CN1292893C - Waterproof tongue and groove flooring - Google Patents

Abstract

The present invention provides a novel floor covering panel (10) and floor covering system wherein the floor covering panel (10) comprises first and second generally planar surfaces (11, 12), first and second lateral ends (13, 14) comprising first and second complementary engagement members (20, 22), respectively, and a barrier composition (60) selectively applied to at least a portion of at least one of the first and second engagement members (20, 22) for providing a moisture barrier to the penetration of water into the floor covering panel (10) across the first surface (11). The barrier composition (60) may be applied to at least one of the first or second joiners (20, 22) during a floor covering panel manufacturing process.

Description

Waterproof tongue and groove flooring

Background of the Invention

field of invention

The present invention relates generally to floor covering panels for use in commercial, industrial or domestic environments. More particularly, the present invention relates to a floor covering panel having complementary coupling members and having a barrier composition applied to the side edges of the floor covering panel.

Background technique

In flooring applications, the use of a variety of laminates including high pressure laminates and fiberboard core laminates is well known in the art. Fiberboard core laminates used in the manufacture of flooring products generally comprise multiple layers including a fiberboard or organic composite core layer, a decorative layer and a hard and flat resin impregnated melamine protective wear layer. These layered structures generally form standard size panels which are joined together at the installation site to form the floor covering system.

Although the uppermost layer of such flooring systems is usually fabricated from waterproof or impermeable materials, the floor covering system may be susceptible to water damage at the joints of adjacent floor covering panels that make up the floor covering system. Minor imperfections in the fit (joints) between adjacent floor boards may allow water or other fluids to penetrate into the joints between the boards, resulting in damage, distortion, accelerated wear or deterioration of the fit of the individual boards. Additionally, cleaning materials often contain surfactants that may speed up the penetration of water into joints. Because the materials making up the inner layers of the floor are not completely waterproof, these layers may absorb water or other liquids causing damage or reduced product life.

In real residential as well as commercial building environments, laminate and wood flooring materials are often in contact with liquids, consciously or unconsciously. Cleaning floors with detergent solutions can cause up to 35% swelling of the flooring material at the seams. Accidentally wet floors can also be caused by water spills, animal or children's urine. Each of these liquids has a lower surface tension than water and may enter the joint formed by the mating of two floor covering panels, causing swelling.

Manufacturers often apply paraffin-based materials to floor covering panels with the aim of enhancing the waterproofing properties of said product. However, such materials are generally not durable, and therefore do not provide good water resistance over the life of the floor covering system. Furthermore, such materials do not provide an adequate barrier when, for example, floor coverings are repeatedly used with cleaning agents, or when low surface tension substances are spilled on the floor.

Accordingly, there is a need in the industry for floor covering panels and floor covering panel systems having joints that are robust, reliable and resistant to water and other liquids. Additionally, there is a need for floor covering panels and floor covering systems that provide a durable waterproof barrier.

Contents of the invention

According to the invention, as embodied and described in this specification, the invention relates in one aspect to floor covering panels. In this aspect, the invention includes a first generally planar surface and a second generally planar surface opposite the first surface. Between the first and second surfaces are respectively a first side end and an opposite second side end. Within the first side end of the plate is a first engagement member including a protrusion extending therefrom and a first abutment surface between the protrusion and the first surface. A complementary second engagement member is defined at the second side end of the plate and includes a recess sized and shaped to receive the first protrusion, and a second joint surface between the recess and the first surface. The barrier composition can be selectively applied to at least a portion of at least one of the first and second joint surfaces.

In use, the first engagement member of the first panel is received into the second engagement member of the second panel such that the barrier composition is between the respective first and second joint surfaces of the two panels. A water-resistant barrier is thus formed between the two joints to which the barrier composition is applied. Multiple panels can be joined together in this way to form a floor covering system.

Specifically, the barrier composition may be applied to at least one of the first or second joint surfaces at some stage in the floor covering manufacturing process. In another aspect, the barrier composition can be applied over the entire surface of one or both of the first and second joint surfaces. Still further, the barrier composition provides a waterproof barrier that substantially reduces the likelihood of water or other liquids penetrating into the joint of two mating floor covering panels under normal use conditions.

Additional advantages of the present invention will be set forth in part in the following description, and in part can be learned from the description, or be learned by practice of the present invention. The advantages of the invention may be realized and obtained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed.

Description of drawings

Figure 1 is a top view of a plurality of floor covering panels joined together to form a floor covering panel system.

Figure 2 is a cross-sectional side view of an embodiment of the floor covering panel of the present invention.

Fig. 3 is a partial cross-sectional side view of the pair of floor covering panels of Fig. 2, more particularly showing the connection of the first joint to the second joint.

Fig. 4 is a schematic diagram of a testing device for testing the waterproof performance of the floor covering board of the present invention.

Detailed ways

The present invention is more particularly described in the following embodiments, which are intended to be illustrative only, since various modifications and changes may be apparent to those skilled in the art. In the specification and claims, one, one, the may represent one or more, depending on its usage. Aspects of the invention are now described with reference to the drawings, wherein like numerals represent like parts throughout.

Referring to Figures 1 and 2, in one embodiment, the present invention is a floor covering panel 10. Plate 10 includes a generally planar first surface 11 and a generally planar second surface 12 opposite first surface 11 . Extending between the surfaces 11, 12 are respectively a first side end 13 and an opposite second side end 14, each extending along the length of the floor covering panel. Defined in the first side end 13 is a first engaging member 20 including a protrusion 21 extending therefrom. The first joint 20 also includes a first joint surface 50 between the protrusion 21 and the first surface 11 . The second side end 14 includes a complementary second engagement member 22 defined therein, the second engagement member 22 including a recess 23 sized and shaped to receive a second floor covering panel protrusion 21 . The second joint 22 also includes a second joint surface 52 between the recess 23 and the first surface 11 . A barrier composition 60, described in more detail below, is selectively applied to at least a portion of at least one of the first or second joint surfaces 50, 52 as desired. Multiple floor covering panels may be joined together to form a floor covering system 15 as shown in FIG. 1 .

The present invention encompasses a variety of constructions of floor covering panels that are known in the industry or that may be developed in the future. For example, floor covering panels may be manufactured from a laminate with a fibreboard core. Additionally, the invention may be constructed from other types of laminates, such as high pressure laminates marketed under the trade names "Formica ^(R) " and "Wilson Art ^(R) ". Other materials can also be used to construct the floor, such as natural organic materials, recycled or synthetic materials. Still further, the floor covering panels may be a tongue and groove wooden flooring material such as those manufactured by Bruce Hardwood Floors, a division of Armstrong Flooring Company (Lancaster, PA). Still further, the present invention is applicable to any flooring substrate that would benefit from the formation of a non-refastenable bond as detailed herein.

Referring to FIG. 2 , a typical laminate flooring is constructed of a plurality of separate layers, which may include some or all of the following layers: base layer 16 , core layer 17 , decorative layer 18 , and wear layer 19 . The various layers may be bonded, joined or joined to each other by chemical adhesives, mechanical bonding, or other methods known in the art for forming panels. In embodiments comprising each of the above layers, as shown in FIG. ,as shown in picture 2. After the panels 10 are installed, the bottom layer 16 faces the subfloor of the lower floor (not shown).

While the base layer 16 is not required but is optional, it can provide enhanced moisture resistance to the floor 10 since the core layer 17 is generally not completely impermeable to moisture or contaminants. In addition, the bottom layer 16 can enhance the structural integrity of the floor 10 by increasing the overall thickness of the uncoated core material and reducing the tendency to warp and wear. For example, the structure of the bottom layer 16 may comprise a transparent sheet of melamine reinforced with aluminum oxide ( _AlO2 ) and impregnated with a suitable thermosetting resin. In other embodiments, the bottom layer 16 may be composed of other materials that provide suitable moisture resistance, such as phenolic resin or other natural, synthetic or recycled materials.

The next layer of a typical laminated floor covering panel is the core layer 17 . In one embodiment, the core layer 17 may be formed from medium density or high density fiberboard, such as those marketed by companies such as Louisiana Pacific, Georgia Pacific, Temple Inland and Weyerhauser. One fibreboard core material which has been found to produce acceptable results is a high density fibreboard which is a hardwood/softwood fiber composite compressed at 900-960 kg/ ^m3 . The fiberboard core material is usually 4 or 5 feet wide (1.22-1.52 meters) and can be up to 18 feet (5.49 meters) in length. In other embodiments, a core layer 17 constructed of different materials or having different properties may be used, including but not limited to other wood-based products such as plywood, particle board, or particleboard.

In one embodiment, the decorative layer 18 comprises a paper sheet substantially covering the upper surface of the core layer 17 . The decorative layer 18 can display a desired aesthetic appearance, such as color or pattern, on one side. For example, some patterns to consider include faux hardwood floors as well as faux tile, each of which comes in a variety of styles, shapes and colors. Faux hardwood styles currently under consideration include pine, American longleaf pine, cherry, maple, beech, oak, and walnut. The imitation tile look is expected in a variety of styles, including a variety of marble and tile colors, including grout lines on tile styles. Other patterns to consider include floral patterns, abstract patterns, geometric patterns, and company logos. Other patterns can be selected by the manufacturer or user according to their aesthetic preferences or design goals.

Decorative layer 18 may be formed from paper impregnated with a thermosetting resin and provided with the desired aesthetic color and/or pattern. Other materials can also form the decorative layer 18, such as solid wood veneer, stone powder or other materials. In addition, a similar decorative appearance can also be obtained by directly or indirectly printing on the upper surface of the core layer 17 . In such embodiments, the decorative layer 18 includes ink, dye, pigment or other marking substance applied to the core layer 17 . Alternatively, the decorative appearance may be provided by etching, burning or other methods of marking the upper surface of the core layer 17 . Any such treatment that provides such a decorative appearance to the upper surface of the core layer 17 is considered to constitute a decorative layer 18 as defined herein. Alternatively, the decorative appearance can be imparted directly to the upper surface of the wear layer 19 so that the decorative layer 18 is not required in the floor 10 .

The abrasion resistant layer 19 may be bonded, connected or bonded to the decorative layer 18 to protect the panel from the external environment. In one embodiment, the abrasion resistant layer 19 is substantially transparent so that the aesthetic appearance of the decorative layer 18 is not obstructed by the abrasion resistant layer 19 . Although the anti-wear layer 19 is not required but is optional, the anti-wear properties of the floor 10, preventing the aesthetic image of the decorative layer 18 from staining or fading can generally be achieved by providing an anti-wear layer on the floor covering board 10. 19 to enhance. The wear layer 19 may comprise a sheet of melamine reinforced with _AlO2 and impregnated with a thermosetting resin. Alternatively, the abrasion resistant layer may comprise a layer of varnish or other UV curable scratch resistant coating. Furthermore, the wear layer 19 may be made of any material that provides suitable resistance to moisture and resistance to the loads and wear to which the floor is subjected, such as phenolic resin or other natural, synthetic or recycled material.

As shown in Figures 1 and 3, the joints 20 and 22 of the present invention provide a means for joining adjacent two floor covering panels 10a, 10b together. An illustrative example of this method for joining adjacent plates is set forth in US Patent No. 6,006,486 to Moriau et al. (which is hereby incorporated by reference in its entirety).

In the embodiment shown in FIGS. 2 and 3 , the first end face 13 of the plate 10 comprises a first engagement member 20 . The first engagement member 20 includes a protrusion 21 having a rib 30 formed thereunder. On the second end face 14 , the second engagement piece 22 includes an upper lip 33 , a lower lip 31 and a detent 32 formed in the lower lip 31 . Recess 23 is sized and shaped to receive protrusion 21 , while groove 32 is sized and shaped to receive rib 30 . In the present embodiment, groove 32 and rib 30 represent a locking structure, which will be discussed in more detail below.

Referring to Figures 2 and 3, the joining of a floor covering panel 10a to an adjacent floor covering panel 10b is obtained by placing the first joint 20 of the panel 10a into the second joint 22 of the panel 10b. In the exemplary embodiment, the top end of the protrusion 21 of the plate 10a is inserted into the recess 23 of the plate 10b at an angle higher than the horizontal direction, and the plate 10a is then rotated clockwise until the plate 10a and plate 10b are substantially as shown in the same horizontal plane.

In the exemplary embodiment, as shown in FIG. 3 , the contact between the complementary joints 20 , 22 of the two plates 10 a , 10 b is located in four contact areas. The protrusion 21 of the plate 10a is in contact with the upper lip 33 and the lower lip 31 of the plate 10b at contact areas 40 and 41 respectively. Contact areas 40 and 41 help to position the plates in substantially the same horizontal plane. The ribs 30 ( FIG. 2 ) of the plate 10 a engage the grooves 32 of the plate 10 b in contact areas 42 . In this embodiment, the contact area 42 is substantially flat; however, any contact area may be formed into any shape according to the desired profile. The angle formed between the substantially planar contact region 42 and the substantially planar second surface 12 is an acute angle when measured from the second surface 12 in a counterclockwise direction to the plane of the contact region 42 . This configuration ensures that contact forces between adjacent plates 10a, 10b on the contact area 42 urge the plates together and create a tight connection. This locking structure defined by the rib 30 of the plate 10a and the groove 32 of the plate 10b prevents the two plates 10a and 10b from moving in a direction perpendicular to the side ends 13, 14 of the plates 10a, 10b and parallel to the respective first surface 11. substantial separation. Another contact area 43 is in the embodiment shown in Figure 3, adjacent to the first surface 11 of each plate, at the junction between the first joint surface 50 of the plate 10a and the second joint surface 52 of the plate 10b.

It should be noted that the floor covering panel 10 can be manufactured in a variety of shapes and sizes, generally including square, rectangular, and other polygonal embodiments. In the case of squares and rectangles, each plate has four sides. Thus, according to the invention, each plate 10 may comprise two first lateral ends 13 , and two opposite second lateral ends 14 , each extending between the upper and lower surfaces 11 , 12 of the plate 10 .

It should also be noted that the embodiments shown in FIGS. 2 and 3 are for illustrative purposes only, and that the invention is equally applicable to other coupling profiles known in the industry or that may be developed in the future. ). In other embodiments, the number, size and location of the contact areas can vary with the desired profile, but different profiles are still within the scope of the invention. For example, tongue and groove profiles without locking structures benefit from and fall within the scope of the present invention. As another example, a tongue and groove profile wherein substantially full contact is maintained along the entire mating side ends of the panels is also considered within the scope of the present invention.

The barrier composition 60 can optionally be pre-applied at the factory to the floor covering panels in any desired location and in any desired quantity by one of a variety of methods known to those of ordinary skill in the art. In an example embodiment, the barrier composition may be applied to the desired location by spraying. According to the present invention, barrier composition 60 may be selectively applied to at least a portion of at least one of first or second joint surfaces 50, 52, such as contact areas 40-43, as desired. Still further, barrier composition 60 may be selectively applied to at least a portion of first joint surface 50 . Still further, the barrier composition 60 can be selectively applied to at least a portion of the second joint surface 52 . In another aspect, the barrier composition 60 may be selectively applied simultaneously to at least a portion of the first and second joint surfaces 50, 52, the portions applied may be corresponding to each other or independent of each other as desired .

In the embodiment shown in FIGS. 2 and 3 , the barrier composition 60 may be selectively applied only to substantially all of the first joint surface 50 at a location corresponding to the contact area 43 . "Selectively applied" means that the barrier composition 60 is only applied to the area required for the application, and the barrier composition 60 is not applied to the adjacent area or any other area other than the selected and required area.

When the adjacent panels 10a, 10b are assembled together as shown in FIG. 3, the barrier composition 60 forms a moisture-resistant barrier between the first and second joint surfaces 50, 52, which substantially prevents water and other liquids from moving along the phase. The first surface 11 of the adjacent panels 10a, 10b is permeated through the moisture barrier. In another embodiment, the barrier composition 60 may be selectively applied only to substantially all of the second joint surface 52 at a location corresponding to the contact area 43 . In another embodiment, the barrier composition 60 may be selectively applied to substantially all of the first and second joint surfaces 50 at locations corresponding to the contact areas 43 .

In other embodiments, the barrier composition 60 may be applied to some or all of one or both of the joints 50,52. As noted above, in various embodiments, the barrier composition 60 may optionally be applied only at the location of the first joint surface 50 . Alternatively, the barrier composition 60 may optionally be applied only at the location of the second joint surface 52 . In another embodiment, the barrier composition 60 may be selectively applied at the location of the first joint surface 50 and the second joint surface 52 .

In another embodiment, the barrier composition 60 may be applied to substantially all of the first side end 13, the second side end 14, or both, as desired.

A variety of methods may be used to apply the barrier composition 60 to the floor covering panel 10, as is known. In the first aspect, a vacuum coating method may be employed. In this aspect, the floor covering panels are passed through a machine to apply the barrier composition under pressure to one side of the respective side ends of the floor covering panels. A vacuum was applied on the opposite side of the side ends of the panels to remove excess barrier composition from the floor covering panels. Return excess barrier composition to the container for reuse. The vacuum brushing method can be used to precisely apply the barrier composition to the floor covering by adjusting the pressure/vacuum ratio.

Another method that can be used to apply the barrier composition to the floor covering panels is with a roll coat applicator. In this method, a plurality of large diameter rollers are fabricated to fit the area to be painted on the floor covering slab. The barrier composition may be applied to the floor covering panels by a transfer roller with the barrier composition supplied from a reservoir. By adjusting the application parameters, the application of the barrier composition can be precisely controlled.

Another method of applying the barrier composition to the surface of the floor covering board is obtained by using a multi-spray head applicator. This method allows accurate and precise application of the barrier composition amount to the floor outline. In this method, a multi-head applicator may be equipped with a plurality of nozzles and positioned to spray the barrier composition onto selected portions of the side ends of the floor covering panels. Spray applicators can apply the barrier composition to the desired location of the floor covering panels in high frequency pulses, where the pulsing action can also assist in keeping the spray head clean. The barrier composition is supplied to the spray head by a conventional pump system that draws the composition from a supply container. Such spray application systems are known to those skilled in the art, and spray applicators are sold by manufacturers including Spraymation Corporation (Ft. Lauderdale, FL).

Other methods of applying barrier compositions may be employed in accordance with the present invention, including other existing methods of applying barrier compositions, and including future developed methods of applying barrier compositions.

The amount of barrier composition applied to the floor covering is not critical so long as it provides the desired water barrier properties. In general, about 0.1, 0.5, 1.0, 2.0 or 5.0 grams of composition per 8" x 48" (0.20 x 1.22 meters) panel will provide the desired waterproof barrier qualities on the finished floor covering.

As used herein, "barrier composition" means a composition comprising an active ingredient, the chemical material providing the primary barrier properties, along with any solvent or diluent and other ingredients. In one aspect, the barrier composition is selectively applied to the floor covering panels, the active ingredient can be any material suitable for providing water or oil repellency to the surface. For this purpose, materials from the following non-exhaustive list of materials can be used as active ingredients in barrier compositions: fluorochemicals, metal stearates, oils, paraffins, acrylate (latex) polymers or silicones polymer. In another aspect, the active ingredient of the barrier composition does not include paraffin. In yet another aspect, the barrier composition excludes synthetic isoparaffins. Still further, the active ingredient of the barrier composition consists essentially of the fluorochemical.

Those of ordinary skill in the art will appreciate that application of a barrier composition comprising one or more of the active ingredients disclosed herein will result in a reduction in the wettability of the floor covering surface. Due to the lower wettability of the floor covering panels, the likelihood of water or other damaging materials migrating through the joint of a mated pair of floor covering panels is reduced. Said waterproof barrier properties are important so that floor coverings can be used in places where they are normally exposed to water, such as bathrooms, kitchens and other areas.

In accordance with the present invention, it has been found that by positioning a barrier composition on top of the vertical side ends of a mating pair of floor covering panels comprising a floor covering system, a durable and effective water barrier or waterproofing performance can be obtained. The selective application of such barrier compositions is not known in the prior art.

In one aspect, the barrier composition applied to floor covering panels comprises a fluorochemical as an active ingredient. Suitable fluorochemicals are those that have been used to provide water repellency to textiles and other materials. These materials are well known to those of ordinary skill in the art. Any fluorochemical suitable for providing stain or oil repellency to textile materials may be used in the present invention.

Fluorochemicals may include any brand of fluoropolymer. Suitable fluorochemical textile treatment agents include, but are not limited to, commercially available fluorochemical compositions. Commercially available fluorine-containing chemicals are useful in the present invention, such as SCOTCHGUARD FC255, SCOTCHGUARD FC214-230 from 3M Company (St. Paul, MN), and TEFLON, TEFLON from DuPont (E.I. DuPontde Nemours Corp., Wilmington, DE). TEFLON8070 and TEFLON8787 and Zonyl8412. Other suitable fluorochemical compounds include: FX1367F and FX1355 from 3M Specialty Chemicals, NRD-372 from DuPont Flooring System, TG-232D from Advanced Polymers, Inc. (Carlstadt, NJ), and Hoechst Celanese (Munich, Germany). ) of the Nuva3555. Other similar fluorochemicals available from these or other manufacturers may also be suitable.

In one aspect of the invention, the barrier composition does not include organic solvents. Still further, the diluent of the active ingredient of the barrier composition comprises water, or, in another aspect, consists essentially of water. Still further, the barrier composition comprises an emulsion or dispersion of the active ingredient in water. In another aspect, the barrier composition is substantially non-flammable and can be used in industrial settings without the use of explosion and fire protection equipment.

In particular, to obtain a durable barrier composition, it may be desirable to use a polymeric material as the active ingredient. Non-exhaustive examples of suitable polymers include silicone polymers, acrylate (latex) polymers, and fluoropolymers. The materials generally have a higher molecular weight, thus allowing for a more durable deposition of the barrier composition on the floor covering. In other aspects, the barrier composition provides a treatment such that the durability of the floor covering panel is at least about 6 months, or at least about 1 year, or at least about 5 years, or at least about 7 years, or at least about 12 years, or is the entire service life of the floor covering slab.

In one suitable aspect of the invention, the barrier composition comprises a fluorinated alkyl acrylate copolymer. Fluoroalkyl acrylate polymers can form emulsions. Specific examples of such emulsions for use in the barrier compositions of the present invention are Unidyne TG-572 and TG-472 (Daikin America, Signal Mtn., TN). TG-472 is believed to comprise about 30% by weight (weight percent) fluoroalkyl acrylate copolymer and emulsifier, about 5.4% tripropylene glycol, with the remainder comprising water. The composition of TG-572 is believed to be similar.

The barrier composition may comprise approximately 100% by weight of a composition comprising the active ingredient as supplied by the supplier, that is to say undiluted. Compositions provided by suppliers may contain any amount of active ingredient. Typically, however, the composition is provided as a solution or dispersion of the water-repellent barrier compound in water or other solvent. It is believed that the concentration of the barrier compound supplied by the supplier is not critical so long as the appropriate dilution is achieved to provide a barrier composition suitable for use in the present invention. Alternatively, the provided compositions may be diluted prior to use on the floor covering panels. Any suitable solvent can be used for dilution, but for industrial application of the active ingredient, water presents less environmental impact. Thus, the barrier composition may comprise water as the main solvent.

In certain aspects, the active ingredient of the barrier composition can be crosslinkable. "Crosslinkable" means that the active ingredient can react or condense with itself to give a final product that has a molecular weight that is at least about 1.5 times, or about 2 times, or about 3 times that of the non-crosslinked active ingredient. The active ingredient may also be crosslinkable with a second ingredient, such as a melamine/formaldehyde resin.

The active ingredient may be crosslinkable by applying energy to the barrier composition after application of the barrier composition to the floor covering board. Energy can be provided by heat, infrared lamps or microwave energy. The active ingredient can also be made crosslinkable by incorporating a crosslinker in the barrier composition. In other aspects, the active material is fully crosslinked when the heating is complete, however, it can be appreciated that with increasing time some additional crosslinking may have occurred.

The final amount of active ingredient in the barrier composition can vary within wide limits. Specifically, the amount of active ingredient in the barrier composition (referring to the aqueous barrier chemical) may be about 1, 2, 5, 10, 15, 20, 25, 30, 40 or 50% by weight of the barrier composition, wherein Any value can be upper and lower bounds. The remaining materials in the barrier composition can be primarily water, with minor amounts of other materials.

The barrier composition may include additives known to those of ordinary skill in the art. Specifically, the barrier composition may include one or more of the following: surfactants, viscosity modifiers, preservatives, surface tension modifiers, or opacifiers.

As one of ordinary skill in the art recognizes, any dilution of an active material will depend largely on the type and amount of active ingredient in the composition provided by the manufacturer.

An important aspect of the present invention is that the barrier composition provides a durable waterproofing or barrier treatment to floor covering panels or floor covering systems. As used herein, "durable" means that the treatment provided by the barrier composition will substantially reduce the likelihood of water or other liquids penetrating the joint of two mating floor covering panels. The water resistance provided by the barrier composition will last at least twice as long as the paraffin-based composition. Still further, the barrier composition of the present invention should reduce the amount of water penetrating into the top seam by 1/2 or 3/4, even if the water contains a small amount of surfactant, that is, one percent by weight or less water. The reduction should last for at least about 10, or about 20, or about 40, or about 100 normal wipe cycles, where "wipe cycle" represents the cleaning that the floor covering system will undergo during normal residential use. Still further, the barrier composition of the present invention provides durable water repellency for about 1 year, or about 2 years, or about 5 years, or about 7 years, or about 12 years, or about equal to the specific The normal service life of the floor covering system.

Furthermore, it has been found that other materials can be applied to the floor covering panels together with the barrier composition. Specifically, for example, existing methods of applying waterproofing compositions to tongue and groove flooring rely on a general and non-specific method of applying waterproofing compositions to tongue and groove profiles. This general, non-specific application method may prevent subsequent application of other materials, such as adhesives, because the waterproofing composition may prevent durable bonding of the adhesive (or other materials) to the tenon surface on the groove outline. In some cases, it is desirable to have a floor covering panel that is not only waterproof, but also to which adhesive can be applied.

According to this purpose, the present invention can also be used together with the invention relating to the selective application of adhesive compositions to floor covering panels. The invention relating to such adhesives is described in US Patent Application (Attorney Docket No. 19133.0026U1), filed concurrently with this application, the disclosure of which is incorporated herein by reference in its entirety.

After application of the barrier composition to the floor covering board, heat may be applied to remove solvent from the barrier composition and/or to provide crosslinking, ie curing, of the active ingredients. In other aspects, the barrier composition can be dried for about 5 seconds, about 10 seconds, about 30 seconds, about 1 minute, about 3 minutes, about 5 minutes, about 10 minutes, or about 20 minutes, any value Composition upper and lower bounds. The temperature applied to dry and/or crosslink active ingredients can be from about 100F (37.8°C), about 120F (48.89°C), about 140F (60°C), about 160F (711.1°C), about 180F (82.2°C), About 200F (93.3°C), or about 220F (104.4°C), any value can constitute an upper and lower limit. In certain aspects, it is important to heat the floor covering board to at least about 180F (82.2°C) for at least 10 seconds.

The barrier composition may include additives known to those of ordinary skill in the art. Specifically, the barrier composition may include one or more of the following: surfactants, viscosity modifiers, preservatives, surface tension modifiers, or opacifiers.

When it is only desired that the floor covering panels be waterproof and not, for example, factory pre-applied with adhesive such as disclosed and claimed in co-pending patent application (Attorney Docket No. 19133.0026U1), the barrier may be combined The compound is applied to the entire contour of the floor covering panel to provide the panel with a particularly complete waterproofing, eg both the upper surface and the lower surface are waterproofed. In said aspect, the cross-linked polymer forms the active ingredient of the barrier composition of the invention, which may be applied to the entire part of the first or second joint.

In said aspect, the active ingredient of the barrier composition must be cross-linkable, or in other words it is already cross-linked when the floor covering panel is assembled for use in a commercial or residential installation. According to this aspect of the invention, the crosslinkable material may be a silicone polymer, an acrylate polymer, or a fluoropolymer. In the case of fluoropolymers, the crosslinkable material may be a fluorinated acrylate polymer as described elsewhere in this specification.

Example

The examples published below are intended to provide those of ordinary skill in the art with a complete disclosure and illustration of how the devices and compositions claimed herein were made and evaluated, and are intended to be illustrative of the invention only and not intended to limit the inventors regarded as the scope of the invention. Efforts have been made to ensure accuracy with respect to numbers (eg, amounts, temperature, etc.), but some errors and deviations should be accounted for. Unless indicated otherwise, parts are parts by weight, temperature is in F (° C.) or at ambient temperature, and pressure is at or near atmospheric.

Seam Penetration and Swelling Test Apparatus:

1. Oil sludge for pipelines

2. Digital Caliper

3. 2% liquid detergent solution Ivory with Red dye40 (very low surface tension compared to _H2O ) (very harsh test)

4.10ml graduated cylinder

5. Flat and level surface

6. Saw with blade to cut laminate

Steps of seam testing (Figure 4)

1. Mark 12 inches along the length of the board and cut it as a sample for testing.

2. Mark three two-inch diameter rings R 1.5 inches apart on the edge of the upper lip on one side of the groove.

3. Make three marks half an inch apart in each ring R.

4. Use a digital caliper to measure the thickness of the board at each mark.

5. Join the two plates 210a, 210b together and cut the sample apart.

6. The time required for the specimen to rest on a flat and level place.

7. Place a ring of R-shaped pipe clay around each set of marks.

8. At the expected moment after connecting the plates, pour 10 ml of red detergent solution S into each ring R and then allow the specimen to stand undisturbed in a flat and horizontal position until all the solution has passed through the connection point J or has evaporated . The detergent solution contained 2% liquid Ivory ^(R) or liquid Ajax ^(R) dishwashing detergent with an added small amount of real food coloring.

9. Separate the two plates and re-measure the same marked location. And observe how deeply the red dye solution has penetrated into the joint. Use a spraymation nozzle. About 1 g or less of 25% TG472 or 571/75% water composition. 8" x 48" (0.20 x 1.22 m)" laminate floor covering. The barrier composition was applied to site 50/52.

Seam penetration and swelling

4 hours % 72 hours %

B Only Flexipel XPC (comparison) 9.96 2.98

D Unidyne TG-571 16.70 4.31

E Unidyne TG-472 1.84 0.87

G Original comparison ratio (contrast) 24.45 23.68

H Paraffin ratio (contrast) 30.66 25.63

I Competing ground cover material (comparison, believed to be 21.17 21.49 paraffin treated)

Flexipel XPC (Innovative Chemical Technologies, Cartersville, GA) is a synthetic hydrocarbon (97-98%) and perfluorinated polymer (2-3%). Unidyne 571 and 472 are fluorinated acrylate polymer emulsions. After applying it to the floor covering panels, treat the floor covering panels at 180F (82.2°C) for 10-30 seconds.

Joint penetration and expansion are measured as percent (%) change in flooring material thickness after application of the fluids indicated above.

From the above results, it is clear that the fluorinated acrylate polymer provides a significantly enhanced water barrier compared to the other materials tested.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification of the invention disclosed herein and practice of the invention. It is intended that the specification and examples of this invention be considered as examples only, with a true scope and spirit of the invention being pointed out by the following claims.

Claims (18)

1. floor covering plate comprises:

A) overall smooth first surface,

B) overall smooth second surface,

C) first side and the second relative side, each side all extends between described first and second surfaces respectively,

D) be defined in first fastener of first side of plate, it comprises by its projection of stretching out and first joint surface between projection and first surface,

E) be defined in second fastener of second side of plate, it comprises that size and dimension is fit to receive the depression of described projection, also comprises second joint surface between depression and first surface, and

F) barrier compositions of promptly optionally using in advance in factory, wherein said composition are applied in first joint surface and second joint surface at least a portion of at least one.

2. the floor covering plate of claim 1, it is characterized in that also comprising respectively first and second plates of described floor covering plate, wherein first fastener of first plate receives second fastener of second plate, and at least a portion of first joint surface of first plate contacts with at least a portion of second joint surface of second plate, and wherein barrier compositions is also set up between described first joint surface and described second joint surface and prevented the relative obstruct that moisture infiltrates through floor covering plate, crosses first surface.

3. the floor covering plate of claim 1 is characterized in that barrier compositions uses along whole first joint surfaces basically.

4. the floor covering plate of claim 1 is characterized in that barrier compositions uses along whole second joint surfaces basically.

5. the floor covering plate of claim 1 is characterized in that barrier compositions uses along whole first joint surfaces basically with along whole second joint surfaces basically.

6. the floor covering plate of claim 1 is characterized in that barrier compositions optionally is applied to the part of first joint surface adjacent with upper surface.

7. the floor covering plate of claim 1 is characterized in that barrier compositions optionally is applied to the part of second joint surface adjacent with upper surface.

8. the floor covering plate of claim 1 is characterized in that barrier compositions optionally is applied to the part of first joint surface adjacent with upper surface and the part of second joint surface adjacent with upper surface.

9. the floor covering plate of claim 1 is characterized in that barrier compositions comprises a kind of active component, and this active component comprises one or more in fluorine-containing chemical, Metallic stearates, oil, wax, acrylate polymer or the organosilicon polymer.

10. the floor covering plate of claim 9 is characterized in that active component is crosslinkable.

11. the floor covering plate of claim 9 is characterized in that active component comprises fluorine-containing chemical.

12. the floor covering plate of claim 11 is characterized in that fluorine-containing chemical comprises fluoropolymer.

13. the floor covering plate of claim 12 is characterized in that fluoropolymer comprises the fluorate acrylic acid ester polymer.

14. floor covering plate that is fit to cooperate second floor covering plate, wherein floor covering plate has the crosslinkable fluoropolymer that is applied at least a portion that limits tongue-and-groove outline line zone, when thereby partial cross-linked at least and floor covering plate cooperates with at least one second floor covering plate when polymer, provide durable waterproof to intercept.

15. the floor covering plate of claim 14 is characterized in that crosslinkable polymer is applied to the vertical side of outline line, wherein side comprises the top side (upperedge) of floor covering plate.

16. the floor covering plate of claim 14 is characterized in that floor covering plate cooperates with second floor covering plate, thereby the ground covering system is provided that wherein system comprises that at least one is positioned at the seam of system's upper surface.

17. the floor covering plate of claim 16 is characterized in that second floor covering plate comprises the crosslinkable polymer that is applied to vertical side, the vertical side complementation of described vertical side and first floor covering plate.

18. the floor covering plate of claim 16 is characterized in that crosslinkable polymer provides waterproof to intercept, thus with compare without infiltration with the ground covering system of cross-linked polymer barrier compositions processing, reduced water on to a great extent to infiltrate through system.

Images