U.S. patent application number 10/287575 was filed with the patent office on 2003-07-03 for method for installing wood flooring.
Invention is credited to Bolduc, Manuel.
Application Number | 20030121226 10/287575 |
Document ID | / |
Family ID | 33567082 |
Filed Date | 2003-07-03 |
United States Patent
Application |
20030121226 |
Kind Code |
A1 |
Bolduc, Manuel |
July 3, 2003 |
Method for installing wood flooring
Abstract
There is provided a flooring system for hardwood floors
comprised of a plurality of elongated slats wherein the slats are
held in position by a plurality of connectors, each connector
having a base secured to a substrate, a vertical portion extending
upwardly from the base, and a generally horizontal portion
extending into a groove formed in a side wall of the elongated
slat. The system permits the slats to be installed with a minimum
of labor and also permits removal of the slats and their later
re-use.
Inventors: |
Bolduc, Manuel;
(St-Denis-de-Brompton, CA) |
Correspondence
Address: |
Eric Fincham
316 Knowlton Road
Lac Brome
QC
J0E 1V0
CA
|
Family ID: |
33567082 |
Appl. No.: |
10/287575 |
Filed: |
November 4, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10287575 |
Nov 4, 2002 |
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09915069 |
Jul 25, 2001 |
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Current U.S.
Class: |
52/391 ;
52/489.1; 52/586.1; 52/589.1 |
Current CPC
Class: |
E04F 2201/028 20130101;
E04F 15/04 20130101; E04F 2015/02122 20130101; E04F 2201/0517
20130101 |
Class at
Publication: |
52/391 ;
52/586.1; 52/489.1; 52/589.1 |
International
Class: |
E04F 013/08; E04B
002/30; E04B 002/00; E04B 002/08 |
Claims
I claim:
1. A flooring system for installing a floor of individual boards,
each board comprising an elongated slat having a top wall, a bottom
wall, and first and second opposed side walls; a groove formed in
said first side wall, a first recessed portion formed in said first
side wall below said groove and extending to said bottom wall; a
tongue formed on said second side wall, said tongue being sized and
shaped to fit within said groove formed in said first side wall; a
second recess formed in said second side wall, said second recess
being located below said tongue and above said bottom wall; and a
plurality of connectors, each connector having a main body portion
sized to fit within said first recessed portion formed in said
first side wall, and a lip extending outwardly from said body
portion, said lip being sized to engage said recess formed in said
second side wall.
2. The system of claim 1 wherein said body portion of said
connector has an aperture therein designed to receive a screw
member.
3. A floor comprised of a plurality of elongated slats, each slat
having a top wall,; a bottom wall, and first and second opposed
side walls, said slats being laid in a side by side relationship
with a first side wall of first slat abutting a second side wall of
a second slat, a groove formed in each of said first side walls, a
first recessed portion formed in each of said bottom walls so each
of said slats adjacent said first side wall; a tongue formed on
each of said second side walls, a second recessed portion formed in
each of said second side walls below said tongue portion; and a
plurality of discrete connectors, each connector comprising a body
portion and a lip extending from said body portion, said body
portion fitting within said first recess below said groove in said
first side walls, and said lip portion engaging said second
recessed portion in said second side walls, each of said connectors
being secured to a substrate.
4. The floor of claim 3 wherein each of said connectors is secured
to said substrate by means of a screw extending through said body
portion.
5. The floor of claim 4 wherein said first recessed portion formed
in said side wall comprises a continuous recess.
6. The floor of claim 4 wherein said continuous recess has a width
of between 6 mm and 50 mm and a depth of between 3 mm and 12
mm.
7. The floor of claim 4 wherein said second recess extends inwardly
a distance of between 3 mm and 12 mm.
8. The floor of claim 5 wherein said connectors are spaced apart a
distance of between 10 cm and 15 cm.
9. A method of installing a wood floor comprising a plurality of
elongated slats, each slat having a top wall, a bottom wall and
first and second opposed side walls, a groove formed in each of
said first side walls of each of said slats, a side wall recessed
portion formed in one of said first and second side walls of each
of said slats below said groove, a bottom recess formed in each of
said bottom walls of each of said slats adjacent a respective
second side wall, a method comprising the steps of supplying a
plurality of connectors, a vertical portion extending upwardly from
said base and a generally horizontal portion, a method comprising
the steps of securing a connector to a substrate, placing a slat on
said substrate with said horizontal portion extending into said
groove formed in said first side wall to thereby secure said slat
in position, and continuing to place subsequent slats in a side by
side abutting relationship with a connector holding each slat in
position.
Description
[0001] The present application is a continuation-in-part of
application Ser. No. 09/915,069 filed Jul. 25, 2001.
FIELD OF THE INVENTION
[0002] The present invention relates to a connector and more
particularly, relates to a connector for use in a flooring
system.
BACKGROUND OF THE INVENTION
[0003] There are many different types of flooring which are used
both in residential and commercial applications. Flooring systems
range from hardwood floors to various composite wood products,
tiles, linoleum, slate, carpets, etc. Each of the aforementioned
types of flooring has various advantages and disadvantages, with
some of the parameters for suitability for any particular
installation being cost of the flooring material, cost of
installation, durability, appearance, ease of maintenance, etc.
[0004] For a residential and many commercial installations, the use
of wood and notably a hardwood is considered desirable particularly
from an aesthetic viewpoint. Historically, some of the drawbacks
associated with hardwood flooring have been the cost of
installation and maintenance. Typically, hardwood flooring comes in
slats of solid wood which must be secured to a substrate. In most
instances, the wood slats have a tongue and groove arrangement
formed on their side walls and the slats are secured by toenailing
a nail through the tongue portion. Although there are a number of
automatic nailing guns which are suitable for performing this
operation, thus speeding up the installation, it is still a time
consuming operation. Still further, many of the woods used in the
flooring have a tendency to split when the nail is driven. In order
to prevent this splitting, it then becomes necessary to pre-drill a
pilot hole for the nail. This is again very time consuming and thus
increases the expense of installation.
[0005] Still further, wood floors, in high traffic areas, are
subject to a wear factor. After a certain period of time, it
becomes necessary to refinish the floors which typically comprises
an operation to remove the old surface coating by means of a sander
and subsequently refinishing the floors. This operation is one
which requires some skill on the part of the operator of the sander
in order to maintain a level and smooth surface. It is also an
extremely messy and possibly health threatening operation as fine
particles of dust spread throughout the area. Before applying the
coating to the wood, all dust particles must be removed; this is
often a tedious process.
SUMMARY OF THE INVENTION
[0006] It is an object of the present invention to provide a
flooring system for installing a plurality of elongated slats, the
system being one wherein installation is substantially faster than
the use of nails.
[0007] It is a further object of the present invention to provide a
system for the installation of wood slats having a tongue and
groove configuration.
[0008] It is a further object of the present invention to provide a
connector suitable for use in installing elongated slats having a
tongue and groove arrangement.
[0009] It is a still further object of the present invention to
provide a method for installing elongated hardwood slats to form a
floor.
[0010] According to one aspect of the present invention, there is
provided a floor comprising a plurality of elongated slats, each
slat having a top wall, a bottom wall, and first and second opposed
side walls, the slats being laid in a side by side relationship
with a first side wall of a first slat abutting a second side wall
of a second slat, a groove formed in each of the first side walls,
a side wall recessed portion formed in one of the first and second
side walls below the groove, a bottom recess formed in each of the
bottom walls of each of the slats adjacent the second side wall, a
plurality of connectors, each connector comprising a base secured
to a substrate, a vertical portion extending upwardly from the base
and fitting within the side wall recessed portion, and a generally
horizontal portion extending into the groove formed in the first
side wall to thereby secure the slat in position.
[0011] According to one aspect of the present invention, there is
provided a flooring system for installing a floor of individual
boards, each board comprising an elongated slat having a top wall,
a bottom wall, and first and second opposed side walls, a groove
formed in the first side wall, a first recessed portion formed in
the first side wall below the groove and extending to the bottom
wall, a tongue formed on the second side wall, the tongue being
sized and shaped to fit within the groove formed in the first side
wall, a second recess formed in the second side wall, the second
recess being located below the tongue and above the bottom wall,
and a plurality of connectors, each connector having a main body
portion sized to fit within the first recessed portion formed in
the first side wall, and a lip extending outwardly from the body
portion, the lip being sized to engage the recess formed in the
second side wall.
[0012] According to a further aspect of the present invention,
there is provided a floor comprised of a plurality of elongated
slats, each slat having a top wall, a bottom wall, and first and
second opposed side walls, the slats being laid in a side by side
relationship with a first side wall of first slat abutting a second
side wall of a second slat, a groove formed in each of the first
side walls, a first recessed portion formed in each of the bottom
walls so each of the slats adjacent the first side wall, a tongue
formed on each of the second side walls, a second recessed portion
formed in each of the second side walls below the tongue portion,
and a plurality of discrete connectors, each connector comprising a
body portion and a lip extending from the body portion, the body
portion fitting within the first recess below the groove in the
first side walls, and the lip portion engaging the second recessed
portion in the second side walls, each of the connectors being
secured to a substrate.
[0013] According to a further aspect of the present invention,
there is provided a method of installing a wood floor comprising a
plurality of elongated slats, each slat having a top wall, a bottom
wall and first and second opposed side walls, a groove formed in
each of the first side walls of each of the slats, a side wall
recessed portion formed in one of the first and second side walls
of each of the slats below the groove, a bottom recess formed in
each of the bottom walls of each of the slats adjacent a respective
second side wall, a method comprising the steps of supplying a
plurality of connectors, a vertical portion extending upwardly from
the base and a generally horizontal portion, a method comprising
the steps of securing a connector to a substrate, placing a slat on
the substrate with the horizontal portion extending into the groove
formed in the first side wall to thereby secure the slat in
position, and continuing to place subsequent slats in a side by
side abutting relationship with a connector holding each slat in
position.
[0014] The connector used in the present invention has a first
portion thereof which is adapted to be secured to the substrate.
Typically, the substrate is of a wood material such as a plywood or
composite wood material. Typically, the connector may be secured to
the substrate by mechanical means such as nails or screws. Screws
are a preferred securing mechanism for reasons which will become
apparent hereinbelow. However, it will be understood that other
securement means such as adhesive or the like may be utilized
particularly in the instance wherein the substrate is not a
material easily penetrable by screws.
[0015] The connector will include a upwardly extending vertical
portion having at its upper end thereof at least one horizontally
extending tab portion. The horizontally extending tab portion is
designed to engage a slot or recess formed in a side wall of a
slat. In one embodiment, the horizontally extending tab portion may
engage the groove in a conventional tongue and groove type of
flooring.
[0016] In a preferred embodiment, the upwardly extending vertical
portion has at least a pair of horizontally extending tab portions,
at least one tab portion extending outwardly in each horizontal
direction such that a single connector will engage both of a pair
of abutting slats.
[0017] The connector is designed to be used, as aforementioned, in
a flooring system comprising a plurality of slats engaged in an
abutting side by side relationship. To this end, the slats are
formed with recessed portions to receive both the base portion of
the connector and the vertical portion thereof.
[0018] The connector may be formed of any suitable material and
thus is preferably either of a metal or plastic material. A formed
metal material would be suitable while an extruded plastic material
could also be utilized.
[0019] In one embodiment, the connector is formed of a metallic
material and may easily be formed by a suitable mechanical means to
have the desired configuration. In this configuration, the
connector has a base which has means for securement to the
substrate. Typically, such means may include apertures formed
within the base which lies co-planer with the substrate and may be
secured thereto by a mechanical means such as a screw or the
like.
[0020] The connector also includes a vertical portion which extends
upwardly adjacent to at least a portion of a side wall of abutting
slats. To provide space for the upwardly extending wall, one of the
side walls of the slats has a recess formed therein.
[0021] One or both of the side walls of each of the slats has a
longitudinally extending groove formed therein. A corresponding tab
extends outwardly from the upwardly extending wall of the connector
and is designed to engage within the longitudinally extending slot
and thereby retain the slat in position.
[0022] The bottom end side recesses are formed of a size sufficient
to accommodate the connector. Typically, the bottom recess would
have a width of between 6 mm and 50 mm and a depth of between 3 mm
and 12 mm. Similarly, the side wall recessed portion would be sized
to receive the vertical portion of the connector and accordingly
would generally have a depth of between 3 mm and 12 mm.
[0023] In an alternative embodiment, the connector of the present
invention may be arranged to be used in conjunction with a
conventional tongue and groove flooring with the tab portion being
arranged to engage the groove formed within the slat. Again, proper
sizing of the tongue to permit the same would be provided.
[0024] As above described, the wood slats may have different
configurations. In one embodiment, the side walls of the slats may
also be formed such that one side wall will have a upper recessed
portion designed to receive a projecting portion of an adjacent
slat.
[0025] In a further embodiment of the invention, the connector is
preferably formed of a plastic material and comprises a body
portion having an aperture extending therethrough and a lip
designed to engage the recess in the side wall of the slat.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Having thus generally described the invention, reference
will be made to the accompanying drawings illustrating an
embodiment thereof, in which:
[0027] FIG. 1 is a perspective view of a connector according to one
embodiment of the present invention, with the connector being shown
in place with a slat in broken lines;
[0028] FIG. 2 is an end view of the connector;
[0029] FIG. 3 is a side elevational view thereof;
[0030] FIG. 4 is a top plan view thereof;
[0031] FIG. 5 is a side sectional view illustrating placement of
the connector in conjunction with a pair of slats;
[0032] FIG. 6 is a side view, partially in section, of a
conventional tongue and groove flooring system utilizing a
connector according to the present invention;
[0033] FIG. 7 is a view similar to FIG. 5 showing a modified form
of a slat which may be used in the present invention;
[0034] FIG. 8 is an end elevational view of a slat according to a
further embodiment of the present invention;
[0035] FIG. 9 is a side elevational view of a connector according
to this embodiment of the present invention;
[0036] FIG. 10 is an end elevational view, partially in section,
illustrating the joining together of two slats; and
[0037] FIG. 11 is a perspective view of a flooring system according
to the embodiment of FIGS. 8 to 10.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] Referring to the drawings in greater detail and by reference
characters thereto, and referring initially to FIG. 5, there are
illustrated a first slat 10 and a second slat 12 lying in an
abutting relationship. A connector generally designated by
reference numeral 14 (FIG. 1) is used to secure slats 10 and 12 in
position.
[0039] First slat 10 has an upper wall 18, a bottom wall 20, a
first side wall 22, and a second side wall 24.
[0040] Second slat 12 is placed in an abutting relationship to
first slat 10. Second slat 12 includes an upper wall 28 which will
be co-planer with upper wall 18 of first slat 10; a first side wall
32 which lies in an abutting relationship with second side wall 24
of first slat 10; a bottom wall 30 which is also substantially
co-planer with bottom wall 20 of first slat 10; and a second side
wall 34.
[0041] As may be seen in FIG. 5, slat 10 has a long first side wall
22 in which there is a longitudinally extending slot which is
generally designated by reference numeral 38. Similarly, along
second side wall 24, there is provided an inwardly directed
longitudinally extending slot 40.
[0042] There is also provided a bottom wall recess generally
designated by reference numeral 42 and which is provided within
bottom wall 20 and extends to first side wall 22. A conventional
groove 44 within bottom wall 20 is provided intermediate first side
wall 22 and second side wall 24 in a conventional fashion to
provide dimensional stability to slat 10.
[0043] A side wall recess 46 is provided within second side wall 24
and is located at the point of juncture of second side wall 24 and
bottom wall 20.
[0044] Slat 12 has a similar configuration to slat 10--i.e. slat 12
includes a first longitudinally extending slot 50 within first side
wall 32 and a second longitudinally extending slot 52 within second
side wall 34. A bottom wall recess 54 is provided adjacent first
side wall 32 while a side wall recess 58 is provided in second side
wall 34. A centrally located longitudinally extending groove 56 is
also formed in bottom wall 30.
[0045] As may be best seen in FIGS. 1 to 4, connector 14 has a base
portion 64 which is adapted to lie flat on a substrate to which it
is to be secured. To this end, an aperture 66 is provided within
base portion 64.
[0046] Extending upwardly from base portion 64 is a vertical wall
68. At the distal end of vertical wall 68, there is provided a
first tab member 70 which is substantially perpendicular with
respect to vertical wall 68. A pair of tabs 72 are formed on either
side of first tab 70, tabs 72 lie in the same horizontal plane as
tab 70 but extend in an opposite direction.
[0047] In use, and as may be seen in FIG. 5, a connector is secured
by means of a screw 76 to a substrate through aperture 66 of base
64. Vertical wall 68 fits within side wall recess 46 of slat 10.
Tab 70 then is designed and sized to fit within longitudinally
extending slot 40 while tabs 72 fit within slot 50 formed in side
wall 32 of slat 12. Connector 14 thus functions to stabilize and
maintain slats 10 and 12 in position.
[0048] When installing a floor comprised of a plurality of
longitudinally extending slats such as 10 and 12, a first slat 10
may be placed in position along a wall. In this respect, first side
wall 22 of slat 10 could abut the wall and then a connector 14
secured as shown in FIG. 5. A second slat 12 would then be placed
in position and the process repeated.
[0049] Alternatively, a first row of connectors 14 may be provided
for initial slat 10. The first row of connectors may utilize tab 72
as a spacer from an adjacent wall or alternatively, a special
connector not having a tab 72 may be utilized.
[0050] Utilizing the above system, the only connection required is
the attachment of connector 14 to the substrate by means of a
member such as screw 76. This could be accomplished rapidly using
automated equipment for driving screws 76.
[0051] The connectors 14 may be spaced apart by a suitable
distance. Generally, the spacers may be provided at a distance of
between 10 to 15 centimeters. Naturally, it will be understood that
a continuous connector strip could be utilized. It will also be
understood that the slats may comprise individual slats connected
in an end to end arrangement with a connector being used where the
ends abut each other.
[0052] In FIG. 7, a slightly modified version of the system shown
in FIGS. 1 to 5 is illustrated. In this embodiment, there is
provided a pair of slats 110 and 112 lying in a side by side
abutting relationship. A connector generally designated by
reference numeral 114 is employed between slats 110, 112 and is
secured to the substrate by means of screw 176. Connector 114 is
identical to that previously described.
[0053] In the embodiment of FIG. 7, slat 112 has a first side wall
generally designated by reference numeral 132 and which includes an
upper vertical portion 133 and a lower tapered portion 135. A
recess generally designated by reference numeral 158 and which is
similar to recess 58 of the previous embodiment is formed in side
wall 132.
[0054] Side wall 134 includes a vertical section 137 and an
outwardly tapered wall section 139. A bottom recess 154 is provided
to receive base 164 of connector 114. In this arrangement, a
thinner slat may be utilized.
[0055] Turning to FIG. 6, there are illustrated two slats 210 and
212. Referring to slat 212, this is formed in a substantially
conventional manner in that there is provided a tongue 220 and a
groove 230 on the opposite side wall. In this arrangement, a
connector generally designated by reference 214 has a base portion
264 with apertures therein to permit the passage of screws 276. A
vertical portion 268 is also provided as well as a tab 270.
[0056] In this arrangement, groove 230 is formed to have a
sufficient height to accommodate both tongue 220 and the thickness
of tab 270. The side wall having groove 230 has the bottom portion
thereof forming a recess to accommodate vertical portion 268 while
a bottom recess 254 is provided to accommodate base 264 and the
head of screw 276.
[0057] Turning now to FIGS. 8 to 11, there is illustrated a further
embodiment of the present invention and to which reference will now
be made.
[0058] In this embodiment, and as seen in FIG. 8, there are
provided slats generally designated by reference numeral 310. Slat
310 has a top wall 312, a bottom wall 314, a first side wall 316,
and a second side wall 318.
[0059] First side wall 316 has a generally V-shaped groove 320
extending inwardly thereof. Located below groove 320 is a recess
generally designated by reference numeral 322 and which is defined
by an upper surface 324 and a vertical surface 326.
[0060] Located on second side wall 318 is a tongue 328 which is
sized and located to fit within the groove 320 of an adjacent slat.
Situated below tongue 328 is a second side wall recess 330.
[0061] A connector generally designated by reference numeral 334
includes a body portion 336 of a rectangular configuration and
having an aperture 338 formed therein. Extending outwardly from one
side is a lip 340 which is sized and positioned so as to fit within
second side wall recess 330. In this respect, body portion 336 is
of a length and height to substantially fill recess 322 formed in
first side wall 316.
[0062] In use, and as shown in FIG. 11, connector 334 is secured to
a substrate (not shown) by means of an attachment member such as a
screw through aperture 338. It will engage second side wall recess
330 formed within second side wall 318 and securely hold the
member.
[0063] An advantage of using the above system is that the floor may
be securely attached in a manner which permits removal of the same.
Thus, in a typical residential application, the sub-flooring or
substrate would be plywood or similar material. When it is desired
to refinish the floor, it can be rapidly lifted and the individual
slats forwarded to a commercial facility for refinishing. The
floor, after refinishing, could then be reinstalled. For the
average consumer, this would both be less time consuming and less
expensive than performing the refinishing on site. The use of this
system will also permit one to replace a floor and use the removed
floor in another location.
[0064] It will be understood that the above described embodiments
are for purposes of illustration only and that changes or
modifications may be made thereto without departing from the spirit
and scope of the invention.
* * * * *