Abstract:
A floor or wall covering has blocks with mating strips having multiple ridges and multiple grooves in both mating members. Ridges and grooves can have different sizes and cross-sectional shapes from one another, and can mate in a manner that provides expansion gaps. Male/female positioning pairs can advantageously be included to facilitate alignment of the blocks during installation and use. Preferred floor blocks comprise a ribbed support portion that supports a working surface, and the ribbed support portion defines a plurality of cells that collectively reduce the weight of the block by a factor of at least 20% relative to corresponding block without such cells.

Description:
[0001]     This application claims the benefit of our U.S. provisional patent application with the Ser. No. 60/697,466, which was filed Jul. 7, 2005. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The field of the invention is floor coverings.  
       BACKGROUND  
       [0003]     There is a need for modular floor covering systems that are relatively easy to install, maintain, and provide reasonably good seal against water infiltration.  
         [0004]     Various types of modular floor covering systems are well known, including for example systems having edges that mate using a single ridge and a single groove (see US 2002/0189183, U.S. Pat. No. 5,630,304). The known single-ridge, single-groove floor covering blocks (also called tiles) are relatively easy to install and maintain, but can come apart too easily. In addition, use of only a single ridge and a single groove on each strip provides a relatively poor water barrier.  
         [0005]     More sophisticated water barriers have been developed that use multiple ridges and grooves in only one of the strips, and a removable seal disposed in one of the multiple grooves. For example, Flooring Surfaces™ markets a floor covering system in which an upper edge strip mates with a lower edge strip having a separate seal. Interestingly, there do not appear to be any flooring or wall covering systems in which both mating strips have multiple ridges and multiple grooves. Thus, there is still a need for a modular floor covering system in which both mating strips have multiple ridges and multiple grooves.  
         [0006]     In addition, there is a long-standing problem with alignment of ridged mating systems that has never been resolved. Since any portion of a block edge can mate with any other portion of a mating block edge, larger installations frequently get out of alignment. Thus, there is still a need for systems and methods for aligning blocks having grooved mating systems.  
       SUMMARY OF THE INVENTION  
       [0007]     The present invention provides apparatus, systems and methods for covering a floor or wall surface, in which blocks have mating strips with multiple ridges and multiple grooves in both mating members.  
         [0008]     In one aspect of preferred embodiments, the ridges on the various strips can have different cross-sectional shapes from one another. Accordingly, the ridges on one of the strips can combine to be more massive than the ridges on the opposing strip, and the strip having the more massive ridges can be used advantageously as the upper strip. The strip having the less massive ridges can be used advantageously as the lower strip.  
         [0009]     In another aspect the various ridges and grooves mate in a manner that provides expansion gaps. Such gaps allow expansion room for easier assembly and disassembly.  
         [0010]     In yet another aspect, systems and methods are contemplated in which at least some of the blocks have both ridged mating strips and at least one mechanical positioner. Preferred positioners are male and female pairs, including for example locator and slot pairs, and boss and hole pairs. Blocks can have multiple positioners.  
         [0011]     Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components. 
     
    
     BRIEF DESCRIPTION OF THE DRAWING  
       [0012]      FIG. 1  is a vertical cross-section of a mating region of prior art floor covering blocks, before installation.  
         [0013]      FIG. 2  is a vertical cross-section of a mating region of prior art floor covering blocks of  FIG. 1 , after installation.  
         [0014]      FIG. 3  is a vertical cross-section of a mating region between two modular floor covering blocks, before installation.  
         [0015]      FIG. 4  is a vertical cross-section of the mating region between the two modular floor covering blocks of  FIG. 3 , after installation.  
         [0016]      FIG. 5  is a perspective view of the bottom of a block, showing a waffle pattern that supports a main or “working surface”.  
         [0017]      FIG. 5A  is a perspective view of a portion of block having a locator in the middle of one of the sides, and a boss at a corner.  
         [0018]      FIG. 5B  is a perspective view of a portion of another block having a female connector that mates with the boss of  FIG. 5A .  
         [0019]      FIG. 5C  is a perspective view of a portion of the block of  FIG. 5B , having a slot that mates with the locator of  FIG. 5A . 
     
    
     DETAILED DESCRIPTION  
       [0020]     In prior art  FIGS. 1 and 2 , a modular floor covering system  100  generally comprises blocks  110  and  120 , having edge strips  112 ,  122 , respectively. Edge strip  112  has a single ridge  115  and a single groove  117 . Edge strip  122  has two ridges  125 A,  125 B, and two grooves  127 A,  127 B. A resiliently compressible tubular seal  129  is disposed in groove  127 B.  
         [0021]     In  FIGS. 3 and 4 , a floor covering system  200  generally has a plurality of modular blocks. Here, edge portions of blocks  210  and  220  are shown prior to installation.  
         [0022]     Each block generally has four sides. In a preferred embodiment, two of the sides have edge strips arranged as strip  212 , and two other sides have edge strips arranged as strip  222 . This configuration allows identical blocks to interlock in a manner that covers a large area. Of course, other embodiments are also contemplated that have other than four sides. Thus, contemplated embodiments include those that have three sides (triangular), five sides (pentagonal), and so forth, as well as embodiments where the sides do not define a regular geometric shape.  
         [0023]     Floor covering block  200  generally has a thickness of at least 2 mm, preferably at least 5 mm, more preferably at least 10 mm, most preferably at least 15 mm. In preferred embodiments, block  100  is contemplated to be at least 10 cm long, more preferably at least 50 cm long, and most preferably at least 80 cm long. The modular floor covering blocks can be made of any suitable material common known for floor covering, including clay, stone, wood, polymeric materials, and especially material selected from the list consisting of vinyl, rubber, linoleum, and resin. Especially contemplated materials include PVC, DOP, polypropylene, TPR, TPE, and blends of these, along with smaller amounts of fillers and stabilizers.  
         [0024]     Along one edge of block  210  is edge strip  212  having two parallel ridges  215 A,  215 B and grooves  217 A,  217 B. A second block  220  has edge strip  222 , with corresponding parallel grooves  227 A,  227 B sized and dimensioned to mate with the two ridges  215 A,  215 B. Edge strip  222  also has two parallel ridges,  225 A,  225 B, sized and dimensioned to mate with the two grooves  217 A,  217 B. Those skilled in the art will immediately appreciate how any number of such blocks could be configured together to make a square, rectangular or other grouping to cover a desired area of floor, lawn, wall, etc.  
         [0025]     Edge strips can be any practical width, thickness, and length. The ridges and grooves on edge strips need not be at the lateral ends of the strips, and indeed in many cases (such as that shown in  FIGS. 3, 4 ), the most laterally positioned ridge  215 A can be positioned several mm from the lateral-most edge of the strip.  
         [0026]     The two ridges of each strip  212 ,  222  are preferably separated by at least 2 mm, more preferably at least 5 mm, most preferably at least 8 mm. As used herein the term “parallel” means substantially parallel, and includes ridges that are wavy or out of parallel by an amount that does not adversely affect performance to a significant degree. Thus, ridges that are out of parallel by 5-10% may well fall within the meaning of the term parallel, as used herein, provided that the arrangements does not adversely affect performance to a significant degree.  
         [0027]     In preferred embodiments, ridge  225 A is sized and dimensioned to abut groove  217 A so as to prevent infiltration of moisture. All four of the ridges  215 A,  215 B,  225 A,  225 B are sufficiently thick to provided needed strength. In many cases this would mean that the ridge are at least 2 mm thick, more preferably at least 4 mm thick, and most preferably 6 mm thick. In a preferred embodiments, top ridges  215 A and  215 B are larger than bottom ridges  225 A,  225 B, preferably at least 5% larger, more preferably at least 15% larger, and most preferably at least 35% bigger. Bigger ridges are thought to allow relatively easier coupling of the upper and lower edge strips  220 ,  222 , and relatively better locking performance.  
         [0028]     With a given strip, the ridges can have same sizes as one another, or different sizes. Thus, top ridges  215 A,  215 B can be the same or different sizes from one another, and bottom ridges  225 A,  225 B can be the same or different sizes from one another. There is a potential benefit in having different sized ridges on a given strip in that different sizes can improve the ease of coupling the strips together. To that end a more lateral ridge is preferably larger than a more medial ridge.  
         [0029]     It is also possible, although not desirable from a manufacturing cost standpoint, for different ridges on a given strip to be made of different materials, densities, shapes, colors and so forth. In  FIGS. 3 and 4 , ridges  215 A,  215 B project downwardly at angle slightly off normal, and have a laterally extending bulbous portion  218  that acts as a lead-in region. Those features also assist in locking strip  212  in place when mated with strip  222 . Of course, various other shapes, sizes, and configurations of the ridges are also possible.  
         [0030]     Further contemplated embodiments have edge strips shaped to create expansion gaps  300 A-D when two blocks are installed. These expansion gaps allows relatively easier installation, relatively more aggressive snaps, and allows relatively easier disassembly. Size of the gap is defined by the distance between corresponding ridges and grooves. Preferred size of the gap is at least 0.05 mm, more preferably at least 0.5 mm, most preferably at least 1.0 mm.  
         [0031]     It is further contemplated that a propositioned adhesive is disposed on the strips. Such an adhesive can help in preventing water and moisture penetration through the seals, and can assist in preventing unwanted separation of mating strips.  
         [0032]     In  FIG. 5 , a tile system  300  has a “waffle design” portion  330  that supports a main or working surface  350 . The waffle design portion  330  is shown here as orthogonal ribs  332  that define substantially square cells  334 . In a preferred embodiment there are 20 ribs in each direction, forming 361 cells (a matrix of 19×19), but there could be a greater or lesser number of ribs in either direction. The ribs  332  can be any suitable thickness, or even have varying thicknesses, but preferably have a uniform thickness of 0.155 inch (or about 3 mm). The ribs could, of course, be oriented in some other manner, which would produce cells having a diamond, round, ovoid, or any other suitable shape. The cells can have any suitable depth, but are preferably about 4 mm deep, with a ceiling (the working surface) having a thickness of 0.063 inch (or about 2-3 mm). There can be any suitable number of cells, including especially at least 100 cells, more preferably at least 200 cells, and most preferably at least 300 cells.  
         [0033]     It turns out that using a ribbed (“waffle design”) on the underside of a polymeric floor block provides sufficient structural integrity to support the weight of normally expected garage-based or other activity, including supporting the weight of cars, gym equipment, etc. The ribbed (“waffle design”) also provides significant cost and weight reduction. For example, use of a ribbed (“waffle design”) in place of a solid design can reduce the weight of the block by at least 20%, more preferably at least 30%, and most preferably at least 40%.  
         [0034]     In  FIG. 5A-5C  a tile system  300  includes at least two pieces of block  310 . In  FIG. 5A , block  310  has a locator  312  in the middle of one of the sides, and a boss  314  at a corner. Each of the locator  312  and boss  314  could be placed elsewhere on the block  310 , or replaced and/or supplemented with other types, sizes, and configurations of positioners. The boss  314 , for example, could be rectangular or diamond shaped rather than round. In  FIGS. 5B and 5C , a slot  322  on a first of the blocks  310 , mates with the locator  312  on a second of blocks  310 , and a ring  324  defining a hole on the first of blocks  310  that mates with the boss  314  on the second of blockss  310 . The mating pairs, (locator  312  and slot  322 ; and boss  314  and ring  324 ), serve to maintain alignment among the various blocks of system  300  during installation and use.  
         [0035]     Thus, specific embodiments and applications of plastic flooring with improved seal have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.