U.S. patent application number 10/280413 was filed with the patent office on 2004-04-29 for floor assemblies including a number of structural elongated flooring members extending across transverse supports.
Invention is credited to Bergeron, Bruno, Biro, Michael Julius, Gidney, Ken.
Application Number | 20040079041 10/280413 |
Document ID | / |
Family ID | 32106930 |
Filed Date | 2004-04-29 |
United States Patent
Application |
20040079041 |
Kind Code |
A1 |
Bergeron, Bruno ; et
al. |
April 29, 2004 |
Floor assemblies including a number of structural elongated
flooring members extending across transverse supports
Abstract
A floor assembly includes a number of spaced apart horizontal
support members to which a number of elongated flooring members are
attached. The flooring members have features allowing their use in
two versions of the floor assembly. In a first version, the
flooring members are attached to the support members by clamping
blocks having tabs extending over strips extending along opposite
sides of the flooring members, which have outer walls extending
downward and inward to provide space for the blocks. In a second
version, the flooring members are attached by downward extending
latching arms that engage upward extending latching arms of clips
fastened to the support members.
Inventors: |
Bergeron, Bruno; (Davie,
FL) ; Biro, Michael Julius; (Boca Raton, FL) ;
Gidney, Ken; (Boca Raton, FL) |
Correspondence
Address: |
RONALD V. DAVIDGE
SUITE 514
3300 UNIVERSITY DRIVE
CORAL SPRINGS
FL
33065
US
|
Family ID: |
32106930 |
Appl. No.: |
10/280413 |
Filed: |
October 25, 2002 |
Current U.S.
Class: |
52/489.1 ;
52/177 |
Current CPC
Class: |
E04F 2201/05 20130101;
E04F 2203/04 20130101; E04F 2015/02094 20130101; E04F 15/10
20130101; E04F 19/061 20130101; E04F 2015/02072 20130101; E04F
15/02161 20130101 |
Class at
Publication: |
052/489.1 ;
052/177 |
International
Class: |
E04F 011/16; E04F
015/00; E04B 002/30 |
Claims
What is claimed is:
1. A floor assembly comprising: a support structure including a
first plurality of spaced-apart, horizontally extending support
members, wherein each of said support members includes an upper
surface; a second plurality of elongated flooring members extending
above and across said first plurality of support members, wherein
each of said elongated flooring members includes a lower surface
extending adjacent said upper surface of said support members, and
a clamping strip extending along each side of said elongated
flooring member and outward from said lower surface of said
elongated flooring member, an upper surface extending outward along
each side of said elongated flooring member to overhang said
clamping strip; and a third plurality of clamping blocks, wherein
each of said clamping blocks is fastened to a support member in
said first plurality to extend along said upper surface of said
support member between lower surfaces of adjacent elongated
flooring members in said second plurality, wherein each of said
clamping blocks includes a clamping tab extending toward each
elongated flooring member in said adjacent elongated flooring
members over an adjacent clamping strip of said elongated flooring
member to hold said lower surface of each of said adjacent
elongated flooring members against said upper surface of said
support member, and wherein each of said clamping blocks extends
under portions of said upper surfaces extending outward along said
adjacent elongated flooring members.
2. The floor assembly of claim 1, wherein each of said clamping
blocks is fastened to said support member by a screw extending
through a hole within said clamping block into said support
member.
3. The floor assembly of claim 2, wherein said hole within said
clamping block is offset from a center of clamping block to dispose
said screw outward from an edge of an elongated flooring member
adjacent said clamping block.
4. The floor assembly of claim 1, additionally comprising a fourth
plurality of edge clamps, wherein said second plurality of
elongated flooring members includes a first elongated flooring
member extending along an edge of said floor assembly, each of said
edge clamps is fastened to said support structure to extend along
an upper surface of said support member outwardly adjacent a lower
surface of said first elongated flooring member, and each of said
edge clamps includes a clamping tab extending toward said first
elongated flooring member, over an adjacent clamping strip of said
first elongated flooring member to hold said lower surface of said
first elongated flooring member against said upper surface of said
support structure.
5. The floor assembly of claim 4, wherein each of said edge clamps
is fastened to said support structure by a screw extending through
a hole within said support clamp into said support structure.
6. The floor assembly of claim 5, wherein said hole in said
clamping block is disposed outward from an adjacent edge of said
first elongated flooring member.
7. The floor assembly of claim 6, additionally comprising an edge
strip extending outwardly adjacent said first elongated flooring
member and over said edge clamps.
8. The floor assembly of claim 7, wherein each of said edge clamps
includes a strip engaging surface, said edge strip includes a clamp
engaging surface fastened to each said strip engaging surface.
9. The floor assembly of claim 7, wherein each said strip engaging
surface includes a first latching surface, said clamp engaging
surface includes a second latching surface, said second latching
surface is moved away from said first latching surface by
deflection of said edge strip as said clamp engaging surface is
moved toward engagement with said strip engaging surface, and said
second latching surface is moved into engagement with said first
latching surface as said clamp engagement is moved fully into
engagement with said strip engaging surface.
10. The floor assembly of claim 7, wherein said edge strip includes
a first web extending over said edge clamps and a second web
extending downward from said first web, and said floor assembly
additionally comprises a plurality of fasteners attaching said
second web to an end of said support structure.
11. The floor assembly of claim 10, wherein each of said fasteners
includes a head outwardly disposed from a surface of said second
web, and said edge strip additionally includes a cover strip
pivotable between an open position exposing said surface of said
second web and a closed position covering said surface of said
second web and each head of said fasteners.
12. The floor assembly of claim 1, wherein each elongated flooring
member in said second plurality additionally includes: an upper
web, wherein said upper surface of said elongated flooring member
extends along said upper web; a lower web, wherein said lower
surface of said elongated flooring member extends along said lower
web; and a first plurality of walls extending between said upper
web and said lower web.
13. The floor assembly of claim 12, wherein each elongated flooring
member in said second plurality additionally includes a second
plurality of thermoplastic foam members extending between said
upper web and said lower web and additionally between adjacent
walls within said first plurality of walls.
14. The floor assembly of claim 12, wherein said upper and lower
webs and said walls are composed of an extruded thermoplastic
resin.
15. The floor assembly of claim 12, wherein said first plurality of
walls includes an outer wall extending downward and inward along
each side of said elongated flooring member.
16. The floor assembly of claim 1, wherein said lower surface of
each elongated flooring member in said second plurality
additionally includes an upwardly disposed central portion
extending along said elongated flooring member, and each elongated
flooring member in said second plurality additionally includes a
pair of latching surfaces facing upward under said central portion
of said lower surface.
17. The floor assembly of claim 16, wherein each elongated flooring
member in said second plurality additionally includes a pair of
latching arms extending downward from said central portion of said
lower surface, and said latching surfaces extend outward from
opposite sides of said pair of latching arms.
18. An elongated flooring member comprising: an upper web; a lower
web including a raised central portion; a first plurality of walls
extending between said upper web and said lower web; and a pair of
latching arms extending downward from said central portion of said
lower web, wherein said pair of latching arms includes a pair of
latching surfaces facing upward and extending outward from opposite
sides of said pair of latching arms.
19. The elongated flooring member of claim 18, additionally
comprising a second plurality of thermoplastic foam core sections
extending between said upper web and said lower web and
additionally between adjacent walls within said first
plurality.
20. The elongated flooring member of claim 18, additionally
comprising a pair of clamping surfaces facing upward and extending
along opposite sides of said lower web, wherein said upper web
extends outward along each side of said elongated flooring member
over said pair of clamping surfaces.
21. The elongated flooring member of claim 20, wherein said first
plurality of walls includes an outer wall extending downward and
inward along each side of said elongated flooring member.
22. The elongated flooring member of claim 18, additionally
including a tread pattern having a plurality of ridges extending
along an upper surface of said upper web.
23. The elongated flooring member of claim 22, wherein each of said
ridges is divided into a plurality of truncated pyramids.
24. An elongated flooring member comprising: a lower web; an upper
web extending over said lower web and outward, beyond said lower
web along each side of said elongated flooring member; a first
plurality of walls extending between said upper web and said lower
web, including an outer wall extending downward and inward along
each side of said elongated flooring member; an upward-facing
clamping surface extending along each side of said elongated
flooring member under a portion of said upper web extending outward
beyond said lower web.
25. The elongated flooring member of claim 24, additionally
comprising a plurality of thermoplastic foam core sections
extending between said upper web and said lower web and
additionally between adjacent walls within said first
plurality.
26. A floor assembly including: a first plurality of spaced-apart,
horizontally extending support members, wherein each of said
support members includes an upper surface; a second plurality of
elongated flooring members fastened to said support members to
extend above and across said support members, wherein each of said
elongated flooring members includes an upper web, a lower web
extending adjacent said upper surface of each of said support
members, a plurality of walls extending between said upper and
lower webs, and a plurality of thermoplastic foam core sections
extending between said upper and lower webs and additionally
between adjacent walls within said plurality of walls.
27. The floor assembly of claim 26, wherein each elongated flooring
member in said second plurality includes an upward-facing clamping
surface extending along each side of said elongated flooring
member, and said floor assembly additionally comprises a third
plurality of clamping blocks attached to said support members, each
of said clamping blocks includes a tab extending above a portion of
said clamping surface of an adjacent elongated flooring member to
fasten said elongated flooring member to a support member in said
first plurality.
28. The floor assembly of claim 26, wherein said lower web includes
an upwardly-disposed central portion, each elongated flooring
member in said second plurality includes a pair of upward-facing
latching surfaces extending under said central portion of said
lower web, said floor assembly additionally comprises a third
plurality of attachment clips, each attachment clip in said third
plurality is fastened to a support member in said first plurality,
each attachment clip in said third plurality includes a latching
portion, extending upward under said central portion of said lower
web of an elongated flooring member in said second plurality,
having a pair of downward-facing latching surfaces engaging said
upward-facing latching surfaces of said elongated flooring
member.
29. The floor assembly of claim 28, wherein each elongated flooring
member in said second plurality additionally includes a pair of
latching arms extending downward from said central portion of said
lower web, each of said upward-facing latching surfaces is attached
to a latching arm in said pair of latching arms, and said upward
facing latching surfaces are deflected toward one another by
engagement with said downward facing latching surfaces.
30. A floor assembly including: a first plurality of spaced-apart,
horizontally extending support members, wherein each of said
support members includes an upper surface; a second plurality of
elongated flooring members, wherein each of said elongated flooring
members includes an upper web, a lower web extending adjacent said
upper surface of each of said support members, including an
upwardly disposed central portion, a plurality of walls extending
between said upper and lower webs, a pair of latching arms
extending downward from said upwardly disposed central portion, an
upward facing latching surface extending outward from each of said
latching arms, and a plurality of walls extending between said
upper and lower webs; and a third plurality of attachment clips,
fastened to support members in said second plurality, wherein each
of said attachment clips includes a pair of latching arms,
extending upward below said upwardly disposed central portion of a
lower web in an elongated flooring member in said second plurality,
and an inward extending, downward facing latching surface engaging
said upward facing latching surface of said elongated flooring
member.
31. The floor assembly of claim 30, wherein said upward facing
latching surfaces are deflected toward one another by engagement
with said downward facing latching surfaces.
32. The floor assembly of claim 30, wherein each attachment clip in
said second plurality additionally includes an attachment hole
disposed between said latching arms of said attachment clip, and
said floor assembly additionally comprises a screw extending
through each said attachment hole to fasten said attachment clip to
said support member.
33. The floor assembly of claim 30, wherein each said attachment
clip includes a first type of interlocking structure at a first end
and a second type of interlocking structure at a second end,
opposite said first end, and said interlocking structure of a first
type in said attachment clip engages said interlocking structure of
a second type in an adjacent attachment clip to establish the
spacing of attachment clips adjacent one another.
34. The floor assembly of claim 32, wherein said first interlocking
structure includes a groove, and said second interlocking structure
includes a ridge fitting within said groove in an adjacent
attachment clip.
35. The floor assembly of claim 30, wherein each of said attachment
clips is composed of a metal.
36. The floor assembly of claim 35, wherein each of said attachment
clips is composed of an extruded aluminum alloy.
37. The floor assembly of claim 30, additionally comprising an edge
strip extending adjacent an edge of said support structure, wherein
said edge strip includes a first web extending over a portion of an
adjacent elongated flooring member in said second plurality and a
second web extending downward from said first web, and said floor
assembly additionally comprises a plurality of fasteners attaching
said second web to an end of said support structure.
38. The floor assembly of claim 37, wherein each of said fasteners
includes a head outwardly disposed from a surface of said second
web, and said edge strip additionally includes a cover strip
pivotable between an open position exposing said surface of said
second web and a closed position covering said surface of said
second web and each head of said fasteners.
39. A method for assembling a floor atop a support structure
including a plurality of spaced-apart, horizontally extending
support members, wherein said method comprises: a) fastening a
first elongated flooring member to extend across said support
members adjacent a first edge of said support structure by a
plurality of edge clamps fastened to said support structure,
wherein each of said edge clamps includes a tab extending over a
first clamping strip of said first elongated flooring member,
wherein said first clamping strip extends along a first side of
said first elongated flooring member adjacent said first edge of
said support structure, and additionally by a plurality of clamping
blocks fastened to said plurality of support members, wherein each
of said clamping blocks includes a first tab extending over a
second clamping strip of said first elongated flooring member, and
wherein said second clamping strip extends along a side of said
first elongated flooring member opposite said first side; b)
sliding an additional elongated flooring member into place to
extend adjacent said elongated flooring member last fastened to
extend across said support members, with a first clamping strip of
said additional elongated flooring member extending under a second
tab of each of said clamping block in said plurality of clamping
blocks attaching said elongated flooring member last fastened to
extend across said support structure, wherein said first clamping
strip of said additional elongated flooring member extends along a
first side of said additional elongated flooring member, adjacent
said elongated flooring member last fastened to extend across said
support members; c) fastening said additional elongated flooring
member to said support structure by a plurality of clamping blocks
fastened to said plurality of support members, wherein each of said
clamping blocks includes a first tab extending over a second
clamping strip of said first elongated flooring member, and wherein
said second clamping strip extends along a side of said additional
elongated flooring member opposite said first side of said
additional elongated flooring member; d) repeating steps b) and c)
to fasten a plurality of additional elongated flooring members to
said support structure until a space for only a last additional
elongated flooring member remains along said support structure; e)
repeating step b) to fasten said last additional elongated flooring
member to said support structure; and f) fastening said last
additional elongated flooring member to said support structure by a
plurality of edge clamps fastened to said support structure,
wherein each of said edge clamps includes a tab extending over a
second clamping strip of said first elongated flooring member, and
wherein said second clamping strip extends along a side of said
last additional elongated flooring member opposite said first side
of said additional elongated flooring member.
40. The method of claim 39, wherein each of said clamping blocks is
fastened to a support member by driving a screw into said support
member through a hole in said clamping block, and said hole in said
clamping block is offset from a center of said clamping block
through a distance sufficient to allow clearance between a
screwdriver engaging said screw and an adjacent edge of a most
recently installed elongated flooring member.
41. The method of claim 39, additionally comprising attaching an
edge strip to said edge clamps along an edge of said floor.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to floor assemblies including a
number of extruded thermoplastic members extending across
transverse support members, such as boards forming support
structures below the extruded thermoplastic members, and, more
particularly, to the shape of such extruded thermoplastic members
and to methods for fastening such members to the support
members.
[0003] 2. Summary of the Background Art
[0004] U.S. Pat. No. 5,904,011 and D443,936 describe an elongated
flooring surface. The elongated flooring member includes features
for mounting the flooring member to extend along the top surfaces
of a wooden plank. What is needed is the application of this type
of anti-skid surface to a flooring member configured to extend atop
and between support members. Such a flooring member must be
sufficiently stiff and strong to support a useful load in a span
extending between adjacent support members extending transverse to
the flooring member.
[0005] U.S. Pat. No. 5,553,427 describes an extruded flooring
member for use in a floor assembly that is secured to a rigid
underlying support. A number of these flooring members are shown as
extending atop and between wood joists acting as support members
within a flooring assembly. In one version of the flooring system
described in this patent, each of the flooring members is fastened
to each of the underlying joists by a central snap connector,
extending under a central portion of the flooring member. Each
flooring member includes a load bearing horizontal portion, two
outer leg members, two inner leg members, and two angular
cross-members, each of which extends between an outer leg member
and an inner leg member to form a closed section. Each of the inner
leg members includes a foot forming a portion of a lower surface
and extending into a central portion of the flooring member. The
central snap connector, fastened to the underlying joists to extend
within the central portion, has outward facing flanges that bend
the inner leg members outward as the flooring member is pressed
downward atop the central snap connector. When the flooring member
is pressed down to the underlying joists, the inward extending feet
snap inward under the flanges of the central snap connector, to be
held down by the flanges.
[0006] U.S. Pat. No. 6,112,479 describes an extruded flooring
member that is fastened into place on a number of joists with the
same type of fastening clip as the central snap connector used
within the first version of the flooring assembly of U.S. Pat. No.
5,553,427. The extruded flooring member includes a pair of outer
leg members and a pair of inner leg members, each of the outer leg
members being connected to an adjacent inner leg member by a
horizontal support member. Each inner leg member includes a
retaining tab extending therefrom to be caught by an outward-facing
flange of the central snap connector as the extruded flooring
member is pressed down on the connector.
[0007] However, the outward forces exerted on the feet by the
flanges as the flooring member is pressed into place over the
central snap connector produce a torque on the load-bearing
horizontal member tend to bend the lower surfaces of the flooring
member into a convex shape. Depending on the alignment of the feet
with the flanges, some of these forces may remain after the
flooring member is installed, with the resulting convex shape
allowing slight movements of the flooring member on the underlying
joists, along with the production of associated noises, when
someone walks on the flooring member. Thus, what is needed is an
apparatus for snapping an extruded flooring member into place
without bending the lower surface of the flooring member into a
convex shape.
[0008] In a second version of a flooring system described in U.S.
Pat. No. 5,553,427, the flooring member is held in place on a joist
by means of an elongated snap connector extending atop the joist
and under the entire width of the flooring member. The elongated
snap connector includes four short hook-shaped snap members that
snap in place over feet extending from the leg members of the
flooring member and two short pilot members that guide the flooring
member as it is pressed downward on the elongated snap connector.
However, what is needed is a snap connector having longer, more
flexible snap members, providing for greater flexibility and
therefore for ease of assembly.
[0009] U.S. Pat. No. 6,233,886 describes a flooring system
including a different kind of elongated snap connector, which can
be applied to hold either the extruded flooring member described in
U.S. Pat. No. 5,553,427 or the extruded flooring member described
in U.S. Pat. No. 6,112,479. This different kind of elongated snap
extends, for example, under a right portion of one flooring member
and a left portion of an adjacent flooring member. A rigid hook
holds a foot extending from an intermediate leg of one of the
flooring members, while a hook-shaped flexible snap member holds a
foot extending from an intermediate leg of the other flooring
member. Again, what is needed is a snap connector having longer,
more flexible snap members to provide for greater flexibility and
ease of assembly.
[0010] Additionally, what is needed is a system providing small
mounting members that can be attached to individual joists for
fastening in place an extruded flooring member extending at an
oblique angle with respect to the individual joists. Such mounting
members may be needed, for example, in fabricating a curved or
otherwise non-rectangular deck structure. U.S. Pat. Nos. 5,553,427
and 6,112,479 show the central snap connector being used as an
elongated part, extending atop and between several joists, which
can be used even when the joists extend at an oblique angle
relative to the flooring members. However, it is desirable to use
snap connectors that are only as wide as the individual joists,
both to reduce the cost of materials and to make the snapping
process easier, with less force being required, and more reliable,
with the flooring members only being snapped onto portions of the
snap connector that are backed up directly by the joists extending
under the connector during the snapping process. For example, the
elongated connectors of U.S. Pat. Nos. 5,553,427 and 6,233,886 can
be used in a width equal to that of the joist, but such an
application precludes the use of such connectors extending along
individual joists if the flooring member is to extend at an oblique
angle relative to the joists.
[0011] Other problems associated with the use of elongated extruded
flooring members result from noises that may occur as someone walks
on the flooring members. Various examples of the prior art,
including U.S. Pat. Nos. 6,018,925 and 5,553,427 describe the use
of a layer of soft material extending along the surfaces of the
flooring members where contact will occur with an underlying
support structure to prevent or minimize squeaking when a person
walks across the flooring member, causing small relative movements
to occur between the flooring member and the underlying structure.
However, what is additionally needed is a method to deaden a
hollow, reverberating sound that may occur as someone walks along
an extruded flooring member including one or more hollow
sections.
SUMMARY OF THE INVENTION
[0012] According to a first aspect of the invention, a floor
assembly is provided including a support structure having a first
plurality of spaced-apart, horizontally extending support members,
a second plurality of elongated flooring members, and a third
plurality of clamping blocks. Each of the support members includes
an upper surface. The elongated flooring members extend above and
across the support members, with each of the elongated flooring
members including a lower surface extending adjacent the upper
surface of the support members, a clamping strip extending along
each side of the elongated flooring member and outward from the
lower surface of the elongated flooring member, and an upper
surface extending outward along each side of the elongated flooring
member to overhang the clamping strip. Each of the clamping blocks
is fastened to a support member in the first plurality to extend
along the upper surface of the support member between lower
surfaces of adjacent elongated flooring members in the second
plurality. Each of the clamping blocks includes a clamping tab
extending toward each elongated flooring member in the adjacent
elongated flooring members over an adjacent clamping strip of the
elongated flooring member to hold the lower surface of each of the
adjacent elongated flooring members against the upper surface of
the support member. Each of the clamping blocks extends under
portions of the upper surfaces extending outward along the adjacent
elongated flooring members.
[0013] To provide structural strength and rigidity while extending
between adjacent support members, each elongated flooring member
includes upper and lower webs and a number of walls extending
between the upper web and the lower web. To provide space for the
clamping blocks while adjacent elongated flooring members are
spaced close to one another, the elongated flooring member
includes, at each side, a wall extending downward and inward.
[0014] According to a second aspect of the invention, a flooring
system is provided, including a first plurality of spaced-apart
horizontally extending support members, a second plurality of
elongated flooring members, and a third plurality of attachment
clips fastened to the support members. Each of the elongated
flooring members includes a lower web having a raised central
portion, from which a pair of latching arms extends downward. Each
of the latching arms includes an upward facing, outward extending
latching surface. Each of the attachment clips includes a pair of
latching arms extending upward under the raised central portion of
the lower web of an elongated flooring member disposed above the
attachment clip. Each of the latching arms of the attachment clip
includes a latching surface facing downward and extending inward to
engage the latching surfaces of the elongated flooring member. In
this way, the elongated flooring member is held in place on the
support member by the attachment clip, and a torque is provided at
the center of the elongated flooring member to hold the opposite
edges of the elongated flooring member against the underlying
attachment clip, preventing squeaking as someone walks across the
elongated flooring member.
[0015] Preferably, an elongated flooring member is composed of an
extruded thermoplastic resin to include all of the features
necessary for use in either the first or second aspects of the
invention. An elongated flooring member may also include core
formed with a foamed thermoplastic resin in each of the cavities
between an upper web and a lower web and between walls extending
between the upper and lower webs. Such foam cores prevent the
generation of hollow sounds otherwise formed by reverberation in
hollow cavities as a person walks on the flooring members.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a front elevation of a floor assembly built in
accordance with a first embodiment of the present invention;
[0017] FIG. 2 is a fragmentary transverse cross-sectional elevation
of the floor assembly of FIG. 1, taken as indicated by section
lines II-II therein;
[0018] FIG. 3 is a vertical transverse cross-sectional view an edge
strip of the floor assembly of FIG. 1 in an exploded relationship
with an edge clamp;
[0019] FIG. 4 is a fragmentary plan view of the floor assembly of
FIG. 1 in a partly assembled condition, showing an elongated
flooring member attached to an underlying support member;
[0020] FIG. 5 is a fragmentary plan view similar to FIG. 4, except
that the support member extends at an oblique angle to the
elongated flooring member;
[0021] FIG. 6 is a fragmentary transverse cross-sectional elevation
of a floor assembly built in accordance with a second embodiment of
the present invention;
[0022] FIG. 7 is a fragmentary transverse cross-sectional elevation
of the floor assembly of FIG. 6, having installed therein an
alternative edge strip;
[0023] FIG. 8 is a fragmentary transverse cross-sectional elevation
of the floor assembly of FIG. 2, having installed therein an
alternative edge strip;
[0024] FIG. 9 is a fragmentary transverse cross-sectional elevation
similar to FIG. 8, except that a width of an elongated flooring
member therein has been reduced; and
[0025] FIG. 10 is a transverse cross-sectional elevation of an
elongated flooring member in FIG. 2 or FIG. 6, including foam cores
formed within internal cavities.
DETAILED DESCRIPTION OF THE INVENTION
[0026] FIGS. 1 and 2 show a floor assembly 10 built in accordance
with a first version of the invention, with FIG. 1 being a front
elevation thereof, and with FIG. 2 being a fragmentary transverse
cross-sectional view thereof, taken along section lines II-II in
FIG. 1. The floor assembly 10 includes a support structure 12,
having a first plurality of horizontally extending support members
14, and a second plurality of elongated flooring members 16
extending above and across the support members 14. Each of the
elongated flooring members 16 includes a clamping strip 18,
extending along each side 20 of the elongated flooring member 16.
For example, the floor assembly 10 forms a part of a deck or dock
supported by a number of posts 22.
[0027] The floor assembly 10 additionally includes a third
plurality of clamping blocks 24, each of which is fastened to an
underlying support member 14 by means of a screw 26 extending
through a hole 28 in the clamping block 24. A clamping tab 30
extends from each end of the clamping block 24, engaging an
upward-facing clamping surface 32 of the clamping strip 18
extending along an adjacent elongated flooring member 16. In this
way, the lower surface 33 of the elongated flooring member 16 is
held against the upper surface 34 of the underlying support member
14.
[0028] Preferably, the clamping blocks 24 are used to establish a
gap between adjacent elongated flooring members 16. For example,
the clamping blocks 24 and the elongated flooring members 16 are
configured so that, when adjacent elongated flooring members 16 are
each held against a clamping block 24 placed between them, a gap 35
of approximately 1.6 mm ({fraction (1/16)} inch) is established
between the adjacent flooring members 16.
[0029] The elongated flooring member 16 is configured to serve as a
load-supporting beam through distance between adjacent support
members 14. For strength and stiffness, the elongated flooring
member 16 includes a number of enclosed structures formed by an
upper web 36, a lower web 37, and a number of walls 38 extending
between the webs 36, 37. The outermost walls 39 extend downward and
inward to provide a space for a clamping block 24 between adjacent
elongated flooring members 16, while allowing these adjacent
members 16 to touch or to come into close proximity near their
upper webs 36. Preferably, the elongated flooring member 16 is
composed of an extruded thermoplastic resin, such as polyvinyl
chloride (PVC).
[0030] Preferably, the floor assembly 10 additionally includes a
fourth plurality of edge clamps 40, each of which is fastened to
the support structure 12 by means of a screw 41 extending through a
hole 42 within the edge clamp 40. Each of the edge clamps 40
includes a clamping tab 44 extending over the clamping strip 18 of
a first elongated flooring member 46 extending along an edge 48 of
the floor assembly 10. (The numeral 46 is used to designate the
first of a number of similar or identical elongated flooring
members 16). The hole 42 is preferably disposed outwardly from an
adjacent overhanging edge 50 of the first elongated flooring member
46 to an extent allowing the screw 41 to be tightened with the
first elongated flooring member 46 in place. Preferably, the floor
assembly 10 further includes an edge strip 54 extending outwardly
adjacent the first elongated flooring member 46 and above the edge
clamps 40.
[0031] FIG. 3 is a vertical cross-sectional view of the edge strip
54 in an exploded relationship with an edge clamp 40. A strip
engaging surface 60 of the edge clamp 40 extends along opposite
sides of a tab 62, including a number of first latching surfaces
64. A clamp engaging surface 56 extends along inward facing
opposite sides of a trough 66, including a number of second
latching surfaces 68. As the edge strip 54 is moved downward, in
the direction of arrow 70, for attachment to the edge clamp 40,
second latching surfaces 68 are moved away from the adjacent first
latching surfaces 64 by deflection occurring within the trough 66.
As each second latching surface 68 is moved past a first latching
surface 64, the second latching surface 68 moves back into
engagement with the first latching surface 64, preventing upward
movement of the edge strip 54, out of attachment with the edge
clamp 40.
[0032] Referring again to FIG. 2, the process of building a
flooring system on top of the support structure 12, begins with
fastening the first elongated flooring member 46 in place by means
of a number of edge clamps 40 and a number of clamping blocks 24. A
clamping tab 44 of each of the edge clamps 40 is clamped over an
adjacent clamping strip 18, extending along a side of the first
elongated flooring member 46 that is adjacent the edge clamps 40. A
first tab 30 of each of the clamping blocks 24 is clamped over the
other clamping strip 18 of the first elongated flooring member
46.
[0033] Then, an elongated flooring member 16 is moved into place
next to the first elongated flooring member 46, with the clamping
strip 18 of this under a portion of the adjacent clamping blocks
24. Pushing and even hammering may be used to accomplish the
movement of the elongated flooring member 16 into engagement with
the clamping blocks 24. This process is then repeated until all of
the elongated flooring members 16 forming the floor assembly 10
have been installed, with a number of clamping blocks 24 being
screwed into place after each of the elongated flooring members 16
has been installed, until the last of the elongated flooring
members 16 is to be installed. Preferably, the installation of the
last of the elongated flooring members 16 is similar to this
process, except that a second group of edge clamps is installed
along the outer edge of this last elongated flooring member 16 in
preparation for receiving another edge strip 54.
[0034] FIG. 4 is a fragmentary plan view of the floor assembly 10,
showing a clamping block 24, fastened to an underlying support
member 14 by means of a screw 26 extending through a hole 28 in the
clamping block 24. The hole 28 is preferably displaced from the
center of the clamping block 24 in the direction of arrow 74
through a distance sufficient to allow clearance past the
overhanging edge 76 of the adjacent elongated flooring member 26
for a screwdriver driving the screw 26 into the support member
14.
[0035] The top surface of the upper web 36 of the elongated
flooring member 16 preferably is formed as a tread pattern 78
including a number of truncated pyramids 80 extending along flutes
separated by grooves 82 between the flutes and by troughs 84
between adjacent pyramids 80 within each flute.
[0036] FIG. 5 is a fragmentary plan view similar to FIG. 4, except
that the clamping block 24 is fastened to a support member 88
extending at an oblique angle to the elongated flooring member 16.
This arrangement can occur, for example, at a corner of an
"L"-shaped floor assembly or in a floor assembly having a curved
edge.
[0037] In accordance with the first embodiment of the invention,
the clamping blocks 24 are fastened in place after an adjacent
elongated flooring member 16 has been installed, in a process step
that includes drilling holes for the screws 26 or otherwise fixing
the locations of these screws 26. In this way, the width of the
elongated flooring member 16, with the clamping blocks 24 held in
place, determines the locations at which the new clamping blocks 24
will be installed. This process works equally well whether the
support member extends perpendicular to the elongated flooring
member 16, as shown in FIG. 4, or at an oblique angle, as shown in
FIG. 5, providing the first embodiment of the invention with an
advantage over various prior art methods in which mounting clips
are spaced to extend along support members that must be
perpendicular to the elongated flooring members.
[0038] FIG. 6 is a fragmentary transverse cross-sectional elevation
of a floor assembly 100 built in accordance with a second
embodiment of the invention. This floor assembly 100 includes a
number of elongated flooring members 16, which are identical to the
elongated flooring members 16 described above in reference to FIGS.
1 and 2. The floor assembly 100 also includes a support structure
12 including a number of horizontally extending support members 14,
which is, for example, identical to the support structure 12
described above in reference to FIGS. 1 and 2. However, in floor
assembly 100, each of the elongated flooring members 16 is fastened
to the support members by an attachment clip 102, with each of the
attachment clamps 102 being in turn fastened to one of the support
members 14 by means of a screw 104 extending downward through a
hole 106 within the attachment clip 102.
[0039] The lower web 37 of the elongated flooring member 16
includes an upwardly disposed central portion 108, from which a
pair of latching arms 110 extends downward. Each of the latching
arms 110 includes an upward facing latching surface 112 that
extends outward as a part if the latching arm 110. Thus, the upward
facing latching surfaces 112 of each elongated flooring member 16
extend away from one another.
[0040] Each attachment clip 102 includes a pair of upward extending
latching arms 114, each of which includes a downward facing
latching surface 116 that extends inward as part of the latching
arm 114. Thus, the downward facing latching surfaces of each
attachment clip 102 extend toward one another.
[0041] This arrangement allows each elongated flooring member 16 to
be installed on the support structure 12 by being pressed downward
on a number of attachment clips 102. During this process, the
latching arms 114 of the elongated flooring member 16 are deflected
inwardly, toward one another. In a preferred version of the
invention, some of this deflection remains, for example, due to the
angle of orientation of the latching surfaces 112, 144, resulting
in the application of a torque to the elongated flooring member at
its center causing the lower web 37 to bow into a slightly concave
shape. Thus, each of the opposite edges 120 of the lower web 37 is
held downward against the surface of the underlying attachment
clips 102, as a downward force acting on the center 118 of the
elongated flooring member 16 is maintained through contact between
the latching surfaces 112, 116.
[0042] In this way, an advantage is achieved over prior art
flooring systems described, for example, in U.S. Pat. No.
6,112,479, the disclosure of which is incorporated herein by
reference. Such prior art flooring systems include upward facing
latching surfaces extending inward as portions of an elongated
flooring member to engage a pair of downward facing latching
surfaces extending outward as portions of an attachment clip. In
such a system, while a downward force is exerted along the areas of
engagement between the latching surfaces, holding a central portion
of the elongated flooring member against the underlying support
members, the engagement of the latching surfaces may be expected to
also provide a torque tending to raise the edges of the lower web
from the support members. If this occurs, squeaking sounds may be
emitted as someone walks across the flooring members, resulting
from relative motion occurring between the flooring members and the
support members.
[0043] Since the attachment clips 102 determine the location of an
individual elongated flooring member 16 as it is installed, these
attachment clips 102 further include interlocking alignment
features that space adjacent attachment clips 102 so that the
elongated flooring members 16 attached thereto are properly aligned
with one another. For example, each attachment clip 102 includes a
downward facing groove 122 at a first end and an upward facing
ridge 124 at an opposite end. As the attachment clips 102 are
installed to extend along a support member 14, the groove 122 of
one attachment clip 102 is brought into place over the ridge 124 of
an adjacent attachment clip 102, so that the attachment clips 102
are spaced to provide a proper spacing of the elongated flooring
members 16 subsequently attached thereto.
[0044] The process of building the floor assembly 100 may proceed
with all of the attachment clips 102 being installed on the
underlying support members 14 before any of the elongated flooring
members 16 are installed on the attachment clips 102. Alternately,
each of the elongated flooring members 16 may be installed as soon
as all of the attachment clips 102 under it are installed on the
support members 14. Alternately a combination of these approaches
may be used.
[0045] Preferably, the floor assembly 100 additionally includes an
edge strip 130 extending along an edge 132 of the support structure
12, with the edge strip 130 including a first web 134 extending
over a portion of an adjacent elongated flooring structure 15 and a
second web 136 extending downward from the first web 134. The
second web 136 is fastened to the support structure 12 by means of
a number of fasteners 138, which are, for example, screws or nails.
The second web 136 also includes a cover strip 140 pivotable
between a first position, indicated by dashed lines 142, allowing
the fasteners 138 to be driven or hammered into place, and a second
position, in which the cover strip 140 is shown, and in which the
heads 144 of the fasteners 138 are hidden to improve the appearance
of the floor assembly 100.
[0046] Preferably, the edge strip 130 is formed as an extrusion of
thermoplastic material, such as PVC, with a notch 146 being
provided to serve as a hinge for pivoting the cover strip 140, and
with a ridge 148 being provided for holding the cover strip 140 in
it closed position. Holes for the fasteners 138 may be formed in
the edge strip 130 before its installation on the support structure
12, or such holes may be formed during this installation
process.
[0047] FIG. 7 is a fragmentary transverse cross-sectional elevation
of a floor assembly 150 built in accordance with the second
embodiment of the invention having an alternative edge strip 152 in
the form of a "C"-shaped channel formed from an extruded
thermoplastic material, such as PVC. The edge strip 152 includes an
upper web 154 extending above a portion of the adjacent elongated
flooring member 16, a lower web 156 extending under a portion of
this elongated flooring member 16, and an outer web 158 extending
between the upper web 154 and the lower web 156. The edge strip 152
may be adhesively attached to the adjacent elongated flooring
member 16, or it may be held in place by a number of fasteners 160,
such as flat head nails. An adjacent spring clip 164 is cut off at
an edge 164 to provide for the placement of the lower web 156 under
the elongated flooring member 16 held in place by this spring clip
164. Each of the spring clips 102 may have a number of notches 166
to facilitate such a modification.
[0048] FIG. 8 is a fragmentary transverse cross-sectional elevation
of a floor assembly 170 built in accordance with the first
embodiment of the invention, having a second type of edge strip,
the edge strip 130 described above in reference to FIG. 6,
installed thereon. As described above in reference to FIG. 2, the
floor assembly 170 includes a number of elongated flooring members
16, with a first such flooring member 46 being held in place by a
number of edge clamps 40 and additionally by a number of clamping
blocks 24. The edge clamps 40 are covered by the edge strip 130. As
described above in reference to FIG. 6, the edge strip 130 is held
in place by a number of fasteners 138. The tab 62 of each edge
clamp 40 is not used.
[0049] FIG. 9 is a fragmentary transverse cross-sectional elevation
of a floor assembly 170 built in accordance with the first
embodiment of the invention, having the second type of edge strip
130 and a first elongated flooring member 176 that has been cut off
along an edge 178 because the overall width of the floor assembly
170 in the direction of arrow 180 does not provide for the use of
an integral number of elongated flooring members 16 (shown in FIG.
2). The configuration of the elongated flooring members 16, with a
number of vertical walls 38 extending between an upper web 36 and a
lower web 37, allows the elongated member 16 to be cut off at a
number of points while retaining suitable support for the upper web
36 and a suitable clamping surface 182 for attachment by means of
end clamps 39 or clamping blocks 24.
[0050] FIG. 10 is a transverse cross-sectional elevation of an
alternative elongated flooring member 186, which is similar to the
elongated flooring member 16 described above in reference to FIGS.
2 and 6, except that the alternative elongated flooring member 186
includes a core 188 filled with a foam resin, such as a foamed
polystyrene resin, filling the gaps between the upper web 36 and
the lower web 37, and also between adjacent walls 38, 39. This
alternative elongated flooring member 186 provides a floor assembly
with an additional advantage that a hollow sound is not produced as
someone walks on the floor assembly, due to reverberation otherwise
occurring within the empty chambers between webs 36, 37 and walls
38, 39. This alternate elongated flooring member 186 is used as
described above in reference to FIGS. 1-9, as a replacement for the
elongated flooring member 16.
[0051] While the edge strips 54, 130, 152 have been shown as
extending along a single edge of exemplary floor assemblies in a
direction parallel to the elongated flooring members 16, it is
understood that such edge strips 54, 130, 152 are readily installed
to extend along both (opposite) edges of such a floor assembly, in
a direction parallel to the elongated flooring members 16. It is
further understood that the edge strips 130, 152 may readily be
installed to extend along one or both edges of such a floor
assembly across the ends of the elongated flooring members 16, i.e.
in a direction perpendicular to the elongated flooring members
16.
[0052] While the invention has been described in terms of its
preferred versions or embodiments with some degree of
particularity, it is understood that this description has been
given only by way of example, and that numerous changes may be made
without departing from the spirit and scope of the invention, as
presented in the appended claims.
* * * * *