ONE-PIECE FLOORING APPARATUS FOR USE IN FLOOR COVERINGS,

AN EDGE CUTTING METHOD OF FORMING SAME, AND

A FLOOR COVERING FORMED FROM SAME

FIELD OF THE INVENTION

[0001] The present invention relates to the field of floor tiles and/or planks for use in floor coverings, and more particularly, to a one-piece flooring apparatus for use in floor coverings, an edge-cutting method of forming same, and a floor covering formed from same.

BACKGROUND OF THE INVENTION

[0002] Various known methods may have been previously used to apply and/or secure different prior art types of flooring (i.e., tiles, floor planks, linoleum, hardwood, etc.) to each other and/pr to a floor base to form floor coverings. One such exemplary method may have involved a first application of an adhesive material to the floor base and/or to the back of the flooring, with the aim of securely adhering the flooring in place on the floor base. It may have been relatively time consuming and/or difficult to install prior art floor coverings, especially in the case of prior art floor coverings which may have required an adhesive in order to be affixed to the floor base and/or to the back of the flooring. This problem is one which may have been still further exacerbated in situations requiring the selection, preparation and/or application of a suitable adhesive. For example, in some cases, it may have been necessary to select a specific adhesive suitable to the type of flooring being utilized. Further, it may have been necessary to precisely apply the adhesive to the floor base in an amount sufficient to hold the flooring in place.

[0003] In the prior art, additional time may also have been required to allow for adequate drying of the adhesive once the flooring was installed. Post-application cleanup of any adhesive located on the surface of the flooring may also have been required. Further, a "two-part" installation of such prior art floorings may have involved costs associated with the preparation and/or application of specific adhesives during the first part of the installation process, and costs associated with the application of the flooring itself (during the second part of the installation process).

[0004] Moreover, many adhesives utilized in prior art floor coverings may have released hazardous fumes and/or noxious odors. Additional steps may have been required to remove indoor air pollutants, hazardous fumes, and/or noxious odors, so that such prior art installations could proceed safely. Accordingly, proper and safe installation of prior art floorings may have required a professional installation team experienced in, and/or cognizant of, the requirements and hazards associated with same.

[0005] In addition, after installation, removal of prior art floorings secured by adhesives (during home renovation and/or retrofitting) may also have been costly and/or time-consuming. Removal of the flooring and adhesive layer may have required substantial effort and/or often may have resulted in an unsightly and otherwise problematic adhesive residue being left on the floor base. In fact, in some cases, it may not have been possible to readily and completely remove the adhesive residue from the floor base. This shortcoming may have resulted in additional problems during any subsequent installation of floor coverings, and may have led to an expenditure of additional time, effort, and/or expense.

[0006] Somewhat more recently in the prior art, adhesive coatings may have been pre-applied to the back of flooring materials during the manufacturing process. Such

prior art self-adhesive flooring (e.g., peel-and-stick vinyl tiles and/or sticky-back tiles) may have been somewhat less costly and/or somewhat easier to install than previous flooring materials which required the adhesive to be applied on-site.

[0007] Prior art self-adhesive floor coverings may, however, have suffered from their own inherent and/or related problems. For example, prior art self-adhesive floor coverings may have been manufactured with an insufficient amount of adhesive material applied to the undersides thereof. As such, these prior art floor coverings may have failed to stick properly and/or completely to the floor base, and/or they eventually may have peeled away from the floor base in places, thus requiring the application of additional adhesive and/or the replacement of floor covering in whole or in part. Additionally, some prior art self-adhesive floorings may have been somewhat unsuitable for installation over a wide variety of floor surfaces — e.g., floor surfaces that may not be flat, smooth, and/or clean. Additionally, when attempting to install prior art self-adhesive floorings over other existing floorings (e.g., over an existing vinyl flooring), they may not have been properly and/or permanently securable in place, such as to have then required the application of a further adhesive coating.

[0008] As with other floorings, it may have been costly and/or time-consuming to remove prior art self-adhesive flooring, especially in situations where an additional adhesive coating was required during the installation process. Similarly, their removal may have left an adhesive residue on the underlying floor surface.

[0009] Additionally, and in general, the installation of prior art floorings may have been associated with one or more of the following potential problems: (1) prior art floorings may have required the maintenance of relatively precise temperature and/or humidity levels during installation; (2) they may have involved additional costs and/or time associated with providing a level and/or clean floor base, potentially requiring

additional floor processing steps to be performed (e.g _v applying an additional layer of leveling cement and/or concrete to the floor base); and (3) prior art floorings may have involved additional costs, after installation, insofar as they may have been subject to shrink cracks and/or wraps appearing in the floor covering due to differential expansion and/or contraction of the floor base (e.g., in response to temperature changes) relative to the floor covering.

[0010] Additionally, a number of wooden floor materials may be generally well known in the prior art. U.S. Patent Nos. 1,978,075 (Butterworth), 2,914,815 (Alexander) and 3,554,850 (Kuhle) may be exemplary in this regard. Regardless of whether such prior art floorings may have been provided as wooden planks and/or tiles (e.g., parquet tiles), however, they may generally have been substantially rigid and/or inflexible. As such, they may not have readily conformed to surface contours and/or surface irregularities of the floor base. Wooden floorings may also be subject to significant expansion and/or contraction in humid and/or arid environments, and/or with temperature variations. Also, gaps may develop between adjacent wooden floor planks and/or tiles. Wooden floorings also may be highly subject to moisture damage — whether from surface moisture or from moisture trapped under the flooring or between flooring gaps, or whether by rotting and/or warping of the wooden flooring material. Additionally, many prior art wooden floorings may have been required to be secured to the floor base using mastic, nailing and/or by other fastening means.

[0011] Other prior art floor coverings may have been adapted for installation, and/or to be maintained in place, without the need for any adhesive between the flooring material and the floor base. Exemplary in this regard are prior art "two-piece" floor plank and/or tile structures. These two-piece flooring structures may typically have included a floor surface layer and a floor base layer. An intermediate adhesive layer

may also have been provided, in prior art two-piece flooring structures, to join the floor surface and base layers to one another in a laterally offset relation, such as to provide an overhanging portion of the floor surface layer and a complementary underlying portion of the floor base layer. Disadvantageously, prior art two-piece flooring structures may have required a significant additional expenditure of manufacturing time, effort and/or costs - e.g., to properly and/or consistently join the two layers in laterally offset relation to one another and/or within acceptable installation tolerances. Additionally, prior art two-piece flooring structures may have been subject, over time, to potential slippage and/or separation of their two distinct layers.

[0012] It is an object of the present invention to provide a flooring apparatus, a floor covering formed from a plurality of flooring apparatuses, and/or a method of forming a flooring apparatus.

[0013] It is an object of one preferred embodiment according to the present invention to provide a flooring apparatus which readily conforms to surface contours and/or surface irregularities of a floor base.

[0014] It is an object of one preferred embodiment according to the present invention to provide a one-piece flooring apparatus formed from a single undivided piece.

[0015] It is an object of one preferred embodiment according to the present invention to provide a one-piece flooring apparatus which has an overhanging portion and an underlying portion.

[0016] It is an object of one preferred embodiment according to the present invention to provide a one-piece flooring apparatus operatively adapted to matingly engage at least one other such one-piece flooring apparatus to form a floor covering.

[0017] It is an object of one preferred embodiment according to the present invention to provide a one-piece flooring apparatus adapted to form a floor covering without requiring an adhesive between the flooring apparatus and the floor base.

[0018] It is an object of one preferred embodiment according to the present invention to provide a one-piece flooring apparatus with a slip-resistant backing and/or cushioning member.

[0019] It is an object of one preferred embodiment according to the present invention to provide a method of edge-cutting a single undivided piece to form a one-piece flooring apparatus.

[0020] It is an object of one preferred embodiment according to the present invention to minimize and/or reduce the amount of time, effort, and/or costs that may previously have been associated with the installation and/or removal of floor coverings.

[0021] It is an object of one preferred embodiment according to the present invention to overcome one or more of the aforementioned mentioned disadvantages associated with the prior art.

[0022] It is an object of the present invention to obviate or mitigate one or more of the aforementioned mentioned disadvantages associated with the prior art, and/or to achieve one or more of the aforementioned objects of the invention.

SUMMARY OF THE INVENTION

[0023] According to the invention, there is disclosed a one-piece flooring apparatus for use with a floor base to form a floor covering. The apparatus includes a single undivided piece formed from a resilient material. The single undivided piece has an upper portion and a lower portion substantially contiguous with the upper portion.

The upper portion defines a substantially planar upper shape. The upper portion has a top surface and an upper marginal portion substantially about a perimeter of the planar upper shape. The upper marginal portion includes an overhanging portion extending out from over the lower portion. The lower portion defines a substantially planar lower shape. The lower portion has a bottom surface and a lower marginal portion substantially about a perimeter of the planar lower shape. The lower marginal portion includes an underlying portion extending out from under the upper portion. The bottom surface operatively engages the floor base in substantially juxtaposed relation. The overhanging portion of at least a first aforesaid apparatus operatively engages the underlying portion of at least a second aforesaid apparatus to form the floor covering. The top surface of the first aforesaid apparatus together with the top surface of the second aforesaid apparatus is operatively presented, from the floor covering, as a substantially continuous visible surface.

[0024] According to an aspect of one preferred embodiment of the invention, the upper shape and/or the lower shape may preferably, but need not necessarily, be congruent polygons. Each of the polygons may preferably, but need not necessarily, have three or more substantially straight sides.

[0025] According to an aspect of one preferred embodiment of the invention, the polygons may preferably, but need not necessarily, be substantially rectangular. Each aforesaid overhanging portion and/or each aforesaid underlying portion may preferably, but need not necessarily, respectively have a longitudinal side portion and/or an end portion which may preferably, but need not necessarily, together define a substantially horizontal "L"-shape.

[0026] According to an aspect of one preferred embodiment of the invention, the polygons may preferably, but need not necessarily, be substantially square. Each

aforesaid side portion may preferably, but need not necessarily, have a length substantially equal to that of each aforesaid end portion.

[0027] According to an aspect of one preferred embodiment of the invention, the overhanging portion may preferably, but need not necessarily, include an overhanging bottom portion and/or an overhanging edge portion. The overhanging edge portion may preferably, but need not necessarily, substantially engage the overhanging bottom portion, preferably in substantially normal relation. The overhanging bottom portion and/or the overhanging edge portion may preferably, but need not necessarily, together define a substantially vertical overhanging "L"-shape. The overhanging bottom portion of at least the first aforesaid apparatus may preferably, but need not necessarily, operatively engage the underlying portion of at least the second aforesaid apparatus.

[0028] According to an aspect of one preferred embodiment of the invention, the overhanging portion may preferably, but need not necessarily, include an overhanging bottom portion and/or an overhanging edge portion. The overhanging edge portion may preferably, but need not necessarily, substantially engage the overhanging bottom portion. The overhanging edge portion may preferably, but need not necessarily, be substantially arcuate. The overhanging bottom portion and/or the overhanging edge portion may preferably, but need not necessarily, together define a substantially vertical overhanging "J"-shape. The overhanging bottom portion of at least the first aforesaid apparatus may preferably, but need not necessarily, operatively engage the underlying portion of at least the second aforesaid apparatus.

[0029] According to an aspect of one preferred embodiment of the invention, the underlying portion may preferably, but need not necessarily, include an underlying top portion and/or an underlying edge portion. The underlying edge portion may preferably, but need not necessarily, substantially engage the underlying top portion,

preferably in substantially normal relation. The underlying top portion and/or the underlying edge portion may preferably, but need not necessarily, together define a substantially vertical underlying "L"-shape. The overhanging portion of at least the first aforesaid apparatus may preferably, but need not necessarily, operatively engage the underlying top portion of at least the second aforesaid apparatus.

[0030] According to an aspect of one preferred embodiment of the invention, the underlying portion may preferably, but need not necessarily, include an underlying top portion and/or an underlying edge portion. The underlying edge portion may preferably, but need not necessarily, substantially engage the underlying top portion. The underlying edge portion may preferably, but need not necessarily, be substantially arcuate. The underlying top portion and/or the underlying edge portion may preferably, but need not necessarily, together define a substantially vertical underlying "J"-shape. The overhanging portion of at least the first aforesaid apparatus may preferably, but need not necessarily, operatively engage the underlying top portion of at least the second aforesaid apparatus.

[0031] According to an aspect of one preferred embodiment of the invention, the overhanging portion may preferably, but need not necessarily, include an overhanging bottom portion. The underlying portion may preferably, but need not necessarily, include an underlying top portion. The overhanging bottom portion and/or the underlying top portion may preferably, but need not necessarily, be each provided with a substantially texturized surface. The overhanging bottom portion of at least the first aforesaid apparatus may preferably, but need not necessarily, operatively engage the underlying top portion of at least the second aforesaid apparatus.

[0032] According to an aspect of one preferred embodiment of the invention, the upper marginal portion may preferably, but need not necessarily, also include an upper

marginal edge portion. The overhanging portion of at least the first aforesaid apparatus may preferably, but need not necessarily, operatively engage the upper marginal edge portion of at least the second aforesaid apparatus.

[0033] According to an aspect of one preferred embodiment of the invention, the lower marginal portion may preferably, but need not necessarily, also include a lower marginal edge portion. The lower marginal edge portion of at least the first aforesaid apparatus may preferably, but need not necessarily, operatively engage the underlying portion of at least the second aforesaid apparatus.

[0034] According to an aspect of one preferred embodiment of the invention, the overhanging portion may preferably, but need not necessarily, have a width substantially equal to that of the underlying portion.

[0035] According to an aspect of one preferred embodiment of the invention, the width of the overhanging portion and/or the underlying portion may preferably, but need not necessarily, be at least about five millimeters (5 mm). According to an aspect of a further preferred embodiment of the invention, the width of the overhanging portion and/or the underlying portion may preferably, but need not necessarily, be at least about ten millimeters (10 mm). According to an aspect of a still further preferred embodiment of the invention, the width of the overhanging portion and/or the underlying portion may preferably, but need not necessarily, be at least about twenty millimeters (20 mm).

[0036] According to an aspect of one preferred embodiment of the invention, the overhanging portion may preferably, but need not necessarily, be operatively positioned at an overhanging height, above the floor base, which may preferably be about equal to the thickness of the lower portion.

[0037] According to an aspect of one preferred embodiment of the invention, the underlying portion may preferably, but need not necessarily, be located at an underlying depth, below the top surface, which may preferably be about equal to the thickness of the upper portion.

[0038] According to an aspect of one preferred embodiment of the invention, the single undivided piece may preferably, but need not necessarily, have an overall thickness such as to afford a flexibility, which preferably enables the single undivided piece to conform to surface contours of the floor base.

[0039] According to an aspect of one preferred embodiment of the invention, the overall thickness may preferably, but need not necessarily, be about 3.5 millimeters (mm) or less. According to an aspect of a further preferred embodiment of the invention, the overall thickness may preferably, but need not necessarily, be about three millimeters (3 mm) or less. According to an aspect of a still further preferred embodiment of the invention, the overall thickness may preferably, but need not necessarily, be about 2.5 millimeters (mm) or less.

[0040] According to an aspect of one preferred embodiment of the invention, the single undivided piece may preferably, but need not necessarily, have a predetermined yieldability to surface irregularities of the floor base, such that the bottom surface, preferably when lying in flat contact on the floor base, may preferably conform to surface irregularities of the floor base.

[0041] According to an aspect of one preferred embodiment of the invention, the resilient material may preferably, but need not necessarily, include a synthetic plastic material.

[0042] According to an aspect of one preferred embodiment of the invention, the resilient material may preferably, but need not necessarily, include a linoleum material, a vinyl material, a polyvinyl chloride material, and/or a derivative thereof.

[0043] According to an aspect of one preferred embodiment of the invention, the resilient material may preferably, but need not necessarily, include a non-synthetic material.

[0044] According to an aspect of one preferred embodiment of the invention, the resilient material may preferably, but need not necessarily, include an inorganic compound material, a rubber mineral composite material, a chlorine-free material, and/or a derivative thereof.

[0045] According to an aspect of one preferred embodiment of the invention, the top surface may preferably, but need not necessarily, be provided with a wood grain design resembling natural wood.

[0046] According to an aspect of one preferred embodiment of the invention, the apparatus may preferably, but need not necessarily, also include at least one adhesive layer applied to the single undivided piece.

[0047] According to an aspect of one preferred embodiment of the invention, the adhesive layer may preferably, but need not necessarily, be applied to the overhanging portion, to the underlying portion, and/or to the bottom surface.

[0048] According to an aspect of one preferred embodiment of the invention, the apparatus may preferably, but need not necessarily, also include a flexible cushioning material securely engaging the bottom surface. The cushioning material may preferably, but need not necessarily, be operatively interposed between the bottom

surface and the floor base. The cushioning material may preferably, but need not necessarily, substantially conform to surface contours of the floor base.

[0049] According to an aspect of one preferred embodiment of the invention, the cushioning material may preferably, but need not necessarily, be a foam material and/or a rubber material.

[0050] According to an aspect of one preferred embodiment of the invention, the cushioning material may preferably, but need not necessarily, have a multi-layer structure.

[0051] According to an aspect of one preferred embodiment of the invention, the apparatus may preferably, but need not necessarily, also include a self-adhesive strip securely engaging the cushioning material. The self-adhesive strip may preferably, but need not necessarily, be operatively interposed between the cushioning material and the floor base. The self-adhesive strip may preferably, but need not necessarily, be operatively secured to the floor base.

[0052] According to an aspect of one preferred embodiment of the invention, the apparatus may preferably, but need not necessarily, be for use as a floor plank.

[0053] According to an aspect of one preferred embodiment of the invention, the apparatus may preferably, but need not necessarily, be for use as a floor tile.

[0054] According to the invention, there is also disclosed a floor covering apparatus for use with a floor base. The apparatus includes at least the first aforesaid apparatus, and the second aforesaid apparatus. The overhanging portion of at least the first aforesaid apparatus engages the underlying portion of at least the second aforesaid apparatus. The top surface of the first aforesaid apparatus, together with the top

surface of the second aforesaid apparatus, is presented as the substantially continuous visible surface. Each aforesaid bottom surface operatively engages the floor base in substantially juxtaposed relation.

[0055] According to the invention, there is also disclosed a method of forming the one-piece flooring apparatus. The method includes step (a) of edge cutting a first upper perimeter section from an upper portion of a single undivided piece. The first upper perimeter section is edge cut to a predetermined depth below a top surface of the upper portion. In this manner, at least a first underlying portion is defined in a lower portion of the single undivided piece. The method also includes step (b) of edge cutting a first lower perimeter section from the lower portion of the single undivided piece. The first lower perimeter section is edge cut to a predetermined height above a bottom surface of the lower portion. In this manner, at least a first overhanging portion is defined in the upper portion of the single undivided piece.

[0056] According to an aspect of one preferred embodiment of the invention, the method may preferably, but need not necessarily, also include step (a.l), preferably after step (a), of edge cutting a second upper perimeter section from the upper portion of the single undivided piece. The second upper perimeter section may preferably, but need not necessarily, be edge cut to the predetermined depth below the top surface of the upper portion. In this manner, a second underlying portion may preferably, but need not necessarily, be defined in the lower portion of the single undivided piece, preferably substantially adjacent to the first underlying portion. The first underlying portion and/or the second underlying portion may preferably, but need not necessarily, together define a substantially horizontal "L"-shape.

[0057] According to an aspect of one preferred embodiment of the invention, the method may preferably, but need not necessarily, also include step (c), preferably after

step (b), of edge cutting a second lower perimeter section from the lower portion of the single undivided piece. The second lower perimeter section may preferably, but need not necessarily, be edge cut to the predetermined height above the bottom surface of the lower portion. In this manner, a second overhanging portion may preferably, but need not necessarily, be defined in the upper portion of the single undivided piece, preferably substantially adjacent to the first overhanging portion. The first overhanging portion and/or the second overhanging portion may preferably, but need not necessarily, together define a substantially horizontal "L"-shape.

[0058] According to an aspect of one preferred embodiment of the invention, step (b) may preferably, but need not necessarily, be performed after step (a). According to an aspect of one alternate embodiment of the invention, step (a) may alternately be performed after step (b).

[0059] Other advantages, features and/or characteristics of the present invention, as well as methods of operation and/or functions of the related elements of the apparatus and method, and/or the combination of steps, parts and/or economies of manufacture, will become more apparent upon consideration of the following detailed description and the appended claims with reference to the accompanying drawings, the latter of which are briefly described hereinbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

[0060] The novel features which are believed to be characteristic of the present invention, as to its structure, organization, use, method of operation, and/or functions of the related elements of the apparatus and method, and/or the combination of steps, parts and/or economies of manufacture, together with further objectives and advantages thereof, will be better understood from the following drawings in which

presently preferred embodiments of the invention will now be illustrated by way of example. It is expressly understood, however, that the drawings are for the purpose of illustration and description only, and are not intended as a definition of the limits of the invention. In the accompanying drawings:

[0061] Figure IA is a top plan view of a one-piece flooring apparatus according to a preferred embodiment of the present invention;

[0062] Figure IB is a side elevational view of the apparatus shown in Figure IA;

[0063] Figure 1C is a sectional view along sight line 1C-1C of Figure IA;

[0064] Figure ID is a front elevational view of the apparatus shown in Figure IA;

[0065] Figure IE is a sectional view along sight line IE-IE of Figure IA;

[0066] Figure 2A is a top plan view of a floor covering apparatus according to a preferred embodiment of the present invention, shown in a partially assembled configuration;

[0067] Figure 2B is a side elevational view of the apparatus shown in Figure 2A;

[0068] Figure 2C is a sectional view along sight line 2C-2C of Figure 2A;

[0069] Figure 2D is a front elevational view of the apparatus shown in Figure 2A;

[0070] Figure 2E is a sectional view along sight line 2E-2E of Figure 2A;

[0071] Figure 3 is a top front right isometric view of the apparatus of Figure 2A, with a one-piece flooring apparatus shown removed therefrom;

[0072] Figure 4 is an enlarged view of encircled area 4 of Figure 2E;

[0073] Figure 5 is a view similar to Figure 4 showing "J"-shaped overhanging and underlying portions of a floor covering apparatus according to an alternate embodiment of the present invention;

[0074] Figure 6A is a top front right isometric view of a single undivided piece after a first edge-cutting step in a method according to a preferred embodiment of the present invention;

[0075] Figure 6B is a view similar to Figure 6A after a second edge-cutting step in the method;

[0076] Figure 6C is a view similar to Figure 6A after a third edge-cutting step in the method; and

[0077] Figure 6D is a view similar to Figure 6A after a fourth edge-cutting step in the method, so as to form the apparatus shown in Figure IA.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0078] Referring now to Figures IA to IE of the drawings, there is shown a one-piece flooring apparatus 20 for use with a floor base 10 according a preferred embodiment of the present invention. The apparatus 20 includes a single undivided piece 22,52 which has an upper portion 22 and a lower portion 52. As best seen in Figures 1C and IE, the lower portion 52 is substantially contiguous with the upper portion 22. In a preferred embodiment, the single undivided piece 22,52 is a resilient material, preferably a synthetic plastic material. More preferably, the resilient material is a vinyl plastic material, such as polyvinyl chloride (PVC).

[0079] As best seen in Figures 1A-1E, the upper portion 22 defines a substantially planar upper shape 24. Similarly, the lower portion 52 defines a substantially planar

lower shape 54. Preferably, both the upper shape 24 and the lower shape 54 are substantially rectangular (as shown in Figures IA to 3 and in Figures 6A to 6D) and/or square (not shown). As best seen in Figure IA, the upper portion 22 has two longitudinal side portions 36 and two opposing end portions 38. Similarly, the lower portion 52 has two longitudinal side portions 66 and two opposing end portions 68. All of the side portions 36, 66 and end portions 38, 68 are preferably substantially straight.

[0080] As best seen in Figure IA, the upper portion 22 preferably includes a top surface 28 that may be provided with an aesthetically pleasing design (not shown) in a wide variety of different patterns, including, for example, a wood grain design resembling natural wood. The upper portion 22 also includes an upper marginal portion 30, which is provided substantially about a perimeter 26 of the planar upper shape 24. As best seen in Figures IB to IE, the upper marginal portion 30 includes an overhanging portion 32 and an upper marginal edge portion 46 which is preferably distinct from the overhanging portion 32. The overhanging portion 32 extends out from over the lower portion 52. In the overhanging portion 32, and as best seen in Figure IA, one of the side portions 36 together with an adjacent one of the end portions 38 defines a substantially horizontal "L"-shape 34.

[0081] As best seen in Figures IB to IE, the lower portion 52 preferably includes a bottom surface 58, as well as a lower marginal portion 60. The lower marginal portion 60 is provided substantially about a perimeter 56 of the planar lower shape 54. As best seen in Figure IB to IE, the lower marginal portion 60 includes an underlying portion 62 and a lower marginal edge portion 76 which is preferably distinct from the underlying portion 62. The underlying portion 62 extends out from under the lower portion 52. In the underlying portion 62, and as best seen in Figure IA, one of the side

portions 66 together with an adjacent one of the end portions 68 defines a substantially horizontal "L"-shape 64.

[0082] As best seen in Figures 4 and 5, the overhanging portion 32 preferably includes overhanging edge and bottom portions, 42 and 44 respectively. Preferably, the overhanging edge and bottom portions, 42 and 44, engage one another in substantially normal relation, such as to together define a substantially vertical overhanging "L"- shape 4OA (as best seen in Figure 4). Alternately, the overhanging edge portion 42 may be substantially arcuate, such that the overhanging edge and bottom portions, 42 and 44, together define a substantially vertical overhanging "J"-shape 4OB (as shown in Figure 5).

[0083] Likewise, and as also best seen in Figures 4 and 5, the underlying portion 62 preferably includes underlying edge and bottom portions, 72 and 74 respectively, which engage one another in substantially normal relation. As such, the underlying edge and bottom portions, 72 and 74, together define a substantially vertical underlying "L"- shape 7OA (as best seen in Figure 4). Alternately, the underlying edge portion 72 may be substantially arcuate, such that the underlying edge and bottom portions, 72 and 74, together define a substantially vertical overhanging "J"-shape 7OB (as shown in Figure 5).

[0084] Although not shown, it is to be appreciated that alternate embodiments of the apparatus 20 according to the present invention may include an overhanging "L"-shape 4OA (as best seen in Figure 4) in conjunction with an underlying "J"-shape 7OB (as shown in Figure 5), and vice-versa.

[0085] In use, and as best seen in Figures IB-IE and 2B-2E, the bottom surface 58 of each apparatus engages the floor base 10 in substantially juxtaposed relation. The

single undivided piece 22,52 has a predetermined yieldability to surface irregularities of the floor base 10. Preferably, the predetermined yieldability is such that the bottom surface 58, when lying in substantially flat contact on the floor base 10 (as best seen in Figures IB to IE), can conform to surface irregularities (not shown) of the floor base 10.

[0086] Now, with reference to Figures 2A to 5, there is shown a flooring covering 100 formed by connecting a plurality of one-piece flooring apparatuses 20 with one another. According to the present invention, the flooring apparatus 20 may be employed independent of floor covering 100, and vice versa. During installation, and as best seen in Figures 2A to 2E, the overhanging portion 32 of a first flooring apparatus 20 operatively engages the underlying portion 62 of an adjacent second flooring apparatus 20. More specifically, and as best seen in Figures 4 and 5, the overhanging bottom portion 44 of the first flooring apparatus 20 engages with the underlying top portion 74 of the adjacent second flooring apparatus 20.

[0087] Additionally, at the same time, the overhanging edge portion 42 and the lower marginal edge portion 76 of the first flooring apparatus 20 respectively engage the upper marginal edge portion 46 and the underlying edge portion 72 of the adjacent second flooring apparatus 20, in abutting relation.

[0088] As best seen in Figures 4 and 5, the top surfaces 28, 28 of adjacent flooring apparatuses 20, 20 together form a substantially continuous visible portion 102 of the floor covering 100. As may be best appreciated from Figures 2A and 3, the top surfaces 28 are visibly presented by the floor covering 100. As such, the floor covering 100 may be provided with the same aesthetically pleasing design (not shown) as the top surfaces 28 - i.e., in a wide variety of different patterns, including, for example, a wood grain design resembling natural wood.

[0089] Preferably, the overhanging portion 32 has a width (as indicated generally by dimension "W" in Figures 4 and 5) which is substantially equal to that of the underlying portion 62. As such, the overhanging portion 32 and the underlying portion 62 preferably enable substantially seamless connection, in a horizontal plane, between neighboring ones of the apparatus 20, 20 (as best seen in Figures 2C, 2E and 4-5). Preferably, the width "W" of the overhanging and underlying portions 32, 62 may be between about five millimeters (5 mm) and about twenty millimeters (20 mm). In one preferred embodiment, the width "W" is about ten millimeters (10 mm).

[0090] As may be best appreciated from a consideration of Figure 6D, the overhanging portion 32 is positioned at a height (as indicated generally by dimension "H" in Figures 6C and 6D) above the bottom surface 58. Preferably, the height "H" is approximately equal to the thickness of the lower portion 52. Similarly, and as may be best appreciated from a consideration of Figure 6B, the underlying portion 62 is positioned at a depth (as indicated generally by dimension "D" in Figures 6A and 6B) below the top surface 28. Preferably, the depth "D" is approximately equal to the thickness of the upper portion 22. From the foregoing, it may be appreciated that a substantially seamless vertical connection is preferably provided between neighboring ones of the apparatus 20, 20 (as best seen in Figures 2C, 2E and 4-5).

[0091] As may be appreciated from a consideration of Figures 6A to 6D, the single undivided piece 22,52 has an overall thickness (as indicated generally by dimension "T" in Figures 6 A to 6C). Preferably, the overall thickness "T" is such as to afford a flexibility which enables the single undivided piece 22,52 to conform to surface contours (not shown) of the floor base 10. (As an aside, it is noted that the overall thickness "T" is preferably the sum of the thickness "D" of the upper portion 22 and the thickness "H" of the lower portion 52.) Preferably, the overall thickness "T" of the single undivided

piece 22,52 is between about 2.5 millimeters (mm) and about 3.5 millimeters (mm). In one preferred embodiment, the overall thickness "T" is about three millimeters (3 mm).

[0092] In forming the floor covering 100, each aforesaid flooring apparatus 20 may be installed with or without an adhesive layer 80 substantially interposed between the bottom surface 58 thereof and the floor base 10.

[0093] Additionally, the floor covering 100 may be installed with or without an adhesive substantially interposed between adjacent or neighboring ones of the flooring apparatus 20. In Figures 4 and 5, the floor covering 100 is shown installed without adhesive between adjacent flooring apparatuses 20, 20. In some preferred embodiments according to the present invention, one or more of the overhanging bottom portion 44 and the underlying top portion 74 may be provided with substantially texturized surfaces (not shown), so as to facilitate mating engagement, and increase a coefficient of static and/or kinetic friction, between the two. Similarly, the overhanging edge portion 42, the lower marginal edge portion 76, the upper marginal edge portion 46, and/or the underlying edge portion 72 may be provided with substantially texturized surfaces to similar effect. Frictional engagement between neighboring flooring apparatuses 20, 20 may advantageously enable same to be held in place in relation to one another and/or in relation to the floor covering 100 as a whole.

[0094] Since, strictly speaking, the adhesive layer 80 is required neither between neighboring ones of the flooring apparatus 20 nor between the bottom surface 58 thereof and the floor base 10, the flooring apparatus 20 and floor covering 100 according to the present invention may advantageously allow for ready installation, renewal, replacement and/or removal of the floor covering 100. Additionally, the flooring apparatus 20 and floor covering 100 may afford (i) lower costs during installation and/or manufacturing, (ii) reduced installation times, (iii) ready and facile movement

and/or arrangement during and/or after installation to a desired location and/or configuration on the floor base 10, (iv) a reduced likelihood of forming shrink cracks and/or wrapping at the joints, and/or (v) an increased ability to reuse and/or recycle the flooring apparatus 20 and floor covering 100 once removed from the floor base 10.

[0095] That said, in some preferred embodiments according to the present invention (and as best seen in Figures 4 and 5), the flooring apparatus 20 may include the adhesive layer 80 interposed between its bottom surface 58 and the floor base 10. The flooring apparatus 20 may be manufactured with the adhesive layer 80 (as a peel-and- stick adhesive and/or a self-adhesive) already provided as a part thereof, and/or the adhesive layer 80 may be applied to the bottom surface 58 after manufacture and/or during installation of the flooring apparatus 20.

[0096] Similarly, and though not shown in the accompanying drawings, the overhanging edge portion 42, the overhanging bottom portion 44, the lower marginal edge portion 76, the underlying edge portion 72, the underlying top portion 74, and/or the upper marginal edge portion 46 may be provided with an adhesive. The flooring apparatus 20 may be manufactured to provide the adhesive layer (as a peel-and-stick adhesive and/or a self-adhesive) thereon, and/or the adhesive may be applied thereto after manufacture and/or during installation.

[0097] The adhesive may preferably enhance and/or strengthen the secure engagement and/or connection between neighboring ones of the flooring apparatus 20 and/or between the bottom surface 58 thereof and the floor base 10. In some embodiments that lie within the scope of the present invention, the adhesive may be selected specific to the floor base 10 and/or the resilient material used to form the flooring apparatus 20.

[0098] In some preferred embodiments according to the present invention (and as best seen in Figures 4 and 5), the flooring apparatus 20 may additionally include a flexible cushioning material 90 - e.g., a foam materials and/or a rubber material - securely interposed between the adhesive layer 80 and the floor base 10. The cushioning material 90 may preferably be secured to the bottom surface 58 via the adhesive layer 80. The flooring apparatus 20 may be manufactured with the cushioning material 90 already secured to the bottom surface 58, and/or the cushioning material 90 may be applied to the bottom surface 58 after manufacture and/or during installation of the flooring apparatus 20. (Alternately, the cushioning material 90 may interposed between the bottom surface 58 and the floor base 10, without being fixed and/or secured to the bottom surface 58 other than by compression after installation of the floor covering 100.) Preferably, the cushioning material 90 may help bottom surface 58 and/or the flooring apparatus 20 to conform to surface contours and/or irregularities of the floor base 10. Preferably, the cushioning material 90 may also help the flooring apparatus 20 and/or the floor covering 100 resist lateral movement (e.g., slippage) along and/or relative to the floor base 10.

[0099] In further preferred embodiments according to the present invention, the flooring apparatus 20 may be manufactured with a slip-resistant material (not shown) - e.g., an adhesive material, a foam material and/or a rubber material - securely affixed to the bottom surface 58 thereof. Alternately, the cushioning material 90 may act as the slip-resistant material. Preferably, the slip-resistant material may help to increase the frictional forces and/or the coefficient of static and/or kinetic friction between the flooring apparatus 20 and the floor base 10. Preferably, this feature may help to reduce movement of the flooring apparatus 20 along the floor base 10. Preferably, an adhesive strip (not shown) may be provided on a lower surface of the slip-resistant material (e.g., the cushioning material 90). The adhesive strip may preferably be a self-adhesive strip

and is adapted for contact with floor base 10. The adhesive strip may operatively secure the flooring apparatus 20 to the floor base 10, preferably so as to resist slippage and/or lateral movement of the flooring apparatus 20 along or relative to the floor base 10.

[0100] Reference will now be made, briefly, to Figures 6A-6D and to an edge-cutting method of forming the flooring apparatus 20 according to a preferred embodiment of the present invention. According to the present invention, the below-described method may be employed independent of the flooring apparatus 20 and/or of the floor covering 100 which are described hereinabove, and vice versa. Preferably, the method includes steps (a), (a.l), (b) and/or (c).

[0101] In step (a), and as may be best appreciated from a consideration of Figure 6A, a first upper perimeter section 162 is edge-cut, from the upper portion 22, to a predetermined depth "D" below the top surface 28. In this manner, a first underlying portion 62A is defined in the lower portion 52 of the single undivided piece 22,52.

[0102] Preferably, step (a.l) is performed after step (a). In step (a.l), and as may be best appreciated from a consideration of Figure 6B, a second upper perimeter section 262 is edge-cut, from the upper portion 22, to the predetermined depth "D". In this manner, a second underlying portion 62B is defined in the lower portion 52 of the single undivided piece 22,52. Preferably, and as shown in Figure 6B, the second underlying portion 62B is substantially adjacent, and substantially normal, to the first underlying portion 62A. It may be additionally appreciated, from a consideration of Figures IA and 6B, that the first and second underlying portions, 62A and 62B, together define the horizontal "L"-shape 64 (shown in Figure IA) of the underlying portion 62.

[0103] Step (b) may be performed before or after step (a). In step (b), and as may be best appreciated from a consideration of Figure 6C, a first lower perimeter section 132 is edge-cut from the lower portion 52 to a predetermined height "H" above the bottom surface 58. In this manner, a first overhanging portion 32A is defined in the upper portion 22 of the single undivided piece 22,52.

[0104] Preferably, step (c) is performed after step (b). In step (c), and as may be best appreciated from a consideration of Figure 6D, a second lower perimeter section 232 is edge-cut, from the lower portion 52, to the predetermined height "H". In this manner, a second overhanging portion 32B is defined in the upper portion 22 of the single undivided piece 22,52.

[0105] Preferably, and as may be best appreciated from a consideration of Figure 6D, the second overhanging portion 32B is substantially adjacent, and substantially normal, to the first overhanging portion 32A. It may be additionally appreciated, from a consideration of Figures IA and 6D, that the first and second overhanging portions, 32A and 32B, together define the horizontal "L" -shape 34 (shown in Figure IA) of the overhanging portion 32.

[0106] Other modifications and/or alterations may be used in the design and manufacture of the flooring apparatus 20 or the floor covering 100, and/or in performing the steps of any associated methods, according to other embodiments of the present invention, without departing from the spirit and scope of the invention, which, is limited only by the accompanying claims of this application.

[0107] For example, while the above flooring apparatus 20 has been presented in the context of a substantially rectangular shape, the flooring apparatus 20 is equally applicable to other polygon shapes, including triangle shapes, square shapes, and/or

diamond shapes. The polygons may or may not be regular polygons. Likewise the planar upper and lower shapes, 24 and 54 respectively, may or may not be congruent with one another. In situations where the planar upper and lower shapes, 24 and 54, are not congruent with one another, two or more different types of flooring apparatus 20 may be provided to form an interlocking pattern of differently shaped floor planks and/or tiles.

[0108] Additionally, while many advantages may stem from the use of synthetic plastic, vinyl and/or PVC materials in the flooring apparatus 20, other materials may also be used. Other exemplary materials which may be suitable for use according to the present invention may include other elastic materials, linoleum materials, inorganic compound materials, rubber mineral composite materials, chlorine-free materials, resilient non-synthetic materials (e.g., wood, ceramic and/or stone-based materials), and/or derivatives of any of these materials.

[0109] The foregoing description and the accompanying drawings have been presented for the purpose of illustration, only. They are not intended to be exhaustive, nor are they intended to limit the invention to any of the precise form(s) disclosed. It may be worthwhile, therefore, to one again note that many modifications and/or variations are possible in light of the above teachings and/or disclosures, as will be apparent to those skilled in the art. The scope of the present invention is not intended to be limited by this description, but only by the accompanying claims.