Flooring system having assembly clip and related method

Abstract

A flooring system includes a plurality of individual flooring pieces, such as floor panels, each having a wear surface, an opposing mounting surface and a retention groove disposed within the mounting surface. A floor panel connector used to interconnect at least two of the floor panels has a base, at least one mast extending from an upper surface of the base and a pair of flexible arms. Each flexible arm extends transversely from opposing sides of the at least one mast and has an extending end. Contacting portions extending from a lower surface of the base are configured to engage the support surface and create a spacing between each flexible arm and the support surface to permit each flexible arm to elastically deflect toward the support surface when pressure is exerted on a floor panel. This deflection enables the extending end of each flexible arm to engage the retention groove of a corresponding floor panel.

Claims

1. A flooring system comprising: a pair of flooring pieces disposed above a support surface, each of the flooring pieces comprising: an upper wear surface; an opposing lower mounting surface; an inner edge; and an outer edge, in which at least one of the flooring pieces further includes a retention groove disposed within the lower mounting surface, the retention groove formed at an intermediate part of the lower mounting surface between the inner and outer edges and defined by an acute angle extending upwardly toward the upper wear surface and inwardly toward the inner edge; and a floor panel connector that secures the pair of flooring pieces to one another, the floor panel connector comprising: a base having a lower surface and at least one contacting portion projecting from the lower surface, said at least one contacting portion configured for engaging the support surface; and at least one flexible cantilevered arm having an inwardly curved engagement end wherein the at least one contacting portion creates a spacing between the at least one flexible cantilevered arm and the support surface to enable the arm to be elastically deflected toward the support surface when pressure is exerted on a flooring piece and cause the inwardly curved engagement end of the at least one flexible cantilevered arm to engage and be retained within the retention groove of the flooring piece.

2. The flooring system according to claim 1, wherein the floor panel connector includes at least one mast extending upwardly from the base.

3. The flooring system according to claim 2, wherein the at least one mast includes an alignment feature for engaging the inner edge of a connected flooring piece.

4. The flooring system according to claim 3, wherein at least one of the pair of flooring pieces and the mast includes an alignment feature.

5. The flooring system according to claim 2, wherein the floor panel connector includes at least two contacting portions for engaging the support surface.

6. The flooring system according to claim 5, including at least one contacting portion projecting downwardly from the lower surface of the base on each opposing side of the at least one mast.

7. The flooring system according to claim 6, wherein the at least one contacting portion is defined by a hemispherical surface.

8. The flooring system according to claim 1, wherein the floor panel connector is made from plastic.

9. A flooring piece for use in a subfloor system, the flooring piece comprising: an upper wear surface; a lower mounting surface; an inner edge; an outer edge; and a retention groove disposed within the lower mounting surface between the inner edge and outer edge, said retention groove defined by an acute angle in which the retention groove extends inwardly from an intermediate portion of the lower mounting surface toward the inner edge and upwardly toward the upper wear surface of the flooring piece at the acute angle.

10. The flooring piece according to claim 9, wherein the inner edge includes at least one alignment feature.

11. The flooring piece according to claim 9, wherein the retention groove is further defined by a recessed portion in an upper portion of the groove.

12. The flooring piece according to claim 9, in which the acute angle is 38 degrees.

13. A method for manufacturing a flooring system, said method comprising: forming a pair of flooring pieces, the forming step including the steps of forming an upper wear surface, a lower mounting surface, an inner edge and an outer edge for each flooring piece; forming a retention groove in at least one of the flooring pieces, the retention groove being formed in the lower mounting surface between the inner edge and the outer edge and extending upwardly toward the upper wear surface from an intermediate portion of the lower mounting surface and extending inwardly toward the inner edge at an acute angle; and forming a floor panel connector having a base for engaging a support surface and at least one cantilevered arm configured for engaging the retention groove of the at least one flooring piece such that an inwardly curved end of the at least one cantilevered arm of the floor panel connector engages and is retained within the acutely angled retention groove.

14. The method according to claim 13, including the step of providing the floor panel connector with at least one contacting portion projecting downwardly from the base.

15. The method according to claim 14, including the step of forming the at least one contacting portion with a hemispherical surface.

16. The method according to claim 13, wherein the at least one contacting portion is configured for contacting a support surface and creating a spacing to permit the flexible cantilevered arm to deflect to permit engagement with the retention groove of a flooring piece.

17. The method according to claim 13, including the step of forming the floor panel connector with a pair of flexible cantilevered arms extending from opposite ends of the base.

18. The method according to claim 17, including the step of forming a pair of contacting portions on the base of the connector in relation to each of the pair of flexible cantilevered arms.

19. The method according to claim 13, including the step of providing the floor panel connector with at least one mast extending upwardly from the base.

20. The method according to claim 19, including the step of providing at least one alignment feature on the at least one mast.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a side elevational view, taken in section, of an exemplary embodiment of a floor panel connector for use in a floating floor system;

(2) FIG. 2 is a perspective view, partially in section, of the floor panel connector of FIG. 1;

(3) FIGS. 3 and 4 are partial assembly views, shown in section, of the floor panel connector of FIGS. 1 and 2, sequentially depicting the interconnection of adjacent floor panels to the floor panel connector;

(4) FIG. 5 depicts a sectioned elevational view of the floor panels of FIGS. 3 and 4 by the floor panel connector of FIGS. 1-4; and

(5) FIG. 6 is a sectioned elevational view of a portion of a flooring system, including a floor panel connector which is made in accordance with another exemplary embodiment.

DETAILED DESCRIPTION

(6) 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.

(7) 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.

(8) 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.

(9) 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.

(10) 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.

(11) 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.

(12) Referring to FIGS. 1 and 2, there is shown a floor panel connector 112 that is made in accordance with an exemplary embodiment and for use as part of a floating flooring system 100, which is partially shown in FIGS. 3-5. As discussed herein, the floating flooring system 100 comprises a plurality of flooring pieces (i.e., floor panels) in which specific engagement or interconnection is achieved between a pair of individual flooring pieces 104, 108 using the floor panel connector 112, and in which the floating flooring system 100 is entirely disposed above or onto a planar support surface or substrate 116.

(13) 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.

(14) Referring to FIGS. 3-5, each of the flooring pieces 104, 108 used in combination with the floor panel connector 112 are defined by a wear or upper surface 160, as well as an opposing mounting or lower surface 164. An angled clamping or retention groove 168 is formed within the mounting surface 164 of each flooring piece 104, 108 that is spaced a predetermined distance from an inner edge 169 of each flooring piece 104, 108. More specifically and according to this embodiment, the mounting surface 164 includes a recessed portion 172 adjacent the inner edge 169 of each of the flooring pieces 104, 108 and extending to the angled retention groove 168, the latter being defined between the recessed portion 172 and the remainder of the mounting surface 164. As discussed herein, the recessed portion 172 is defined by a width dimension that is slightly smaller than a corresponding dimension between the base 120 and the flexible arm 124 in order to provide a snap-fit accommodation for the floor panel connector 112. The lower corners of the recessed portion 172 are preferably rounded and wherein the retention groove 168 is defined by an acute angle of approximately 38 degrees, though this parameter can be suitably varied to cover other suitable angles that enable retention of a complementary flooring piece. The flooring pieces 104, 108 can be manufactured from solid wood in accordance with this specific embodiment, although other suitable structural materials such as laminate, metal and the like can also be utilized.

(15) Referring to FIGS. 3-5, the formation of a floating floor in accordance with this exemplary embodiment is herein described, which includes the interconnection of the flooring pieces 104, 108 being shown in sequence. First, one of the flooring pieces 104 is initially attached to the floor panel connector 112 by hand. To effect this attachment, the floor panel connector 112 aligned with the first flooring piece 104. More specifically, the inner edge 169 of the first flooring piece 104 is aligned with and engaged with the center alignment mast 132 and the recessed portion 172 is pressed into engagement with the upper surface 123 of the base 120 of the connector 112. The flooring piece 104 or the floor panel connector 112 is initially tilted to create this engagement and in which the flexible arm 124 is caused to deflect downwardly and outwardly (relative to the center mast 132) in order to accommodate the recessed portion 172, which has a slightly wider dimension than the initial spacing between the flexible arm 124 and the mast 132. When secured as shown in FIG. 3, the inwardly extending end 144 of the flexible arm 124 is caused to engage the angled retention groove 168, thereby releasably securing the first flooring piece 104 in place. In this position, the lower portion of the inner edge 169 is engaged with the center mast 132 and the bottom surface of the recessed portion 172 is engaged with the upper surface 123 of the base 120 of the connector 112. When assembled, the bulbous upper end 152 of the center alignment mast 132 is engaged with a corresponding groove 176 that is formed in the inner edge 169 of the first flooring piece 104, which further aligns and effectively retains the assembly to permit the attachment of the second flooring piece 108, as herein discussed onto the support surface 116.

(16) Referring to FIGS. 3 and 4, the second flooring piece 108 is then initially tilted with the mounting surface 164 being placed in contact with the support surface 116. As the second flooring piece 108 is pressed downwardly toward the support surface 116, the flexible arm 148 of the floor panel connector 112 is caused to deflect, as shown in FIG. 4, due to the spacing provided by the contacting portions 136, 138 and with the curved end 148 of the flexible arm 128 being moved into engagement with the angled retention groove 168 of the second flooring piece 108. The first flooring piece 104 is retained by the connector 112 during this part of the assembly process. In this assembled position and with reference to FIG. 5, the recessed portion 172 of the second flooring piece 108 is retained tightly within the space provided between the center alignment mast 132 and the curved end 148 of the flexible arm 128 of the floor panel connector 112. As noted, the flexible nature of the arm 128 and the spacing created by the lower contacting portions 136, 138 enable sufficient elastic deformation to enable a snap fit of the curved engagement end 148 with the angled retention groove 168 of the second flooring piece 108 and due to the recessed portion 172 having a slightly larger width dimension than that between the center mast 132 and the flexible arm 128 to achieve the snap fit.

(17) The completed assembly 100 is depicted in FIG. 5 between the two adjacent flooring pieces 104, 108 in which the contacting portions 136, 138 engage the support surface 116 and the mounting surface 164 is in close, but spaced proximity with the support surface 116. The bulbous upper end 152 of the center alignment mast 132 is retained within the space formed by the aligned grooves 176. Other individual flooring pieces (not shown) can be interconnected similarly at the edges thereof to create an overall floating floor structure onto the support surface 116 without the use of adhesives, nails or similar types of fasteners and wherein applied loads to the wear surface 160 of the assembled flooring pieces are adequately distributed to the defined structure.

(18) Referring to FIG. 6, there is shown another exemplary embodiment of a floating floor assembly or system 300. Similar parts are herein labeled with the same reference numerals for the sake of clarity. As in the preceding version, a pair of flooring pieces 104, 108 (i.e., floor panels, partially shown) can be disposed onto a planar support surface 116 in which each of the panels are defined by corresponding upper (wear) and lower (mounting) surfaces 160, 164, respectively. As in the preceding, the mounting surface 168 is further defined by an angled retention or clamping groove 168 as well as a rounded recessed portion 172 adjacent an inner edge 169 of the flooring pieces 104, 108.

(19) 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.

(20) 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.

(21) In terms of assembly and still referring to FIG. 6, the first flooring piece 104 is attached to the floor panel connector 312 in a manner similar to that of the prior embodiment. More specifically and according to this embodiment, the recessed portion 172 of the first flooring piece 104 is engaged with upper surface 323 of the base 320 of the panel connector 312 with the inner edge 169 of the first flooring piece 104 being engaged against the first mast member 332. Due to the larger size (width) of the recessed portion 172 relative to the spacing initially provided between the first post member 332 and the flexible arm 324, the flexible arm 324 is caused to deflect elastically to accommodate the recessed portion 172 with the curved end 344 of the flexible arm 324 being sized and configured to engage the angled retention groove 168 of the first flooring piece 104. In this position, the rounded recessed portion 172 of the first flooring piece 104 is tightly and snap fittingly engaged between the angled retention groove 168 and the first post member 332 with the bulbous upper end 352 of the first post member 332 being engaged with a groove 176 intermediately formed along the upper edge 169.

(22) 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.

(23) 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.

(24) 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.

(25) 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.

(26) 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.

(27) 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.

PARTS LIST FOR FIGS. 1-6

(28) 100 floating flooring system 104 flooring piece 108 flooring piece 112 floor panel connector (assembly clip) 116 support surface 120 base 123 upper surface, base 124 flexible arm 125 lower surface, base 128 flexible arm 132 center alignment mast 136 contacting portion 138 contacting portion 140 substantially hemispherical surface 143 slot or recess 144 end, inwardly curved 148 end, inwardly curved 152 bulbous upper end, center alignment mast 160 upper (wear) surface 164 lower (mounting) surface 168 retention groove 169 inner edge 172 recessed portion, mounting surface 176 groove, inner edge 300 flooring assembly or system 312 floor panel connector 320 base 323 upper surface 324 flexible arm 325 lower surface 328 flexible arm 332 post or mast member, first 334 post or mast member, second 335 spacing 336 contacting portion 338 contacting portion 340 contacting portion 342 substantially hemispherically shaped surface 344 end, flexible arm 348 end, flexible arm 352 bulbous upper end, post members 390 inlay or insert

(29) 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: