Water resistant tongue and groove flooring

Abstract

The invention provides a new floor covering panel and floor covering system in which the floor covering panels include first and second generally planar surfaces, first and second side edges containing first and second complementary coupling members, respectively, and a barrier composition selectively applied to at least a portion of at least one of the first and second coupling members for providing a moisture barrier to prevent water penetration below the first surface of the floor covering panel. The barrier composition may be applied to at least one of the first or second coupling members during the floor covering manufacturing process.

What is claimed is:  
     
         1 . A floor covering panel, comprising: 
 a. a first generally planar surface,    b. a second generally planar surface,    c. a first side edge and an opposed second side edge, each respective side edge extending between said first and second surfaces, respectively,    d. a first coupling member defined within the first edge of the panel and comprising a protrusion extending therefrom and a first abutment surface between the protrusion and the first surface,    e. a second coupling member defined within the second edge of the panel and comprising a recess sized and shaped to receive said protrusion therein, and further comprising a second abutment surface between the recess and the first surface, and    f. a barrier composition selectively applied to at least a portion of at least one of the first abutment surface and the second abutment surface    
     
     
         2 . The floor covering panel of  claim 1 , further comprising a first and a second one of said floor covering panels, respectively, the first coupling member of the first panel being received within the second coupling member of the second panel, and at least a portion of the first abutment surface of the first panel contacting at least a portion of the second abutment surface of the second panel, wherein the barrier composition is positioned between said first abutment surface and said second abutment surface and creates a relative barrier against moisture penetrating into the respective floor covering panels beyond the first surface.  
     
     
         3 . The floor covering panel of  claim 1 , wherein the barrier composition is applied along substantially all of the first abutment surface.  
     
     
         4 . The floor covering panel of  claim 1 , wherein the barrier composition is applied along substantially all of the second abutment surface.  
     
     
         5 . The floor covering panel of  claim 1 , wherein the barrier composition is applied along substantially all of the first abutment surface and along substantially all of the second abutment surface.  
     
     
         6 . The floor covering panel of  claim 1 , wherein the barrier composition is selectively applied along a portion of the first abutment surface adjacent the upper surface.  
     
     
         7 . The floor covering panel of  claim 1 , wherein the barrier composition is selectively applied along a portion of the second abutment surface adjacent the upper surface.  
     
     
         8 . The floor covering panel of  claim 1 , wherein the barrier composition is selectively applied along a portion of the first abutment surface adjacent the upper surface and along a portion of the second abutment surface adjacent the upper surface.  
     
     
         9 . The floor covering panel of  claim 1 , wherein the barrier composition comprises an active ingredient that comprises one or more of a fluorochemical, metal stearate, oil, wax, acrylate polymer or a silicone polymer.  
     
     
         10 . The floor covering panel of  claim 9 , wherein the active ingredient is crosslinkable.  
     
     
         11 . The floor covering panel of  claim 9 , wherein the active ingredient comprises the fluorochemical.  
     
     
         12 . The floor covering panel of  claim 11 , wherein the fluorochemical comprises a fluoropolymer.  
     
     
         13 . The floor covering panel of  claim 12 , wherein the fluoropolymer comprises a fluoroacrylate polymer.  
     
     
         14 . A floor covering panel suitable for mating with a second floor covering panel, wherein the floor covering panel has a crosslinkable polymer applied to at least part of an area defining a tongue and groove profile, thereby providing a durable water barrier when the polymer is at least partially crosslinked and floor covering panel is mated with at least one second floor covering panel.  
     
     
         15 . The floor covering panel of  claim 14 , wherein the crosslinkable polymer is applied to a vertical edge of the profile, wherein the edge comprises an upper edge of the floor covering panel.  
     
     
         16 . The floor covering panel of  claim 14 , wherein the floor covering panel is mated with a second floor covering panel, thereby providing a floor covering system, wherein the system comprises at least one seam on an upper surface of the system.  
     
     
         17 . The floor covering system of  claim 16 , wherein the second floor covering panel comprises a crosslinkable polymer applied to a vertical edge that is complementary to the vertical edge of the first floor covering panel.  
     
     
         18 . The floor covering system of  claim 16 , wherein the crosslinkable polymer provides a water barrier, thereby substantially reducing water seepage into the system in comparison to seepage in a floor covering system not treated with a crosslinked polymer barrier composition.  
     
     
         19 . The floor covering panel of  claim 14 , wherein the polymer comprises one or more of a silicone polymer, an acrylate polymer or a fluoropolymer.