A FLOOR PANEL AND METHODS OF USE THEREOF

Abstract

The present invention relates to a floor panel, a flooring system including the panel and methods of use thereof for forming a graded wet area, floor, pathway or decking. In one form, the present invention provides a floor panel for forming a graded wet area. The panel includes a pair of opposed surfaces including an upper surface and an opposed lower surface interconnected by opposed side edges, a first end edge and an opposed second end edge. The panel further includes a plurality of protrusions protruding from one of the opposed surfaces and extending at least partially across the panel between the opposed side edges, said protrusions protruding at differing heights from the one of the opposed surfaces to define a panel gradient extending between the first end edge and the second end edge.

Claims

1. A floor panel for forming a graded wet area for tiling, said panel comprising: a pair of opposed surfaces comprising an upper surface and an opposed lower surface interconnected by opposed side edges, a first end edge and an opposed second end edge; and a plurality of protrusions protruding from the lower surface and extending at least partially across the panel between the opposed side edges, said protrusions protruding at differing heights from the one of the opposed surfaces to define a panel gradient extending between the first end edge and the second end edge.

2. (canceled)

3. The panel of claim 1, wherein the plurality of protrusions comprise a plurality of nodules arranged in discrete locations across the lower surface and extending to differing heights from the lower surface to define the panel gradient.

4. The panel of claim 1, wherein the plurality of protrusions protrude from and longitudinally extend at least partially across the lower surface of the panel at least partially between the opposed side edges in an orientation parallel with the first and second end edges.

5. The panel of claim 4, wherein the plurality of protrusions comprises a plurality of inverted T-shaped protrusions.

6. The panel of claim 4, wherein the plurality of protrusions are formed by a plurality of depressions formed in the lower surface thereby forming the plurality of protrusions extending therebetween.

7. The panel of claim 4, wherein the plurality of protrusions comprise a plurality of ridges protruding from the lower surface.

8. The panel of claim 1, wherein the plurality of protrusions are integrally formed with the panel.

9. The panel of claim 1, wherein the plurality of protrusions define a negative said panel gradient ranging from about 0.005% to about 2.0%.

10. The panel of claim 1, further comprising part of a connecting mechanism extending along each of the first and second end edges for connecting the panel with a further like panel in an end edge to end edge connection.

11. The panel of claim 10, wherein the connecting mechanism comprises a male formation defined on the first end edge of the panel and a female formation defined on the second end edge of the panel and wherein the male and female formations are configured to mate or couple with corresponding female and male formations provided on at least one said further like panel.

12. The panel of claim 11, wherein the female formation comprises a channel extending longitudinally along the first end edge of the panel, the channel comprises a first channel sidewall defined by the panel and a second channel sidewall defined by a substantially L-shaped member extending from the lower surface of the panel at or near the first end edge to define a channel base wall and the second channel sidewall.

13. The panel of claim 12, wherein the male formation comprises a pair of edge members extending from and at least partially along the second end edge of the panel and wherein the pair of end edges are configured to be at least partially frictionally fitted into the channel of the female formation of a further like panel.

14. The panel of claim 13, wherein at least one of the pair of edge members further comprises a retention portion extending from an outer end and configured to be snugly received in and frictionally engage with the channel to retain the male formation and the female formations of the connecting mechanism together when connected.

15. The panel of claim 14, wherein the retention portion extends from an outwardly turned outer edge of the at least one of the pair of edge members to define a shaped groove and wherein the shaped groove is configured to at least partially receive an inwardly turned edge portion of a corresponding said first channel sidewall of the female formation for retaining the male and female formations together when connected.

16. The panel of claim 10, wherein the connecting mechanism is a snap fitting mechanism enabling adjacent end edges of the panel and at least one further like panel to be readily joined in an aligned and correctly orientated manner to provide the graded wet area.

17. (canceled)

18. (canceled)

19. A method of forming a graded wet area, said method comprising: fastening a plurality of floor panels as defined in claim 1 to a support surface such that a gradient of each panel forms a desired fall towards a floor waste defined in the support surface; and applying tiling atop the plurality of floor panels.

20. The method of claim 19, wherein the fastening comprises fastening each panel to the support surface with one or more mechanical fasteners and/or chemical fasteners.

21. The method of claim 19, wherein the fastening further comprises one or more of trimming and and/or mitring one or more of the panels along one or more of a side edge and an end edge to enable the panels to be arranged.

22. (canceled)

23. The method of claim 19, wherein the applying comprises applying a sealing member or agent between edges of adjacently positioned panels and tiling on an upper surface of the panels.

24. The panel of claim 1, wherein the upper surface of the panel is configured to have tiling applied thereon.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0153] 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:

[0154] FIG. 1 is a side view of a floor panel according an embodiment of the present invention for defining a graded floor. The floor panel has an inner end edge and an opposed outer end edge;

[0155] FIGS. 2A and 2B respectively show side views of further floor panels configured to be selectively joined to the outer end edge of the floor panel shown in FIG. 1 in an end edge-to-end edge arrangement to provide an extended graded floor;

[0156] FIG. 3 is a sectional side view of the connecting mechanism for joining the floor panel of FIG. 1 with either further floor panel as shown in FIG. 2A or 2B;

[0157] FIG. 4 is a building floor plan showing wet areas in a typical residential dwelling in which a plurality of the floor panels as shown in FIGS. 1, 2A and 2C are installed to form graded wet area floors;

[0158] FIG. 5 is a sectional side view showing a plurality of the floor panel shown in FIG. 1 located atop a step down defined in a slab for forming a graded wet area floor;

[0159] FIG. 6 is a sectional upper perspective view of a wet area fitted with a wet area flooring system according to an embodiment of the present invention to form a graded and waterproofed wet area floor; and

[0160] FIGS. 7A to 7C respectively show side views of floor panels according to other embodiments of the present invention.

DETAILED DESCRIPTION

[0161] FIG. 1 shows a floor panel (100) according to an embodiment of the present invention.

[0162] The floor panel (100) has an upper surface (102), an opposed lower surface (104), opposed side edges (105), a first or inner end edge (106) and an opposed second or outer end edge (108). The panel (100) further includes a plurality of ridges (110; i.e., protrusions) protruding from and longitudinally extending at least partially across the lower surface (104) between the opposed side edges (105) in an orientation parallel with the end edges (106, 108).

[0163] The ridges (110) are arranged across the lower surface (104) in a spaced arrangement, wherein the ridges (110) are spaced from one another at regular intervals between the end edges (106, 108).

[0164] The ridges (110) are integrally formed with the panel (100) and protrude from the lower surface (104) at differing heights as they extend across the lower surface (104) between the end edges (106, 108) to define a panel gradient extending between the end edges (106, 108). The gradient is a negative gradient extending from the second or outer end edge (108) to the first or inner end edge (106) to permit the drainage of water towards the first or inner end edge (106) when the panel (100) sits atop a support surface.

[0165] The panel (100) has a rectangular or square shape and is formed from a durable, heat resistant and load bearing plastic or plastics material or materials by injection moulding.

[0166] The panel (100) is provided in a standard length extending between the opposed end edges (106, 108) of 900 mm. However, and with brief reference to FIGS. 2A and 2B, the length is extendable by a further 450 mm or 300 mm, respectively, by the addition of panel extensions (200).

[0167] Referring again to FIG. 1, the panel (100) is provided in standard widths of 600 mm, 900 mm, 1,200 mm, 1,350 mm or 1,500 mm extending between the opposed side edges (105).

[0168] The panel has a standard thickness as measured between the opposed surfaces (102, 104) of 2.5 mm and the ridges (110) range in height from about 0.1 mm to about 8.5 mm from the lower surface (104) to define a gradient of between about 0.008% and about 0.01%.

[0169] Each ridge (110) includes a pair of opposed side surfaces (112) interconnected by opposing edges, including a pair of opposed side edges (114) and an outer end edge (116) longitudinally extending along a length of the ridge (110). The opposed side surfaces (112) extend substantially parallel to one another and the outer end edge (116) is substantially flat for resting atop a support surface.

[0170] Each ridge (110) has a thickness, as measured between the opposed side surfaces (112) of about 1.5 mm.

[0171] 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.

[0172] Referring to FIGS. 1, 2A and 2B, the panel (100) is generally 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.

[0173] In some embodiments, the panel (100) shown in FIG. 1 may be laid atop or fastened to a support surface in a side edge-to-side edge arrangement to form a graded surface. In such embodiments, the panel (100) may need to be trimmed or mitred along one or both side edges (105) to be suitably arranged and/or joined. If joined together, the side edges (105) are waterproof bonded to one another by plastic welding.

[0174] Referring to FIGS. 2A and 2B, in some embodiments, the panel extensions (200) may be joined to the second or outer end edge (108) of the panel (100) shown in FIG. 1 to form a continuous graded surface.

[0175] The panel extensions (200) and the panel (100) are joined together by way of a connection mechanism. The connecting mechanism includes mateable male and female formations (310, 320) that are respectively associated with the first or inner end edges (206) of the panel extensions (200) and the second or outer end edge (108) of the panel (100) shown in FIG. 1 and couple together.

[0176] Referring to FIG. 3, the female formation (320) includes a channel (322) defined at and extending longitudinally along the second or outer end edge (108) of the panel (100). The channel (322) includes a first channel sidewall (324) defined by the panel (100) and a substantially L-shaped member (321) that extends from the lower surface (104) of the panel (100) at or near the second or outer end edge (108) to define a channel base wall (326) and a second channel sidewall (328). The inner surfaces of the channel sidewalls (324, 328) narrow at or near the base wall (326) to provide a snug fit for the corresponding male formation (310).

[0177] The first channel sidewall (324) includes an inwardly turned edge portion (325) and the second channel sidewall (328) includes a taper edged portion (327) that expands rearwardly from a tapered edge to define an enlarged inwardly extending portion (329).

[0178] The male formation (310) includes a pair of edge members (312A, 312B) extending from and at least partially longitudinally along a side surface (112) of an innermost ridge (110) located at or near the first or inner end edge (206) of the panel extension (200). The pair of edge members (312A, 312B) are configured to frictionally fit at least partially into the channel (322) of the female formation (320). The side surface (112) of the ridge (110) functions as a biasing member for biasing the edge members (312A, 312B) apart from one another to engage with the sidewalls (324, 328) of the channel (322) of the female formation (320) when the male formation (310) is at least partially inserted into the female formation (320).

[0179] Edge member (312A) further include a retention portion (314) extending from an outer end that is configured to be snugly received in and frictionally engage with the channel (322) of the female formation (320). The retention portion (314) includes a linear portion (315) extending at an angle from the edge member (312A) and a curved portion (316) extending from the linear portion (315) and curving back at least partially towards the other edge member (312B).

[0180] The retention portion (314) extends from an outwardly turned outer edge of the edge member (312A) to define a shaped groove (318). The shaped groove (318) being defined by the retention portion (314), the edge member (312A) and a portion of the side surface (112) of the ridge (110). The shaped groove (318) is configured to at least partially receive the inwardly turned edge portion (325) of the first channel sidewall (324) of the female formation (320) for retaining the male and female formations (310, 320) together when connected.

[0181] The channel (322) of the female formation (320) further includes a positioning member (340) for correctly positioning the retention portion (314) of the male formation (310) when received in the female formation (320). The positioning member (340) extend from an inner surface of the first channel sidewall (324) for positioning or biasing the retention portion (314) at least partially towards the second channel sidewall (328) and for positioning an outer end of the retention portion (314) at least partially against the enlarged inwardly extending portion (329) of the tapered edge portion (327) of the second channel sidewall (328). In such embodiments, the tapered edge portion (327) at least partially abuts against and presses, urges or biases edge member (312B) towards opposed edge member (312A).

[0182] In use, the male formation (310) including the pair of edge members (312A, 312B) and the retention portion (314) are at least partially inserted into the channel (322) of the female formation (320) until the inwardly turned edge portion (325) of the first channel sidewall (324) snap fits into the shaped groove (318) defined by the retention portion (314) extending from edge member (312A) and the outer end of the retention portion (314) abuts against the enlarged inwardly extending portion (329) of the tapered edge portion (327) of the second channel sidewall (328).

[0183] Advantageously, the snap fitting of the inwardly turned edge portion (325) and the abutment of the end of retention portion (314) provides tactile and audible feedback to an installer thereby allowing the installer to join the panels and panel extensions (100, 200) quickly without necessarily relying on visual cues.

[0184] The connecting mechanism also enable the edges (108, 206) to be readily joined in an aligned and correctly oriented manner to form a continuous graded floor.

[0185] FIG. 4 shows the panel (100) and panel extensions (200) of the present invention being used to form graded wet area surfaces (420) atop a slab (410) in a building (400).

[0186] As shown, a plurality of the panel (100) and panel extension (200) are used to form each wet area surface (420) in the bathroom (430), laundry (440), en-suite (450) and in the showers (460) located in the bathroom (430) and en-suite (450).

[0187] To form each wet area surface (420), the panels (100) are fastened atop slab (410) in a side edge-to-side edge (105) arrangement about the floor waste (480) defined in each wet surface area (420) and corresponding panel extensions (200) are fastened and connected to the second or outer end edge (108) where needed. Each panel (100) and panel extension (200) is oriented and arranged such that the gradient is able to direct water or any other liquid towards the floor waste (480) for drainage.

[0188] The side edges (105, 205) of the panels (100) and panel extensions (200) are mitred to allow them to be suitably arranged in each wet area surface (420). Likewise, the first or inner end edge (106) of each panel (100) is trimmed and/or shaped to snugly fit about the floor waste (480).

[0189] Each panel (100) and panel extension (200) is fastened to the slab (410) with a chemical adhesive, such as, e.g., a cement-based tile adhesive.

[0190] FIG. 5 shows sectional side views of a plurality of the panel (100) being respectively fastened atop a slab (410) for forming a graded wet area surface (420). The panels (100) are fastened atop a step down (510) defined in the slab (410) where the wet area is intended to be located.

[0191] FIG. 6 shows a wet area flooring system (600) according to an embodiment of the present invention for forming a graded and waterproof wet area surface (420) floor in a room (900).

[0192] The system (600) includes a plurality of floor panels (100) configured to be arranged on a support surface around a floor waste (480) in a side edge (105) to side edge (105) arrangement and a plurality of panel extensions (200) configured to be arranged in an end edge (108) to end edge (206) arrangement with panels (100) as needed so as to form a graded wet area surface (420) in the bathroom (430) of the room (900). A preformed shower tray (920) having a gradient to an associated floor waste (480) is arranged in the shower (460). The gradient of each floor panel (100), panel extension (200) and shower tray (920) directs water or any other liquid in a direction towards an associated floor waste (480).

[0193] The system (600) includes one or more skirting boards (610) 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 second or outer end edges (108, 208) of adjacently arranged floor panels (100) or panel extensions (200).

[0194] Each skirting board (610) includes a wall abutting surface (612), an opposed outer surface (614), opposed end edges (616) and opposed longitudinal side edges (618).

[0195] The system (600) further includes one or more shower wall panels (620) 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 (460) is to be located in the room (900).

[0196] Like with the skirting boards (610), each shower wall panel (620) is of a rectangular shape and includes a wall abutting surface (622), an opposed outer surface (624), opposed end edges (626) and opposed longitudinal side edges (628).

[0197] The floor panels (100), the panel extensions (200), the skirting boards (610), the shower wall panels (620) and the shower tray (920) are waterproof bonded to one another by plastic welding to form the waterproofed wet area surface (420) in the room (900).

[0198] Each of the upper surfaces (102, 202) of the floor panels (100), panel extension (200), and the outer surfaces (614, 624) of the skirting boards (610) and the shower wall panels (620) are configured to have tiling applied thereon.

[0199] FIGS. 7A to 7C respectively show other embodiments of the floor panel (100). For convenience, features that are similar or correspond to features of the embodiment shown in FIG. 1 will be referenced with the same reference numeral.

[0200] Referring to FIG. 7A, the floor panel (100) has an upper surface (102), an opposed lower surface (104), opposed side edges (105), a first or inner end edge (106) and an opposed second or outer end edge (108). The panel (100) further includes a plurality of inverted T-shaped protrusions (110; i.e., protrusions) protruding from and longitudinally extending at least partially across the lower surface (104) between the opposed side edges (105) in an orientation parallel with the end edges (106, 108).

[0201] The protrusions (110) are arranged across the lower surface (104) in a spaced arrangement, wherein the protrusions (110) are spaced from one another at regular intervals between the end edges (106, 108).

[0202] The protrusions (110) are integrally formed with the panel (100) and protrude from the lower surface (104) at differing heights as they extend across the lower surface (104) between the end edges (106, 108) to define a panel gradient extending between the end edges (106, 108). The gradient is a negative gradient extending from the second or outer end edge (108) to the first or inner end edge (106) to permit the drainage of water towards the first or inner end edge (106) when the panel (100) sits atop a support surface.

[0203] Referring to FIG. 7B, the panel (100) in this embodiment includes a plurality of broad ridge protrusions (110; i.e., protrusions) protruding from and longitudinally extending at least partially across the lower surface (104) between the opposed side edges (105) in an orientation parallel with the end edges (106, 108).

[0204] Again, the protrusions (110) are arranged across the lower surface (104) in a spaced arrangement, wherein the protrusions (110) are spaced from one another at regular intervals between the end edges (106, 108).

[0205] Further, the protrusions (110) are integrally formed with the panel (100) and protrude from the lower surface (104) at differing heights as they extend across the lower surface (104) between the end edges (106, 108) to define a panel gradient extending between the end edges (106, 108). The gradient is a negative gradient extending from the second or outer end edge (108) to the first or inner end edge (106) to permit the drainage of water towards the first or inner end edge (106) when the panel (100) sits atop a support surface.

[0206] Referring to FIG. 7C, the panel (100) in this embodiment includes a plurality of depressions (710) formed in the lower surface (104) of the panel (100) and thereby forming a plurality of protrusions (110) extending therebetween. The resulting protrusions (110) again protrude from and extend longitudinally at least partially across the lower surface (104) between the opposed side edges (105) in an orientation parallel with the end edges (106, 108).

[0207] The resulting protrusions (110) again protrude from the lower surface (104) at differing heights as they extend across the lower surface (104) between the end edges (106, 108) to define a panel gradient extending between the end edges (106, 108). The gradient is a negative gradient extending from the second or outer end edge (108) to the first or inner end edge (106) to permit the drainage of water towards the first or inner end edge (106) when the panel (100) sits atop a support surface.

[0208] 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.

[0209] 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.

[0210] 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.