Panel and process for sealing of a panel joint

• US 8,037,657 B2
• Filed: 03/08/2004
• Issued: 10/18/2011
• Est. Priority Date: 03/11/2003
• Status: Active Grant

• Current Assignee: Pergo Europe AB (Mohawk Industries Incorporated)
• Original Assignee: Pergo Ag (PAI Partners)
• Inventors: Nilsson, Magnus, Hansson, Krister, Wernersson, Hakan, Sjoberg, Ake, Engstrom, Nils-Erik, Kornfalt, Sven
• Primary Examiner(s): Canfield; Robert
• Assistant Examiner(s): Herring; Brent W
• Application Number:
  US10/793,944
• Publication Number:
  US 20040182036A1
• Time in Patent Office: 2,780 Days
• Field of Search: 525/921, 525/922, 525/924, 525/913, 525/911, 527/414, 428/192, 156/304.5
• US Class Current: 52/592.1
• 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 15/02005 Construction of joints, e.g. dividing strips E04F15/024, E04F15/04, E04F15/06, E04F15/10 and E04F15/14 take precedence; separate provisional spacers E04F21/0092
• CPC Class Codes: E04F 15/02011 with joint fillings integrated in the flooring elements
• 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 2201/0115 with snap action of the edge connectors
• CPC Class Codes: E04F 2201/0138 by moving the sheets, plates or panels perpendicular to the main plane
• CPC Class Codes: E04F 2201/0153 by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
• CPC Class Codes: E04F 2201/026 with rabbets, e.g. being stepped
• CPC Class Codes: E04F 2201/03 Undercut connections, e.g. using undercut tongues or grooves
• CPC Class Codes: E04F 2201/07 with connections using a special adhesive material
• CPC Class Codes: Y10T 403/472 including mechanical interlock
• CPC Class Codes: Y10T 428/24777 Edge feature

Abstract

A joint for panels, the panels comprising a core, a decorative upper surface and edges provided with joining means for positioning the panels towards one another. Predetermined portions of the edges are provided with a layer of polymer. The panels are joined to one another by use of the joining means where the polymer forms a seal in the joint preventing penetration of water into the joint wherein a highly water resistant unit of a plurality of panels is formed.

Claims

1. A panel comprising:

a core having an upper surface;

a decorative surface layer atop said upper surface of said core, wherein said decorative surface layer covers all of said upper surface;

edges, said edges comprising at least one joining element, said joining element being selected from the group consisting of a tongue and a groove;

at least one of said edges comprising a mating surface below the decorative surface layer, and a recess extending from said upper surface towards said joining element, and

a non-curing elastomeric polymer sealant positioned in said recess, wherein said sealant extends beyond the at least one of said edges of said panel to form said mating surface and the sealant being dyed or lacquered such that said sealant is visible when the panel is joined with an adjacent panel.

2. The panel of claim 1, wherein said sealant is a thermoplastic polymer.

3. The panel of claim 2, wherein said sealant comprises at least one component selected from the group consisting of nitrile butyl rubber, butyl rubber, ethyl-vinyl-acetate, and natural bitumen.

4. The panel of claim 3, wherein the sealant comprises butyl rubber.

5. The panel of claim 2, wherein said sealant comprises an expansion agent.

6. A system comprising:

the panel of claim 1, and

a second panel, said second panel comprising;

a core having an upper surface,

a decorative surface layer atop said upper surface of said core; and

edges, said edges comprising at least one joining element, said joining element being selected from the group consisting of a tongue and a. groove;

wherein said panel and said second panel are joined at said respective joining elements, such that said sealant is visible in the joint between the panels and forms a seal therebetween.

7. The system of claim 6, wherein at least one of said edges of said second panel further comprises:

a recess in the core below said decorative surface, and

a sealing component positioned in said recess.

8. The system of claim 7, wherein said sealing component is a second sealant.

9. The system of claim 8, wherein said sealing component in said recess comprises a component to activate said sealant on said panel.

10. The system of claim 9, wherein said first sealant lacks a plasticizer and said second component contains a plasticizer which migrates info said first sealant.

11. A method of forming a joint between adjacent panels comprising:

providing a first panel, said first panel comprising;

a core having an upper surface;

a decorative surface layer atop said upper surface of said core, wherein said decorative surface layer covers all of said upper surface;

edges, said edges comprising at least one joining element, said joining element being selected from the group consisting of a tongue and a groove;

at least one of said edges comprising a mating surface below the decorative surface layer, and a recess extending from said upper surface towards said joining element, and

a sealant positioned in said recess;

wherein said sealant extends beyond an edge of said panel to form said mating surface and said sealant being dyed or lacquered, and,

joining a second panel to said first panel by connecting a joining element on said second panel to said first panel, whereby said sealant is visible and seals the joint formed between the first and second panels.

12. The method of claim 11, whereby said second panel further comprises a sealant component on an edge thereof, said joining step comprising bringing together said first sealant and said sealant component.

13. The method of claim 12, wherein said bringing together step comprises activating said first sealant.

14. The method of claim 12, further comprising allowing said first sealant and said second sealant to form an elastic seal.