CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims benefit of United States Provisional Application Number 60/ — , — , filed May 23, 2005, which is hereby incorporated herein by reference in its entirety.

INTRODUCTION

[0002] The invention relates to a floor panel, and more particularly, to a floor panel having a tongue and groove generally perpendicular to a plane of the floor panel. The invention also relates to a connection between pieces of flooring and a method of connecting such flooring, and more particularly, to a connection and method of connecting such flooring permitting an efficient joining of such adjacent pieces with minimal use of tools.

BACKGROUND OF THE INVENTION

[0003] Laminate floor tiles, which are commonly rectangular in shape, typically include interlocking edge profiles to join adjacent pieces of the floor tiles together. These interlocking profiles commonly utilize interlocking tongue and groove connections that generally extend outwardly from the edges generally parallel to the plane of the finished flooring. The traditional interlocking profiles generally require a "two-step" attachment process to join each successive floor tile. That is, two adjacent pieces of laminate flooring are initially connected at their long sides in a slightly staggered arrangement. Subsequently, a third piece of laminate flooring is then attached to the long side of one of the other adjacent pieces, pivoted downwardly to the floor, and then attached to the short side of the remaining adjacent piece through the use of a tool, such as a mallet or hammer, to effect a snapping of the adjacent short

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sides together. In other words, the first step generally involves joining the edges of the long sides and the second step generally involves joining the edges of the short sides in separate steps or motions.

[0004] In some systems, either or both steps utilize a "snap" connection where a portion of one floor tile deflects out of its normal position to receive a portion of a second floor tile. Once the flooring is received, the connection snaps into a position locking the edges together. For instance, a typical "snap" connection includes an edge profile having a protuberance on a lower portion of a tongue that is received in a complementary recess formed a lower lip of the groove on an adjacent floor panel. To receive the tongue, the lower lip deflects downwardly by the protuberance during installation. The groove lower lip, following assembly, "snaps" into a locking position to ensure locking integrity of the tongue and groove connections between the adjacent panels.

[0005] The two-step installation procedure in such systems, however, has several shortcomings. First, laminate flooring using the two-step installation procedure typically involves a more complex installation. With such flooring, the attachment of both the long and short sides of a floor tile can not be completed in one single, continuous motion, but require separate motions, repositioning of the installer's hands, or the use of tools. For example, the long sides of a first and second tile are first joined. Thereafter, a third piece is joined to the first piece and then pivoted to the floor while still unconnected to the second tile. Once on the floor, the third piece is slid on the floor until it contacts the second piece. Once in contact with the second piece, the third piece is forced into locking association (i.e., the snap connection) with the second piece while remaining on the floor.

[0006] The snap-connection also presents several shortcomings during installation. In order to force the two pieces together and deform the locking

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connections, significant force is often required. In fact, often a rubber mallet or hammer is often required to move the two adjacent pieces into locking association because of the necessity for bending the edge profile for the snap action. In addition, the use of a mallet or hammer often damages the edge profile, which may render the edge unsuitable for further assembly. Moreover, if the assembled flooring needs to be disassembled for purposes of moving the flooring or re-laying a poorly positioned piece, the snap connection can render disassembly more difficult.

[0007] Accordingly, there is a desire for an interlocking floor tile and simplified method of installation thereof that does not require the use of separate installation tools or excessive force.

SUMMARY

[0008] In one aspect, a floor panel is described that may be coupled to an adjacent floor panel with a downwardly pivoting motion. The floor panel preferably includes a floor member extending in a plane and defined by spaced sides. The floor member has an upper surface with a decorative layer and a lower surface. In another aspect, the floor panel further includes a first locking connection formed in one of the sides that includes a tongue extending downwardly from the upper surface and generally perpendicular to the plane of the floor member. The floor panel preferably also includes a second locking connection formed in another of the sides configured to receive the first locking connection of an adjacent floor panel during installation thereof. The second locking connection also preferably including a groove extending upwardly from the lower surface and generally perpendicular to the plane of the floor member.

[0009] In another aspect, the floor panel defines an opening or cutaway portion in the second locking connection. The cutaway portion generally extends from the upper surface to the lower surface at an intersection of the spaced sides and is sized to

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receive a portion of the first locking connection of an adjacent floor panel in a tilted orientation during installation thereof. Preferably, the cutaway is formed because the second locking connection does not extend the full length of the panel edge. In this manner, the cutaway portion permits the first locking connection of an adjacent floor panel to be incrementally received in the second locking connection through downward pivoting of the adjacent floor panel.

[0010] According to another aspect, a locking connection between first, second and third adjacent pieces of laminate flooring is provided. An exemplary connection includes a female and a male connection along the long sides of the first and third adjacent pieces of flooring and a male and female connection along the short sides of said second and third adjacent pieces flooring. The female and male connections between the long sides of the first and third adjacent pieces preferably allow a limited amount of relative movement therebetween. In another aspect, the female and male connections between the short sides of the second and third pieces extend in a plane that is generally perpendicular to the plane of the flooring in a final assembled configuration.

[0011] According to a further aspect, a method of connecting first, second and third adjacent pieces of laminate flooring is provided to join the first and third adjacent pieces along their long sides and to join the second and third adjacent pieces along their short sides. In one form of the method, the third adjacent piece is moved into contact with the first adjacent piece while being tilted relative thereto. In this tilted configuration, a portion of the short side of the third piece may be moved into contact with the short side of the second piece while in the tilted configuration. Once in contact with the short side of the second piece, the third piece is pivoted downwardly into a generally horizontal final position in a single motion. Once joined to the second piece, the short side of the third piece is received into a compressive relationship with the short side of the second piece to hold the pieces together.

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BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 is a top plan view of three adjacent pieces of flooring that are intended to be joined together;

[0013] FIG. 2 is an elevational view of an exemplary connection on the long sides of the adjacent pieces of flooring in FIG.1;

[0014] FIGS.3A and 3B are perspective views of the adjacent pieces of flooring from FIG. 1 during an assembly operation;

[0015] FIG. 3C is a plan view of one of the three adjacent pieces of flooring of FIG. 1;

[0016] FIG. 4 is a bottom plan view of the three pieces of adjacent flooring from FIG. 1 following assembly;

[0017] FIG. 5 is an elevational view of an exemplary connection on the short sides of the adjacent pieces of flooring in FIG. 1;

[0018] FIG. 6 is an elevational view of another exemplary connection on the short sides of the adjacent pieces of flooring in FIG.1;

[0019] FIG. 7 is an elevational view of another exemplary connection on the short sides of the adjacent pieces of flooring in FIG. 1;

[0020] FIG. 8 is an elevational view of another exemplary connection on the short sides of the adjacent pieces of flooring in FIG. 1;

[0021] FIG. 9 is an elevational view of another exemplary connection on the short sides of the adjacent pieces of flooring in FIG. 1;

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[0022] FIG. 10 is an elevational view of another exemplary connection on the short sides of the adjacent pieces of flooring in FIG. 1;

[0023] FIG. 1OA is a detailed view of the connection of FIG. 10;

[0024] FIG. 11 is an elevational view of another exemplary connection on the short sides of the adjacent pieces of flooring in FIG.1; and

[0025] FIG. 12 is an elevational view of another exemplary connection on the short sides of the adjacent pieces of flooring in FIG. 1;

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] Referring FIG. 1, there is illustrated interconnectable flooring in the form of a first piece 10, a second piece 11 and a third piece 12. As illustrated, the first piece 10 and the second piece 11 are already joined, and the third piece 12 is shown in an unassembled condition.

[0027] Each of the three flooring pieces 10, 11, and 12 are preferably formed from a rectangular flooring member and, therefore, has both short and long edges. For example, the third piece 12 has spaced short edges 13 and spaced long edges 21 (only one short edge is shown). The second piece 11 has short edges 14 and long edges 22 (only one short edge is shown). Similarly, the first piece 10 has long edges 20 and short edges (not shown). The short edges of the first piece 10 are not being illustrated for efficacy. During assembly, the long edges are configured for connection and the short edges are configured for connection. For instance, the long edge 20 of the first piece is configured for connection with both the long edge 21 of third piece 12 and the long edge 22 of the second piece 11. While rectangular flooring pieces are preferred, the flooring pieces may also be other shapes.

[0028] It is preferred that the flooring pieces 10, 11, and 12 are laminated flooring, such as flooring formed from a laminate including a composite core and at least a

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decorative covering on top of the core. For instance, the composite core includes compressed ground wood particles that are held together with a binder, such as HDF or MDF. However, the flooring pieces 10, 11, and 12 may also be solid wood, engineered wood, or other wood-based flooring materials. Furthermore, the flooring pieces 10, 11, and 12 may also be ceramic, plastic, tile, metal, or other material suitable for use as interconnectable flooring.

[0029] Referring to FIG. 2, an exemplary connection along the long edges 20, 21, and 22 is illustrated in greater detail. The connection will be described with respect to the long edges 20 and 21, but a similar connection may also be found in edge 22. In one aspect, the long edge 20 of the first piece 10 includes a female receiving groove 20a adapted to receive a male tongue 21a of the third piece long edge 21. One example of a suitable tongue and groove connection for the long edges 20 and 21 is illustrated and described in United States Patent No. 4,426, 820 to Terbrack.

[0030] The connection on the long edge 22 of the second piece 11 also preferably includes a similar male tongue (not shown) configured to be received in the female receiving groove 20a. The long edges 20, 21, and 22 may also include other types of interconnectable profiles. As is known in the art, one long side of a panel would have the groove configuration and the opposite long side of a panel would have the tongue configuration permitting a tongue from one panel long edge to be coupled to a groove of an adjacent long edge of a panel.

[0031] The interlocking profiles of the first, second, and third pieces 10, 11, and 12 permit the long and short edges thereof to be interconnected in a staggered configuration as illustrated in FIGS. 1, 3A, and 3B. Such a configuration is achieved by connecting portions of the long edges 20 and 22 of the first and second pieces 10 and 11 where the first and second pieces 10 and 11 are staggered longitudinally with respect to each other. In one aspect, this connection is first completed by tilting the

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second piece 11 at an angle relative to the first piece 10 and then inserting a long side (or first) male tongue (not shown) of the second piece 11 into the long side (or a first) female receiving groove 20a of the first piece 10, and secondly, pivoting the second piece 11 downwardly to a horizontal position on the floor. However, the long sides may also be joined through other motions depending on the particular connection profile defined in the panel long sides.

[0032] Next, the third piece 12 may then be connected to both the first piece 10 and to the second piece 11. For instance, a connection between the long edges 20 and 21 of the first and third pieces 10 and 12 is initially effected by tilting the third piece 12 at an angle relative to the first piece 10 and then inserting the long side tongue 21a into the long side groove 20a while in this tilted configuration as generally illustrated in FIG. 2 (i.e., arrow C). At this point, prior flooring connections and installation methods would require the third piece 12 to be pivoted down to the floor while unconnected to the second piece 11 into its normal horizontally assembled condition and then moved until it contacts the short edge 14 of the second piece 11 in order to assembly the short sides. Such movement of the third piece 12 used in prior assembly methods typically would require repositioning of the hands or the use of a hammer or mallet, which can damage the flooring. Moreover, the assembly using such prior art methods typically requires elastic bending of at least a portion of the connection in order to couple the third piece 12 to the second piece 11 while in such horizontal position. On the other hand, the methods and panel connections described herein simplify the continued assembly of the panels and minimize such shortcomings.

[0033] Referring to FIGS.3A and 3B, the short edge 13 of the third piece 12 can be connected to the short edge 14 of the second piece 11 in a generally single motion. For example, the connection between the long sides 20 and 21 permits the third piece 12 to be slid longitudinally along the first piece 10 towards the second piece 11 while remaining in the tilted configuration (i.e., arrow A in FIG. 3A). The above described

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connection between the long sides of the first piece 10 and the third piece 12 permits relative movement therebetween where the first piece 10 preferably remains relatively stationary while the third piece 12 is moved.

[0034] Once the short edge 13 of the third piece 12 is adjacent to and preferably contacting, as described in more detail below, the short edge 14 of the second piece 11, the third piece 12 may then be pivoted downwardly (i.e., arrow B in FIG. 3A) to a horizontal position on the floor to complete the assembly to the second piece 11. FIG. 3B illustrates the third piece 12 is a partially coupled position with the second piece 11 where a substantial portion of the downward pivoting of the third piece 12 has been completed. Such longitudinal sliding and pivoting of the third piece 12 may be completed in relatively a single motion with minimal repositioning of the hands and preferably without the use of additional tools so as to minimize any damage to the flooring panels.

[0035] As will be further described below, the preferred and simplified installation procedure is possible due to an opening or cutaway portion 26 in the short edge 14 of the second piece 11. Referring to FIGS. 3A, 3C, and 4, the opening 26 is preferably at the intersection of the long side 22 and the short side 14 and extends from and upper surface of the floor panel through the panel to the lower surface of the floor panel. In one aspect, as will be further described below, the opening 26 is formed because the connecting member on the short side 14 does not extend the full extend of the short side. That is, the connecting member of the short side 14 has a first length Ll that is less than the full length L3 of the short side 14. Additionally, when the second piece 11 is coupled to the first piece 10 as described above, the opening 26 has a sufficient length L2 along the short side 14 such that the opening 26 is accessible along the short side 14 when the long side 22 and long side 20 are coupled theretogether and available to receive a portion 28 of the short side 13 therein during

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installation. For example, the opening 26 preferably extends about.lO to about 20 mm along the short side 14.

[0036] The opening 26 is advantageous because it's length L2 along the short side 14 permits the portion 28 of the third piece short side 13 to be received therein, even when the long sides of the first and second pieces 10, 11 are coupled together, which positions the tilted third piece 12 in a configuration for the pivoting assembly with the second piece 11 as best illustrated in FIG.3A. The opening 26 permits the short edge

13 to be assembled with the short edge 14 with minimal, if any, deleterious elastic bending of the second piece short edge 14. When coupled, the panels 10, 11, and 12 form a joint having an integrity substantially similar to prior joints even with the opening 26 in the short side 14, which provides a short side 14 having less of an interconnectable profile for coupling the panels together than prior connections.

[0037] It will be appreciated that sliding the short edge 13 toward the short edge

14 in a horizontal configuration as in prior art installation methods will result in interference between the two edges 13 and 14. In this aspect, unless the third piece 12 is tilted upwardly relative to the second piece 11 and then pivoted downwardly to the horizontal position once the edge portion 28 is received in the cutaway opening 26 as illustrated in FIG. 3 A, the coupling of the short edges 13 and 14 will be difficult without damage to the joint profiles. In other words, the opening 26 on the edge 14 (FIGS. 4A and 5) preferably allows the initial entry of the edge 13 without interference by the edge 14. Thus, the profile of the edge 13 may be received in the profile of the edge 14 via the downward pivoting motion described above.

[0038] A variety of profiles may be employed on the short sides 13 and 14 of the panels 11 and 12 to accomplish the above described coupling. Preferred examples of these profiles are illustrated in FIGS. 5 - 12. In general, to accomplish the coupling of the panel short sides, the sides 13 and 14 define interconnecting members and include

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a variety of different locking structures to secure the panels together. Referring to FIG. 5, for example, a general illustration of the interconnecting members is shown. In one form, the edge 14 of the second piece 11 defines a first interconnecting member 30, which spans from an outer edge 31a to an inner edge 31b. As illustrated, the outer edge 31a is preferably contiguous with the panel outer edge 14 while the inner edge 31b is spaced inwardly to the panel 11. In this form, the first interconnecting member 30 defines a female connection 30a and a male connection 30b. As described above, the opening 26 may be formed because the female connection 30a and the male connection 30b doe not extend the full length of the short edge 14.

[0039] Likewise, the edge 13 of the third panel 12 defines a second interconnecting member 32, which spans from an outer edge 33a to an inner edge 33b. The outer edge 33a is also preferably contiguous with the panel outer edge 13 while the inner edge 33b is spaced inwardly to the panel 12. The second interconnecting member 32 preferably defines a female connection 32a and a male connection 32b. The male and female connections 30a and 30b of the first interconnecting member 30 are configured to receive the male and female connections 32a and 32b of the second interconnecting member 32 (and vise-versa) to couple the panels short edges 13 and 14 theretogether.

[0040] The male connection 32b of the second interconnection member 32 preferably is a downwardly extending tongue 34, which extends downwardly from an upper surface 36 of the floor panel 12. In one aspect, the tongue 34 is substantially perpendicular to a plane of the floor panel 12 and sized for receipt in the female connection 30a via a friction or interference fit. In this manner, the tongue 34 in such substantially perpendicular arrangement permits the second interconnection member 32 to be coupled with the first interconnection member 30 via the downwardly pivoting of the third piece 12 as described above. In addition, as shown in FIG.5, the tongue 34 also preferably is contiguous with the outer edge 33a of the second

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interconnection member 32 as well as the outer edge 13 of the third piece 12. In this manner, the fabrication of the profile is also simplified because fewer cuts are needed due to the tongue sharing a boundary with other portions of the edge profile.

[0041] The female connection 32a of the second interconnection member 32 is preferably a downwardly extending groove or opening 35 on the underside of the panel that is adjacent the tongue 34. In one form, as shown in FIG. 5, the groove 35 is spaced inwardly from the edge 33a and defined by an inner edge portion 40 of the tongue 34 on one side and the inner edge 33b of the second interconnection member 32 on the other side. The groove 35 is preferably sized for receipt of the male connection 30b of the first interconnection member 30 via a friction or interference fit. hi addition, similar to the tongue 34, the groove 45 is also preferably substantially perpendicular to the plane of the floor panel 12 to permit the pivoting coupling of the panels.

[0042] The first interconnection member 30 includes similar features. For instance, the male connection 30b of the first interconnection member 30 is also preferably an upwardly extending tongue 42 that extends substantially perpendicularly upwardly from a lower surface 44 of the second piece 11. Similar to the tongue 34, one edge of the tongue 42 preferably is contiguous or shares a boundary with the edge 31a of the first interconnection member 30 and also with edge 14 of the second piece 11.

[0043] The female connection 30a of the first interconnection member 30 is spaced inwardly from the edge 31a and is preferably an upwardly extending groove 46 bounded by an inner edge portion 48 of the tongue 42 on one side and the edge 31b on the other side. As with the tongue 42, the groove 46 is also preferably substantially perpendicular to the plane of the floor panel. As previously mentioned, the upwardly

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extending tongue 42 and the upwardly extending groove 46 do not extend the full length of the short side 14 so as to form the opening 26.

[0044] It will be appreciated by one skilled in the art that one short side of the panel preferably includes the first interconnection member 30 and the opposite short side of the panel preferably includes the second interconnection member 32. Furthermore, the panels described herein may also include the first and second interconnection members 30 and 32 on the long sides if desired.

[0045] In another aspect of the illustrated floor panels, the first and second interconnection members 30 and 32 define at least one locking structure 50 thereon. In addition to the locking structure being the friction or interference fit between the tongue and groove, other embodiments of the locking structure^) 50 are illustrated in FIGS. 6 - 12. The locking structure^) 50 hold or secure the short edges 13 and 14 of the panels together.

[0046] Referring to FIG. 6, the locking structure 50 is illustrated on the second interconnection member 32. In this embodiment, the locking structure 50 is formed on the inner edge portion 40 of the tongue 34. In this form, the locking structure 50 is an extension or protuberance 52 on the inner portion 40 that permits the tongue 34 to be received within the groove 30a via a tight friction or interference fit. For instance, the protuberance 52 extends the width of the tongue 34 to be the same as or slightly larger than the width of the groove 46 on the first interconnection member 30. In this manner, the tongue 34 and protuberance 52 are designed to be squeezed or compressed between the walls defining the female groove 30a (i.e. walls 48 and 31b) to more securely join the edges 13 and 14 when the tongue 34 is received in the groove 46. As illustrated, the protuberance 52 is a preferably a rounded, curved, or other arcuate extension of the tongue edge portion 40. However, the protuberance 52

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may also be other shapes or even extend the entire length of the tongue 34 such that the protuberance 52 is a portion of the tongue 34 that is wider than the groove 46.

[0047] Referring to FIGS. 3A and 6, when piece 12 is tilted upwardly and the protuberance 52 is initially positioned into the groove 46, the subsequent pivot of piece 12 downwardly as illustrated by the arrow B in FIG. 3A results in the tongue 34 and the protuberance 52 being received along the length of the groove 46 in an incremental fashion as the third piece 12 is pivoted downwardly toward a horizontal position (i.e., more of the tongue being received in the groove the closer the third piece is pivoted to horizontal). During such motion, it is believed that the protuberance 52 will press on the tongue 42 of the first connection member (i.e. the tongue inner portion 48) and draw the adjacent pieces closer together so that the final connection between the two adjacent pieces 11 and 12 has increased integrity. Additionally, it is believed that the protuberance 52 preferably creates a force between the male and female connections 32b and 30a that enhances the integrity of the final connection between third piece 12 and second piece 11.

•

[0048] Referring to FIG. 7, an alternative locking structure 50 is illustrated. In this form, the locking structure 50 is defined on the tongue 42 of the first interconnection member 30. In this form, the locking structure 50 is an extension or protuberance 62 defined on the tongue inner edge portion 48. Similar to the protuberance 52 described above, the protuberance 62 permits the tongue 42 of the first interconnection member 30 to be tightly received within the groove 35 of the second connection member 32 via a friction or interference fit. The protuberance 62 will preferably provide the same function as the protuberance 52; that is, creating a force between the male connection 30b and the female connection 30a that will increase integrity of the final connection between third piece 12 and second piece 11.

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[0049] Referring to FIG. 8, another embodiment of the locking structure 50 is illustrated. In this form, the locking structure 50 is defined on both the first interconnection member 30 and the second interconnection member 32. Here, the locking structure 50 includes corresponding curved or arcuate surfaces on the inner edge 31b of the first interconnection member 30 and the outer edge 33a of the second interconnection member 32. The corresponding curvatures of the edges 31b and 33a hold the panels together. While in this aspect the curvatures of edges 31b and 33a are similar, the curvatures can also be different.

[0050] Referring to FIG.9, another variation of the locking structure 50 is

■ illustrated. In this form, the locking structure 50 is defined on the outer edge 31a of the first interconnection member 30 and also on the inner edge 33b of the second interconnection member 32. In this aspect, the locking structure 50 includes an extension or protuberance 64 on the outer edge 31a that interacts or interferes with an extension or protuberance 66 on the inner edge 33b. The protuberance 64 is preferably a curved or arcuate extension of a portion of the edge 31a, and, in this aspect, the protuberance 66 is a curved or arcuate extension of a portion of the edge 33b. Each protuberance 64 and 66 is positioned along the respective edges 31a or 33b such that a contact point or surface 68 is formed when the panels 11 and 12 are joined together. That is, when the pieces 11 and 12 are coupled together, a lower portion or lower lock surface 68a of the protuberance 64 is configured to contact an upper surface or upper lock surface 68b of the protuberance 66.

[0051] Optionally, the width of the protuberances 64 or 66 may>also be greater than the space provided in the opposite interconnection member for their receipt therein. Therefore, the protuberances 64 or 66 may also create a force on the opposite flooring piece. While the protuberances 64 and 66 are illustrated as curved, they may also be other shapes and sizes. Furthermore, while it is preferred that the locking

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structure include both protuberances 64 and 66, it is also desirable to include either protuberance 64 or protuberance 66.

[0052] Referring to FIGS. 10 and 1OA, another aspect of the locking structure 50 is illustrated. In this form, the locking structure 50 is defined on both edges of the tongue 34 (i.e., tongue edge portion 40 and outer edge 33a) and both edges of the groove 46 (i.e., tongue edge portion 48 and inner edge 31b). However, if desired, the locking structure in this form may also only be on one side or the other of the tongue 34 and groove 46.

[0053] In this aspect, the locking structure 50 includes facing serrated surfaces 71 and 72 that each include teeth 74 that are configured to inteπnesh or interfere with each other when the pieces 11 and 12 are joined as illustrated in FIG. 1OA. The serrated surfaces 71 and 72 are advantageous because they permit the entry of the tongue 34 into the groove 46, but resist separation therefrom. FIG. 1OA illustrated a preferred meshing relationship between the serrated surfaces 71 and 72. The serrated surface 71 and 72, therefore, preferably increase joint integrity. The tongue 42 and groove 35 may also define serrated surface 71 and 72 in a similar fashion.

[0054] Referring to FIG. 11, yet another aspect of the locking structure 50 is illustrated that incorporates a combination of the other locking structures previously described. In this form, the locking structure 50 is defined on both edges of the tongue 42 (i.e. tongue edge portion 48 and outer edge 31a) and also on title inner edge 33b of the second interconnection member 32. For instance, in this form, the outer edge 31a and inner edge 33b includes the serrated surfaces 71 and 72 as described above with the embodiment of FIG. 10, and the tongue inner edge portion 48 includes the protuberance 62 as described above with the embodiment of Fig. 7.

[0055] The combination of the two different types of locking structures 50 simultaneously secure the second and third pieces 11 and 12 together, in this aspect,

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preferably through a locking interference via the inteπneshing serrated surfaces 71 and 72 and also with a compression force via the protuberance 62 being compressed by the groove walls (i.e., walls 33b and 40). This simultaneous securement of two different locking structures 50 preferably provides a more enhanced level of integrity in the joint.

[0056] Referring to FIG. 12, another aspect of the locking structure 50 is illustrated. This form of the locking structure is similar to the aspect of FIG. 9 as it includes interacting protuberances 64 and 66, but the protuberances are defined on the inner edge portions 40 and 48 of the tongues 34 and 42. That is, the inner edge portion 40 of the tongue 34 includes the protuberance 64, while the inner edge portion 48 of the tongue 42 includes the protuberance 66. As with the protuberances in the embodiment of FIG. 9, the outer surfaces of the protuberances 64 and 66 act, interference, or contact each other during assembly and when assembled to provide an interference that locks the panels 11 and 12 together and improve the integrity of the joint that maintains the boards in their assembled position. Accordingly, the protuberances 64 and 66 also preferably define the contract point or surface 68 from the lower portion 68a and upper portion 68b.

[0057] The various aspects of the first and second interconnection members 30 and 32 as well as the various locking structure(s) 50 are formed on the short edges of third piece 12 and second piece 11. It will be appreciated that the short edges of the first piece 10 may also include similar features. In addition, the first and second interconnection members 30 and 32 or separate features thereof may also be included on the long edges of any of the pieces 10, 11, or 12.

[0058] The assembly of the first piece 10, the second piece 11, and the third piece 12 will now be described in more detail It will be appreciated that additional pieces may be assembled in a like manner. In the method described below, it will be

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assumed that the first and second pieces 10 and 11 illustrated in FIG. 1 have already been joined together, as described above, and are existing horizontally on the floor on which they are laid. The following procedure will describe an example of a method to connect the third piece 12 to both of the previously laid pieces 10 and 11.

[0059] To begin with, the long edge 21 of third piece 12 will be brought into proximity with the long edge 20 of first piece 10. The third piece 12 will be tilted upwardly relative to the first piece 10 to the position generally illustrated in FIG. 2. The male connection 21a of the third piece long side 21 is then partially inserted into the female connection 20a of the first piece long side 21 (i.e., arrow C in FIG. 2). At the same time, the third piece 12 is moved longitudinally relative to the first piece 10 (i.e., arrow A in FIG. 3A) while remaining tilted and partially coupled thereto until the portion 28 of the side 13 is received within the opening 26 (FIGS.3A). In this manner, a portion of the second interconnection member 32 is preferably received in the opening 26 such that the second interconnection member 32 is positioned above the first connection member 30 (FIG.3A).

[0060] The third piece 12 is then pivoted downwardly to the horizontal position with the second interconnection member 32 pivotably moving relative to the first interconnection member 30 (Le., arrow B in Fig. 3A) such that the second interconnection member 32 is incrementally coupled with the first interconnection member 30. During assembly, it is preferred that the male connection 32b is acted upon (i.e., compressed, squeezed, interfered, friction-fit, etc.) by the edge 48 as the third piece 12 piovtably moves downwardly until a position resembling that illustrated in FIG. 3B is reached with the male protuberance 32b being entirely received by female groove 30a. The third piece 12 is then completely moved into the horizontal position and the connection is complete. Another piece (not shown) may then be joined in a similar manner.

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With reference now to Figures 7 and 8, a typical laminate floor panel is generally illustrated at 100. The laminate floor panel 100 has a high density fiberboard (HDF)

core which provides the strength and durability of the panel 100. A joint generally illustrated at 101 can take the form of any of the joints illustrated and described as well as additional joints not set forth in the present application.

The laminate floor panel 100 has a covering or "decor layer" 102 which is decorative and can take the prom of a design or decorative color which may be impregnated with a melamine resin to give the color-fastness and clarity. The HDF core 100 is composed of cellulose fibers combined with synthetic resins or other suitable bonding systems under heat and pressure. The HDF fiberboard typically has ,a density grater than 50 pounds per cubic foot or 800 kg per cubic meter.

A wear layer 103 is provided to protect the decor layer 102. The wear layer 103 is transparent and made from an alpha cellulose paper impregnated with melamine/formaldehyde resin. The combination is highly durable and provides resistance to the stains, heat, scratches and abrasion to which a floor panel is typically subjected. A backing or balancing layer (not illustrated) on the bottom of the panel 100 may also be used to provide dimensional stability and such a backing layer will typically use a melamine moisture barrier for added

protection .

A bevel 104 is provided on each of the joined panels 100 in the decorative or wear layer 103 as is seen more clearly in Figure 7B. The bevel 104 allows for the panels 100 to be more easily joined and also contributes to less damage to the ends 110 of the joined panels 100 both when the panels 100 are joined in the assembly process and when the panels 100 are assembled and under operating and wear conditions .

Referring now to Figure 8 , a method of manufacturing the panel 100 and, more particularly, the bevel 104 uses a hot roller 111 which is brought into contact with the wear layer 103 when the layer 103 is square with the end of the panel 110 as is illustrated at 105 in Figures 7A and 7B. The hot roller 111 rotates about its axis 112 and the panel member 100 is moved by the roller 111 while pressure and temperature applied to the wear layer 103 melts the layer 103 and provides for the required bevel shape. The hot roller 111 maintains its temperature during the rolling process until the entire edge of the panel is provided with the desired bevel 104.

Many modifications may readily be envisioned to the

process just described. The roller 111 may move relative to the panel member 100 while the panel member 100 is maintained in its stationary position. Indeed, rather than a heated roller 111, a heated die and shoe could likewise be used to provide the necessary bevel shape while relative movement takes place between the heated die and shore and the panel member 100. However, it is the wear layer 103 which is intended to be melted and formed into the required bevel shape 104.

Many furtπer embodiments will readily occur to those skilled in the art to whuLch the invention relates and the specific embodiments (described should be considered as illustrative of thβr invention qnly and riot as limiting its scope as defined/in accordance wiτh the accompanying claims.

A bevel 104 is provided on each of tfie joined panels

100 in the decorative or wear layer 103 as is seen more clearly in Figure 7B. The bevel ΛO4 allows .✓for the panels 100 to be more easily joined and also (contributes to less damage to the

ends 110 of the joined panels 100 both when the panels 100 are joined in the assembly/process ami when the panels 100 are assembled and under operating and webr conditions.

Referring initially Figures/ 12A and 12B , the panel

member 10 has a tongue 100 which extends beyond the long edge

101 of the surface 102 of the panel 10 when viewed in plan. The tongue 100 is seen more clearly in Figure 12B. The tongue 100 extends to the short edge 103 of the surface 102 of the panel 10 where a generally upwardly open groove 104 is formed inwardly from and parallel to the short edge 110 of the panel 10 and which groove 104 is defined by an upper generally flat portion 112 which portion 112 extends the length of the short edge 110 on the panel member 10.

A receiving groove 111 for a tongue on an adjacent panel 11, 12 which is identical to the tongue 100 on panel 10 is formed along the long edge 113 of the panel member 10 and terminates in a cutout portion to accommodate the open groove and flat portion of an adjacent panel as will be described.

The receiving groove 111 terminates the flat portion 112 of groove 104 at groove edge 114 and the flat portion 120 (Figure 12B) of groove 111 terminates at the edge 110.

Referring now to Figure 13A, the assembly of panels

10 and 12 is illustrated. The method of assembly is identical to that shown in Figure 2; that is, the tongue of panel 12 is inserted into the groove 111 of panel 10 with the panel 12 in an upwardly tilted position and, upon the entrance of the tongue into the groove 111, the panel 12 is rotated downwardly into a generally horizontal position. The groove 122 of the panel 12 along the short edge 121 of panel 12 is. formed precisely the same as the groove 104 described in association with panel 10. Since the flat surface 123 of groove 122 is slightly above the flat surface 120 of groove 111, the flat surface may extend to the long edge 124 of panel 10. However, since the thickness of the flat surface 123 is minimal in the area of groove 111, the flat surface 123 can terminate at the vertical surface 130 (Figure 12B) of panel 10. In fact, upon assembly, the portion 131 of the flat surface 123 which extends over groove 111 generally breaks off without affecting the integrity of the assembly of the two panels 10, -12 or the efficiency of the assembly operation and the cutout area 163 in

the lower corner of the panel 12 which cutout area 163 will accommodate the movement of panel 11 towards the right as seen in Figure 15 and which allows the two short edges 133 , 142 to abut against each other in final assembly. The existence of this weakened portion 131 allows for increased machine tolerances during the production of the flooring.

Reference is now made to Figure 14A which is a plan view of panel 11 prior to assembly. Tongue 132 of panel 11 extends the length of the long side of panel 11 identical to the tongue 100 of panel 10 as has been described. In the area of the short edge 133 of panel 11 which is to be assembled to the panel 12 , a recess 134 appears . The recess 134 is created by the formation of a downwardly open groove in the bottom of the panel 12 as will be described and accommodates the flat surface portion 123 of panel 12 as panel 11 is rotated downwardly after the entrance of tongue 132 on panel 11 into the receiving groove 111 of panel 10.

A cutout portion generally illustrated at 140 in

panel 11 is also provided as will be described. The cutout portion 140 has a vertical edge 141 as also will be described. The vertical edge 141 provides for an abutting relationship with the short edge 121 of panel 12 upon assembly. The width

"w" of cutout 140 is slightly longer than the width "w" of panel 140 between the flat vertical surface 142 >of panel 12 and the short edge 121.

Figure 14B, taken along B-B of Figure 14A, illustrates the vertical flat surface 141 which extends from the tongue 142 to the vertical flat surface 143 which abuts the vertical surface 144 (Figure 12B) of panel 10 following assembly. Edge 144 likewise abuts long edge 124 (Figure 12) of panel 10 following assembly. The flat portion 150 of the downwardly opening groove 151 extends from the flat portion of

groove 142 to the tongue 132 as is illustrated.

Reference is now made to the bottom of panel 11 as viewed in Figure 14C. To properly orient this figure, it will be appreciated that vertical edge 152 abuts vertical edge 121 of panel 12 (Figure 13A) and that tongue 153 is accommodated by receiving groove 111 of panel 10 (Figure 13A) . The downwardly opening groove 154 on the short edge of panel 11 extends from the flat portion 151 of groove 142 to the vertical surface 144 of panel 11. The flat portion 150 which defines the outside of recess 154 has a vertical wall 160 which is conterminous with the flat surface 151 of groove 142. The vertical wall 160 is slightly inwardly of edge 144 as is illustrated.' The flat

portion 150 extends to the outside of tongue 153 also as illustrated. The downwardly opening recess 154 is adapted to accommodate the upwardly extending flat surface 123 of groove 122 of panel 12 (Figure 13A) when assembled and to provide for a tight fit upon assembly.

The assembly operation is straightforward. It will be assumed that panel 10 is lying in its horizontal position in its final installed position on the surface over which it is desired to install the flooring. Panel 12 is brought into proximity with panel 10 and tongue 161 (Figure 13Λ) of panel 12 will be inserted into receiving groove 111 of panel 10 with the panel 12 in a generally tilted position as is illustrated in Figure 4A. The panel 12 is then rotated downwardly until it likewise reaches its horizontal position as shown in Figure 13A. It is noted that the

Panel 11 is then brought into proximity with panels 10, 12 and the tongue 132 is inserted into receiving groove 111 of panel 10 in a manner similar to the assembly of panels 11, 12. When the panel 11 is in its tilted position with the tongue 132 engaged within receiving groove 111, the panel 11 will be moved rightwardly as viewed in Figure 15 until short edge 133 abuts vertical flat surface 142 of panel 12 (Figure

13A) again with the panel 11 in its tilted position. Panel 11 will be rotated downwardly with the recess 134 accommodating the upwardly extending flat surface 123 of paneϊ 12 as it is rotated downwardly. The flat surface 123 will be received within recess 134 incrementally until panel 11 is likewise horizontal with edge 162 abutting long edge 124 of panel 10 and short edge 133 abutting edge 142 of panel 12. The assembly of the flooring is then continued in a likewise fashion until the flooring is assembled.

Referring now to Figure 8 , a method of manufacturing the panel 100 and, more particularly, the bevel 104 uses a hot roller 111 which is brought into contact with the wear layer

103 when the layer 103 is square with the end of the panel 110 as is illustrated at 105 in Figures 7A and 7B. The hot roller 111 rotates about its axis 112 and the panel member 100 is moved by the roller 111 while pressure and temperature applied to the wear layer 103 melts the layer 103 and provides for the required bevel shape. The hot roller 111 maintains its temperature during the rolling process until the entire edge of the panel is provided with the desired bevel 104.

Many modifications may readily be envisioned to the process just described. The roller 111 may move relative to

the panel member 100 while the panel member 100 is maintained in its stationary position. Indeed, rather than a heated

roller 111, a heated die and shoe could likewise be used to provide the necessary bevel shape while relative movement takes place between the heated die and shore and the panel member 100. However, it is the wear layer 103 which is intended to be melted and formed into the required bevel shape 104. In addition and rather that utilising a heating operation to form the bevel shape, it is contemplated that a sanding process could be used. In such a process, a sander would provide the necessary bevel shape while relative movement takes place between the panel member 100 and a sander (not shown) .

Many further embodiments will readily occur to those skilled in the art to which the invention relates and the specific embodiments described should be considered as illustrative of the invention only and not as limiting its

scope as defined in accordance with the accompanying claims.

CLAIMS

What is claimed is:

1. A floor panel configured to be coupled to an adjacent floor panel, the floor panel comprising: a floor member extending in a plane and defined by spaced sides, the floor member having an upper surface with a decorative layer and a lower surface; a first locking connection formed in one of the sides including a tongue extending downwardly from the upper surface and generally perpendicular to the plane of the floor member; a second locking connection formed in an opposite side including a groove extending upwardly from the lower surface and generally perpendicular to the plane of the floor member, the groove configured to receive a tongue from an adjacent floor panel during installation thereof, the second locking connection extending partially about the opposite side such that a first length of the second locking connection being less than a full length of the opposite side; and a cutaway portion in the second locking connection extending from the upper surface to the lower surface at an intersection of the opposite side and another side, wherein the cutaway is formed from the partial extension of the second locking connection on the opposite side, the cutaway portion defining an opening having a second length sufficient to receive a portion of the first locking connection of an adjacent floor panel in a tilted orientation during installation thereof to permit the first locking connection of an adjacent floor panel to be incrementally received in the second locking connection through downward pivoting of the adjacent floor panel.

2. The floor panel of claim 1, wherein the floor member is a laminate floor panel.

]AC/455,255/May 19, 2006 Attorney Docket 8241/87643

3. The floor panel of claim 1, wherein the first locking connection further comprises a second groove extending downwardly from the upper surface and generally perpendicular to the plane of the floor member.

4. The floor panel of claim 3, wherein the second locking connection further comprises a second tongue extending upwardly from the lower surface and generally perpendicular to the plane of the floor member.

5. The floor panel of claim 4, wherein the first locking connection has an outside edge and an inside edge and a first locking structure defined on the inside edge.

6. The floor panel of claim 5, wherein the second locking connection has an outside edge and an inside edge and a second locking structure defined on the outside edge of the second locking connection such that when the floor panel is coupled to an adjacent floor panel the second locking structure interferes with the first locking structure to hold the adjacent floor panels theretogether.

7. The floor panel of claim 6, wherein the first locking structure includes a serrated surface.

8. The floor panel of claim 7, wherein the second locking structure includes a serrated surface.

9. The floor panel of claim 6, wherein the first locking structure includes a first protrusion extending outwardly from the first locking connection inside edge and generally parallel to the plane of the floor panel.

) ' AC/455, 255/May 19, 2006 Attorney Docket 8241/87643

10. The floor panel of claim 9, wherein the second locking structure includes a second protrusion extending outwardly from the second locking connection outside edge and generally parallel to the plane of the floor panel.

11. The floor panel of claim 10, wherein the first protrusion includes a lower contact portion and the second protrusion includes an upper contact portion configured to engage the lower contact portion of a coupled adjacent floor panel.

12. The floor panel of claim 11, wherein the lower contact portion is a curved surface on the first protrusion.

13. The floor panel of claim 9, wherein the upper contact portion is a curved surface of the second protrusion.

14. The floor panel of claim 1, wherein the outside edge of the first locking connection spans the entire extent of the tongue.

15. The floor panel of claim 14, wherein the outside edge of the second locking connection spans the entire extent of the second tongue.

16. The floor panel of claim 1, wherein the opening has a second length of about 10 to about 20 mm.

) 'AC/455 ,255/May 19, 2006 Attorney Docket 8241/87643

17. A floor panel assembly between first, second and third adjacent floor panels, each floor panel defined by spaced long and short sides, said assembly comprising a first female connection along one of the long sides of the first floor panel, a first male connection along one of the long sides of the second floor panel and a second male connection along one of the long sides of the third floor panel, the first and second male connections received in the first female connection and permitting a limited amount of relative movement between the first floor panel and the third floor panel; a second female connection along one of the short sides of the second floor panel and extending in a plane generally perpendicular to a plane of the floor panel;

» a third male connection along one of the short sides of the third floor panel and extending in a plane generally perpendicular to the plane of the floor panel, the third male connection received in the second female connection; and a cutaway portion in the second floor panel at the intersection of the long side and the short side thereof that extends through the second female connection, the cutaway portion having a first length along the second female connection such that it forms an opening extending through the second floor panel when joined to the first floor panel, the first length of the cutaway portion being formed due to the second female connection along the one of the short sides of the second floor panel having a second length less than the full length of the one of the short sides of the second floor panel.

18. The floor panel assembly of claim 17, wherein the first, second, and third floor panels are laminate flooring.

JAC/455,255/May 19, 2006 Attorney Docket 8241/87643

19. The floor panel assembly of daim 17, wherein the second female connection is defined by an outer lip extending generally perpendicular to the plane of the floor panels and the outer lip defines a first locking structure.

20. The floor panel assembly of claim 19, wherein the one of the short sides of the third floor panel defines a second locking structure that interferes with the first locking structure to hold the second and third floor panels theretogether.

21. A method of connecting first, second and third adjacent pieces of floor panels, each floor panel defined by spaced long and short sides and defining a coupling member on each side, the method comprising: coupling the long side of the first floor panel to a portion of the long side of the second floor panel such that the first and second floor panels are arranged in a staggered configuration; partially coupling the long side of the third floor panel to another portion of the long side of the first floor panel, the third floor panel being tilted relative to the first floor panel; moving the short side of the third floor panel into contact with the short side of the second floor panel while the third floor panel remains in the tilted position, pivoting the third floor panel downwardly into a generally horizontal final position such that the coupling member of the third floor panel short side incrementally couples with the coupling member of the second floor panel short side during the pivoting motion.

22. The method in claim 21, wherein the short side of the second floor panel defines a cutaway portion having a length along the second floor panel short side

]AC/455,255/May 19, 2006 Attorney Docket 8241/87643

such that the cutaway portion is exposed when the long side of the second floor panel is coupled to the long side of the first floor panel and positioned to receive a portion of the third floor panel short side when in the tilted position.

23. The method of claim 21, wherein the first, second, and third pieces of adjacent floor panels are laminate flooring.

JAC/455,255/May 19, 2006 Attorney Docket 8241/87643