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Interlocking floor panels and floor system

  • US 9,650,792 B2
  • Filed: 12/23/2014
  • Issued: 05/16/2017
  • Est. Priority Date: 12/23/2014
  • Status: Expired due to Fees
First Claim
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1. A floating floor system comprising:

  • a plurality of floor panels, each of the floor panels comprising;

    a base layer formed from a first material having a first hardness;

    a body comprising a top surface and a bottom surface, the body formed from the base layer;

    a first locking edge portion formed from the base layer and extending from a first side of the body, the first locking edge portion comprising a locking channel defined by a channel floor, a first channel sidewall extending upward from the channel floor toward the top surface, and a second channel sidewall extending upward from the channel floor toward the top surface;

    a second locking edge portion formed from the base layer and extending from a second side of the body opposite the first side, the second locking edge portion comprising a locking ridge protruding downward away from the top surface, the ridge defined by a first ridge sidewall, a second ridge sidewall, and a ridge top surface;

    wherein at least one of the first channel sidewall, the second channel sidewall, the first ridge sidewall, and the second ridge sidewall comprises a portion formed from a second material having a second hardness that is less than the first hardness;

    wherein the plurality of floor panels are arranged in a mechanically interlocked arrangement in which the locking ridge of one floor panel is pressed into and nested within the locking channel of an adjacent floor panel such that the portion formed from the second material is compressed, thereby achieving an interference fit between the first and second channel sidewalls and the first and second ridge sidewalk;

    wherein the locking channel comprises an upper channel section defined by upper portions of the first and second channel sidewalls and a lower channel section defined by lower portions of the first and second channel sidewalls, the upper channel section comprising a first channel width and the lower channel section comprising a second channel width, the first channel width being less than the second channel width;

    wherein the locking ridge comprises a base section defined by upper portions of the first and second ridge sidewalls and a distal section defined by lower portions of the first and second ridge sidewalls, the base section comprising a first ridge width and the distal section comprising a second ridge width, the first ridge width being less than the second ridge width; and

    wherein at least one of the upper portion of the first channel sidewall, the upper portion of the second channel sidewall, the upper portion of the first ridge sidewall, and the upper portion of the second ridge sidewall is formed from the second material.

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