US20170234018A1

US20170234018A1 - Surface covering system

Info

Publication number: US20170234018A1
Application number: US15/314,130
Authority: US
Inventors: Dries Bovijn; Niels LEHOUCK
Original assignee: Beaulieu International Group NV
Current assignee: Beaulieu International Group NV
Priority date: 2014-05-28
Filing date: 2015-05-28
Publication date: 2017-08-17
Also published as: WO2015181295A1; EP3149258A1

Abstract

A new surface covering system (1) comprising a panel (10) and a base (20), suitable for covering at least a portion of a surface of a building or at least being part of a portion of such surface is presented, wherein the panel (10) and the base (20) are provided with complementary mechanical means (30), (40) for removably fixing or securing the panel (10) on the base (20).

Description

FIELD OF THE INVENTION

The invention relates to surface covering systems and elements (panel, base) and packages of such elements thereof.

BACKGROUND OF THE INVENTION

In the domain of building structures and interior architecture, a first class of surface covering systems, usually meant for flooring, comprise panels laid out next to each other and preferably removably fixed or secured to each other via locking mechanisms such as e.g. tongue and groove. As described in for instance WO2011153916 A1, US2013036695 A1, WO2013032391 A1 or EP2599933 A2 the locking mechanisms allow change of panels whenever required e.g. due to a problem with one or more panels or just when the user likes to modify the surface for esthetic reasons, however this is not performed in an easy way. Replacing panels may further lead to local damages of the locking mechanism or of the panel itself.
In a second class of surface covering systems, a flooring or other surface covering can be tiles, e.g. stone or textile, laid out next to each other, and being permanently fixed or secured to a subflooring, for instance by using glue or cement or another type of adhesive. Particularly in case of glued surfaces, the overall installation time is rather long compared to other surface covering systems where there is no drying or stabilizing process involved. In this case, removing or changing the tiles is difficult, time consuming and usually also involves extra means such as special tools or additives, e.g. dissolvents. There is further a real risk of damaging the tiles.
A third class of surface covering systems rather refers to wall or ceiling covering. Apart from the panels and tiles as mentioned above, and which sometimes also could be used as a wall or ceiling covering, a more common way of covering walls or ceilings is by using thin layer or light weight structures composed of either natural or synthetic materials, such as paper or polyester based fabrics. Moreover, other thicker layer structures including e.g. acoustic or isolating functionality are known for wall or ceiling covering. In any of these wall or ceiling covering systems, typically an adhesive is applied to fix or secure the layer structures to the wall or ceiling surface.
In general, specific skills are required to install a surface covering system according to one of the classes as mentioned above. Furthermore, particular tools and additional materials are also often required for installing or removing surface coverings and the installation as well as the removal of these surface coverings is time consuming.

AIM OF THE INVENTION

It is the aim of the invention to provide easily and removably fixing or securing of surface coverings in order to overcome the disadvantages of the art, while maintaining the advantages of the classes of surface coverings as described above.

SUMMARY OF THE INVENTION

In a first aspect the new surface covering system comprises a panel and a base, suitable for covering at least a portion of a surface of a building, characterized in that the panel and the base are provided with complementary mechanical means for removably fixing or securing the panel to the base. The base acts as an interlayer between the panel and the surface to be covered and may absorb imperfections present in the surface to be covered. The complementary mechanical means are mounted respectively onto, or either respectively integrated within, the panel and the base surfaces facing each other, in a direction perpendicular to these surfaces. The panel and the base are substantially plate-shaped, however the panel and base surfaces may have different geometrical sizes and shapes, as long as the complementary mechanical means match shape and/or size. The complementary mechanical means are sufficient for fixing or securing the panel onto the base without the use of glue or adhesive, which will allow quick installation or easy removal of the panel to/from the base. The surface covering system can be a floor, a wall or a ceiling covering system, and can be used for interior or exterior surfaces. The removably fixing or securing of the panels results in a modular surface covering system.
In one embodiment of the invention, the complementary mechanical means, provided onto the panel and the base of the surface covering system, comprise cavitites and protrusions being substantially complementary in shape. Due to the complementarity of the mechanical means, they may also serve as positioning means for placing the panels to the base. Hence, the complementary mechanical means may incorporate the advantage of easily installing panels for surface covering, without requiring precision tools or particular craftsmanship.
In a further embodiment of the invention, the complementary mechanical means are locking means for locking the panel onto the base providing both a lock parallel to the base as well as a lock perpendicular to the base.
In an embodiment the panel comprises a core part with mechanical means on one side oriented to the surface to be covered; and a décor layer to the opposite side of the core part. In another embodiment the panel comprises a core part with mechanical means on one side oriented to the surface to be covered; while a décor is integrally formed in the opposite side of the core part. The integration of a décor on one side of the core part of the panel is possibly realized by means of additive manufacturing. The décor can be either plane, or can have a rather rough or uneven texture.
In an embodiment of the invention the base comprises of one or more 3D geometrical shapes (such as protrusions, cavities, ribs, rails or sleeves), whereas the panel comprises one or more complementary 3D geometrical shapes, at corresponding positions, and thereby realizing removably fixing or securing the panel on the base.
In a further embodiment the base can be flexible or rigid.
In an embodiment of the invention the system has a plurality of said panels, respectively bases, laid out adjacent by their various sides (along or parallel to the surface), whereby preferably the geometrical shapes of said panels, respectively bases, are selected to facilitate such laying out next to each other for instance by selecting a same or similar shape (like rectangular or square) however any contiguous shape is in essence sufficient. Multiple bases are placed next to each other onto the surface to be covered, thereby forming a base layer, onto which a layer of multiple panels is mounted. Multiple panels, respectively multiple bases, are typically assembled in a contiguous way. The surface covering system has a high end of life value because it can be disassembled and reused, in part or as a whole. Moreover, the surface covering system only involves replacements where needed or wanted, and hence removing panels and/or bases can be performed very locally.
According to further embodiment of the invention, the material for making up the panel, in particular the décor layer or the side of the core part adapted to serve as décor, is chosen from the group consisting of carpeting, PVC, linoleum, caoutchouc, rubber, cork, powders, wood, paper, rock materials, laminates, or ceramics. It is further possible to combine panels with different types of décor allowing creative surfaces.
In another aspect of the invention an installation method is provided comprising the steps of

- placing a base onto the surface to be covered, the base having a side facing the surface to be covered, and mechanical means on the opposite side;
- mounting a panel having mechanical means complementary to the mechanical means of the base, onto the base thereby removably fixing or securing the panel to the base.

In a further aspect of the invention, a floor, wall, ceiling or other surface of a building is provided, comprising one or more surface covering systems as described above.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a cross sectional schematic of various embodiments in accordance with the invention.

FIG. 2 shows an embodiment of the present invention in perspective view.

FIG. 3 shows an alternative embodiment of the present invention in perspective view.

FIG. 4 shows another alternative embodiment of the present invention in cross sectional and perspective view.

FIG. 5 shows various embodiments of the complementary mechanical means, in perspective (a), (b), (c3), or top (c2) or cross sectional (c1) view, in accordance with the present invention.

FIG. 6 shows a further embodiment in accordance with the present invention, in perspective view, wherein the base is incorporated in the surface to be covered.

FIG. 7 shows an even further embodiment in accordance with the present invention in perspective view.

FIG. 8 shows further various embodiments of the complementary mechanical means, illustrating (a) a horizontal lock, and (b) a combination of a horizontal and a vertical lock, in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Throughout the description the use of complementary mechanical means for removably fixing or securing of elements is discussed. Indeed when one mechanical means for removably fixing or securing is foreseen in a first element, the second element to which the first element must be removably fixed or secured is provided with another mechanical means which is complementary in nature, hence said mechanical means are denoted complementary mechanical means throughout the description. Removably is meant to be the opposite of permanent (e.g. by use of glue). Removably may include a smooth way of fixing or securing but alternatively also a click approach. Moreover, removably is also referring to the modular aspect of the surface covering system created. A kind of plug-and-play is generated due to the complementary mechanical means provided with the system. Hence, different type of panels provided with the mechanical means can be easily removed, replaced or installed elsewhere or being replaced by others. Explicitly exluded from the present invention as mechanical means is velcro-type fasteners.
FIG. 1 shows various embodiments in accordance with the invention. Each of the embodiments depicted by FIG. 1 a, 1 b, 1 c, 1 d and 1 e respectively, represent either two or three parts 5 showing the layer connecting structure of a surface covering system 1 in cross sectional view. While FIG. 1 b, 1 c and 1 e show a basic scheme with a panel 10 and a base 20 with complementary mechanical means 30, 40, FIG. 1a and 1d both show an alternative scheme wherein the panel 10 comprises a core part 50 and a décor layer 60. Actually designating which part 5 belongs to the panel 10 and which part 5 belongs to the base 20 is arbitrary as long as it is clear that at least two parts 5 are removably fixed or secured by use of the complementary mechanical means 30, 40. In case multiple parts 5 are present (as in FIG. 1a and 1d ) they can be further removably fixed or secured, again by complementary mechanical means 30, 40 (which not necessarily have to be the same as previous ones mentioned) or by known adhesive means like glue. FIG. 1 shows embodiments where the base 20 is essentially completely covered by the corresponding portion, represented by matching panel, on top of it, whenever the parts 5 are fixed or secured, meaning that there is no space in between while considering a cross section.
The panel 10 in itself may be suited on one end to serve as décor 80 (FIG. 1 b, 1 c and 1 e) or a designed décor layer 60 may be exposed (FIG. 1a and 1d ). In case one of the panel's surfaces serves as décor 80, the panel 10 is e.g. developed by means of additive manufacturing as commonly known, and thereby all functionalities of the panel 10 are represented by the core part 50. Typical panel materials, i.e. materials used for the core part 50 are e.g. (bio)composites, wood or wood fibers and plastics, whereas typical décor or décor layers are made of carpeting, PVC, linoleum, caoutchouc, rubber, cork, powders, wood, paper, rock materials, laminates, or ceramics. Any of these may be fiber reinforced or reinforced by any other method as known in the art.
The base 20 may be a stand-alone part, rigid or flexible, to be mounted onto the surface to be covered, or else, as illustrated in FIG. 6, the base 20, 20′ may be incorporated in the surface 2 to be covered thereby represented by the surface top layer, i.e. being exposed before any surface covering is applied. As depicted in FIG. 6, the mechanical means 40, 40′ can be provided as either cavities within or protrusions onto the respective base 20, 20′. In case of mounting the base 20 onto the surface 2 to be covered, a base material, shape and size are particulary chosen or designed, such that an adhesive between the base 20 and the surface may no longer be necessary. Typical base materials are e.g. (bio)composites, wood or wood fibers and plastics, whereas typical shapes used are rectangular, square or triangular formed plates or mats or blocks or panels or any other 3D structure having a substantially plane surface on one side to be attached to the surface 2 to be covered, and having an opposing surface comprising mechanical means on the other side in order to match complementary mechanical means of one or more corresponding panels. Furthermore, having the base 20 already integrated in the surface 2 to be covered, which is typically achieved by means of additive manufacturing as known in the art, an adhesive has become completely redundant. The base material being part of the surface 2 to be covered may be e.g. (bio)composites, wood or wood fibers and plastics, but also concrete, or chape, or PUR (polyurethaan).
The perspective view of FIG. 2 shows an embodiment of the surface covering system 1 wherein the complementary mechanical means 30, 40 are represented as 3D shapes, more particularly a grid structure is shown with ribs 40 protruding from the base 20 and whereby corresponding inverse ribs or sleeves 30 are provided in the core part 50 of the panel 10. According to FIG. 2, the panel 10 is a two-layer squared structure comprising also a décor layer 60. Further this embodiment illustrates a plurality of panels 10, laid out next to each other in a contiguous way, in particular with no connection between their standing edges 55 being required as they are removably fixed or secured via the base 20.
FIG. 3 shows an alternative embodiment, illustrating that the panels 10 do not need to be the same in shape but contiguous in shape to achieve covering of a surface by laying out the suitable panels 10 adjacent to each other. As depicted here, the panels 10 can be rectangular, squared, triangular or other polygon-formed plates or mats or blocks or panels or any other 3D plate-like structure having a décor layer 60 or a surface acting as décor 80 on one side to be exposed, and having a surface comprising mechanical means 30 on the other side in order to match complementary mechanical means 40 of a corresponding base 20. Moreover, as can be seen in FIG. 3, the panels 10 may have different sizes, in other words representing large or either small pieces of base covering.
Note here in FIG. 3 also the dimensions or shape of the mechanical means 30, 40. The complementarity of the mechanical means 30, 40 must be such that when placed together lead to removably fixing or securing, however no movement of the panel 10 along the base surface is possible, i.e. a lock parallel to the base is generated. In other words due to protrusions 40 extending from the base 20 and fitting cavities 30 provided in the core part 50 of the panel 10, in shape or size and position, the panel 10 and the base 20 are connected by means of the complementary mechanical means 30, 40. A panel 10 is fixed or secured to the base 20 due to a pressure force applied onto the composite layer structure of the surface covering system 1. The complementary character does not imply that the mechanical means 30, 40 entirely map in shape and size e.g. as shown in FIG. 1, where no spaces are observed between the layer connections or mechanical means 30, 40 when the parts 5 are fixed or secured. A perfect mapping of the positions of the complementary mechanical means 30, 40 however, is always mandatory in order to fix or secure the parts 5 together and generate smoothly covered surfaces. FIG. 3 demonstrates a non-entirely mapping embodiment, while the protrusions 40 extending from the base 20 show a rail structure, whereas the cavities 30 foreseen in the core part 50 of the panel 10 represent a grid structure. The protruding rails 40 correspond to sleeves 30 a along the same surface direction of the grid matrix in the core part 50, although spaces are left when the panels 10 are fixed or secured, due to sleeves 30 b in a surface direction perpendicular to the direction along rails 40, respectively sleeves 30 a, of the non-entirely mapping mechanical means 40, 30. Therefore when stipulating that the base 20 is essentially completely covered by the corresponding portion on top of it (when the parts are fixed or secured), the panels 10 are not floating above the base 20 except for some supports. More specifically, there is no space in between (when considering a cross section) except for either the non-entirely mapping aspects of the mechanical means 30, 40 and/or for some predetermined spaces foreseen in the base 20 and/or core parts 50 of the panels 10 suitable for placing electric or other connections. These other connections referred to, can for instance provide for other utilities than electricity, such as (part of) isolation, heating or air conditioning infrastructures, or even acoustic (e.g. sound) or waterproof functionalities can be interpreted here.
FIG. 4 shows an embodiment wherein the mechanical means 40 are protrusions on a base 20, being a basemat, i.e. preferably made out of flexible material such as rubber. In the cross sectional view of FIG. 4 a, as well as in the perspective view of FIG. 4 b, the composite structure of the surface covering system 1 is clearly depicted, comprising respectively a basemat and panel elements A and B, which in turn both have a coreboard as core part 50 and a décor layer 60. The protrusions 40 are cylindrically shaped and extending perpedicularly from the base 20, and further map being complementary with corresponding cylidrical holes 30, provided in the respective coreboard 50 of the panel elements A and B. The cylindrical shapes of the protrusions 40 match with the cylinder holes 30 in shape, size and position, such that when a pressure force is applied onto the different layers defining the composite structure, the complementary mechanical means 30, 40 as well as the layers' surfaces are fully connected and hence no spaces are left between any of the different layers nor of the complementary mechanical means 30, 40.
As illustrated in FIG. 5, showing various embodiments of the complementary mechanical means 30, 40, in perspective view (a), (b), (c3), or top view (c2) or either cross sectional (c1) view, in accordance with the present invention, the removable aspect of the complementary mechanical means 30, 40, including a smooth way of fixing or securing, may comprise a click approach.
The panel 10 shown in FIG. 7 has a surface side serving as décor 80 made visible in the drawing, whereas the other panel side provided with complementary mechanical means 30 is not depicted in this perspective view. The mechanical means 40 mounted onto the base 20 at particular positions in a kind of ordered matrix structure, are partially visible. These mechanical means 40 comprise protrusions, e.g. a set of 4 protrusions per mechanical means 40, are used to fit within the cavities provided in the panel surface (not shown).
In FIG. 8 further embodiments of complementary mechanical means 30, 40 are illustrated schematically. With FIG. 8 a, a horizontal lock is shown, meaning that the panel 10 can no longer be moved in a horizontal (parallel to the base 20) direction, still can easily be lifted in a vertical (perpendicular to the base 20) direction. A combination of a horizontal/parallel and a vertical/perpendicular lock is shown in FIG. 8 b.
Further aspects of the invention are now discussed.
The technique as described according to the present invention of a surface covering system 1 comprising a panel 10 and a base 20, suitable for covering surfaces, and characterized by the fact that the panel 10 and the base 20 are provided with complementary mechanical means 30, 40 for removably fixing or securing the panel 10, may also be applied to surfaces in a building representing e.g. the doors of a built-in cupboard. Moreover, the surfaces to be covered with the surface covering system 1 according to the invention, could be the inner or outer walls of a cupboard, or of another interior closet-alike object, or even of a vehicle for special purposes.
Being applicable to the embodiments as illustrated in FIGS. 1-4, an installation method for generating a surface covering system 1 according to the present invention is described comprising of the following steps:

- Optionally clearing, cleaning and substantially smoothing the surface 2 to be covered;
- Placing a base 20 onto the surface 2 to be covered, preferably having a substantially plane surface on one side facing the surface 2 to be covered, and provided with mechanical means 40 on the opposite surface;
- Mounting a panel 10, having mechanical means 30 complementary to the mechanical means 40 of the base 20, onto the base 20 thereby removably fixing or securing the panel 10 to the base 20.

Referring particularly to FIGS. 1 a, 1 d, 2, 3 and 4, the panel 10 is a two-layer structure comprising a core part 50 and a décor layer 60. For these specific embodiments, the description of the installation method can be extended with constituting the panel 10 before it is mounted as a whole, or either can be amended while mounting the panel 10 by assembling layer per layer, i.e. first the core part 50 is mounted onto the base 20, followed by the décor layer 60 being mounted onto the core part 50. The mounting of the décor layer 60 onto the core part 50 can either be done by using again complementary mechanical means 30, 40, or by using an adhesive such as glue.
Referring particularly to FIGS. 1 b, 1 c and 1 e, the panel 10 is represented as a one-layer structure having a décor surface side and an opposing surface side comprising complementary mechanical means 30. In this case the panel 10 is possibly developed by additive manufacturing as known from the art, and hence an additional step describing the additive manufacturing of the panel 10 as one part can be added to the installation method, before step of mounting the panel 10 onto the base 20.
Referring particularly to FIG. 6, illustrating part of a building area, the base 20 can be incorporated in the surface 2 to be covered, e.g. realized by additive manufacturing. In this particular case, an amendment in the installation method is required, whereas the step of placing the base 20 onto the surface is no longer necessary, and hence this step can be deleted, taking into account that the surface 2 to be covered is then provided with the mechanical means 40 as exposed.

Claims

1. A surface covering system, comprising: a panel; and a base, wherein said panel and said base are provided with complementary mechanical means for removably fixing or securing the panel on the base.

2. The surface covering system of claim 1, wherein said complementary mechanical means comprise cavities and protrusions being substantially complementary in shape.

3. The surface covering system according to claim 1, wherein said complementary mechanical means are positioning means for positioning said panel onto said base.

4. The surface covering system according to claim 1, wherein said complementary mechanical means provide locking in a direction parallel to said base as well as in a direction perpendicular to said base.

5. The surface covering system according to claim 1 wherein the material making up said panel is chosen from the group consisting of carpeting, PVC, linoleum, caoutchouc, rubber, cork, powders, wood, paper, rock materials, laminates, and ceramics.

6. A floor, wall, ceiling or other surface of a building comprising one or more surface covering systems according to claim 1.

7. An installation method for a surface covering system according to claim 1 comprising:

a. placing a base onto a surface to be covered, said base having a side facing said surface to be covered, and mechanical means on the opposite side;

b. mounting a panel having mechanical means complementary to said mechanical means of said base, onto said base thereby removably fixing or securing said panel to said base.