Patent Application
20160060880
This application relates generally to the field of building construction, and more specifically to a flooring system that includes complementary fastening clips and a related construction method using same.
Wood floors are a durable and elegant flooring option for purposes of either constructing or remodeling an interior space. However, wood is not a simple material, at least for purposes of fabrication. That is, wood is both hydroscopic and anisotropic. As is generally known, the term “hydroscopic” means that wood will readily exchange water with its surroundings, in which any gain or loss of water can result in dimensional changes to the machined shape of a wooden object. In addition, these dimensional changes are also “anisotropic”, meaning that the wooden object being fabricated does not change dimension with equal magnitude in every direction. Resulting unequal dimensional changes can lead to several problems or issues during the service life of wood floors. These issues can include crowning or cupping of individual flooring pieces, gapping between adjacent flooring pieces, and localized or widespread heaving of the floor, among others.
Many of the current floor installation assembly methods employed by those in the industry mitigate the above-noted dimensional issues by mechanically restraining the connected sections of wood with fasteners and adhesives, bonding each section to a structural substrate. These assembly systems are sufficient as long as the dimensional variation in the material does not create forces that exceed either the elastic limit of the flooring material or the forces created by the fasteners and adhesives bonding the flooring material to the structural substrate.
So-called “floating floors” are an ideal way to compensate for dimensional changes in a flooring material, since the floor is not directly fastened (and therefore constrained) to a structural substrate. Instead, the floor is joined to the remaining flooring components making up the floating floor. This latter technique allows the floor to change dimension as a single composite sheet, preventing noticeable gapping between adjacent flooring pieces. Providing for lateral movement also prevents failure of the flooring material that can result from confining dimensional changes. The joining of the various flooring components is primarily achieved by forming or milling small interlocking tongue and groove sections into the flooring planks. While this technique has been made possible with engineered laminate and composite wood floors, success has not been achieved with solid wood due to directional weaknesses in the material.
There are known static connector systems that can be used with more dimensionally stable materials, such as so-called “compact laminate.” These latter systems rely on relatively precise matching between grooves and/or protrusions on each wood panel with corresponding protrusions and/or grooves on the static connector, thereby creating a mechanical interference or press fit. Connectors of this type have not found widespread application in wood product flooring assembly systems. The dimensional variation(s) experienced by wood products following installation changes the shape of all machined services. Therefore, as the flooring components are caused to shrink or swell, creating forces that the connector would need to overcome, the shape and size of grooves and protrusions on the wood product flooring components needed to interface with the static connector will also change accordingly. The change could reduce or otherwise compromise effectiveness of the mechanical interference or press fit that is required to hold the various flooring components together.
According to a first aspect, there is provided a flooring system comprising a plurality of flooring pieces configured to be disposed onto a support surface, each flooring piece having a wear surface, an opposing mounting surface and a mounting groove disposed within the mounting surface; and a plurality of connectors, each connector being configured for securing a pair of individual flooring pieces together on the support surface. Each connector comprises a base, at least one center mast vertically extending from the base for retaining a first flooring piece and aligning a second flooring piece therewith, and a pair of flexible arms. Each flexible arm extends transversely from opposing sides of the at least one center mast and has a inwardly curved engagement end wherein the base comprises contacting portions extending from a lower surface of the base that are configured to engage the support surface. The contacting portions are sized to create a spacing between each flexible arm and the support surface, thereby permitting each flexible arm to elastically deflect toward the support surface when pressure is exerted on a flooring piece and thereby enable the inwardly curved engagement end of each flexible arm to engage the mounting groove of the flooring pieces.
According to another aspect, there is provided a connector for enabling attachment of a pair of floor panels relative to a support surface. Each floor panel includes a wear surface and an opposing mounting surface having an angled retention or clamping groove, the connector comprising at least one center mast extending from a base configured for retaining a first floor panel prior to attachment of a second floor panel; and a pair of flexible arms extending transversely from opposing sides of the at least one center mast. Each of the flexible arms includes a curved extending end that is configured for engaging the retention groove of a floor panel, wherein the base comprises contacting portions that extend from a lower surface of the base and are configured to contact the support surface and define a spacing between the flexible arms and the support surface to enable either of the flexible arms to elastically deflect toward the support surface to permit the engagement end to mate with the angled retention groove.
According to yet another aspect, there is provided a method for forming a sub-floor onto a support surface, the method comprising:
As such, a flooring system is provided in which flooring components are joined to each other over the top of, but otherwise unattached to, an underlying subfloor by the use of a plurality of the herein described connectors that eliminate the need for adhesives or fasteners extending through the various flooring components and into a structural substrate. In one version, the connectors comprise clip members that include sections having a continuous profile including a supporting base, a beaded alignment mast extending transversely from the center of the supporting base and two hooked or suitably shaped clamping arms extending outwardly from opposing sides of the mast along the base. The beaded alignment mast is configured to index into an alignment groove provided on an edge of one of the flooring pieces, while the hooked clamping arms are configured to engage a clamping or retention groove formed on the bottom of each of the interconnected flooring pieces. With this described system, flooring pieces may be secured to one another simply by pressing the flooring pieces into place on the floor panel connectors.
Advantageously, the herein described system enables dimensional changes to the floating floor to be distributed, minimizing the effects of stress.
Another advantage is that the herein described fastening clip is durable and relatively inexpensive to manufacture.
Yet another advantage realized is the ability to incorporate flooring components made from different materials (i.e., solid hardwood and marble) into a single continuous floor despite these components having widely different physical and mechanical properties.
Still another advantage is that the herein described flooring system does not require special equipment typically used in hardwood flooring installation, such as flooring nail guns and flooring jacks.
Yet another advantage provided is that flooring installation using the herein described system and method may be done without advanced training or need of specialized tradesman.
Still another advantage is a better yield being realized from the flooring material in that material is not lost, for example, to the molding of a tongue on one edge of each flooring panel, as in presently known installation systems.
Another advantage is that a floor installed in accordance with the herein described system and method will not require sanding or other finishing steps after installation because the connector used retains each flooring piece (panel) in the same plane supported above the subfloor (support) surface and/or underlayment.
Furthermore, wooden flooring components may be completely finished on all surfaces at the manufacturer's facility because sanding and finishing is not required after installation.
The herein described system provides additional advantages in that individual flooring pieces can be removed and replaced with minimal disturbance to the remainder of the floor in the event a flooring piece is damaged. Moreover, entire floors can be easily removed and replaced or otherwise reconfigured using the herein described system. For example, the flooring panels can be removed and refinished elsewhere, then returned for easy reassembly. Having the ability to conduct refinishing remotely avoids the associated dust, noise and finishing chemicals that are associated with refinishing known nailed or glued hardwood floors.
These and other features and advantages will be readily apparent from the following Detailed Description, which should be read in conjunction with the accompanying drawings.
The following relates to exemplary embodiments of a sub-flooring system (also herein referred to as a “floating floor”), including an floor panel connector (also synonymously referred to throughout as an “assembly clip”, or “assembly connector”) that is configured to secure together a pair of floor components (i.e., floor panels) onto a supporting surface or substrate. It will be readily apparent that other variations and modifications can be contemplated by a person of sufficient skill that further embodies the inventive ambits which are described herein. Throughout the course of discussion, a number of descriptive terms are used in order to provide a suitable frame of reference with regard to the accompanying drawings. These terms, which may include “outer”, “inner”, “internal”, “external”, “above”, “below”, “top”, “beneath”, and the like are not intended to otherwise limit the effective scope of this application, including the appended claims, unless so specifically indicated.
In addition, it should be noted that the accompanying drawings are not drawn to scale and therefore the reader should not overly rely upon same for scaling purposes.
For purposes of the description that follows, the terms “a”, “the” though referring specifically to single items are to be interpreted to mean “at least one”. Therefore, in referring for example to a center mast, a description made herein is “a center mast” or “the center mast” may infer “at least one” center mast.
The terms “including”, “include”, “comprises”, “comprising” and the like are intended to be open-ended terms that are minimally inclusive of the terms or elements associated with these terms.
The terms “flooring components”, “flooring pieces” and “flooring panels” are used synonymously throughout this discussion and relate to sections of the floor that are assembled together using connectors, as described herein.
The terms “floor panel connectors” and “connectors” refer to those portions of the herein described flooring system and method that are used to interconnect individual flooring components.
Referring to
The floor panel connector 112 according to a first exemplary embodiment is defined by a unitary member which is fabricated from a durable flexible material, such as, for example, a molded or extruded plastic. The floor panel connector 112 includes a base 120 having an upper surface 123 and an opposing lower surface 125. The base 120 of the floor panel connector 112 is further defined by a pair of flexible arms 124, 128, each flexible arm 124, 128 being disposed transversely from opposing sides of a center alignment mast 132. The base 120 further includes a pair of contacting portions 136, 138, each projecting from the lower surface 125 of the base 120 and spaced from one another on adjacent sides of the center alignment mast 132 and configured to directly engage the support surface 116. Each contacting portion 136, 138 is commonly defined by a substantially hemispherical surface 140 in which a slot or recess 144 is provided between the contacting portions 136, 138 at substantially the center of the connector 100. Respective ends 144, 148 of the flexible arms 124, 128 are each curved inwardly in a direction extending toward the center mast 132. The center alignment mast 132 extends from the upper surface 123 of the base 120 and includes a bulbous upper end 152 having a widened thickness, as compared to the thickness of the remainder of the center alignment mast 132.
Referring to
Referring to
Referring to
The completed assembly 100 is depicted in
Referring to
A floor panel connector 312 used to interconnect the flooring pieces 104, 108, is made from a suitable material, preferably a molded or extruded plastic although other suitable structural materials can also be substituted. According to this specific embodiment, the floor panel connector 312 is defined by a base 320 having an upper surface 323 and a lower surface 325, the floor panel connector 312 further including a pair of post or mast members 332, 334 that extend upwardly from the upper surface 323 of the base 320 with a defined spacing 335 therebetween. The post members 332, 334 commonly include a bulbous upper end 352, the latter having a thickness which is larger than the remainder of each post member 332, 334.
The base 320 further includes a pair of flexible arms 324, 328 that each extend transversely from the post members 332, 334 and include respective inwardly curved ends 344, 348 that are curved inwardly (i.e., toward the post members 332, 334). The base 320 further includes a plurality of contacting portions configured to engage the support surface 116. According to this specific embodiment, three (3) contacting portions 336, 338, 340 are provided in spaced relation extending from the lower surface 325 in which one of the support portions 340 is disposed at substantially the center of the span of the base 320, with each of the remaining contacting portions 336, 338 being disposed adjacent each of the post members 332, 334 and outboard in relation thereto. Each of the contacting portions 336, 338, 340 are further defined by a substantially hemispherical surface 342.
In terms of assembly and still referring to
The second flooring piece 108 is then attached to this assembly initially tilting the second flooring piece 108 toward the support surface 116 and providing downward force against the flexible arm 328, causing the arm 328 to deflect due to the spacing provided by the contacting portions 338, 340 and the curved end 348 to be engaged with the angled groove 168 with the recessed portion 172 of the second flooring piece 108 being tightly retained between the second post member 334 and the retention groove 168 in a snap fitting arrangement. An inlay or insert 390 made from marble or other material can be introduced to this assembly within the spacing 335 that is defined by the post members 332, 334, which is sized to retain same. The inlay 390 can be provided either at the end of the assembly process or prior to attachment of either the first and/or second flooring pieces 104, 108, depending on the rigidity of the inlay and to insure the connector 320 can maintain a level of flexibility to permit attachment of the flooring pieces 104, 108. As such and according to this embodiment, the insert 390 would be removable and permit replacement thereof, but without having to replace or remove the remainder of the flooring assembly 300. In one version, the inlay 390 can at least partially comprise a material that includes a flexible undersurface that facilitates attachment and removal of same. In this manner, various styles of inserts 390 could be interchangeably utilized.
The exemplary embodiments disclosed herein are not intended as a restriction or limitation on the application, composition, structure and manufacturing method of the invention. It will be readily apparent that other variations and modifications are possible within the inventive ambits that are described herein.
The present inventive system and method is directed to the application of floor assembly systems including flooring panels, squares, rectangles and other varied shapes of either solid wood, laminate or composite wood products. However, the application of the presently described system and method to other alternative materials such as bamboo, filled and unfilled polymeric materials (naturally occurring or man-made), ceramics, stone, and metals is also contemplated. In addition, this application is further suitable for any rigid backed panel assembly having a non-rigid wear surface (e.g., carpet, rubber, athletic padding, or artificial turf) as well as combinations of any of the above.
The above-described flooring panels are manufactured utilizing techniques known in the art. During or after manufacturing, panels may be machined or otherwise modified or formed by any technique known in the art to create the appropriate recesses in the bottoms and edges thereof that cooperate with the herein described fastening clips.
These appropriate recesses shall be defined as any structural feature or group of features that promotes the interface with and function of any rendition or manner of the floor panel connector described herein.
Moreover, the connector(s) described may be manufactured from materials selected from the group that includes filled and unfilled polymeric materials (naturally occurring or man-made), ceramics, metals, and combinations thereof. Preferably, in use with the above-described flooring panels, the floor panel connector of the claimed system is manufactured from polymeric materials or metal. Depending on the material and size, the connector may also be manufactured from techniques known in the art, e.g., the connector is preferably fabricated from extruded, filled or unfilled polymeric materials.
These and other modifications and variations of the system, connector and methods of using and fabricating same will be readily apparent to one of sufficient skill from the following claims:
This application claims priority under relevant portions of 35 U.S.C. §119 to U.S. Patent Application No. 62/042,466, filed Aug. 27, 2014 and entitled: Dynamic Floating Floor Assembly Clip. The entire contents of this referenced application is herein incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 62042466 | Aug 2014 | US |
