FLOORING SYSTEM, A PANEL AND METHODS OF USE THEREOF

Abstract

The present invention relates to a system and floor panel for use in forming a graded floor, wet area, pathway or decking and to methods of use thereof. The panel has two opposed surfaces including a lower surface and an opposed upper surface. The opposed surfaces are interconnected by opposing edges, including opposed end edges and opposed side edges. The panel tapers in thickness from a first said end edge to an opposed second said end edge with a gradient ranging from about 0.1% to about 2.0%.

Claims

1. A wet area flooring system for forming a graded and waterproofed wet area floor in a room, said system comprising: a plurality of preformed load bearing floor panels configured to be arranged on a support surface around at least one floor waste in a side edge-to-side edge arrangement so as to form a graded wet area floor in which a gradient of each panel directs water or any other liquid in a direction towards the at least one floor waste, wherein each said panel comprises: two opposed surfaces comprising a lower surface and an opposed upper surface, said opposed upper surface configured to have tiling applied thereon, said opposed surfaces being interconnected by opposed end edges and opposed side edges, each said panel tapering in thickness from a first of said opposed end edges to a second of said opposed end edges with a gradient ranging from about 0.1% to about 2.0% to thereby direct said water or any other liquid atop the panel from the first of said opposed end edges to the second of said opposed end edges; and one or more skirting boards configured to be arranged around an outer edge of the room at a junction between an adjacent wall and said first said opposed end edge of an adjacent said panel, wherein each skirting board comprises: two opposed surfaces comprising a wall abutting surface and an outer surface, said opposed surfaces being interconnected by opposed end edges and opposed side edges, each said skirting board extending longitudinally between said opposed end edges, wherein the plurality of the preformed load bearing floor panels and the one or more skirting boards are each formed from a waterproof material, and wherein when arranged said plurality of preformed load bearing floor panels and said one or more skirting boards are waterproof bonded to form the waterproofed wet area floor in the room.

2. The system of claim 1, wherein said plurality of preformed load bearing floor panels and said one or more skirting boards are waterproof bonded to adjacently arranged floor panels and/or skirting boards.

3. The system of claim 2, wherein said plurality of preformed load bearing floor panels and said one or more skirting boards are waterproof bonded to adjacently arranged floor panels and/or skirting boards by plastic welding between adjacent said end edges and adjacent said side edges.

4. The system of claim 2, wherein said plurality of preformed load bearing floor panels and said one or more skirting boards are waterproof bonded to adjacently arranged floor panels and/or skirting boards by application of a sealant between adjacent said end edges and adjacent said side edges.

5. The system of claim 1, wherein said outer surface of each said skirting board is configured to have tiling applied thereon.

6. The system of claim 1, wherein the wall abutting surface of each said skirting board is adhesively bonded to the adjacent wall of the room.

7. The system of claim 1, wherein the lower surface of each preformed load bearing floor panel is adhesively bonded to the support surface.

8. The system of claim 1, wherein the support surface comprises a portion or part of a slab.

9. The system of claim 1, wherein the support surface is comprises two or more horizontal support beams with a panel or sheet laid atop to cover any gaps between the two or more horizontal support beams.

10. The system of claim 1, wherein each said preformed load bearing floor panel tapers from the first of said opposed end edges to the second of said opposed end edges with a gradient ranging from about 0.2% to about 0.45%.

11. The system of claim 1, further comprising one or more shower wall panels configured to be arranged at a junction between an adjacent wall and said first said opposed end edge of an adjacent said floor panel at a location in which a shower is to be located.

12. The system of claim 11, wherein said one or more shower wall panels each comprising two opposed surfaces comprising a wall abutting surface and an outer surface, said opposed surfaces being interconnected by opposed edging, and said outer surface configured to have tiling applied thereon.

13. The system of claim 11, wherein the one or more shower wall panels are formed from a waterproof material.

14. The system of claim 13, wherein the one or more shower wall panels are waterproof bonded to adjacently arranged floor panels and/or skirting boards.

15. A method of forming a graded and waterproofed wet area floor in a room, said method comprising: arranging a plurality of preformed load bearing floor panels around at least one floor waste in the room in a side edge-to-side edge arrangement so as to form a graded wet area floor in which a gradient of each panel directs water or any other liquid in a direction towards the at least one floor waste, wherein each said panel is formed from a waterproof material and comprises: two opposed surfaces comprising a lower surface and an opposed upper surface, said opposed upper surface configured to have tiling applied thereon, said opposed surfaces being interconnected by opposed end edges and opposed side edges, each said panel tapering in thickness from a first of said opposed end edges to a second of said opposed end edges with a gradient ranging from about 0.1% to about 2.0% to thereby direct said water or any other liquid atop the panel from the first of said opposed end edges to the second of said opposed end edges; arranging one or more skirting boards around an outer edge of the room at a junction between an adjacent wall and said first said opposed end edge of an adjacent said panel, wherein each skirting board is formed from a waterproof material and comprises: two opposed surfaces comprising a wall abutting surface and an outer surface, said opposed surfaces being interconnected by opposed end edges and opposed side edges, each said skirting board extending longitudinally between said opposed end edges; and waterproof bonding said plurality of preformed load bearing floor panels and said one or more skirting boards when arranged to form the waterproofed wet area floor in the room.

16. The method of claim 15, wherein the waterproof bonding comprises bonding said plurality of preformed load bearing floor panels and said one or more skirting boards to adjacently arranged floor panels and/or skirting boards by plastic welding.

17. The method of claim 16, wherein the plastic welding is applied between adjacent said edges and adjacent said side edges.

18. The method of claim 15, further comprising arranging one or more shower wall panels at a junction between an adjacent wall and said first said opposed end edge of an adjacent said floor panel at a location in which a shower is to be located.

19. The method of claim 18, wherein said one or more shower wall panels are formed from a waterproof material and each comprise two opposed surfaces comprising a wall abutting surface and an outer surface, said opposed surfaces being interconnected by opposed edging, and said outer surface configured to have tiling applied thereon.

20. The method of claim 19, wherein the waterproof bonding further comprises bonding the one or more shower wall panels to adjacently arranged floor panels and/or skirting boards.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0152] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[0153] FIG. 1 is a side view of a floor panel according to an embodiment of the present invention;

[0154] FIG. 2 is building floor plan showing wet areas in typical residential dwelling in which a plurality of the floor panel shown in FIG. 1 are installed to form graded wet area floors;

[0155] FIG. 3 is a sectional side view showing a plurality of the floor panel shown in FIG. 1 located atop a step down defined in slab for forming a graded wet area floor;

[0156] FIG. 4 is another sectional side view also showing a plurality of the floor panel shown in FIG. 1 located directly atop a slab for forming a graded wet area floor; and

[0157] FIG. 5 is a sectional upper perspective view of a wet area with a wet area flooring system according to an embodiment of the present invention installed to form a graded and waterproofed wet area floor.

DETAILED DESCRIPTION

[0158] FIG. 1 shows a floor panel (100) according to an embodiment of the present invention.

[0159] The floor panel (100) has an upper surface (102), an opposed lower surface (104), opposed side edges (105) and opposed end edges, including a first end edge (106) and an opposed second end edge (108). The panel (100) tapers in thickness from the first end edge (106) to the second end edge (108) with a gradient of at least 0.1%. The gradient is a negative gradient configured to direct water or any other liquid towards the second end edge (108).

[0160] The floor panel (100) has a rectangular or square shape and is formed from concrete or plastic material and/or materials.

[0161] The panel (100) is provided in standard lengths of 1,800 mm, 2,100 mm, 2,400 mm, 2,700 mm, 3,000 mm or 4,000 mm extending between the opposed end edges (106, 108), and standard widths of 600 mm, 900 mm, 1,200 mm, 1,350 mm or 1,500 mm extending between the opposed side edges (105).

[0162] Likewise, the panel (100) can have a maximum thickness, as measured at the first end edge (106) between the upper surface (102) and the lower surface (104), of about 25 mm to about 12 mm.

[0163] As mentioned, the panel (100) tapers from the first end edge (106) to the second end edge (108) with a negative gradient of at least 0.1%.

[0164] Generally, the panel (100) is intended to be laid atop or fastened to a support surface such as, e.g., a concrete slab or one or more floor joists, for forming a graded floor, a graded pathway, a graded wet area floor or a graded decking area.

[0165] For panels (100) intended for forming a graded wet area or floor over a slab, the panel (100) has a thickness at the first end edge (106) of about 12 mm and a thickness at the second end edge (108) of about 4 mm. Thus, the panel (100) has a negative gradient of 0.44%, 0.38%, 0.33%, 0.30%, 0.27% and 0.2% at the respective standard lengths of 1,800 mm, 2,100 mm, 2,400 mm, 2,700 mm, 3,000 mm and 4,000 mm.

[0166] For panels (100) intended for forming a graded wet area or floor over one or more 12 floor joists, the panel (100) has a thickness at the first end edge (106) of about 22 mm and a thickness at the second end edge (108) of about 15 mm. Thus, the panel (100) has a negative gradient of 0.39%, 0.33%, 0.29%, 0.26%, 0.23% and 0.18% at the respective standard lengths of 1,800 mm, 2,100 mm, 2,400 mm, 2,700 mm, 3,000 mm and 4,000 mm.

[0167] For panels (100) intended for forming a graded decking area or pathway, the panel (100) has a thickness at the first end edge (106) of about 25 mm and a thickness at the second end edge (108) of about 10 mm. Thus, the panel (100) has a negative gradient of 0.83%, 0.71%, 0.63%, 0.56%, 0.50% and 0.38% at the respective standard lengths of 1,800 mm, 2,100 mm, 2,400 mm, 2,700 mm, 3,000 mm and 4,000 mm.

[0168] The upper and lower surfaces (102, 104) of the panel (100) are textured to at least partially assist in fastening material to the upper surface (102) of the panel (100), such as, e.g., water proofing, tiling, decking or the like, and for fastening the lower surface (104) of the panel (100) to a support surface.

[0169] FIG. 2 shows the panel (100) of the present invention being used to form graded wet area surfaces (220) atop a slab (210) in a building (200).

[0170] As shown, a plurality of the panel (100) are used to form each wet area surface (220) in the bathroom (230), laundry (240), en-suite (250) and in the showers (260) located in the bathroom (230) and en-suite (250).

[0171] To form each wet area surface (220), the panels (100) are fastened atop the slab (210) in a side edge (105) to side edge (105) arrangement with the first end edge (106) of each panel (100) located against an outer perimeter of the wet area surface (220) and the second end edge (108) located adjacent the floor waste (280) defined in each wet surface area (220) such that the gradient or taper of the panel (100) is able to direct water or any other liquid towards the floor waste (280) for drainage.

[0172] The side edges (105) of the panels (100) are mitred to allow them to be suitably arranged around the floor waste (280) in each wet area surface (220). Likewise, the second end edge (108) of each panel (100) is trimmed and/or shaped to snugly fit about the floor waste (280).

[0173] Each panel (100) is fastened to the slab (210) with a chemical adhesive, such as, e.g., a cement-based tile adhesive.

[0174] FIGS. 3 and 4 show sectional side views of a plurality of the panel (100) being respectively fastened atop a slab (210) for forming a graded wet area surface (220).

[0175] FIG. 3 shows the panels (100) fastened atop a step down (310) defined in the slab (210) where the wet area is intended to be located.

[0176] In contrast, FIG. 4 shows the panels (100) being fastened directly atop the slab (210) without a step down being defined in the slab (210).

[0177] A method of forming a graded wet area surface (220) using a plurality of the panel (100) of the present invention is now described in detail with reference to FIG. 2.

[0178] The method includes an initial step of preparing the support surface by cleaning the slab (210) where the wet area is intended to be located.

[0179] At least four of the panels (100) are then arranged around each floor waste (280) defined in the slab (210) where an intended wet area is to be located. The panels (100) are arranged in a side edge (105) to side edge (105) arrangement and orientated such that the first end edge (106) of each panel (100) is located near or against an outer perimeter of the intended wet area and the opposed second end edge (108) is located near or against the floor waste (280).

[0180] The side edges (105) of each panel (100) are mitred to enable the panels (100) to snugly fit side edge (106) to side edge (106) about the floor waste (280). Likewise, the second end edge (108) of each panel (100) is trimmed and shaped, if needed, to snugly fit about the floor waste (280).

[0181] Each panel (100) is then fastened to the slab (210) with a chemical adhesive, such as, e.g., a cement-based tile adhesive.

[0182] In wet areas including a shower (260), such as, e.g., a bathroom (230) or en-suite (250), one or more panels (100) forming the graded wet area surface (220) of the bathroom (230) or the en-suite (250) are further trimmed to fit about or around the intended wet area for the shower (260).

[0183] FIG. 5 shows a wet area flooring system (500) according to an embodiment of the present invention for forming a graded and waterproof wet area surface (220) floor in a room (900).

[0184] The system (500) includes a plurality of preformed load bearing floor panels (100) configured to be arranged on a support surface around a floor waste (280) in a side edge (105) to side edge (105) arrangement so as to form a graded wet area surface (220) in the bathroom (230) of the room (900). A preformed shower tray (920) having a gradient to an associated floor waste (280 is arranged in the shower (260). The gradient of each floor panel (100) and shower tray (920) directs water or any other liquid in a direction towards an associated floor waste (280).

[0185] As with the embodiment shown in FIG. 1, each floor panel (100) includes an upper surface (102), an opposed lower surface (104), opposed side edges (105) and opposed end edges, including a first end edge (106) and an opposed second end edge (108). The floor panel (100) tapers in thickness from the first end edge (106) to the second end edge (108) with a gradient of at least 0.1%. The gradient is a negative gradient configured to direct water or any other liquid towards the second end edge (108), which is configured to be located adjacent a floor waste (280).

[0186] The system (500) includes one or more skirting boards (510) configured to be arranged at least partway around an outer edge of the room (900) at a junction between an adjacent wall (910) and the first end edges (106) of an adjacently arranged floor panels (100).

[0187] Each skirting board (510) includes a wall abutting surface (512), an opposed outer surface (514), opposed end edges (516) and opposed longitudinal side edges (518).

[0188] The system (500) further includes one or more shower wall panels (520) configured to be arranged at the junction between an adjacent wall (910) and a side edge (922) of the shower tray (920) at a location in which a shower (260) is to be located in the room (900).

[0189] Like with the skirting boards (510), each shower wall panel (520) is of a rectangular shape and includes a wall abutting surface (522), an opposed outer surface (524), opposed end edges (526) and opposed longitudinal side edges (528).

[0190] In this embodiment, the preformed load bearing floor panels (100), the skirting boards (510) and the shower wall panels (520) are all formed from the waterproof material polyvinyl chloride (PVC) as is the shower tray (920). The floor panels (100), the skirting boards (510), the shower wall panels (520) and the shower tray (920) are waterproof bonded to one another by plastic welding to form the waterproofed wet area surface (220) in the room (900). The load bearing floor panels (100), the skirting boards (510) and the shower wall panels (520) are each formed as plastic extrusions.

[0191] In this embodiment, each floor panel (100) has a thickness of about 10 mm at the first end edge (106) and a thickness at the second end edge (108) of about 2 mm. Thus, the panel (100) has a negative gradient of 0.88%, 0.66%, 0.59%, 0.44%, 0.38% and 0.33% at the respective standard lengths of 900 mm, 1,200 mm, 1,350 mm, 1,800 mm, 2,100 mm, 2,400 mm, 2,700 mm, 3,000 mm and 4,000 mm.

[0192] Each of the upper surface (102) of the floor panels (100) and the outer surfaces (514, 524) of the skirting boards (510) and the shower wall panels (520) are configured to have tiling applied thereon.

[0193] The floor panels (100) are fastened to an underlying support surface with a chemical adhesive. Likewise, the wall abutting surfaces (512, 522) of the skirting boards (510) and the shower wall panels (520) are adhesively bonded to a lower portion of the wall (910) with a chemical adhesive.

[0194] As indicated, the floor panels (100), the skirting boards (510) and the shower wall panels (520) are waterproof bonded to one another by plastic welding to form the waterproofed wet area surface (220) in the room (900). Specifically, the abutting edges (105, 106, 108) of the floor panels (100) are welded together as well to adjacent objects, such as, e.g., the floor wastes (280), the shower tray (920), a skirting board (510) and/or shower wall panel (520).

[0195] Generally, abutting side and end edges (516, 518) of the skirting boards (510) are welded to adjacent objects, such as, e.g., adjacently positioned floor panels (100), skirting boards (510), the shower tray (920) and/or the shower wall panels (520).

[0196] Further, abutting side edges and end edges (526, 528) of shower wall panels (520) are welded to adjacent objects, such as, e.g., adjacently positioned floor panels (100), skirting boards (510), the shower tray (920) and/or shower wall panels (520).

[0197] In use, each floor panel (100), board (510) and wall panel (520) is trimmed, mitred and/or shaped, prior to being arranged and fastened in place, to fit around, and to, adjacent structures.

[0198] A method of forming a graded and waterproofed wet area floor surface (220) using the system (500) is now described in detail.

[0199] The method includes an initial step of preparing the support surface by cleaning the underlying support surface where the wet area is intended to be located.

[0200] At least four of the floor panels (100) are then arranged around each floor waste (280) defined in the support surface (210) where an intended wet area is to be located. The panels (100) are arranged in a side edge (105) to side edge (105) arrangement and orientated such that the first end edge (106) of each panel (100) is located near or against an outer perimeter of the intended wet area and the opposed second end edge (108) is located near or against the floor waste (280).

[0201] The edges (105, 106, 108) of each panel (100) are mitred, trimmed and/or shaped to enable the panels (100) to snugly fit side edge (106) to side edge (106) about the floor wastes (280) and other adjacent structures.

[0202] Each floor panel (100) is then fastened to the underlying support surface with a chemical adhesive, such as, e.g., a cement-based tile adhesive.

[0203] The preformed shower tray (920) is fastened in place to the underlying support surface with chemical adhesive, such as, e.g., a cement-based tile adhesive, about its associated floor waste (280).

[0204] At least two shower wall panels (520) are then arranged side edge (528) to side edge (528) at a junction between a wall (910) and an edge (922) of the shower tray (920) at a location in which a shower (260) is to be located. Each shower wall panel (520) is fastened to the wall (910) with a chemical adhesive, such as, e.g., a cement-based tile adhesive.

[0205] Once the shower wall panels (520) are arranged and fastened in place, skirting boards (510) are then arranged around outer edges of the room (900) at the junction between the wall (910) and first end edges (106) of adjacently positioned floor panels (100). Each skirting board (510) extends longitudinally along the junction and is fastened to the wall (910) with a chemical adhesive, such as, e.g., a cement-based tile adhesive.

[0206] Once the floor panels (100), the shower tray (920), the shower wall panels (520) and skirting boards (510) are arranged and fastened in place, the respective and abutting edges (105, 106, 108, 922, 516, 518, 526, 528) are waterproof bonded to one another and adjacent structures such as the floor wastes (280). The edges (105, 106, 108, 922, 516, 518, 526, 528) are waterproof bonded by plastic welding to provide the graded and waterproofed wet area floor surface (220).

[0207] In the present specification and claims (if any), the word comprising and its derivatives including comprises and comprise include each of the stated integers but does not exclude the inclusion of one or more further integers.

[0208] Reference throughout this specification to one embodiment or an embodiment means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases in one embodiment or in an embodiment in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0209] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.