Patent Application
20090019804
The present invention relates to size tailorable tracks useful for connecting a first construction element (e.g., a transition molding) to a second construction element (e.g., a surface of a subfloor). In certain non-limiting embodiments, this invention relates to tracks which are scored during the manufacturing process to form weakened break junctions at which sections of the tracks may be separated by hand (e.g., typically “on site”) without the use of a cutting device. The present invention additionally relates to methods of using size tailorable tracks as well as track manufacturing systems, machines, and methods.
Transitions between different flooring materials, such as between wood/laminate flooring and carpet or tile, as well as between flooring materials in different areas, are typically achieved by use of a transition molding piece, such as a T-Molding or specialized transition molding piece to transition between flooring elements of different heights. The transition molding piece is typically coupled to the subfloor through a metal track which must be cut to length for each transition area, a relatively labor intensive process requiring the use of specific cutting tools, which factor into the overall cost of flooring installation. Moreover, the use of these cutting tools increases the risk of worker injury, and may result in imprecise cuts and wasted material.
In view of the above, it is apparent that there exists a need in the art for a track and/or method of its use which addresses, overcomes, mitigates, or solves one or more of the above problems and/or drawbacks and/or inefficiencies in the art. It is a purpose of this invention to fulfill this and/or other needs in the art which will become more apparent to the skilled artisan once given the following disclosure.
Generally speaking, this invention addresses the above-described needs in the art by providing a size tailorable track for securing a first construction element to a second construction element, the track including a plurality of spaced apart weakened or scored regions which permit the track to be manually “broken” at such regions in order to obtain a track of a desired length. In certain preferred but non-limiting embodiments, the track is designed to connect a transition molding piece (a conventional T-molding, for example) to a subfloor (between adjacent flooring elements during installation of wood or laminate flooring, for example).
In certain non-limiting embodiments, there is provided a size tailorable track comprising: a generally u-shaped elongated structure having a plurality of score marks along its length, each score mark being a region which is so weakened such that an end user can manually bifurcate or “break” said track at said weakened region using hand pressure/leverage and without the use of tooling; the score marks being spaced along the length of the track at preselected distances selected such that the track can be broken/bifurcated manually to select a length of track which is suitable for a wide variety of construction spacing applications. In preferred but non-limiting embodiments, the track segments defined by the distance between adjacent score markings are sufficiently short such that they will individually fit with the majority (or preferably all) conventional construction transition spaces (e.g., within the width of a doorway). In such or other preferred but non-limiting embodiments, the track segments are long enough such that the structural integrity of track is not compromised (e.g., due to large numbers of scores weakening the overall track structure) and/or they are particularly sized so that when a functional track length is obtained by breaking the track at a score region, the track is not more than approximately 4-6 inches shorter than the transition space to which the track will be or is being applied or utilized within (for example, conventional transition spaces in flooring installations).
In certain non-limiting embodiments, an optimum track segment length is between approximately 3.5 inches and 6 inches, more preferably between about 3.5 inches and about 4.5 inches, and most preferably is selected to be about 4 inches. Such lengths or length ranges are selected due to their suitability as being shorter than the length of the majority if not all transition applications and/or are selected at such length(s) so that a functional track length can be selected so (by breaking it at the score marks) such that the track is not more than about 4 inches shorter than the length of a conventional transition space (preferably, but not necessarily, not more than 2 inches shorter than the transition space on each side of the track). Other track segment lengths may, of course, be utilized however (such as between 3.5 and 15 inches, for example).
In certain preferred but non-limiting embodiments, the track comprises an elongated base member attached to two laterally spaced arms each extending upward from an opposite edge of said base member, wherein said base member and said arms together define a generally elongate U-shaped channel for receiving and retaining a transition molding piece.
In an alternative, non-limiting embodiment, there is provided a track for securing a molding piece to a subsurface, the track including at least first and second contiguous track sections, each of the first and second track sections including an elongate base member attached to two laterally spaced arms extending upward from the base member, wherein the base member and the arms together define a generally elongate channel for receiving and retaining a molding piece, and a groove formed in the surface of at least the base member between the first and second track sections, wherein the first track section is detachable from the second track section at the groove. The first track section may be detachable from the second track section at the groove upon flexure of the track, the channel may be generally U-shaped, and the track may be machined from a continuous piece of metal.
In any one of the above or in further alternative but non-limiting embodiments, the base member may include holes for receiving fasteners (e.g., mechanical fasteners), such as screws or nails, to secure the track to a construction surface (e.g. a subfloor), and the groove may be formed in the outer surface or the inner surface of the base member. In certain non-limiting embodiments, at least one of the arms includes a gripping member, such as an inwardly directed flange, for retaining and/or gripping a molding piece within the channel.
In still further non-limiting embodiments, there is provided a kit useful for marketing for end consumer or contractor purchase which comprises a package including: a length of transition molding; a size tailorable track as described herein; and hardware (e.g., mechanical fasteners) for securing the size tailorable track to a subfloor or similar construction element; the track having a generally u-shaped channel to accept and secure the transition molding to the subfloor (or similar construction element) when the track is attached thereto; and the track being tailorable in size without requiring the use of cutting tools so that an appropriate length of track can be user selected on a building site, for example, which is useful for a selected transition molding installation.
In still further non-limiting embodiments, there is provided a track for securing a transition molding piece to a subfloor between adjacent flooring elements, the track including at least first and second contiguous track sections, each of the first and second track sections including an elongate base member attached to two laterally spaced arms each extending upward from an opposite edge of the base member, wherein the base member and the arms together define a generally elongate U-shaped channel for receiving and retaining a transition molding piece, and a groove formed in the outer surface of each of the base member and arms between the first and second track sections, wherein the first track section is detachable from the second track section at the groove.
In another aspect, the present invention relates to a track manufacturing system for manufacturing a track useful for securing a molding piece to a subsurface, the track manufacturing system including an unloading machine for receiving and providing to other machines a substantially planar track material; a marking or scoring machine for receiving the track material from the unloading machine and forming score marks or grooves (or other weakened regions) in the surface of the track material at spaced apart distances; and a shaping machine for receiving the track material from the scoring machine and shaping the track material into a generally elongate U-shaped channel. The unloading machine may include a rotating carousel for receiving and delivering the track material which can but is not required to be provided as a spool. The scoring machine may include a drum having cutting or impressing members on its face. In certain preferred but non-limiting embodiments, the drum is designed to score or provide grooves in the track length at spaced apart distances selected in accordance with the criteria discussed elsewhere herein. The track manufacturing system may further include a puncturing machine for receiving the track material and forming holes therein. In certain non-limiting embodiments, the puncturing mechanism is a drum having hole punching members on it face.
In still other embodiments, the present invention relates to a method for securing a molding piece to a subsurface, the method including the steps of: (a) providing a track which includes at least first and second contiguous track sections, each of the first and second track sections including an elongate base member attached to two laterally spaced arms extending upward from the base member, wherein the base member and the arms together define a generally elongated channel for receiving and retaining a molding piece, and a groove or score mark formed in the surface of at least the base member between the first and second track sections, wherein the first track section is manually detachable or breakable from the second track section at the groove or score mark (without requiring tools as elsewhere described herein, for example); (b) securing the track to a subsurface (using mechanical fasteners, for example); and (c) inserting a molding piece into the channel.
In another non-limiting embodiment, the present invention is related to a method for manufacturing a track useful for coupling a first construction element (e.g., a transition molding) to a second construction element (e.g., a subfloor), the method including the steps of: (a) providing a substantially planar track material, such as to an unloading machine; (b) forming grooves in the surface of the track material, such as with a scoring machine; and (c) shaping the track material into a generally elongate U-shaped channel, such as with a shaping machine. The method may further include the step (d) of forming holes in the track material, such as with a puncturing machine.
Certain examples of the invention are now below described with respect to certain non-limiting embodiments thereof as illustrated in the following drawings wherein:
a shows a top perspective view of one embodiment a track according to the present invention indicating areas at which force “F” is applied to remove a section of such track.
b shows a top perspective view of one embodiment of a track according to the present invention having a section removed as a result of the application of force “F” at the areas so indicated in
For a more complete understanding of the present invention and advantages thereof, reference is now made to the following description of various illustrative and non-limiting embodiments thereof, taken in conjunction with the accompanying drawings in which like reference numbers indicate like features.
Generally speaking, this invention relates to size tailorable tracks which provide the advantage of being comprised of a plurality of detachable or breakable segments of pre-selected lengths which can be bifurcated or broken without the use of tools or requiring significant force. Designed as such, a given, standard length of track can be “broken down” into a desired length by an end user for use in molding transition installations of a wide variety of sizes, for example. In this regard, due to the size tailorability of such tracks, standard lengths of track can be commercialized or sold to non-professional or professional builders or handymen without need for the end user to pre-measure the installation areas or for the end user to have specialized tools or skills. In certain preferred but non-limiting embodiments, such tracks are pre-scored or grooved to define weakened junction regions which can thereafter be snapped or bifurcated using manual or hand forces (e.g., to obtain track sections of desired lengths). As discussed in more detail below, such tracks are useful for securing construction elements to one another, such as for securing transition moldings or other molding types to a subfloor, for example.
Referring now to
When a transition molding piece is inserted into channel 110, it is, in this embodiment, held in place by flanges 116a, 116b, respectively on arms 108a, 108b, such that it is generally moveable in a horizontal direction for precise placement during installation but not generally moveable vertically, so that, once installed, it is held securely in place. It is understood that other conventional means for securing a transition molding piece within the channel may be employed (e.g., gluing), either in place of or in addition to the use of flanges, where desirable for particular applications. Further, track 100 may be secured to a subfloor in any conventional way, such as by fastening with nails or screws 113 through holes 114 in base member 106 and/or by gluing track 100 to the subfloor. Of course, holes or fastener apertures 114 are optional and are not used in certain embodiments (not shown), such as when the track is only glued to the subfloor and/or when screws/nails are used that are capable of being driven directly through the track material without the need for holes or pre-drilling (e.g., self-tapping screws).
One non-limiting example of an installation of a track 100 according to the present invention for use in securing a floor molding piece 111 to a subsurface 115 is illustrated in the exploded view shown in
Track 100 further includes at least one groove or score mark 112 formed in a surface of at least base member 106, which generally defines the boundary between first and second track sections or segments 102 and 104. Groove 112 may be formed in the outer surface of base member 106, as shown in
With reference to the embodiment shown in
For example, one non-limiting embodiment of a worker “breaking” track 100 by hand to a desired length is illustrated in
It has been determined that the length of the resulting track 118 in
More specifically, in preferred (but non-limiting) embodiments, the score marks or grooves are spaced along the length of the track at preselected distances such that the resulting segment or section lengths are sufficiently short such that they will individually fit with the majority (or preferably all) conventional construction transition spaces (e.g., within the width of a doorway). Conversely, in such or other preferred (but non-limiting) embodiments, the track segments or sections are particularly sized so that when a functional track length is obtained by breaking the track at a score region (e.g., to break off unneeded segments or sections), the track is not more than approximately 4-6 inches shorter than the transition space to which the track will be or is being applied or utilized within (for example, conventional transition spaces in flooring installations) and preferably, but not necessarily, not more than 2 inches shorter than the transition space on each side of the track. Moreover, it is preferred that the scoring or grooves be sufficiently spaced from one another such that the structural integrity of track is not overly compromised (e.g., due to large numbers of scores weakening the overall track structure).
Although the most preferred track section or segment length which has been discovered is approximately 4 inches (plus or minus 0.5 inch), other segment or section lengths may, of course, be utilized (such as between approximately 3.5 inches and 15 inches, preferably between 3.5 and 8 inches, more preferably between 3.5 and 6 inches, but most preferably between about 3.5 inches and about 4.5 inches).
As shown in
As shown in the embodiment illustrated in
Moreover, in certain embodiments, the inventive track manufacturing system may be under manual or computer control to ensure that the track material is unspooled in an appropriate manner and at an appropriate speed to be fed into scoring machine 130 and/or the remaining machines in the system (in certain embodiments, the track material may be fed into puncturing machine 142 (
Moreover, while material unloading machine 120 permits the commercial manufacture of the inventive tracks, it is understood that the track material may be fed to other machines in the track manufacturing system in other ways, including by hand.
Scoring machine 130 may be any machine that is capable of forming grooves in the track material so that sections of the final track product may be separated from one another by hand. In the embodiment shown in
As shown in the embodiment shown in
The described processes illustrate only one way in which the track material having grooves and holes may be formed; others are also contemplated by the present invention. For example, the holes may be formed prior to formation of the grooves, and other machines may be used to achieve substantially the same end product.
The track material is then fed to a shaping machine 150 (indicated diagrammatically in
Tracks according to the present invention may be formed from a metal, but may also be formed from other suitable materials as needed for a particular application (e.g., such as plastic or ceramics). Notably, if the track material which is employed is not metal, other methods or mechanisms for forming the grooves or score marks in the material may be necessary or more advantageous to employ.
The grooves or score marks may be formed on the tracks during the manufacturing process at predefined distances to permit separation of the tracks by hand upon flexure, and at a depth and width that permits such separation without adversely affecting the functional integrity or general handling or other characteristics of the tracks. The grooves may in certain embodiments be distanced so as to permit the ready removal of track sections for use in standard applications, such as for use in doorways.
Moreover, as tracks used for installation of transition pieces do not need to extend the entire length of the location at which they are installed (but rather may be installed at some length less than that of the location) in order to adequately secure the transition piece in place, tracks according to the present invention may be used in a wide variety of settings without giving prior consideration to the precise lengths of the locations at which they are to be installed, as an appropriate number of track sections may be removed from a given piece and/or two or more adjacent track sections may be laid end-to-end such that they abut one another to accommodate installations of any length. Removed sections may readily be used due to the uniform size of the tracks and as a result of the clean breaks afforded by the score lines, such that separate sections aligned adjacent one another and substantially flush at their ends will form channels that are functionally the same as those provided by unbroken tracks, thus significantly reducing or altogether eliminating waste track material.
The inventive tracks afford a great deal of flexibility in their packaging, transport and handling. For example, they may be manufactured and packaged in relatively long lengths, where such lengths are called for by the intended application, and where such packaging does not generally present adverse material handling concerns (as may be the case in certain large scale applications), while on the other hand they may be manufactured and packaged in relatively short lengths for other intended applications (as may be the case in residential applications where the length of the packaging is of greater concern at retail and installation sites).
The inventive tracks are suitable for use in any application where a molding piece may be coupled to a subsurface through a track. In all such applications, the numerous noted and other benefits realized by sizing the tracks by hand rather than with cutting tools will be realized, and all such embodiments are contemplated by the present invention. With that understanding, the description provided herein is in specific reference to wood/laminate flooring systems, where the inventive tracks are known to be particularly useful in coupling transition molding pieces to subfloors.
Once given the above disclosure, many other features, modifications, and improvements will become apparent to the skilled artisan. Such features, modifications, and improvements are therefore considered to be part of this invention, without limitation imposed by the example embodiments described herein. Moreover, any word, term, phrase, feature, example, embodiment, or part or combination thereof, unless unequivocally set forth as expressly uniquely defined or as otherwise limiting, is not intended to impart a narrowing scope to the invention in contravention of the ordinary meaning of the claim terms by which the scope of the patent property rights shall otherwise be determined.
This application claims priority to U.S. Provisional Patent Application No. 60/948,523, entitled TRACKS FOR SECURING MOLDINGS AND METHODS, APPARATUS AND SYSTEM FOR THE MANUFACTURE THEREOF, and filed on Jul. 9, 2007, the entirety of which is hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 60948523 | Jul 2007 | US |
