“Click-lock” flooring is generally a plank or tile flooring with co-acting tongue and groove joint structures. In the process of connecting and laying these planks or tiles to the floor, their joints tend to draw together tightly and lock without the use of adhesives. In one example, U.S. Pat. No. 6,715,253 B2 to Pervan, FIG. 9 shows floorboard 1 with a groove 36 and a locking surface 10, while floorboard 1′ has a tongue 38 and a locking surface 11. Floorboard 1 is laid flat on a subfloor surface, with groove 36 facing out. Tongue 38 of floorboard 1′ is pointed at groove 36 of floorboard 1 at a downward angle. As tongue 38 of floorboard 1′ enters groove 36 of floorboard 1, locking surface 10 of floorboard 1 co-acts with locking surface 11 of floorboard 1′, drawing and locking tongue 38 and groove 36 together. This process of installation is sometimes referred to as “inward angling” or just “angling.” Many different geometries of tongue and groove and locking edge profiles have been created by different manufacturers of the flooring, but angling is how most of the joints are put together and locked.
The co-action of locking surfaces 10 and 11 is designed to draw floorboard 1′ tightly against floorboard 1, without the use of tools. Once locked together, floorboard 1 and 1′ should not be able to be separated. However, at that point, floorboards 1 and 1′ also can no longer be pushed any closer together. Unfortunately, if there is any variation in the shapes of the tongues and grooves, there can be some undesirable gapping at the joints. Furthermore, different tongue and groove profiles can lock more or less tightly together than others.
If adjustment is needed to get the floorboard 1′ to fit more tightly against floorboard 1, floorboard 1′ must be lifted again to the angle at which the joint is unlocked, and then pushed or tapped somehow to fit more tightly against floorboard 1. One way to force floorboard 1′ more tightly against floorboard 1 is called “angle tapping.” This involves the use of a prior art tapping along with a hammer. As shown in
U.S. Pat. No. 6,715,253 B2 describes the floorboards as being made with an “upper surface layer,” a “fibreboard core,” and a “lower balancing layer.” This method of construction is highly versatile, and so floorboards of this kind with a wide variety of joint profiles, and overall floorboard lengths, widths, and thicknesses have been produced. As far as thicknesses, floorboards from 3 mm to 10 mm thick are most common. For the joint profiles, a wide variety of different multifaceted co-acting tongue and groove joint profiles have been produced. However, as shown in
Therefore, a tapping block is needed that can better assist in the process of angle tapping floorboards. Such a tapping block should also be adjustable to fit the wide variety of tongue and groove joint profiles and floorboard thicknesses that are encountered.
In one embodiment, the angle tapping block includes a beating block that contacts the side of the floorboard (plank) at a surface on the edge of the plank where it can be tapped, and a lifter plate fastened to the beating block which can lift and hold the plank at the angle at which it can be angle-tapped. In one embodiment, the lifter plate includes a beveled edge, making it more easily insertable beneath the plank.
In another embodiment, the angle tapping block includes a beating block, a lifter plate, and a plurality of shims which are insertable between the lifter plate and the beating block. The shims adapt the device to planks of different thicknesses. In one embodiment, shims of different thicknesses are used, allowing the shims to be used in different combinations as needed for different thicknesses of planks. In another embodiment, the beating block and shims are mounted over threaded posts mounted on the lifter plate, and the shims are mounted over the threaded posts as by open-ended slots, allowing the shims to be easily inserted or removed. In another embodiment, the shims have a tab extending from their side surface to allow them to be individually removed from a stack of shims more easily.
In another embodiment, the angle tapping block includes a beating block, a lifter plate, and a contact plate. The contact plate contacts and impacts the plank at a lower surface on the edge of the plank than the beating block. The contact plate may include slots allowing it to be slidably mounted over the threaded posts on the lifter plate. The contact plate may be placed directly on top of the lifter plate, or any number of shims may be placed beneath the contact plate to space it from the top of the lifter plate. Thus, the contact plate can be positioned at various spacings from the lifter plate on shims, and is also slidable in the direction of the plank to contact the plank by way of its slots, to adjustably contact the plank at various points on either the tongue or the groove edge of the plank.
In another embodiment, the angle tapping block includes a beating block, a lifter plate, and a body extension plate attached to the beating block. In one embodiment, the body extension plate is attached at an elevation on an inner side surface of the beating block. Below the body extension plate, a lower inside surface on the beating block has a convenient height for tapping the upper edge portion of a variety of planks. In another embodiment, when a plank is inserted between a bottom surface of the body extension plate, and a top surface of the lifter plate, the bottom surface of the body extension plate and the top surface of the lifter plate contact the plank to stabilize it when it is lifted from a subfloor surface. In another embodiment, the body extension plate is long enough to produce downward pressure on the angled plank, near the tongue and groove joint, so that the planks do not come apart at the joint during the process of angle-tapping. In another embodiment, the body extension plate includes a protective covering on its bottom surface to prevent scratching the surface of the plank. In another embodiment, the body extension plate includes a handle for lifting the plank to the necessary angle. In another embodiment, the handle is at approximately a right angle to the beating block element, so that putting pressure on the handle puts pressure on the beating block element in a direction that tightens the joint between the two planks.
In another embodiment, the tapping block includes a beating block, and a body extension plate, and an area of the beating block beneath the body extension plate forms a surface lower for tapping the upper edge portion of a variety of planks.
In another embodiment, the tapping block includes a beating block having a bottom surface, a plurality of shims, and a contact plate that includes a slot, and the contact plate is slidably fastened to the beating block by a fastener through the slot in the contact plate.
The figures depict various embodiments of the present invention for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the invention described herein.
As shown in
Contact plate 200 is mounted by placing slots 201, 202 over threaded posts 101, 102. Depending on the profile of the joint edge to be tapped, contact plate 200 can simply be used as a shim to space beating block 400 above lifter plate top surface 104. Slots 201, 202 additionally permit contact plate 200 to slide in the direction of a plank so that edge 205 contacts a surface on the edge of the plank to be tapped. Tapping the plank with both beating block 400 and contact plate 200 better distributes the tapping force against the edge of the plank being tapped, protecting it from being easily damaged. In the embodiment of
A plurality of shims 300 are mounted over threaded posts 101, 102. These can be placed on top of contact plate 200, or if contact plate 200 is not included, then on top of lifter plate 100. Furthermore, any of the plurality of shims 300 may be placed beneath the contact plate 200 to adjustably space it to contact a different surface of the edge of the plank to be tapped. Any of the plurality of shims 300 may be inserted or removed to space beating block 400 to contact a surface on the edge of the plank to be tapped. A shim 310 has open-ended slots 311, 312 for mounting over threaded posts 101, 102. A shim 310 also has finger tabs 313, 314, allowing shim 310 to be easily inserted or removed from any stack of the plurality of shims mounted on angle tapping block 1000 at the time. In one embodiment, plurality of shims 300 includes three shims 310, 320 and 330 which are 1 mm in thickness, two shims 340 and 350 which are 3 mm in thickness, and a contact plate 200 with a thickness of about 1.5 mm is also included. In that embodiment, contact plate 200 can be stacked with any of plurality of shims 300 to create stack heights from 1.5 mm to 10.5 mm, to accommodate plank thicknesses from 1 mm to 10 mm, while still providing about 0.5 mm of clearance.
Beating block 400 has post holes 401, 402 allowing it to be mounted over threaded posts 101, 102 and placed on top of any of lifter plate 100, contact plate 200, or any of the plurality of shims 300, as desired. Thus, beating block 400 can be adjustably spaced to contact a surface on the edge of the plank to be tapped. Beating block 400 has a beating block bottom surface 410. The vertical distance between beating block bottom surface 410 and lifter plate top surface 104 is a gap which will be referred to herein as shim insertion area 411. Shim insertion area 411 is an area at which contact plate 200 or any of a plurality of shims 300 is positionable. In the embodiment of
Extension plate 500 is inserted into slot 407 of beating block 400. Extension plate 500 is fastened to beating block 400 by pressing pins 501, 502 into pin holes 405, 406. Pins 501, 502 are further pressed through pin holes 503, 504 of extension plate 500. Beneath slot 407 of beating block 400 where extension plate 500 is inserted, beating block 400 forms lower inside tapping surface 408, which is of convenient height for tapping against an upper edge area of click joint planks.
Extension plate 500 further includes flush-mounted threaded posts 505, 506 for mounting handle 600 using fasteners 507, 508. Handle 600 has a handle top surface 601 which defines the top or topmost surface of angle tapping block 1000. Extension plate 500 has a cover 510 affixed to extension plate bottom surface 509 to prevent it from scratching the face of the plank. Extension plate 500 includes an extension plate long side 512 defining the length of extension plate 500, and an extension plate front side 511, which defines the front of angle tapping block 1000.
Contact plate 200 has a contact plate top surface 206 and a contact plate bottom surface 207, shim 310 has a shim top surface 315 and a shim bottom surface 316, and similarly all other of a plurality of shims 300 have a shim top surface and a shim bottom surface. As shown in the embodiment of
In the adjustment of the device, adding any of contact plate 200 or any of plurality of shims 300 beneath beating block bottom surface 410 as by mounting them over threaded posts 101, 102 and stacking atop lifter plate top surface 104 spaces beating block bottom surface 410 from lifter plate top surface 104. Once a desired combination of contact plate 200, and any of the plurality of shims 300 is stacked on lifter plate 100, any other unneeded plurality of shims 300 (or contact plate 200) is set atop beating block 400 at beating block top surface 404. Nuts 701, 702 are tightened to hold the device together in a configuration.
To adjust the device to the groove side of a plank, as shown in
As shown in
Adjusting the device to the tongue side of a plank is done in a similar manner. As shown in
Angle tapping block 1000 is shown in use in
As shown in
As shown in
As shown in
As shown in
As shown in
As shown in
The foregoing description of the embodiments of the invention has been presented for the purpose of illustration; it is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Persons skilled in the relevant art can appreciate that many modifications and variations are possible in light of the above disclosure. Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter. It is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based hereon. Accordingly, the disclosure of the embodiments of the invention is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.
This application claims the benefit of U.S. Provisional Application No. 62/804,247, filed Feb. 12, 2019, which is incorporated by reference in its entirety.
Number | Name | Date | Kind |
---|---|---|---|
1161207 | Hagel | Nov 1915 | A |
2864581 | Harrison | Dec 1958 | A |
5527014 | Bracewell | Jun 1996 | A |
6715253 | Pervan | Apr 2004 | B2 |
10494823 | Jacober | Dec 2019 | B2 |
20180230700 | O'Connor | Aug 2018 | A1 |
Number | Date | Country | |
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20200256069 A1 | Aug 2020 | US |
Number | Date | Country | |
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62804247 | Feb 2019 | US |