U.S. patent application number 10/937073 was filed with the patent office on 2005-02-10 for interlocked base and an overlaying surface covering.
This patent application is currently assigned to David R. Barlow. Invention is credited to Barlow, David R., Hutzenlaub, John.
Application Number | 20050028475 10/937073 |
Document ID | / |
Family ID | 32823697 |
Filed Date | 2005-02-10 |
United States Patent
Application |
20050028475 |
Kind Code |
A1 |
Barlow, David R. ; et
al. |
February 10, 2005 |
Interlocked base and an overlaying surface covering
Abstract
Multiple polymeric panels molded as a rigid integral body having
a planar top surface and a bottom grid structure are attached
together mechanically along irregular side edges. Each side surface
has alternating upwardly and downwardly facing steps. The steps of
adjacent panels engage each other to form complementary upwardly
and downwardly facing pairs of steps. The multiple polymeric panels
are overlaid with linoleum, carpet, synthetic grass, tile or wood
flooring.
Inventors: |
Barlow, David R.; (Seminole,
FL) ; Hutzenlaub, John; (Oakpark, IL) |
Correspondence
Address: |
LARSON AND LARSON
11199 69TH STREET NORTH
LARGO
FL
33773
|
Assignee: |
David R. Barlow
|
Family ID: |
32823697 |
Appl. No.: |
10/937073 |
Filed: |
September 9, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10937073 |
Sep 9, 2004 |
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10349461 |
Jan 22, 2003 |
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6793586 |
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Current U.S.
Class: |
52/578 |
Current CPC
Class: |
A63B 57/40 20151001;
E01C 5/20 20130101; A63B 69/3676 20130101; A63B 67/02 20130101;
A63B 2210/50 20130101; E01C 13/045 20130101; E01C 13/08 20130101;
E04F 15/10 20130101; E01C 2201/06 20130101; E01C 5/005 20130101;
A63B 2067/025 20130101; E01C 2201/12 20130101; A63B 57/357
20151001; A63B 69/3661 20130101 |
Class at
Publication: |
052/578 |
International
Class: |
E04B 001/00 |
Claims
1. An interlocked base and an overlaying surface covering
comprising: Multiple polymeric panels of an irregular multiple side
surface configuration, each side surface having alternating
upwardly and downwardly facing steps, the steps of adjacent panels
engaging each other to form complementary upwardly and downwardly
facing pairs of steps, each polymeric panel molded as a rigid
integral body having a planar top surface and a grid structure
supporting the top surface; the steps of the side surfaces of one
panel mechanically attached to a complementary step of an adjacent
panel; and the surface covering overlaying the planar top surface
of the attached multiple molded polymeric panels.
2. The interlocked base according to claim 1, wherein the covering
overlaying the planar top surface is a rolled on sheet.
3. The interlocked base according to claim 1, wherein the covering
overlaying the planar top surface is a carpet.
4. The interlocked base according to claim 1, wherein the covering
overlaying the planar top surface is wood flooring.
5. The interlocked base according to claim 1, wherein the covering
overlaying the planar top surface is multiple tiles fastened
together.
6. The interlocked base according to claim 1, wherein the steps of
the molded polymeric panels have a complementary projecting convex
surface from one step engaging a concave dimple on the step from an
adjacent panel to mechanically lock the panels together.
7. The interlocked base according to claim 1, wherein the steps are
mechanically attached by a screw passing through bores in
complementary downwardly and upwardly facing steps from separate
adjacent panels.
8. The interlocked base according to claim 1, wherein the steps are
mechanically attached by a bolt passing through a bore in one step
and engaging a threaded insert in a complementary step in an
adjacent panel.
9. The interlocked base according to claim 2, wherein the rolled on
sheet is linoleum.
10. The interlocked base according to claim 2, wherein the rolled
on sheet is synthetic grass.
11. The interlocked base according to claim 2, wherein the rolled
on sheet is indoor/outdoor carpet.
12. The interlocked base according to claim 1, wherein the
polymeric panels are about four feet by four feet in length and
width.
13. An interlocked base and an overlaying surface covering
comprising: multiple polymeric panels mechanically joined together,
each polymeric panel molded as a rigid integral body having a
planar top surface, bottom grid structure and multiple side
surfaces; a side surface of each panel joined together having
alternating downwardly and upwardly facing steps, the upwardly
facing step of one panel mating with a downwardly facing step of a
side surface of an adjacent panel; and the surface covering
overlaying the planar top surface of the joined multiple molded
polymeric panels.
14. The interlocked base according to claim 13, wherein the mating
steps are mechanically joined by complementary convex projections
entering a concave dimple on adjacent side surfaces of contiguous
panels.
15. The interlocked base according to claim 13, wherein a tapered
edge is attached to at least one side surface.
16. An interlocked base and an overlaying surface covering
comprising: a multiplicity of one piece sectional molded rigid
polymeric panels, each panel having alternating downwardly and
upwardly facing steps in a side surface, a planar top surface, a
grid structure integral with the top surface, the panels
mechanically joined together along adjacent side surfaces; and a
rolled sheet covering the planar top surface of the joined molded
polymeric panels.
17. The interlocked base according to claim 16, wherein the
polymeric panels are molded from filled polypropylene.
18. The interlocked base according to claim 16, wherein the
polymeric panels are formed by compression molding.
19. The interlocked base according to claim 16, wherein the rolled
sheet is carpet.
20. The interlocked base according to claim 16, wherein the rolled
sheet is synthetic grass.
21. The interlocked base according to claim 16, wherein the panels
are mechanically joined together by a step in a side surface of one
panel having a convex projection engaging a concave dimple in a
step on a side surface of an adjacent panel.
22. The interlocked base according to claim 16, wherein the panels
are mechanically joined together by a screw passing through
complementary steps in adjacent panels.
Description
PRIOR APPLICATION
[0001] This application is a continuation-in-part of U.S.
application Ser. No. 10/349,461, filed Jan. 22, 2003.
FIELD OF THE INVENTION
[0002] The present invention relates to a base for supporting an
overlaying cover. More particularly, it refers to multi-sectional
interlocking polymeric panels held together by a mechanical locking
feature, the panels forming a base for an overlaying surface.
BACKGROUND OF THE INVENTION
[0003] Surface coverings, such as carpet, linoleum, wood flooring,
rubberized flooring system, and tile, need to be laid over a base
that will support the surface covering. Commonly, surface coverings
are laid over a base of plywood or cement. These base materials are
expensive to install, and then once installed are more difficult to
remove. Recreational surfaces frequently need to be moved to
different locations because the same site may be used for different
activities, such as a basketball court converted to an ice rink. A
need exists for an inexpensive, easily movable base surface for use
with multiple surface coverings.
SUMMARY OF THE INVENTION
[0004] The invention of this application is a multiplicity of one
piece sectional polymeric panels attachable by locking features to
adjacent panels in various directions to create an indoor/outdoor
base for supporting a desired surface covering. The multiple
polymeric panels are prepared by compression, blow, injection or
like molding process to prepare a smooth, planar top surface
integral with a bottom grid structure. Locking features are mounted
at an end of each panel juxtaposed to an adjacent polymeric panel.
After removing the overlaying surface covering, the interlocked
panels can be disassembled and moved to a different location.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The invention can be best understood by those having
ordinary skill in the art by reference to the following detailed
description when considered in conjunction with the accompanying
drawings in which:
[0006] FIG. 1 is a top perspective view of the multiple molded
polymeric panels employed to form the interlocked base;
[0007] FIG. 2 is a side sectional view in elevation showing
adjacent polymeric panels of FIG. 1 ready to be locked together at
their edges;
[0008] FIG. 3 is a side sectional view in elevation showing the
adjacent polymeric edges in the panels of FIG. 1 locked
together;
[0009] FIG. 4 is a bottom perspective view of a molded polymeric
panel shown in FIG. 1;
[0010] FIG. 5 is a side sectional elevation along line 5-5 of FIG.
4;
[0011] FIG. 6 is a perspective view of the panels according to FIG.
1 with additional bores for screws to facilitate bonding of
adjacent panels;
[0012] FIG. 7 is a side sectional view in elevation showing the use
of screws for locking adjacent panels of FIG. 6 together;
[0013] FIG. 8 is a side sectional view in elevation showing two
adjacent panels in FIG. 6 locked together and firmly joined with a
screw;
[0014] FIG. 9 is a side sectional view in elevation showing the use
of a bolt and threaded insert for locking adjacent panels of FIG. 6
together;
[0015] FIG. 10 is a side sectional view in elevation showing two
adjacent panels of FIG. 6 locked together and firmly joined with
the bolt and threaded insert;
[0016] FIG. 11 is a top perspective view of a stand alone base
prepared for receipt of a surface covering;
[0017] FIG. 12 is a top perspective view showing a tapered side
edge of the base shown in FIG. 11 on one polymeric panel;
[0018] FIG. 13 is an exploded view of the tapered side edges being
attached to one polymeric panel;
[0019] FIG. 14 is an exploded view of a first alternate side edge
with protruding edges removed;
[0020] FIG. 15 is an exploded view of a second alternate side edge
with a molded part snapped into a side edge gap;
[0021] FIG. 16 is a top perspective view of a polymeric panel with
two side edges removed so that the polymeric panel can be laid in a
corner of a structure;
[0022] FIG. 17 is a top perspective view of a multiple polymeric
panel base overlaid with a rolled on covering;
[0023] FIG. 18 is a top perspective view of a multiple polymeric
panel base overlaid with tile; and
[0024] FIG. 19 is a top perspective view of a multiple polymeric
panel base overlaid with wood or synthetic wood flooring.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Throughout the following detailed description the same
reference numerals refer to the same elements in all figures.
[0026] Referring to FIGS. 1-3, panels 12 join together to form an
interlocked series of panels 10 arranged to be mechanically locked
together. Each panel 12 has upright facing sidesteps 14 and
downward facing sidesteps 16. Steps 16 contain a downwardly
pointing convex projection 18 on lower surface 20. Step 14 contains
a concave dimple 22 on upper surface 24, as shown in FIGS. 2 and 3.
The adjacent panels 12 are slid together to engage convex
projections 28 with concave dimples 22. A pry bar can be inserted
in a sideslot 26 in order to disengage adjacent panels 12. The top
planar surface 30 is molded as an integral rigid body with the grid
structure 32 shown in FIG. 4.
[0027] The molded integral rigid body with grid structure 32 is
made from molded filled or non-filled polymers. These polymers can
include polypropylene, structural urethane foams or other suitable
commercially available polyolefins.
[0028] An alternative locking mechanism for panels 12 is shown in
FIGS. 6-8. Bores 34 are drilled in the top surface 30 of panels 12
above each downwardly facing step 16, and bores 36 are drilled in
top surface 20 of upwardly facing step 14. A screw 38, as shown in
FIGS. 6-8, is threaded through bores 34 and 36 to join panels 12
together. Nipple projection 40 is guided into indentation 42 to
join the corners of panels 12 together, as shown in FIG. 6. An
alternative bolt 44 and insert 46, as shown in FIGS. 9 and 10, can
be substituted for screw 38, as shown in FIGS. 7 and 8, to join
panels 12 together.
[0029] As seen in FIG. 11, a stand alone interlock panel
arrangement 10A can be fashioned with a tapered border 28. As seen
in FIGS. 12 and 13, the tapered border 28 has a corresponding
portion 48 that intersects with upright facing sidestep 14 and
downward facing sidesteps 16. In this manner, the tapered border 28
is merely inserted over the sidesteps in the same manner as set
forth above for the juxtaposed individual panels 12. A corner
tapered border 50 is inserted between the tapered sections 28 in
order to complete the look shown on FIG. 12.
[0030] The panels 12 can be configured to fit in the corner of a
building. In this use, the sections 52, as shown in FIG. 14, are
sawed off of panel 12 so that a generally smooth surface 54 is set
forth on the side edge of panel 12. As shown in FIG. 15, plugs 56
are inserted in the openings 58 to create a generally smooth top
surface on panel 12. In order to avoid using the plugs of 56, the
entire corner section 60 on panel 12 can be removed to provide a
smooth side surface 62, as shown in FIG. 16.
[0031] A roll-down top surface 64, as shown in FIG. 17, can be
applied over the interlock panels 10. This roll-down top surface 64
can be synthetic grass, carpet, linoleum, or a film-type surface as
desired. Alternatively as seen in FIG. 18, tile 66 can be laid over
interlocked panels 10 or as seen in FIG. 19, wood or synthetic wood
products 68 can be laid over interlocked panels 10.
[0032] The interlocked panels 10 with a synthetic grass covering
can be used on driving ranges or practice facility for a golf ball
hitting area. The configuration of interlocked panels 10 can be
longitudinal, squared, rectangular or other geometric shape, and
can be used outdoors over turf or sand or indoors over concrete or
plywood or as a substitute for a concrete or plywood base. The
interlocked panels 10 can be covered with commercially available
surfaces, such as SPORT COURT.TM. athletic floor tiles, hardwood
flooring, synthetic wood floor, carpet or linoleum that are easily
installed over the interlocked panels and can be removed and
reassembled at alternate locations.
[0033] The above description has described specific structural
details in applying the invention. However, it will be within one
having skill in the art to make modifications without departing
from the spirit and scope of the underlying inventive concept of
this interlock panel with overlaying surface. The invention is not
limited to the structure described and includes such modifications
as are substantially equivalent to the elements of the interlock
panels with surface covering.
* * * * *