
a force in the engagement direction to the second joints of the engaged substrates.
[0323] Item 69. The surface covering system according to item 68 comprising at least one
a jack demountably attachable to the first substrate the jack comprising a shaft arranged
to pass through a hole formed in the first substrate to bear on the underlying support,
the jack being operable to extend the shaft through the hole to thereby lift the first
substrate form the underlying support.
[0324] Item 70. The surface covering system according to item 68 or 69 wherein the vertical
joint system is in accordance with any one of items 1 -43.
[0325] Item 71. The surface covering system according to any one of items 68 to 70 comprising
a quantity of re-stickable adhesive bonded to the first major surface; and, one or
more release strips covering the re-stickable adhesive.
[0326] Item 72. The surface covering system according to any one of items 68 to 71 comprising
a quantity of re-stickable adhesive bonded to one or both of the first and second
joints and respective release strips overlying the re-stickable adhesive bonded on
the joints.
[0327] Item 73. The vertical joint system according to any one of items 1 to 51 comprising
a quantity of re-stickable adhesive bonded to one or both of the first and second
joints and respective release strips overlying the re-stickable adhesive bonded on
the joints.
[0328] Item 74. A substrate for a surface covering system, the substrate comprising a vertical
joint system according to any one of items 1 - 52.
[0329] Item 75. The substrate according to item 74 comprising a quantity of re-stickable
adhesive bonded to one or both of the first and second joints and respective release
strips overlying the re-stickable adhesive bonded on the joints.
[0330] Item 76. The substrate according to item 75 wherein each joint provided with the
bonded re-stickable adhesive is provide with a recess for seating the bonded re-stickable
adhesive.
[0331] Item 77. The substrate according to any one of items 74 to 76 comprising a quantity
of re-stickable adhesive bonded to the first major surface ; and, one or more release
strips covering the re-stickable adhesive on the first major surface.
[0332] Item 78. The vertical joint system according to any one of items 1 to 52 comprising
a layer of wax being provide on surfaces of the joint which when engaged with a like
joint engage to form the first and second locking planes.
[0333] Item 79. The vertical joint system according to any one of items 9, 28, 35 and any
one of the preceding items which depend directly or indirectly on item 9, 28 or 35,
wherein each recess of one substrate provided with the joint system is configured
to elastically open to enable a corresponding protrusion of a second substrate with
a like joint system to like to enter and engage the recess.
[0334] Item 80. A vertical joint system for a substrate having an opposed major first and
second surfaces, the joint system comprising:
first and second non-symmetrical joints extending along opposite sides of the substrate,
the first and second joints configured to enable two substrates with like joint systems
to engage each other in response to a force applied in an engagement direction which
is perpendicular to the major surfaces;
the first and second joints configured to enable relative rotation of two engaged
substrates by up to 3° while maintaining engagement of the two substrates.
[0335] Item 81. The vertical joint system according to item 80 wherein the first and second
joints each provided with two laterally spaced generally convex surfaces configured
to enable the first joint of one substrate to engage the second joint of a second
substrate with the two generally convex surfaces of the first joint located relative
to the two generally convex surfaces of the second joint to form respective first
and second locking planes on an innermost and an outermost side of each joint, each
locking plane lying parallel to the engagement direction and wherein the generally
convex surfaces associated with each locking plane extend laterally toward each other
from opposite sides of the locking plane with the generally convex surfaces of the
second joint overhanging the generally convex surfaces of the first joint to inhibit
separation if the engaged joints, wherein in at least one of the generally convex
associated with each locking plane has a curved profile.
[0336] Item 82. The vertical joint system according to item 80 or 81 wherein each joint
comprises a protrusion extending in the engagement direction and an adjacent recess
formed along a respective side of the substrate; and the transversely extending surfaces
are formed on an outermost surface of each protrusion and an inner most surface of
each recess.
[0337] Item 83. The vertical joint system according to item 82 each recess configured to
elastically open to enable a protrusion of a substrate with a like joint system to
like to enter and engage the recess.
[0338] Item 84. The vertical joint system according to any one of items 81 to 83 wherein
the first and second joints are configured to form a third locking plane intermediate
the first and second locking planes.