Installation Method for Non-Slip Sanitary Flooring

• US 20080014399A1
• Filed: 07/11/2006
• Published: 01/17/2008
• Est. Priority Date: 07/11/2006
• Status: Active Grant

• Current Assignee: Allied Industries International Incorporated
• Original Assignee: Joel E. Martin, Richard C. Neale
• Inventors: Neale, Richard C., Martin, Joel E.
• Granted Patent: US 7,678,215 B2
• Time in Patent Office: Days
• US Class Current: 428/57
• CPC Class Codes: B29C 2073/264 for cutting out or grooving the area to be repaired
• CPC Class Codes: B29C 65/00 Joining or sealing of preformed parts , e.g. welding of plastics materials; Apparatus therefor general aspects of processes or apparatus for joining preformed parts B29C66/00; using porous material formed by internal pressure generated therein for joining preformed parts B29C44/1228, B29C44/326
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29C 65/04 Dielectric heating, e.g. high-frequency welding , i.e. radio frequency welding of plastic materials having dielectric properties, e.g. PVC
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 65/10 using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
• CPC Class Codes: B29C 65/12 and welding bar
• CPC Class Codes: B29C 65/1425 Microwave radiation
• CPC Class Codes: B29C 65/4815 Hot melt adhesives, e.g. thermoplastic adhesives
• CPC Class Codes: B29C 65/4835 Heat curing adhesives
• CPC Class Codes: B29C 65/5042 covering both elements to be joined
• CPC Class Codes: B29C 65/505 and placed in a recess formed in the parts to be joined, e.g. in order to obtain a continuous surface
• CPC Class Codes: B29C 66/022 Mechanical pre-treatments, e.g. reshaping
• CPC Class Codes: B29C 66/02241 Cutting, e.g. by using waterjets, or sawing using heat B29C66/0246; cutting-off or cutting-out a part of a strip-like or sheet-like material, transferring that part and fixing it to an article B29C69/005
• CPC Class Codes: B29C 66/1142 Single butt to butt joints
• CPC Class Codes: B29C 66/1162 Single bevel to bevel joints, e.g. mitre joints
• CPC Class Codes: B29C 66/1282 comprising at least one overlap joint-segment
• CPC Class Codes: B29C 66/12841 comprising at least two butt joint-segments
• CPC Class Codes: B29C 66/14 the joint having the same thickness as the thickness of the parts to be joined B29C66/1142 takes precedence
• CPC Class Codes: B29C 66/43 Joining a relatively small portion of the surface of said articles B29C66/45 takes precedence
• CPC Class Codes: B29C 66/71 : characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/712 : the composition of one of the parts to be joined being different from the composition of the other part
• CPC Class Codes: B29C 66/721 : Fibre-reinforced materials B29C66/729 takes precedence
• CPC Class Codes: B29C 66/7212 : characterised by the composition of the fibres
• CPC Class Codes: B29C 66/72141 : Fibres of continuous length
• CPC Class Codes: B29C 66/72143 : Fibres of discontinuous lengths
• CPC Class Codes: B29C 66/73921 : characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29C 66/73941 : characterised by the materials of both parts being thermosets
• CPC Class Codes: B29C 66/836 : Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table B29C66/65 takes precedence
• CPC Class Codes: B29C 66/8362 : Rollers, cylinders or drums moving relative to and tangentially to the parts to be joined
• CPC Class Codes: B29C 66/861 : Hand-held tools
• CPC Class Codes: B29C 66/9141 : by controlling or regulating the temperature
• CPC Class Codes: B29C 66/91411 : of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
• CPC Class Codes: B29C 66/9161 : by controlling or regulating the heat or the thermal flux, i.e. the heat flux
• CPC Class Codes: B29C 66/919 : characterised by specific temperature, heat or thermal flux values or ranges specific electrical resistance values B29C66/81262
• CPC Class Codes: B29C 73/06 : using plugs sealing in the hole
• CPC Class Codes: B29K 2023/06 : PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/12 : PP, i.e. polypropylene
• CPC Class Codes: B29K 2025/00 : Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
• CPC Class Codes: B29K 2027/06 : PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2031/00 : Use of polyvinylesters or derivatives thereof as moulding material
• CPC Class Codes: B29K 2055/02 : ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
• CPC Class Codes: B29K 2061/04 : Phenoplasts
• CPC Class Codes: B29K 2063/00 : Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2065/00 : Use of polyphenylenes or polyxylylenes as moulding material
• CPC Class Codes: B29K 2067/00 : Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2069/00 : Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2071/00 : Use of polyethers , e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2071/12 : PPO, i.e. polyphenylene oxide; PPE, i.e. polyphenylene ether
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/00 : Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/10 : Aromatic polyamides [polyaramides] or derivatives thereof
• CPC Class Codes: B29K 2081/06 : PSU, i.e. polysulfones; PES, i.e. polyethersulfones or derivatives thereof
• CPC Class Codes: B29K 2101/10 : Thermosetting resins
• CPC Class Codes: B29K 2101/12 : Thermoplastic materials
• CPC Class Codes: B29K 2105/0845 : Woven fabrics
• CPC Class Codes: B29K 2105/0854 : in the form of a non-woven mat
• CPC Class Codes: B29K 2105/10 : Cords, strands or rovings, e.g. oriented cords, strands or rovings
• CPC Class Codes: B29K 2105/12 : of short lengths, e.g. chopped filaments, staple fibres or bristles
• CPC Class Codes: B29K 2277/10 : Aromatic polyamides [Polyaramides] or derivatives thereof
• CPC Class Codes: B29K 2307/00 : Use of elements other than metals as reinforcement
• CPC Class Codes: B29K 2307/04 : Carbon
• CPC Class Codes: B29K 2309/08 : Glass
• CPC Class Codes: B29K 2705/10 : Copper
• CPC Class Codes: B29K 2705/12 : Iron
• CPC Class Codes: B29L 2031/732 : Floor coverings piles carpets B29L2031/7652; for vehicles B29L2031/3017
• CPC Class Codes: E04F 15/02 : Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: E04F 15/02016 : with sealing elements between flooring elements sealings of joints between building constructions in general E04B1/68
• CPC Class Codes: E04F 15/02172 : Floor elements with an anti-skid main surface, other than with grooves
• CPC Class Codes: Y10T 156/108 : Flash, trim or excess removal
• CPC Class Codes: Y10T 428/19 : Sheets or webs edge spliced or joined

Abstract

A method of installing flooring and resulting structure are disclosed. The method is particularly useful for sanitary nonslip applications such as kitchens. The method includes the steps of positioning a first sheet of polymer flooring material with an upwardly-facing step cut along one edge of the first sheet on a floor to be covered, and applying a second sheet of polymer flooring material with a complementary downwardly-facing step cut along one edge of the second sheet to the upwardly facing step cut of the first sheet and to the floor adjacent the first sheet while concurrently sealing the respective faces to one another in a step lap joint.

Claims

1. A method of installing flooring that is particularly useful for sanitary non-slip applications such as kitchens, the method comprising:

positioning a first sheet of polymer flooring material with an upwardly-facing step cut along one edge of the first sheet on a floor to be covered; and

applying a second sheet of polymer flooring material with a complementary downwardly-facing step cut along one edge of the second sheet to the upwardly facing step cut of the first sheet and to the floor adjacent the first sheet while concurrently sealing the respective faces to one another in a step lap joint

2. A method according to claim 1 comprising positioning respective first and second sheets of thermoplastic material on the floor and applying sufficient heat to the respective step faces to melt the polymer.

3. A method according to claim 1 comprising positioning respective first and second sheets of thermosetting material on the floor and applying sufficient heat to the respective step faces to melt the polymer.

4. A method according to claim 1 comprising:

forming a step cut along one edge of a first sheet of thermoplastic polymer flooring material; and

forming a complementary step cut along one edge of a second sheet of thermoplastic polymer flooring material;

both prior to the step of positioning the first sheet on a floor to be covered with the step cut facing upwardly.

5. A method according to claim 1 comprising applying pressure to the surface of the second sheet above the downwardly facing step cut to seal the respective step cuts to one another in a step lap joint and thereby join the first and second sheets to one another.

6. A method according to claim 2 comprising positioning sheets of thermoplastic polymer that are selected from the group consisting of polypropylene, polyethylene, polystyrene, ABS (acrylonitrile-butadiene-styrene), nylon, polycarbonate, thermoplastic polyester, polyphenylene oxide, polysulfone and PEEK (poly-ether-ether-ketone).

7. A method according to claim 3 comprising positioning sheets of thermosetting polymer that are selected from the group consisting of unsaturated polyester, vinyl ester, epoxy, urethane and phenolic.

8. A method according to claim 3 comprising positioning sheets of a polymer matrix composite resin system that includes reinforcing fibers selected from the group consisting of carbon, graphite, aramid polymers, glass, and combinations thereof.

9. A floor covering on a floor, said floor covering comprising:

a first sheet of polymer material with at least one upwardly-facing step cut edge facing upwardly from the floor;

a second sheet of polymer material with at least one downwardly-facing step cut edge facing downwardly towards the floor and immediately overlying the upwardly facing step cut of said first sheet; and

a heat seal joining said upwardly-facing step cut to said downwardly-facing step cut and thereby joining said first and second sheets of polymer material together all on said floor.

10. A floor covering according to claim 9 wherein at least one of said first and second sheets is a thermoplastic polymer.

11. A floor covering according to claim 10 wherein both of said first and second sheets are thermoplastic polymers.

12. A floor covering according to claim 9 wherein at least one of said first and second sheets is a thermosetting polymer.

13. A floor covering according to claim 12 wherein both of said first and second sheets are thermosetting polymers.

14. A floor covering according to claim 9 wherein said first and second sheets are polyvinyl chloride.

15. A floor covering according to claim 11 wherein said thermoplastic polymer is selected from the group consisting of polypropylene, polyethylene, polystyrene, ABS (acrylonitrile-butadiene-styrene), nylon, polycarbonate, thermoplastic polyester, polyphenylene oxide, polysulfone and PEEK (poly-ether-ether-ketone).

16. A floor covering according to claim 12 wherein said thermosetting polymer is selected from the group consisting of unsaturated polyester, vinyl ester, epoxy, urethane and phenolic.

17. A floor covering according to claim 9 comprising a polymer matrix composite resin system that includes reinforcing fibers selected from the group consisting of carbon, graphite, aramid polymers, glass, and combinations thereof.

18. A floor covering according to claim 9 wherein said downwardly-facing step cut edge includes an oblique face adjacent the top surface of said second sheet.

19. A method of repairing a butt joint in polymer flooring materials comprising:

forming a step cut in polymer flooring on both adjacent sides of an existing butt joint; and

sealing a strap of polymer material into the step cut above the remainder of the butt joint to produce a combination strap and step lap joint to replace the butt joint.

20. A method according to claim 19 comprising forming a step cut in a rectangular cross section with the steps substantially parallel to the surface of the polymer flooring.

21. A method according to claim 19 wherein the dimensions of the polymer strap correspond substantially to the dimensions of the step cut to produce a repaired joint in which the strap and the flooring material create a flush surface with respect to one another.

22. A method according to claim 19 comprising applying pressure to the strap and to the surface of the polymer flooring material to enhance the resulting joint.

23. A method according to claim 19 comprising sealing the strap with an adhesive.

24. A method according to claim 19 comprising heat-sealing a strap of thermoplastic polymer to the step cut.

25. A method according to claim 19 comprising heat-sealing a strap of thermosetting polymer to the step cut.

26. A method according to claim 24 comprising heat sealing a thermoplastic polymer selected from the group consisting of polypropylene, polyethylene, polystyrene, ABS (acrylonitrile-butadiene-styrene), nylon, polycarbonate, thermoplastic polyester, polyphenylene oxide, polysulfone and PEEK (poly-ether-ether-ketone).

27. A method according to claim 25 comprising heat sealing a thermosetting polymer selected from the group consisting of unsaturated polyester, vinyl ester, epoxy, urethane and phenolic.

28. A method according to claim 19 comprising heat sealing a polymer matrix composite resin system that includes reinforcing fibers selected from the group consisting of carbon, graphite, aramid polymers, glass, and combinations thereof.

29. A portion of flooring material on a floor comprising:

a first sheet of polymer flooring material;

a second sheet of polymer flooring material abutting said first sheet along respective edges of each sheet;

a partial butt joint between said first and second sheets adjacent the floor;

a channel, portions of which extend into each of said first and second sheets above said partial butt joint;

a polymer strap positioned in said channel above said partial butt joint; and

a seal between and among said polymer strap, said first sheet of polymer flooring material and said second sheet of polymer flooring material that forms a combined strap and lap joint between and among said first sheet, said second sheet, and said strap.

30. A portion of flooring material according to claim 29 wherein:

said first and second sheets comprise thermoplastic polymers;

said strap comprises a thermoplastic polymer and

and said seal between said strap and said sheets is a heat seal.

31. A portion of flooring material according to claim 30 wherein said sheets and said strap comprise polyvinyl chloride.

32. A portion of flooring material according to claim 29 wherein:

said first and second sheets comprise thermosetting polymers;

said strap comprises a thermosetting polymer; and

said seal between said strap and said sheets is a heat seal;

33. A portion of flooring material according to claim 29 wherein said polymer strap has dimensions substantially the same as said channel.

34. A portion of flooring material according to claim 29 wherein said channel is rectangular in cross-section and said strap has dimensions substantially the same as said channel.

35. A portion of flooring material according to claim 30 wherein said thermoplastic polymer is selected from the group consisting of polypropylene, polyethylene, polystyrene, ABS (acrylonitrile-butadiene-styrene), nylon, polycarbonate, thermoplastic polyester, polyphenylene oxide, polysulfone and PEEK (poly-ether-ether-ketone).

36. A portion of flooring material according to claim 32 wherein said thermosetting polymer is selected from the group consisting of unsaturated polyester, vinyl ester, epoxy, urethane and phenolic.

37. A portion of flooring material according to claim 29 comprising a polymer matrix composite resin system that includes reinforcing fibers selected from the group consisting of carbon, graphite, aramid polymers, glass, and combinations thereof.

38. A flooring element comprising:

a generally rectangular three-dimensional solid polymer in a thickness of at least about one quarter inch, a with of at least about four feet and a length of at least about six feet; and

a step cut along each lengthwise edge of said rectangular three-dimensional flooring element.

39. A flooring element according to claim 38 wherein said polymer is selected from the group consisting of thermoplastic polymers, thermosetting polymers and polymer matrix composites.

40. A flooring element according to claim 39 comprising a thermoplastic polymer selected from the group consisting of polypropylene, polyethylene, polystyrene, ABS (acrylonitrile-butadiene-styrene), nylon, polycarbonate, thermoplastic polyester, polyphenylene oxide, polysulfone and PEEK (poly-ether-ether-ketone).

41. A flooring element according to claim 39 comprising a thermosetting polymer selected from the group consisting of unsaturated polyester, vinyl ester, epoxy, urethane and phenolic.

42. A flooring element according to claim 39 wherein said flooring element comprises a polymer matrix composite that includes fibers selected from the group consisting of carbon, graphite, aramid polymers, glass, and combinations thereof.