Floor panel kit and method of forming the same

Patent metadata

Field	Value
Publication number	US-2016368701-A1
Application number	US-201414905340-A
Country	US
Kind code	A1
Filing date	Jul 29, 2014
Priority date	Jul 29, 2013
Publication date	Dec 22, 2016
Grant date	—

Abstract

A kit of floor panels and a method of forming the same. In one aspect, the kit can be a kit of floor panels comprising: a container having an inner cavity containing a stacked assembly of floor panels; the stacked assembly of floor panels comprising: one or more layers of first floor panels having a first width and a first length; one or more layers of second floor panels having a second width and a second length; one or more layers of a third floor panel having a third width and a third length; and wherein the third width is different than the first and second widths and wherein the first length is different than the second and third lengths.

First claim

1 . A kit of floor panels comprising:
a container having an inner cavity containing a stacked assembly of floor panels; the stacked assembly of floor panels comprising:
a first amount of one or more layers of first floor panels, each of the first floor panels having a first width and a first length;
a second amount of one or more layers of second floor panels, each of the second floor panels having a second width and a second length;
a third amount of one or more layers of a third floor panel, each of the third floor panels having a third width and a third length; and
wherein the third width is different than the first and second widths and wherein the first length is different than the second and third lengths; and wherein the first amount is not equal to the second amount and the first amount is not equal to the third amount.

2 . The kit according to claim 1 wherein the first amount comprises two layers of the first floor panels, the second amount comprises four layers of the second floor panels, and the third amount comprises eight layers of the third floor panels contained within the inner cavity of the container.

3 . The kit according to claim 1 wherein each layer of the first floor panels includes four of the first floor panels, each layer of the second floor panels includes two of the second floor panels, and each layer of the third floor panels includes one of the third floor panels, and wherein each layer of the first, second and third floor panels has the same overall width and length.

4 . The kit according to claim 1 wherein the first and second widths are the same.

5 . The kit according to claim 1 wherein the second and third lengths are the same.

6 . The kit according to claim 1 wherein the floor panels are positioned within the package in an upside-down stacked arrangement such that the one or more layers of the third floor panel are at a bottom of the package, the one or more layers of the second floor panels are stacked atop of a top layer of the one or more layers of third floor panels, and the one or more layers of the first floor panel are stacked atop of a top layer of the one or more layers of second floor panels.

7 . The kit according to claim 1 wherein the first width and the first length are each about 200 mm, wherein the second width is about 200 mm and the second length is about 400 mm, and wherein the third width and the third length are each about 400 mm.

8 . The kit according to claim 1 wherein each layer of the first floor panels comprises four of the first floor panels, wherein each layer of the second floor panels comprises two of the second floor panels, and wherein each layer of the third floor panels comprises one of the first floor panels, and wherein each of the layers of the first, second and third floor panels has substantially the same overall width and length.

9 . The kit according to claim 1 wherein the first floor panels, the second floor panels and the third floor panels are arranged on a floor in an opus pattern.

10 . The kit according to claim 1 further comprising an instruction sheet positioned within the container, the instruction sheet containing instructions for positioning the first, second and third floor panels on the floor in an opus pattern.

11 . A kit comprising:
a container containing:
a plurality of floor panels that can be arranged in an opus pattern;
the plurality of floor panels comprising:
a first set of floor panels having a first width and a first length;
a second set of floor panels having a second width and a second length; and
a third set of floor panels having a third width and a third length; and
wherein the first, second and third sets of floor panels are positioned in the package in a stacked arrangement.

12 . The kit according to claim 11 wherein the container is a carton or box.

13 . The kit according to claim 11 wherein the first set of floor panels comprises two layers having four floor panels in each layer, wherein the second set of floor panels comprises four layers having two floor panels in each layer, and wherein the third set of floor panels comprises eight layers having one floor panel in each layer.

14 . The kit according to claim 11 wherein the first and second widths are the same and the third width is different than the first and second widths, and wherein the second and third lengths are the same and the first length is different than the second and third lengths.

15 . The kit according to claim 14 wherein the first width is about 200 mm and the first length is about 200 mm, wherein the second width is about 200 mm and the second length is about 400 mm, and wherein the third width is about 400 mm and the third length is about 400 mm.

16 . A method of packaging a plurality of floor panels comprising:
a) providing an unfolded container; b) positioning one or more layers of first floor panels on the unfolded container, wherein each of the one or more layers of the first floor panels comprises four of the first floor panels each having a first width and a first length; c) positioning one or more layers of second floor panels atop a top layer of the first floor panels, wherein each of the one or more layers of the second floor panels comprises two of the second floor panels each having a second width and a second length; d) positioning one or more layers of a third floor panel atop a top layer of the second floor panels, wherein each of the one or more layers of the third floor panel comprises one of the third floor panels having a third width and a third length; e) folding the container around the layers of the first, second and third floor panels; and f) flipping the carton so that the first, second and third floor panels are upside-down in the container.

17 . The method according to claim 16 wherein the first and second widths are the same, the third width being different than the first and second widths, and wherein the second and third lengths are the same, the first length being different than the second and third lengths.

18 . The method according to claim 17 wherein the first length is the same as the second width and wherein the second length is the same as the third width.

19 . The method according to claim 18 wherein the first width, the first length and the second width are approximately 200 mm, and wherein the second length, the third width and the third length are approximately 400 mm.

20 . The method according to claim 16 wherein step b) comprises positioning two layers of the first floor panels on the unfolded container, wherein step c) comprises positioning four layers of the second floor panels atop the top layer of the first floor panels; and wherein step d) comprises positioning eight layers of the third floor panel atop the top layer of the second floor panels so that eight of each of the first, second and third floor panels are positioned within the container.

21 .- 25 . (canceled)

Assignees

• Armstrong World Ind Inc

Inventors

• Stoll Brent L
• Nyesmith Pamela A
• Hinkle Yon E

Classifications

• B65B5/02

  Machines characterised by incorporation of means for making the containers or receptacles · CPC title

• E04F15/107

  composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04) · CPC title

• B65D85/62 Primary

  for stacks of articles; for special arrangements of groups of articles · CPC title

• E04F15/02

  Flooring or floor layers composed of a number of similar elements (of webs E04F15/16) · CPC title

• B65B5/10

  Filling containers or receptacles progressively or in stages by introducing successive articles, or layers of articles · CPC title