Installation Method for Non-Slip Sanitary Flooring

Abstract

A method of installing flooring and resulting structure are disclosed. The method is particularly useful for sanitary nonslip (or slip resistant) 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 or bonding the respective faces to one another in a step lap joint.

1 . A method of installing flooring that is particularly useful for sanitary slip resistant 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 bonding the respective faces to one another in a step lap joint using radio frequency (RF) welding.    
     
     
         2 . A method according to  claim 1  comprising positioning respective first and second sheets of thermoplastic material on the floor and applying sufficient energy to the respective step faces to bond the polymer flooring material.  
     
     
         3 . A method according to  claim 1  comprising positioning respective first and second sheets of thermosetting material on the floor and applying sufficient energy to the respective step faces to bond the polymer flooring material.  
     
     
         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 bond 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 polyvinyl chloride, 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 method according to  claim 2 , comprising positioning sheets of a polymer matrix system that includes polyvinyl chloride and polyester fibers.  
     
     
         10 . 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 bond formed by radio frequency (RF) welding 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.    
     
     
         11 . A floor covering according to  claim 10  wherein at least one of said first and second sheets is a thermoplastic polymer.  
     
     
         12 . A floor covering according to  claim 11  wherein both of said first and second sheets are thermoplastic polymers.  
     
     
         13 . A floor covering according to  claim 10  wherein at least one of said first and second sheets is a thermosetting polymer.  
     
     
         14 . A floor covering according to  claim 13  wherein both of said first and second sheets are thermosetting polymers.  
     
     
         15 . A floor covering according to  claim 10  wherein said first and second sheets are polyvinyl chloride.  
     
     
         16 . 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).  
     
     
         17 . A floor covering according to  claim 13  wherein said thermosetting polymer is selected from the group consisting of unsaturated polyester, vinyl ester, epoxy, urethane and phenolic.  
     
     
         18 . A floor covering according to  claim 10  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.  
     
     
         19 . A floor covering according to  claim 10  wherein said downwardly-facing step cut edge includes an oblique face adjacent the top surface of said second sheet.  
     
     
         20 . A floor covering according to  claim 10 , wherein at least one of said first and second sheets comprises a polymer matrix system that includes polyvinyl chloride and polyester fibers.  
     
     
         21 . 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    bonding a strap of polymer material using radio frequency (RF) welding 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.    
     
     
         22 . 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 bond between and among said polymer strap, said first sheet of polymer flooring material and said second sheet of polymer flooring material formed by radio frequency (RF) welding that forms a combined strap and lap joint between and among said first sheet, said second sheet, and said strap.    
     
     
         23 . A flooring element comprising: 
 a generally rectangular three-dimensional solid polymer in a thickness of at least about one quarter inch, a width of at least about four feet and a length of at least about six feet; and    an angled edge cut along each lengthwise edge of said rectangular three-dimensional flooring element.    
     
     
         24 . A flooring element according to  claim 23  wherein said polymer is selected from the group consisting of thermoplastic polymers, thermosetting polymers and polymer matrix composites.  
     
     
         25 . A flooring element according to  claim 24  comprising a thermoplastic polymer selected from the group consisting of polyvinyl chloride, polypropylene, polyethylene, polystyrene, ABS (acrylonitrile-butadiene-styrene), nylon, polycarbonate, thermoplastic polyester, polyphenylene oxide, polysulfone and PEEK (poly-ether-ether-ketone).  
     
     
         26 . A flooring element according to  claim 24  comprising a thermosetting polymer selected from the group consisting of unsaturated polyester, vinyl ester, epoxy, urethane and phenolic.  
     
     
         27 . A flooring element according to  claim 24  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.  
     
     
         28 . A flooring element according to  claim 24  wherein said flooring element comprises a polymer matrix system that includes polyvinyl chloride and polyester fibers.  
     
     
         29 . A method of installing flooring that is particularly useful for sanitary slip resistant applications such as kitchens, the method comprising: 
 positioning a first sheet of polymer flooring material with an upwardly-facing angled 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 angled cut along one edge of the second sheet to the upwardly facing angled cut of the first sheet and to the floor adjacent the first sheet while concurrently bonding the respective faces to one another.    
     
     
         30 . A method according to  claim 29  comprising positioning respective first and second sheets of thermoplastic material on the floor and applying sufficient energy to the respective angled edges to bond the sheets.  
     
     
         31 . A method according to  claim 29  comprising positioning respective first and second sheets of thermosetting material on the floor and applying sufficient energy to the respective angled edges to bond the sheets.  
     
     
         32 . A method according to  claim 29 , comprising bonding the respective faces of said first and second polymer sheets using radio frequency (RF) welding.  
     
     
         33 . A floor covering on a floor, said floor covering comprising: 
 a first sheet of polymer material with at least one upwardly-facing angled edge facing upwardly from the floor;    a second sheet of polymer material with at least one downwardly-facing angled edge facing downwardly towards the floor and immediately overlying the upwardly facing angled edge of said first sheet; and    a bond joining said upwardly-facing angled edge to said downwardly-facing angled edge and thereby joining said first and second sheets of polymer material together all on said floor.    
     
     
         34 . A floor covering according to  claim 33  wherein said bond is formed by radio frequency (RF) welding.  
     
     
         35 . A method of installing flooring that is particularly useful for sanitary slip resistant applications such as kitchens, the method comprising: 
 positioning a first sheet of polymer flooring material with an upwardly-facing 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 cut along one edge of the second sheet to the upwardly facing cut of the first sheet and to the floor adjacent the first sheet while concurrently bonding the respective faces to one another.    
     
     
         36 . A method according to  claim 35 , comprising bonding the respective faces of said first and second polymer sheets using radio frequency (RF) welding.