U.S. patent application number 11/802664 was filed with the patent office on 2007-12-13 for break-away multi-purpose flooring transition.
This patent application is currently assigned to PFLEIDERER SCHWEIZ AG. Invention is credited to Wayne Robert Johnston, Sven Kornfalt, Sabad La Serna, Roland Larsson, William T. Pierce, Patrick George Smith, Oliver Stanchfield.
Application Number | 20070283654 11/802664 |
Document ID | / |
Family ID | 38801974 |
Filed Date | 2007-12-13 |
United States Patent
Application |
20070283654 |
Kind Code |
A1 |
Stanchfield; Oliver ; et
al. |
December 13, 2007 |
Break-away multi-purpose flooring transition
Abstract
The invention is a joint cover assembly for covering a gap
adjacent an edge of a panel that covers a sub-surface, and a method
of covering such a gap. The assembly can be manipulated to form an
end molding, a T-molding, a hard surface reducer, a carpet reducer,
and/or a stair nose molding. A kit can include the joint cover
assembly an a tool for forming a flooring transition from a generic
element having break-away sections.
Inventors: |
Stanchfield; Oliver;
(Garner, NC) ; Kornfalt; Sven; (Malmo, SE)
; Larsson; Roland; (Apex, NC) ; Pierce; William
T.; (Smithfield, NC) ; La Serna; Sabad;
(Raleigh, NC) ; Smith; Patrick George; (Raleigh,
NC) ; Johnston; Wayne Robert; (San Marcos,
CA) |
Correspondence
Address: |
STEVENS, DAVIS, MILLER & MOSHER, L.L.P.
1615 L STREET, N.W.
SUITE 850
WASHINGTON
DC
20036
US
|
Assignee: |
PFLEIDERER SCHWEIZ AG
Zug
CH
|
Family ID: |
38801974 |
Appl. No.: |
11/802664 |
Filed: |
May 24, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60808121 |
May 25, 2006 |
|
|
|
Current U.S.
Class: |
52/465 ; 29/592;
52/749.1 |
Current CPC
Class: |
E04F 19/062 20130101;
E04F 19/061 20130101; E04F 19/066 20130101; B26D 3/001 20130101;
E04F 19/065 20130101; Y10T 29/49 20150115; B23D 45/003 20130101;
E04F 11/166 20130101; B23D 45/102 20130101; E04F 19/02
20130101 |
Class at
Publication: |
052/465 ;
029/592; 052/749.1 |
International
Class: |
E04F 19/02 20060101
E04F019/02 |
Claims
1. A method for forming an integral multi-purpose structure for
forming flooring transitions comprising: providing a unitary core
having an outer surface; imparting to the outer surface of the core
at least one cuts thereby defining a plurality of break-away
sections in the core, wherein the cuts are sized, shaped and
positioned such that removal of a break-away section of the core
transforms the structure into a flooring transition; and covering
at least a portion of outer surface of the core having the at least
one cut therein with a decorative material.
2. The method of claim 1, wherein the providing comprises placing
the cuts such that removal of a break-away section transform the
core into a flooring transition selected from the group consisting
of a hard surface reducer, carpet reducer, T-molding, end molding,
quarter-round, shoe molding, wall base and stair nose.
3. The method of claim 1, wherein the decorative material at least
partially covers a cut in the core.
4. The method of claim 1, wherein the imparting step comprises at
least one selected from the group consisting of milling and
cutting.
5. The method of claim 4, wherein the cutting comprises using a
blade or a laser.
6. The method of claim 1, comprising inserting a supporting
material into a cut before the covering step.
7. The method of claim 1, wherein the core comprises an interlayer
positioned between the plurality of break-away sections.
8. The method of claim 1, wherein the core comprises a material
selected from the group consisting of fiber board, particle board,
oriented strandboard, plywood, plastic, wood, engineered wood,
metal, composites, gypsum, high-density reinforced plaster, and
cork.
9. The method of claim 1, wherein the decorative material is
printed at least partially directly on the core to provide a
decorative pattern.
10. The method of claim 1, wherein the decorative material
comprises a patterned paper sheet.
11. The method of claim 1, wherein the decorative material
comprises a wear layer comprising hard particles having a Moh's
hardness of at least approximately 6.
12. The method of claim 1, wherein the decorative material
comprises a wear layer comprising particles selected from the group
consisting of silica, alumina, diamond, silicon nitride, aluminum
oxide, silicon carbide, cerium oxide and glass beads.
13. A method of forming a flooring transition comprising: providing
an integral multi-purpose structure, the structure comprising: a
unitary core; cuts in the core, defining a plurality of break-away
sections in the core; and a decorative material covering at least a
portion of the core and the cuts; and severing the decorative
material over the cuts in the core; and removing at least one
break-away section.
14. The method of claim 13, wherein the flooring transition is
selected from the group consisting of hard surface reducer, carpet
reducer, T-molding, end molding, quarter-round, shoe molding, wall
base and stair nose.
15. A tool for severing a multi-purpose structure into a flooring
transition comprising: a housing defining an interior space for
receiving the structure; a first blade position along a first side
of the tool for severing the structure along a first axis; a second
blade position along a surface of the tool different from the first
side for severing the structure along a second axis; and a blade
located in the first blade position.
16. The tool of claim 15, further comprising a second blade located
in the second blade position.
17. The tool of claim 17, further comprising a third blade located
in a third blade position for cutting the structure along a third
axis, wherein the third blade position is substantially
perpendicular to the first blade position and substantially
parallel to the second blade position.
18. The tool of claim 15, wherein the first blade position is
substantially perpendicular to the second blade position.
19. The tool of claim 15, further comprising means for moving the
blade from the first blade position to the second blade
position.
20. The tool of claim 15, further comprising means for moving the
blade from an operative position to an inoperative position,
21. A kit comprising: the tool of claim 15 and an integral
multi-purpose structure, the structure comprising: a unitary core;
cuts in the core, defining a plurality of break-away sections in
the core; and a decorative material coving at least a portion of
the core and the cuts; wherein at least one of the blade positions
corresponds to the locations of a cut when the structure is moved
through the interior space.
22. The kit of claim 21, further comprising a clamp or track.
23. A flooring transition formed according to the method of claim
1.
24. A unitary structure for forming a flooring transition
comprising: a unitary core having an outer surface and cuts
penetrating the outer surface, and a decorative material covering a
portion of the outer surface and the cuts, wherein the cuts are
sized, shaped and positioned to define a plurality of break-away
sections in the core, such that removal of a break-away section of
the core transforms the structure into a flooring transition.
25. The structure of claim 24, wherein the core comprises a top
face and two opposite lateral faces, and wherein each of lateral
faces and the top face comprise a cut.
26. The structure of claim 25, wherein at least one of the lateral
faces comprises a plurality of cuts.
27. The structure of claim 24, wherein the core comprises a
material selected from the group consisting of fiber board,
plastic, wood, engineered wood, metal, composites, gypsum,
high-density reinforced plaster, and cork
28. The structure of claim 27, wherein the core comprises fiber
board.
29. The structure of claim 24, wherein the decorative material
comprises one selected from the group consisting of a foil,
laminate, wood, wood veneer, ceramic, tiles, metal, vinyl, stone,
paper, composite, and plastic.
30. The structure of claim 24, wherein the decorative material
comprises: a patterned paper sheet impregnated with a thermosetting
resin; and a wear layer, the wear layer comprising hard particles
having a Moh's hardness of at least approximately 6.
31. The structure of claim 24, wherein the decorative material
comprises a wear layer comprising particles selected from the group
consisting of silica, alumina, diamond, silicon nitride, aluminum
oxide, silicon carbide, cerium oxide and glass beads.
32. The structure of claim 24, wherein: the core comprises fiber
board and the decorative material comprises: a patterned paper
sheet impregnated with a thermosetting resin; and a wear layer, the
wear layer comprising hard particles selected from the group
consisting of silica, alumina, diamond, silicon nitride, aluminum
oxide, silicon carbide, cerium oxide and glass beads.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Appl.
No. 60/808,121, having been filed May 25, 2006, incorporated by
reference in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The invention is an integral multi-purpose structure which
can be separated into various flooring transitions such as
T-moldings, hard surface reducers and end moldings.
[0004] 2. Background of the Invention
[0005] Hard surface floors, such as wood or laminate flooring, have
become increasingly popular. As such, many different types of this
flooring have been developed. Generally, this type of flooring is
assembled by providing a plurality of similar panels. The differing
types of panels that have developed, of course, may have differing
widths and thicknesses. The same is true when a laminate floor
(often referred to as a "floating floor") abuts another hard
surface, such as a resilient surface (such as vinyl), tile or
another laminate surface, a ceramic surface, or other surface,
e.g., natural or engineered wood flooring. Thus, when laminate
panels having different thicknesses or different floor covering
materials are placed adjacent to a similar or dissimilar,
transition moldings are often used to create a transition between
the same.
[0006] Additionally, one may desire to install floor panels
adjacent to an area with different types of material. For example,
one may desire to have one type of flooring in a kitchen (e.g.,
resilient flooring, laminate flooring or ceramic tile), and a
different appearance in an adjacent dining room (e.g., solid wood
or carpeting), and an entirely different look in an adjacent bath.
Therefore, it has become necessary to develop a type of molding or
floorstrip that could be used as a transition from one type of
flooring to another, either between rooms, or different portions of
the same room.
[0007] A problem is encountered, however, when flooring materials
that are dissimilar in shape or texture are used. For example, when
a hard floor is placed adjacent a carpet, problems are encountered
with conventional edge moldings placed therebetween. Such problems
include difficulty in covering the gap that may be formed between
the floorings having different height, thickness or texture.
[0008] Moreover, for purposes of reducing cost, it is desirable to
be able to have a molding that is versatile, having the ability to
cover gaps between relatively coplanar surfaces, as well as
surfaces of differing thicknesses.
[0009] It would also be of benefit to reduce the number of molding
profiles that need to be kept in inventory by a seller or installer
of laminate flooring. Thus, the invention also provides a method by
which the number of moldings can be reduced while still providing
all the functions necessary of different styles of transition
moldings.
SUMMARY OF THE INVENTION
[0010] The invention is a joint cover assembly for covering a gap
between edges of adjacent floor elements, such as floor panels of
laminate or wood, although it may also be used as a transition
between a laminate panel and another type of flooring, e.g.,
carpet, vinyl, ceramic, and wood. The assembly typically includes a
body having a foot positioned along a longitudinal axis, and a
first arm or member extending generally perpendicularly from the
foot. The assembly may include a second arm also extending
generally perpendicular from the foot.
[0011] The outward-facing surface of the assembly may be formed as
a single, unitary, monolithic surface that covers both the first
and second arms. This outward-facing surface may be decorated, for
example, with a laminate or a paper, such as a monochromatic or
patterned decor, impregnated with a resin, in order to increase its
aesthetic value, to match, blend or contrast with the floor panels.
Preferably, the outward facing surface has incorporated therein at
least one material to increase its abrasion resistance, such as at
least one type of hard particles of silica, alumina, diamond,
silicon nitride, aluminum oxide, silicon carbide, cerium oxide and
similar hard particles, preferably having a Moh's hardness of at
least approximately 6. This outward-facing surface may also be
covered with other types of coverings, such as cork, foils (such as
paper or thermoplastic foils), paints, papers (optionally
stainable), polyurethane (optionally cured), printable surfaces
(which may be the surface itself), fiber glass, glass fiber
reinforced plastics, or a variety of other decorative elements,
including, but not limited to, wood veneer, ceramic (such as
tiles), metal, vinyl or other decorative materials.
[0012] The assembly is preferably provided with a securing means,
such as a clamp or track, to prevent the assembly from moving out
of position once assembled. In one embodiment, the securing means
is a clamp, designed to grab the foot. Preferably, the clamp
includes a groove into which the foot is inserted. In a preferred
embodiment, the clamp or track may be joined directly to a
subsurface below the floor element, such as a subfloor, by any
conventional means, such as a nail, screw or adhesive.
[0013] A shim may also be placed between the foot and the subfloor
to provide for height adjustments to allow the assembly to be used
in various situations. In one embodiment, the shim may be
positioned on the underside of the clamp; however, if a clamp is
not used, the shim may be positioned between the foot and the
subfloor. The shim may be adhered to either the foot or subfloor
using an adhesive or a conventional fastener, e.g., nail or
screw.
[0014] The assembly is typically formed from one of a variety of
materials, such as a core covered with carpet, laminate, ceramic or
wood tile, linoleum, turf, metal, paper, natural wood or wood
veneer, vinyl, ceramic or composite finish, or any type of surface
covering, while the core is generally formed from wood, engineered
wood, fiberboard, such as high density fiberboard (HDF) or medium
density fiberboard (MDF), flaxboard, plastics, or other structural
material, such as metals (e.g., aluminum, copper, brass, alloys
thereof and stainless steel) or composites, and at least over a
portion of the surface thereof may be covered with a foil (metal,
plastic, etc.), cork, a plastic, a paper, a decor or a laminate to
match or contrast with the first and second arms, or other
materials, such as those discussed by U.S. Pat. Nos. 6,860,074 and
6,898,911, each of which is herein incorporated by reference in its
entirety. Preferred plastics include extrudable and/or moldable
thermosetting and thermoplastic resins, the latter including high
density olefins and PVC.
[0015] The assembly may additionally be used to cover gaps between
tongue-and-groove type panels, such as glued or glueless laminate
floor panels, or even other types of flooring which are secured to
a subsurface.
[0016] An adhesive, such as a glue, a microballoon adhesive,
contact adhesive, or chemically activated adhesive, including a
water-activated adhesive, may be also positioned on any of the
pieces of the assembly to either hold the assembly together or in
place. Of course, such an adhesive is not necessary, but may
enhance or supplement the fit and positioning of the assembly over
the gap between the floor elements. Additionally, the adhesive may
assist in creating a more air-tight or moisture-tight joint.
[0017] The assembly may be used in other non-coplanar areas, such
as the edge between a wall and a floor, or even between the run and
rise of stairs. For example, the assembly may include the first and
second arms, and foot as described above, but instead of
transitioning between two floor elements placed in the same plane,
may form the joint between the horizontal and vertical surfaces of
a single stair element.
[0018] The inventive assembly may be used for positioning between
adjacent tongue-and-groove panels; in this regard, the assembly
functions as a transition molding, which provides a cover for edges
of similar or dissimilar surfaces. For example, when installing
floors in a home, the assembly could be used to provide an edge
between a hallway and a bedroom, between a kitchen and living or
bathroom, or any areas where distinct flooring is desired.
Additionally, the assembly may be incorporated into differing types
of flooring, such as wood, tile, linoleum, cork, carpet, or
turf.
[0019] The invention also is drawn to an inventive method for
covering a gap between adjacent panels of a generally planar
surface. The method includes multiple steps, including, inter alia,
manipulating a generic element by removing a part of the generic
element to produce one or more moldings, and thereafter, installing
the moldings where needed.
[0020] The invention additionally includes a new and innovative
securing means used to install both the inventive moldings as
described herein, as well as other moldings, such as those
described by U.S. Pat. Nos. 6,517,935, and 6,898,911, and WO0240809
(each of which is herein incorporated by reference in its
entirety). This securing means is, most often, a track or clamp
which can be glued, or otherwise secured to a subfloor and/or one
or more flooring elements.
[0021] Other objects, features and advantages of the present
invention will become apparent from the following detailed
description. It should be understood, however, that the detailed
description and the specific examples, while indicating preferred
embodiments of the invention, are given by way of illustration
only, since various changes and modifications within the spirit and
scope of the invention will become apparent to those skilled in the
art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a side-view of a structure from which the moldings
of the invention can be made.
[0023] FIGS. 2, 3 and 4 are side-views of intermediate elements
which can be used in the construction of the molding of the
invention;
[0024] FIG. 5 is a side-view of a completed generic element in
accordance with the invention;
[0025] FIG. 6 is a side-view of a T-molding formed from the generic
element of FIG. 5.
[0026] FIG. 7 is a side-view of one carpet reducer embodiment
formed from the generic element of FIG. 5;
[0027] FIG. 8 is a side-view of a hard surface reducer formed from
the generic element of FIG. 5.
[0028] FIG. 9 depicts two end-moldings in accordance with the
invention.
[0029] FIG. 10 shows a different carpet reducer/hard surface
reducer in accordance with the invention.
[0030] FIG. 11 represents a T-molding installed with the track of
the invention.
[0031] FIG. 12 is a view of the track used in FIG. 11.
[0032] FIG. 13 represents an installation of the reducer of FIG. 10
using the track of FIG. 11.
[0033] FIG. 14 shows an installed end molding in accordance with
the invention.
[0034] FIG. 15 depicts a breakaway combination hard surface
reducer/carpet reducer in accordance with the invention.
[0035] FIG. 16 shows another T-molding embodiment formed from the
combination of FIG. 15.
[0036] FIG. 17 is an end molding formed from the combination of
FIG. 15.
[0037] FIG. 18 represents a carpet transition formed from the
combination of FIG. 15.
[0038] FIG. 19 represents an embodiment similar to the combination
of FIG. 15.
[0039] FIG. 20 shows a carpet transition formed from the
combination of FIG. 19.
[0040] FIG. 21 shows a T-molding formed from the combination of
FIG. 19.
[0041] FIG. 22 shows end moldings formed from the combination of
FIG. 19.
[0042] FIG. 23 represents an additional break away molding of the
invention.
[0043] FIG. 24 is another T-molding with a break away feature.
[0044] FIG. 25 is a reversible CR/HSR.
[0045] FIG. 26 shows two end moldings.
[0046] FIG. 27 shows a track which can be used with embodiments of
the invention.
[0047] FIG. 28 represents an assembled and installed carpet
reducer.
[0048] FIG. 29 represents an assembled and installed hard surface
reducer.
[0049] FIG. 30 shows a combination HSR/CR with two break away
sections.
[0050] FIG. 31 is an end molding with a track after the track has
been separated.
[0051] FIG. 32 shows another T-molding of the invention installed
in its track.
[0052] FIGS. 33 and 34 depict a stair nose attachment of the
invention.
[0053] FIGS. 35-37 show elements of the generic molding of the
invention, indicating a construction method.
[0054] FIGS. 38-41 show additional embodiments of the generic
molding of the invention, and products produced therefrom.
[0055] FIG. 42 schematically represents a generic element, having
been provided with cuts by a laser.
[0056] FIGS. 43 and 44 schematically show shaped core materials
before a surface material is applied and the core material modified
to its final shape.
[0057] FIGS. 45A-E schematically show alternative edges of a
cutting blade which can be used in a tool in accordance with the
invention.
[0058] FIG. 46 is a perspective view of a cutting tool which can be
used in accordance with the invention.
[0059] FIG. 47 is an exploded perspective view of the cutting tool
of FIG. 46.
[0060] FIG. 48 is a schematic representation of an alternate
cutting tool to be used in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0061] FIG. 1 shows a structure 1, from which the present invention
can be formed. Structure 1 typically has a core 1A, an upper face
1B, a first lateral face 1C, a second lateral face 1D and a lower
face 1E.
[0062] Preferably, core 1A is formed from a fiberboard, such as
high-density fiberboard (HDF) or medium-density fiberboard (MDF),
plastic, wood, engineered wood, metal, composites, gypsum,
high-density fiber reinforced plaster, or other natural or
synthetic material such as cork, or any additional material, such
as described in U.S. Pat. No. 6,860,074, herein incorporated by
reference in its entirety. Preferred plastics include extrudable
thermoset and thermoplastic resins, the latter including high
density olefins and polyvinylchloride. In preferred embodiments of
the invention, the core 1A is unitary, i.e., it is a single
piece/unit, not a multi-piece element, held together by glues,
adhesives, joints, etc.
[0063] The decorative outer face can have a variety of finishes,
such as varnishes, lacquers, paints, polyurethane, hard surfaces
(optionally containing hard particles, to increase the durability,
e.g., abrasion and scratch resistance, of the surface materials),
such as laminates (such as taught by U.S. application Ser. No.
10/902,062, herein incorporated by reference in its entirety), or
hardwood flooring finishes, veneers, foils, stainable papers, or
digital printing or other flooring materials, such as vinyl, metal,
composites or plastics or natural materials such as cork. It is
additionally within the scope of the invention to provide the
decorative outer face of quarter round 6 with ceramic or wood
tiles, as taught by U.S. Pat. No. 6,860,074. Typical laminates
which can be used are those taught by U.S. Pat. No. 6,517,935
(herein incorporated by reference in its entirety), including
monochromatic or patterned (including random) decor sheets which
may or may not be impregnated with a thermosetting resin, and a
cellulosic overlay paper, such as one made from alpha-cellulose,
which also may or may not be impregnated with a resin. Other
laminates include ones in which the overlay is eliminated, and may
be substituted by a polymer containing cellulosic particles, evenly
or randomly distributed throughout a (typically otherwise clear)
resin. The outer surface may be a conventional laminate, such as a
high pressure laminate (HPL), direct laminate (DL), compact
laminate (CPL) or a post-formable laminate (as described in U.S.
application Ser. No. 08/817,391, herein incorporated by reference
in its entirety); a foil; a print, such as a photograph or a
digitally generated image; or a liquid coating including, for
example, aluminum oxide. Thus, in the event natural wood or wood
veneer is not selected as the material, the appearance of wood may
be simulated by coating the decorative outer surface with a
laminate having a decor that simulates wood. Alternatively, the
decor can simulate marble, ceramic, terrazzo, stone, brick, inlays,
or even fantasy patterns.
[0064] In a preferred embodiment, the decorative face or surface
includes a laminate formed from a thermosetting resin, having a
decor sheet, optionally an overlay layer (with or without
cellulosic fibers atop or therein) or sheet and hard particles
therein in order to impart an abrasion resistance thereto, which is
affixed or joined to the remainder of the quarter round 6 in a
high-pressure laminate process step. Such laminate may be affixed
as described by U.S. Pat. No. 6,805,951, herein incorporated by
reference in its entirety. The outer face can be other finishing
materials such as thermoplastic containing laminates, wood veneers,
thermosetting polymers, such as melamine or phenolic resins,
thermoplastic polymers such as olefins, foils (such as
thermosetting, thermoplastic, paper or metal foils), optionally
impregnated with or without hard particles, polyesters, vinyls,
metals (such as sheets or strips), or combinations thereof. For
example, the outer face can include multiple elements, as described
herein. It is additionally considered within the scope of the
invention to affix a material to the outer face during a direct
lamination step, as is known in the art.
[0065] Often, the outer face is provided with a patterned paper
sheet therein, wherein the pattern resembles a natural or synthetic
object, such as wood, ceramic, stone (including marble and
granite), or fantasy patterns (i.e., those not found in nature),
including a monochromatic or random field. The specific decor can
be selected to enhance the appearance of the surfaces which will be
adjacent to quarter round 6 when installed. Such enhancement can be
accomplished by matching exactly the visual pattern to that of the
adjacent surface, or by contrasting the patterns, for example, such
that when installed, a visual pattern extends from a flooring
element (wall base or wall), onto and possibly completely across,
the molding, as described by U.S. Patent Application Publication
No. 2002/0038924, filed Sep. 28, 2001, herein incorporated by
reference in its entirety.
[0066] The moldings of the invention typically have a durability
rating. As defined by the European Producers of Laminate Flooring,
such products can have an abrasion resistance rating of anywhere
from AC1 to AC5. Typical abrasion resistances are >300 cycles,
>400 cycles, >500 cycles, at least 900 cycles (AC1), at least
1800 cycles (AC2), at least 2500 cycles (AC3), at least 4000 cycles
(AC4) and at least 6500 cycles (AC5), as measured by European
Standard EN 13329 (Annex E). Typical products according to the
invention can also have impact resistance ratings of IC1, IC2 or
IC3, as measured by European Standard EN 13329.
[0067] Moreover, it is possible to provide a texture which enhances
the pattern of the underlying paper sheet or printed image. Such
texturing can be created to be "in register" with, offset from, or
to contrast with the image of, e.g., the paper sheet. Such
texturing may be created by physical pressing, e.g., embossing (as
taught by U.S. application Ser. No. 10/440,317, U.S. Pat. No.
7,003,364, and WO9731775 and WO9731776, each of which is herein
incorporated by reference in its entirety) or chemically created
(as taught by U.S. Pat. No. 6,991,830, herein incorporated by
reference in its entirety). The texture can be selected to enhance
(e.g., match or contrast with) any texture of adjacent surfaces.
The texture may also be provided such that features of the texture
extend from a flooring element (or wall base or wall) onto, and
possibly completely across, the molding, which texture may, or may
not coincide with the underlying decor.
[0068] Although core 1A is shown as being a single unitary
structure without any joints or connections therein, it is
considered within the scope of the invention to form core 1A by
joining two or more separate elements. Such separate structures
need not be of the same material(s), and may be joined by, for
example, by friction joints, tongue-and-groove joints, compression
joints, glue, adhesive strip, double-sided tape, or any combination
thereof. Although FIG. 1 shows core 1A as being solid, it is
additionally considered within the scope of the invention to
utilize a hollow structure, optionally with one or more supports or
reinforcements provided in the interior thereof, or a composite
core, incorporating an interlayer of a softer and/or resilient
material, e.g., balsa or other relatively soft wood, plastic,
rubber, paper, or foamed materials, in combination with a
wood-fiber layer. Such an interlayer is optionally positioned in
locations to facilitate removal, such as by peeling, to form the
desired shapes of the invention.
[0069] In order to achieve the generic molding of the invention,
preferably, structure 1 is provided with one or more cuts 2. Such
cuts 2 can be created by milling or cutting with, for example, a
blade or even a laser, on or into core 1A of structure 1.
Alternatively, however, it is possible to create structure 1 with
cuts 2 already therein, by, for example, an extrusion or other
molding process. The particular location and number of cuts 2 are
selected based upon the final shapes to be created, as will be
described below. Preferably, however, structure 1 is provided with
a first cut 2A in face 1C, a second cut 2B in upper face 1B, and a
third cut 2C in face 1D, with no cuts in lower face 1E, as is shown
in FIG. 2. Lower face 1E may be provided with a groove, which
groove can be sized and shaped to accommodate for heads of screws
used to affix the securing elements to the subfloor.
[0070] Known lasers include gas lasers (e.g., CO.sub.2, CO, HeNe,
argon), having a power output of between 5 and 100 W, up to 100 kW,
preferably 20-60 W, and more preferably approximately 30 W, having
a wavelength in the range of 5 .mu.m-550 nm, typically 7-15 .mu.m
or 450-550 nm. Other known lasers include metal ion lasers (e.g.,
HeAg and NeCu), having wavelengths between 220 and 250 nm, chemical
lasers (e.g., HF and Deuterium flouride), having wavelengths
between 2700 and 4000 nm, excimer, solid state, semiconductor
(e.g., Nd:YAG) and dye lasers. However, the parameters of any laser
used to produce a cut should be selected depending upon, in part,
on issues such as the material to be cut, the depth and/or length
of the cut. The cutting laser can be part of a flying optic
machine--where the cutting laser moves over the structure to be
cut, although it is considered within the scope of the invention to
process the workpiece by moving the workpiece with respect to the
cutting laser.
[0071] According to a preferred embodiment, laser scoring can
penetrate at any desired depth depending upon the material that is
being used and depending upon the speed and strength of the laser
used when scoring the material. Laser strength can vary from 5 W to
100 kW, preferably within a range of 4 kW to 8 kW when scoring HDF
or MDF material and other strengths used depending upon the
materials and speed of scoring. As the laser cuts are substantially
narrow, the laser cut or scoring does not need to be filled with
shims or other materials for support (although shims are not
prohibited).
[0072] In one generic element 1110 according to the invention (FIG.
42), the preferred opening of each laser score or cut 1110 is
approximately 0.05-1 mm, most preferably approximately 0.3 mm,
however it can be less or greater than this measurement. The
opening typically corresponds to the type and thickness of the
blade used to cut the surface material above the cut, by example a
0.3 mm opening using a blade slightly less than 0.3 mm or even less
than 0.3 mm to 0.2 mm or slightly less can produce a cleaner cut
edge with as little unsupported surface material 1111, surface
material at the edge of the cut that does not have core material
supporting it, as possible. The ideal opening and type blade and
blade thickness will leave a smooth cut of the surface material
with as much supporting core material as possible. When a larger
opening is used with a smaller blade thickness, by example, 0.6 mm
opening with a 0.3 mm blade, a larger portion around the cut edge
of the surface material is left unsupported by core material. This
configuration is less preferred because unsupported surface
material can partially crack, tear and/or separate. In such a
configuration, the cut edge can be sanded or otherwise smoothed to
cure the cracks, tears, etc.
[0073] The horizontal laser cuts 1110 can be parallel to the top
surface of the molding. Specifically, one or both of an upper cut
definition 1010A and a lower cut definition 1010B can be parallel
to the surface of the molding. However, either or both of the upper
cut definition 1010A and lower cut definition 1010B can be at an
angle, i.e., not parallel, to the surface of the molding (the upper
surface and/or the bottom surface, which are preferably, but need
not be, parallel). A vertical laser cut 1112 can be used as well.
FIG. 43 shows an example the generic element 1100, having been
provided with the parallel cuts 1110, but prior to affixing of the
surface material 1111, while FIG. 44 shows the generic element 1100
with angled cuts 1110. Such cuts 1110 are typically approximately
0.8 mm at the opening, and taper to be linear at the innermost
portion, and are typically cleaned (e.g., brushing and/or blowing)
to remove any remaining char and soot. A leg 1113 of this molding
part which is also the material that is held by a track (not
shown), can be penetrated by the vertical laser cut with a
corresponding V groove 1114 formed, e.g., by milling, on the
underside of the "leg" such that when the surface material 1111 is
cut and pressure is applied to separate the generic element 1110
(to form, e.g., the end molding 22 or 402), the material between
the laser cut and the milled groove will break in a desired
location. When milling the underside of the generic element 1110, a
variety of milling techniques can be used. Since the leg 1113 is
almost divided in half by laser scoring or cutting and milling,
additional strength can be given each half by increasing the radius
of the cuts where the underside surface of the T and the junction
where the leg joins the underside of the T. By increasing the
radius at this point additional strength can be given to each half
of the leg 1113. Thus, although shown as being right angles. such
angles may also be rounded.
[0074] Also this same practice can be accomplished where the HSR
and CR parts of the molding are attached to the underside of the
"T", increasing the strength of these parts as desired as well as
the amount of core material that remains between the end of the cut
or laser score and where the underside milling begins on each
piece.
[0075] The preferred use is for cutting laminate, foil, wood
veneer, covered flooring transitions or wall trim.
[0076] Typically, cuts 2 penetrate the respective face 1B-D, but do
not make a separate piece from parts of structure 1. Depending on
the material used for core 1A as well as the desired force
necessary, as will be described below, the depth of cuts 2 can vary
greatly. If, however, covering 4A (as described below) is strong
enough, it is possible for one or more cuts 2 to separate a part of
structure 1, because the covering 4A can maintain the structural
integrity. It is also within the scope of the invention to form
cuts 2 such that a frangible connection is made between various
sections of structure 1.
[0077] In a preferred embodiment, filler material, such as shims
3A-C are inserted into cuts 2A-C, respectively. Shims 3 preferably
have a width slightly smaller than the width of the respective cut
3A-C. As a result, shims 3 typically fit snugly in the cut 3.
Although no particular length for shims 3 is required, it is
preferable that shims 3 are substantially shorter than the length
of the respective cut 2, which cut can have differing dimensions
across its length and/or width. Such may be accomplished by using
tools, e.g., blades and lasers, of different dimensions. Although
cuts 2 and shims 3 are shown as all being of the same
shape/dimensions, it is within the scope of the present invention
to vary the size, shape and dimensions of the respective cut/shim
combination. Although it is preferred that shims 3 are manually or
mechanically inserted into the respective cut 2, and pushed inside
cut 2, it is possible to provide shims 3 having a length greater
than the depth of the respective cut 2, and after insertion, remove
any portion outside cut 2, and optionally a small section to
provide an opening for a cutting blade, as described below. It is
additionally possible to use shims 3 which have a smaller width, in
combination with an adhesive or sealant to maintain shim 3 in
position. If, however, cut 2 is sufficiently small, it is possible
to eliminate the need for shim 3.
[0078] The material for shims 3 is preferably an olefin, polyester,
or other moldable and/or extrudable thermoplastic or thermosetting
material such as vinyl; solid or engineered wood or other
cellulosic material, or metal. It is additionally within the scope
of the invention to provide the material for shims 3 in a flowable
form, which sets, hardens or dries into a solid form. The material
may also be expandable, such as by foaming or by heating or
chemical reaction, such that after expansion, the material
substantially fills the respective cut 2. In preferred embodiments,
the material for shims 3 is substantially incompressible, once
set/hardened/dried.
[0079] In an alternate embodiment, the interlayer (as previously
described) is positioned in alignment with the cuts 2, such that
removal of the various sections is easily accomplished once the
covering 4A is cut, sliced, scored, etc. In one embodiment, the
interlayer allows for the sections to be peeled away. In another
embodiment, the interlayer is provided with a notch therein, to
facilitate easy separation from the remainder of the generic
element 5; however, it is considered within the scope of the
invention to provide an interlayer without any notch, which notch
can be formed during the slicing, cutting, scoring, etc. of the
covering 4A.
[0080] FIG. 4 shows structure 1 having a covering 4A thereon. In a
preferred embodiment, covering 4A is a laminate formed from a
thermosetting resin, having a decor sheet, optionally an overlay
layer (with or without loose cellulosic fibers atop or therein) or
sheet and hard particles in proximity thereto (e.g., in, on, above,
or below, with or without a separate structure therebetween) in
order to impart an abrasion resistance thereto, which is affixed to
structure 1 in a high-pressure laminate process step. Such laminate
may be affixed to structure 1 as described by U.S. Pat. No.
6,805,951, herein incorporated by reference in its entirety.
Covering 4A can also be other finishing materials such as
thermoplastic containing laminates, wood veneers, thermosetting
polymers, such as vinyl or polyesters, thermoplastic polymers such
as olefins, foils (such as thermosetting, thermoplastic, paper or
metal foils), impregnated with or without hard particles,
polyester, metals (such as sheets or single or strips), or
combinations thereof. For example, covering 4A can include multiple
elements, as described herein. It is additionally considered within
the scope of the invention to affix covering 4A during a direct
lamination step, as is known in the art.
[0081] Once covering 4A is applied, structure 1 can be shaped to
form the generic molding 5 as to be sold. As shown in FIG. 5,
generic molding 5 may have one more notches 5A disposed in under
face 1E. Such notches may additionally include elements or
structures as described by U.S. application Ser. No. 11/343,199,
herein incorporated by reference in its entirety. Such shaping may
be performed by manual or automated cutting, such as by severing,
broaching, machining, routing, sawing, chipping, planning, sanding,
or by any other method for removing material from the structure of
structure 1. Of course, the method used to shape structure 1 is
usually selected depending upon the material used for structure 1
and the desired shape for generic element 5. For example, if
structure 1 were extruded or molded, it is possible to form
structure 1 with the notches 5A therein, such that a separate
shaping step is not necessary.
[0082] Typically, generic element 5 can be manipulated by a further
shaping step to form more than one flooring molding. Thus, the
configuration of generic element 5 depends upon the desired
traditional flooring moldings potentially formed by manipulating
generic element 5. Accordingly, FIG. 5 shows a typical generic
element 5 in accordance with the invention.
[0083] As shown in FIG. 5, generic element 5 has a first removable
section 5C and a second removable section 5D connected to a central
section 5E at connections 5B. Connections 5B are typically ledges
or other elements, which hold removable sections 5C and 5D to
central section 5E. Although FIG. 5 shows connections 5B as being
merely extensions of the material of core 1A, it is additionally
within the scope of the invention to form connections 5B as
frangible joints, friction joints, tongue-and-groove joints,
compression joints, glue (or other adhesive), or any combination
thereof, in order to maintain such connections 5B made without any
physical connections because the cut goes all the way, relying, at
least in part, on covering 4A to maintain structural integrity. The
various separable sections of the invention are preferably
break-away sections, i.e., can be separated from other sections in
a single unitary piece by breaking a connection between the
break-away section and at least one other section. In contrast,
when a milled-away section is removed from another section, such
milling does not form a unitary piece, but rather smaller
particles, such as dust.
[0084] Due to the construction of generic element 5, including
covering 4A and connections 5B, various flooring profiles or
moldings can be formed. Removing removable sections 5C and 5D from
generic element 5 can produce a T-molding 6, while removing only
section 5C from generic element 5 can produce a carpet reducer 7,
and removal of only section 5D from generic element 5 can produce a
hard surface reducer 8. If core 1A is provided with a cut 2B in
upper surface 1B, it is further possible to divide T-molding 6 to
form two end moldings 10.
[0085] Similarly, a generic molding can be manufactured having only
two removable sections, such that in its original configuration,
the generic molding is a T-molding 400 (FIG. 24), and when
separated along breakaway 401, two end moldings 402 are produced
(FIG. 26). This T-molding 400 can be used in combination with a
reversible element 402 (FIG. 25) to form a HSR or CR (depending
upon the orientation of reversible element 402), as described by
U.S. application Ser. No. 11/066,099 and U.S. application Ser. No.
11/343,199, each of which is herein incorporated by reference in
its entirety. The T-molding 400 and reversible element 402 can be
used with a different track 404 to hold the resulting assembly in
place (FIGS. 27-32). When the end molding 402 is to be used with a
securing element, preferably an alternate track 405 is used (FIG.
31). The track 405 can be formed by cutting or breaking track 404
to match the latitudinal length of the end molding 402.
[0086] Another generic molding which can be used without
manipulation is T-molding 501 (FIG. 38). This T-molding 501 has a
number of removable sections 502, 503, and 504 (A and B), which can
produce different shapes. For example, removal of sections 503 and
504B can produce a CR 501A (FIG. 39). Removal of section 504B only
could produce a first modified T-molding 501B (FIG. 40), which can
be used for shallow tile, vinyl or low carpet (e.g., Berber).
Removal of sections 502, 503, 504A and 504B can produce a second
modified T-molding 501C (FIG. 41) for higher floorings, such as
tile and hardwoods and deeper carpets.
[0087] In other embodiments, it is possible to create other
flooring profiles or transitions from generic molding 5. For
example, removable section 5C or 5D can be shaped to form a
traditional quarter-round molding when removed from section 5E.
Additionally, generic element 5 may be shaped to form a traditional
stair nose molding when one or both of removable sections 5C and 5D
are separated. Thus, it is considered within the scope of the
invention to shape generic molding 5 such that when separated,
removable section 5C can be used as a quarter-round molding, while
the remaining structure, i.e., section 5D joined to section 5E, can
be used as a stair nose molding, as discussed below.
[0088] In one embodiment, covering 4A must be cut or severed in
order to separate the removable sections. Such a process typically
requires the use of a specialized tool, which divides covering 4A,
e.g., with a blade or other cutting tool, along the respective cut
2. Once covering 4A has been subdivided, it becomes possible to
separate any necessary removable sections. Typically, a great deal
of force is required to break connection 5B, such that if the
generic molding 5 were used with the removable section in place,
the generic molding 5 would maintain its structural integrity,
although in other embodiments, little or no force is required. The
cutting tool or a second tool can be used to provide that force,
for example, a standard flat-head screwdriver or other narrow width
tool can be inserted into cut 2, either through the slot in severed
covering 4A or from a longitudinal end of generic molding 5, and
the removable section pried from the remainder of generic molding
5. Thereafter, the remaining part of generic molding 5 can be
sanded to remove any burrs or other rough surfaces created during
the prying. In one embodiment, the cutting, prying and sanding can
all be performed by the same tool. Thus, it is possible to package
one generic molding 5 along with the three-function tool.
[0089] A cutting blade 1000 can also be used as part of a tool to
separate the elements of the generic molding 5, with different
embodiments shown in FIGS. 45A-E. In one embodiment, the cutting
blade is substantially circular, and can be made of any
conventional cutting material, e.g., ferrous or non-ferrous metals
(such as stainless-steel) or ceramics. While the blade 1000
typically has a thickness of between 0.2 mm and 0.3 mm, the
thickness of the blade 1000 should be selected depending upon the
desired thickness of the resulting cut 2. In a preferred
embodiment, the blade 1000 rotates, as it can be circular or
non-circular. Additionally, the blade 1000 can be stationary or
reciprocate as it cuts. For example, the blade 1000 can have a
substantially rounded shape (e.g., elliptical), such that as it
rotates, the cutting surface reciprocates against the surface to be
cut.
[0090] The cutting blade can have a smooth bevel FIG. 45A, where
one bevel from each side of the blade meets equidistant to the
center thickness of the blade, such that the two bevels are of
equal length. However, one bevel may be longer than the other. The
cutting blade may also have a single non-beveled cutting edge (FIG.
45B), where cutting edges are on each side, running from one side
through the entire thickness of the blade to the opposite side,
resembling a wedge shape around the perimeter of the circular
blade.
[0091] A non-beveled (e.g., square-edge) blade FIG. 45C can be
used, where the cutting edges are on each side of the perimeter of
the circular blade created by a vertical or near vertical or
perpendicular surface rather than the one edge created by a beveled
surface around a circular blade. An advantage of this "vertical
edge" blade, depending upon the material cut, is sanding of the cut
edge of the material may not be necessary, saving an additional
operation that maybe required when using a beveled edge blade.
[0092] In one embodiment a rounded edge blade FIG. 45D is used,
without any cutting edge. This type of blade presses through the
covering material into the void beneath the material creating,
depending upon the material, a rolled edge that in many cases will
not require sanding or smoothing. The perimeter of the blade
typically has a semicircular surface running smoothly from one side
of the blade side surface to its opposite side.
[0093] A reverse double or chevron-shaped blade (FIG. 45E) can also
be used. This blade has the advantage of cutting along both angled
surfaces simultaneously.
[0094] Such cutters or blades can be stationary or moveable, e.g.,
by reciprocating, but are preferably rotating and can be used to
cut surface materials that are placed over a shaped, extruded or
molded core material that is scored, has cuts or extruded or molded
grooves. Typically the core is made of wood based material, e.g.,
fiberboard, such as HDF, MDF, particle board or solid wood,
composites, plastics or metals that can be covered by a variety of
surface materials such as wood veneer, foils, laminate, paper,
metal, plastic, cork, leather, linoleum, vinyl, rubber, bamboo,
ceramic or glass tiles, textiles and the tool may be designed to
score the surface of hard materials such as ceramic, making it
possible to break the ceramic after the scoring. Although it is
preferred that breaking or separating connection 5B require the use
of a tool, it is within the scope of the invention to have a weaker
attachment. For example, connection 5B may be broken by human hand
and arm pressure alone, i.e., without the use of any type of
tool.
[0095] A specialized cutting tool 1100 is preferably used to cut
the structure 1 into the separate parts. The tool 1100 has a body
1101, defining a workspace 1102, into which the structure 1 is
passed. In a preferred embodiment, the tool 1100 has a length no
greater than the width of the structure 1, to allow for simple
packaging of a tool 1100 with a structure 1. The tool 1100
typically includes a horizontal cutter 1103 and a vertical cutter
1104, in which separate cutting blades 1000 are located.
Preferably, each of the cutting blades 1000 in the tool 1100 are of
the same structure, but it is within the scope of the invention to
have different blades 1000. Each of the blades 1000 are connected
to an axis 1107, which axis is mounted in a horizontal cutter
housing 1108 or a vertical cutter housing 1109, respectively. The
vertical cutter 1104 preferably penetrates the body 1101 through
vertical cutter aperture 1110.
[0096] During use of the tool 1100, the structure 1 is relatively
moveable through the workspace 1102 to come in contact with either
the horizontal cutter 1104 and/or vertical cutter 1104, depending
upon the desired shape of the structure 1 after cutting.
Specifically, the structure 1 can be moved with respect to the tool
1100, the tool 1100 may be moved with respect to the structure 1,
or both the 1100 and the structure may be moved with respect to
each other. For example, if the structure has an initial shape as
shown in FIG. 5, and only section 5D is desired to be removed, the
structure can be inserted into the workspace with cut 2C positioned
toward the horizontal cutter 1103. As the structure 1 passes the
blade 1100, the edge of the blade 1100 will penetrate sever the
covering 4A, thereby exposing the cut 2C. Depending upon the
particular configuration of the structure 1, section 5D can then be
removed by, for example, simply allowing it to fall away,
separating a glue, prying and/or snapping section 5D from the
remainder of the structure 1. Additionally, an additional tool,
such as the operative end of a flat-head screwdriver can be
inserted into the cut 2C and twisted to assist in the separation.
Finally, the structure 1, having been cut, can be sanded if needed
to remove any jagged or rough ends formed by the removal step. In a
preferred embodiment, once the covering is severed, the individual
pieces can be separated by hand and arm pressure alone or with the
use of a tool.
[0097] In order to prevent the vertical cutter 1104 from severing
cut 2B when such severing is not desired, the blade 1000 inside the
vertical cutter 1104 is typically moved away. This can be
accomplished by simply pulling up on the vertical cutter 1104 to
move the blade 1000 therein upwards to move the blade to an
inoperative, yet preferably retained in the tool 1100, position, or
the vertical cutter housing 1109 be physically disconnected from
the tool 1104, allowing removal of the blade 1000 therein,
depending upon the particular configuration of the tool 1100.
[0098] If, after section 5D is removed, the user wants to form a
T-molding by removing section 5C, the structure 1 can be relatively
moved through the workspace 1102 a second time, whereby the blade
1000 in the horizontal cutter 1103 severs the covering 4A over cut
2A. Thereafter, section 5C is removed.
[0099] Finally, if the user desires to form an end molding, e.g.,
as shown in FIG. 9, the structure 1 can be passed through the tool
1100, with the blade 1000 inside the vertical cutter 1104 in the
operative or engaged position. Accordingly, the vertical cutter
1104 will sever the covering over cut 2B. As the tool 1100 can be
operated with one or both of the vertical cutter 1104 and the
horizontal cutter 1103 in an operative position, it is possible to
use both cutters simultaneously or in any sequence to achieve the
desired configuration of the structure 1 (e.g., the cut 2B can be
formed before cut 2A or 2C). In a less preferred embodiment, the
tool 1100 is provided with a removable and/or detachable second
horizontal vertical cutter 1103' (not shown) positioned opposite
the first horizontal cutter 1103 to permit all three severing steps
to be performed at the same time or in any desired sequence without
having to install the cutters.
[0100] In a much preferred embodiment, when making the end moldings
using the vertical cut in the center leg, all three cuts are made
before any pieces are separated from the one piece structure. Thus,
the full structure is intact to help the tool 1000 to operate
correctly.
[0101] Once all three cuts are made the "T" can be separated in
half and then the HSR and CT parts can be separated from the "1/2
T" (End Molding Part) and/or the HSR and CT parts can be removed
along the horizontal cuts and then the "T-Molding can be divided in
half along the vertical cut into two end moldings. Ideally we can
break these parts off with hand pressure alone.
[0102] It is also within the scope of the invention to provide each
of the cutters 1103, 1104, 1103' with multiple blades 1000. For
example, the cutters can have 2, 3, 4, or 5 individual blades, each
of which can be of any of the shapes and types described herein.
One or more blades can independently rotate or be stationary,
and/or one or more blades may independently reciprocate. There may
also be a single blade 1000 which is interchangeable between the
different cutters. In a preferred embodiment, the vertical cutter
1104 and horizontal cutter 1103 are designed such that the entire
cutter can be removed from the horizontal position and placed in
the vertical position, or vice versa. In such an embodiment, only
one cutter need be provided to perform all of the cutting
functions.
[0103] A second cutting tool 1200 is schematically shown in FIG.
48, and operates in a substantially similar manner to the first
cutting tool 1100. The cutting tool 1200 includes a body 1201 and a
lower section 1202 defining a workspace 1203 therein, with the
blade(s) 1000 being mounted similarly to as described in connection
with the first cutting tool 1100. Typically, the lower section 1202
is fixedly joined to the body 1201, either by being integrally
formed with or affixed thereto by, e.g., screws, glue, or straps.
Again, in a preferred embodiment, the tool 1200 has a length no
greater than the width of the structure 1, to allow for simple
packaging of a tool 1200 with a structure 1. The tool 1200
typically includes a cutter 1204 which can be placed in its
horizontal position, or in the alternative, in its vertical
position. Depending upon the particular cutting of the structure 1
to be made, the cutter 1204 can be shifted from the first position
to the section position. This is typically accomplished by pulling
the cutter 1204 distally outward to disengage the blade 1000
disposed therein from its location where it can engage the
structure 1, and sliding the cutter 1204 along the body 1201 until
the cutter reaches the second operative position. Preferably, when
in the disengaged position, the blade 1000 is retained inside the
tool 1200. Thereafter, the cutter 1204 can be pushed to move the
blade 1000 such that it can engage the structure 1 in the second
operative position.
[0104] In another embodiment, the cutter 1200 is provided with a
second cutter 1204', such that a vertical cut and a horizontal cut
can be made simultaneously. Accordingly, in order to prevent
unwanted severing of the structure 1, either or both of the cutters
1204, 1204' can be removed entirely or simply disengaged from the
operative location.
[0105] Because shim 3 is inserted into cut 2, separation of a
removable section from generic molding 5 often will cause shim 3 to
fall out. However, instead of simply discarding shim 3 as trash,
shim 3 may be used as a shim to be utilized when installing any
resulting molding, above or below any means for attaching the
resulting molding, such as a track or clamp.
[0106] As covering 4A is preferably applied to core 1A in one
piece, as is described by U.S. Pat. Nos. 6,517,935 and 6,898,911
(each of which is herein incorporated by reference in its
entirety), covering 4A should not have any dividing lines or other
demarcations marring the decorative surface.
[0107] Often, covering 4A is provided with a patterned paper sheet
therein, wherein the pattern resembles a natural or synthetic
object, such as wood, ceramic, stone (including marble and
granite), or fantasy patterns (i.e., those not found in nature),
including a monochromatic or random field. The specific generic
molding 5 can be selected to enhance the appearance of the surfaces
which will be adjacent to the generic molding 5 (or parts thereof)
when installed. Such enhancement can be accomplished by matching
exactly the visual pattern of generic molding 5 to that of the
adjacent surface, or by contrasting the patterns, for example, such
that when installed, a visual pattern extends from a flooring
element onto and possible completely across the molding.
[0108] Moreover, it is possible to provide covering 4A with a
textured upper surface which enhances the pattern of the underlying
paper sheet. Such texturing can be created to be "in register"
with, offset from, or to contrast with the image of the paper
sheet. Such texturing may be created by physical pressing, e.g.,
embossing (as taught by U.S. application Ser. No. 10/440,317 (filed
May 19, 2003), U.S. Pat. No. 7,003,364, WO9731775 and WO9731776,
each of which is herein incorporated by reference in its entirety)
or chemically created (as taught by U.S. Pat. No. 6,991,830, herein
incorporated by reference in its entirety). The texture of the
covering 4A can be selected by the installer to enhance (e.g.,
match or contrast with) any texture of adjacent surfaces.
[0109] It is additionally possible to provide removable sections 5C
and 5D with opposite decorative surfaces (as disclosed by U.S.
application Ser. No. 10/748,852, Ser. No. 11/066,099, and Ser. No.
11/343,199, each of which is herein incorporated by reference in
its entirety), such that after being removed from generic molding
5, removable sections 5C and/or 5D can be re-attached in a reverse
configuration to section 5E by, for example, tongue-and-groove
joints, friction joints, or adhesive. By providing generic molding
5 with reversible structures, the number of functions of the single
product can be greatly increased.
[0110] FIG. 10 shows a different embodiment for a CR/HSR 100. When
installed as a carpet reducer ("CR"), the end of the carpet
adjacent CR/HSR 100 can be tucked or turn against a vertical face
119 of removable section 105. When used as a hard surface reducer
("HSR"), inclined surface 120 provides an angular surface that
graduates the height differences between two flooring surfaces. A
foot 109 is provided on CR/HSR 100 to allow for connection to track
110, as described below. Foot 109 is preferably formed from the
same material as the remainder of CSR/HSR 100, but alternatively,
may be formed from a different material through a different process
and thereafter, joined to the remainder of CR/HSR 100. Similarly,
foot 109 can be joined to the remainder of CR/HSR 100 by, for
example, an additional connection 5B, such that, if desired, foot
109 can be removed. As with generic element 5 (FIG. 5), removable
section 105 is preferably attached by a connection 5B, formed by
the creation of a cut 2 (with or without a shim 3 placed therein),
and can be removed from CR/HSR 100 to form a T-molding, such as
shown in FIGS. 6 and 11. In a preferred embodiment, removable
section 105 is provided with a tab 108 that can fit and rotate with
a corresponding groove 116 in a securing element (described
below).
[0111] In FIG. 11, removable section 105 has been removed to create
a T/End molding 104. T/End molding 104 can be connected to a
securing element 110, which securing element 110 is preferably not
affixed to a sub-floor. Securing element 110 is, however,
preferably affixed to one or both adjacent flooring elements 103A,
103B. This can be accomplished with a fresh adhesive, pre-glue,
magnetically, or by any conventional mechanical device, such as a
screw, nail, etc. Arms or extensions of T/End molding 104, as well
as T molding 6, can overlap finished flooring approximately
0.25''-0.75'' (approximately 6.5-20 mm), preferably approximately
0.5'' (13 mm).
[0112] An underlayment 102 can be placed between flooring elements
103 and subfloor 101. Underlayment 102 can be any conventionally
known underlayment, such as those used as moisture barriers and/or
sound/shock/electric charge dampening, and can be affixed to
flooring elements 103, or simply laid down before flooring elements
are installed. It is additionally considered within the scope of
the invention to utilize an underlayment which creates moisture
channels below flooring elements 103, such as PLATON STOP and/or
PLATON FLOOR, by Isola as of Norway, such as described by U.S.
patent application Ser. No. 11/522,535, herein incorporated by
reference in its entirety.
[0113] As shown, T/End molding 104 overlaps the flooring elements
103A, 103B. This allows the T/End molding 104 to function, with
sufficient space for expansion or contraction of flooring elements
103A and/or 103B without the need to anchor securing element 110 to
the subfloor. Additionally, if the flooring elements 103A, 103B are
not secured to the securing element 110, each of the flooring
elements 103A could move independently of each other. It is also
considered within the scope of the invention to affix securing
element 110 to one of the flooring elements 103A, which would cause
T/End molding 104 to move with flooring element 103A, while the
other flooring element 103B would not be so constrained.
[0114] A preferred securing element, or track 110 to be used with
the moldings of the invention is shown in FIG. 12. Track 110 is
preferably made of a plastic, metal or composite material, and can
be used to secure any of the parts described herein to flooring
elements 103A, 103B and/or a subfloor. Vertical portions 112 are
shown as upstanding from base 111. Although shown as being
perpendicular to base 111, vertical portions 112 can be at any
angle therefrom. For example, while a first vertical portion 112A
can be perpendicular to base 111, a second vertical portion can be
disposed at any angle. In one preferred embodiment, vertical
portions 112 are upstanding from base 111, but angle towards each
other. As a result, vertical portions 112 are biased inwards, and
the biasing assists in holding the molding in place.
[0115] First wing 113 is a portion of base 111 which is designed to
be placed below a flooring element 103 (as shown in FIG. 11). A
distal portion 113A of wing 113 can be folded back 1800 to form a
shim, in order to raise track 110 or other parts to accommodate
thicker flooring elements 103.
[0116] Disposed adjacent to, but preferably not in contact with, a
vertical portion 112 is a second vertical portion 114. This second
vertical portion helps to support, for example, removable section
105, by preventing back and forth movement. When removable section
105 is stepped on, rolled over, or otherwise subjected to forces
tending to push it inwards, second vertical portion 114 acts to
maintain removable section 105 in the correct location.
[0117] Track 110 can also have a second wing 115, which second wing
115 can include a pre-applied adhesive (e.g., an encapsulated glue
as described by U.S. Pat. No. 7,029,741 and application Ser. No.
10/270,163, each of which is herein incorporated by reference in
its entirety), adhesive tape, fresh adhesive or can have a
mechanical or magnetic attachment (as described by U.S. application
Ser. No. 10/747,261, herein incorporated by reference in its
entirety) to affix track 110 to the underside of flooring elements
103 and/or the subfloor. Second wing 115 may also be provided with
a groove 116, sized and shaped to receive tab 108, which helps to
hold removable section 105 in place and, simultaneously, allows
removable section 105 to rotate in adjustment as the height of
flooring elements 103 increases. It is considered within the scope
of the invention to swap the relative locations of the tab 108 and
grove 116.
[0118] It is additionally possible to utilize a track having a
single upstanding section, positioned between lower lateral ends
(such as shown in FIG. 1A of both U.S. Published Patent Appl. No.
2003/0084634 and No. 2003/0154678--each of which is herein
incorporated by reference in its entirety). Such a track can be
inserted into a groove positioned in an underside of generic
structure 5. In one embodiment, the foot, or middle lower depending
portion of generic structure 5 can be reduced in size or
eliminated, as the interaction between this track and groove can be
sufficient to hold the structure in its installed condition.
Additionally, an uppermost end of the track can be provided with
barbs, spikes, projections, joint elements (such as tongue/groove)
or other elements which can enable the track to lock or more
securely hold the structure in its installed condition.
[0119] In FIGS. 13 and 14, T/End molding 104 is shown, in an
installed condition, as a carpet/hard surface reducer (with
removable section 105) and an end molding (without removable
section 105), respectively. As can be seen, foot 109 of T/End
molding 104 is secured in track 110 by vertical sections 112. Track
110 is secured to a subfloor 101 with an adhesive, magnetic forces
or mechanical attachments. In FIG. 14, T/End molding 104 is
installed adjacent a wall 118. A sealant or adhesive 117 may be
placed in any gaps between T/End molding 104 and another structure,
such as a wall 118. As shown in FIG. 14, T/End molding 104 can be
used without any securing element, as the presence of adhesive 117,
may be sufficient to maintain T/End molding 104 in place. Such
sealant or adhesive can be a fresh glue or a pre-applied glue
(e.g., a "preglue" applied at the factory). In a preferred
embodiment, adhesive 117 is a foaming adhesive, e.g., a silicone
sealant or alternate foaming adhesive, such that after adhesive 117
and T/End molding 104 are installed, adhesive 117 foams or expands
to fills voids between wall 118 and T/End molding 104.
[0120] FIGS. 15-22 depict an additional molding assembly of the
invention. This extrudable assembly 202 is preferably formed from
an extrudable polymeric, composite or metal material, but may also
include or be substituted by milled composite materials, wood,
fiberboard, or any other material discussed herein suitable for
core 1A.
[0121] Typically, assembly has a decorative outer surface 201,
which surface 201 is preferably selected from the same materials
for the outer faces of structure 1.
[0122] As shown, assembly 200 can be constructed with a combination
HSR/CR 202 and a T-molding 204 (which need not be of the same
material), joined at breakaways 204. Breakaways 204 can be narrowed
or scored or other sections of assembly 202, allowing for
separation of the parts of assembly 200. Breakaways 204 can also be
joints between two separate elements, formed by, for example,
friction joints, tongue-and-groove joints, compression joints,
glue, or any combination thereof.
[0123] Assembly 200 can be fixed to a subfloor using any material
described herein, such as adhesive (e.g., pre-applied or fresh
glue), tape or magnetic strip (optionally with tape or adhesive).
Installing assembly 200 in a first configuration produces a HSR,
while inverting assembly 200 produces a CR (FIG. 18).
[0124] By providing one set of legs 208 on assembly 200, assembly
200 can be used in a variety of configurations. As can be seen in
FIG. 15, applying force to push or pull the sections of assembly
200, different shapes, to accommodate different flooring heights.
Desired positions for legs 208 can be selected and locked in place
by utilizing a glue, sealant, epoxy, or other chemical element, or
in the alternative (or in combination with), barbs or teeth
212.
[0125] By splitting or breaking assembly 200 at breakaways 206,
different moldings can be realized. Another T-molding 220 is
created by separating assembly 200 at each of breakaways 206B and
206C. This T-molding 220 is preferably joined to one flooring
element with an adhesive 222, which can take the form of any glue
or adhesive described herein, but preferably is a peel-and-stick
adhesive, and is positioned to join to both an upper surface and a
lower surface of the flooring element. Such a construction, similar
to other embodiments, allows T-molding 220 to "float" with the
joined flooring element, independent of other flooring elements. In
another embodiment, T-molding 220 can be affixed to the subfloor
with any glue, adhesive or magnetic means (discussed herein), alone
or in combination with affixing to the flooring element.
[0126] If assembly 200 is split or separated at breakaways 206A and
206C, an end molding 230 can be produced (FIG. 17). The end molding
230 can be affixed to the upper surface of an adjacent flooring
element, or if used in combination with a track 232, both the track
232 can be joined to either the subfloor or the underside of the
adjacent flooring element, alone, or in combination with the end
molding 230 being affixed to the flooring element. If the end
molding 230 is used without the track 232, a lower end of end
molding 230 can also be affixed to the subfloor.
[0127] An alternate embodiment of the assembly 200 shown in FIG. 15
is an additional assembly 250 (FIGS. 19 and 20), which can also
function as a HSR or CR, depending upon its installed orientation.
This assembly 250 has a supporting strut 252 that is adjustable and
can move when adjustable legs 253 are raised/lowered for different
finished flooring thicknesses. The adjustable strut 252 provides
additional strength to the structure of the assembly 250. In order
to prevent strut from moving once installed, it is considered
within the scope of the invention to provide a locking mechanism,
such as barbs, glues/adhesives, or other means for maintaining the
strut 252 in its desired configuration. Just as the assembly 200
can be separated at various breakaways, the assembly 250 can be
broken at breakaways 254A-C for form various products. A T-molding
256, and its optional associated track 256 (FIG. 21), can be formed
by separating assembly 250 at breakaways 254B and C. Two end
moldings 257 (FIG. 22) can be produced by separating assembly 250
at breakaways 254A, B and C.
[0128] Another embodiment of the generic molding of the invention
is shown as generic molding 300 (FIG. 23). The generic molding 300
is a breakaway version with multiple horizontal sections for
forming a versatile molding capable of being used for a large range
of finished flooring thicknesses. This version can be an extrusion
or other milled or shaped material such as HDF, MDF, composites,
metal, wood or plastic. A core 301 of the generic molding 300 can
also be manufactured from any structural material discussed herein
in connection with other embodiments of the invention. Similarly, a
finished surface material 302 covers at least a portion of the core
301 and preferably provides the generic molding 300 with a
decorative outer surface, and may be any type of decorative surface
discussed elsewhere herein. When in a desired configuration, the
generic molding 300 is preferably installed with a track 303, which
track can include one or more gripping flanges 303A which can
interact with one or more gripping grooves 303B (not shown) to help
to maintain the generic molding in place. In a preferred
embodiment, the generic molding 300 is provided with rounded
shoulders 304, formed as part of the core 301 or as an additional
structure, which bears against legs of the track 303 to add support
to each of the sections holding the generic molding 300 in
place.
[0129] In order to use the generic molding 300 in various
configurations, the generic molding 300 is typically provided with
breakaways 305A-D, to independently reduce the height of the core
301 of the generic molding 300 to form a T molding, end molding, CR
or HSR as discussed herein, for a number of heights. Although shown
with a particular number of removable sections on each side of the
generic molding 300, it is considered within the scope of the
invention to increase or decrease the number, size and shape of the
sections, such that, for example, the number of sections on one
side is unequal to the number of sections on the other side.
[0130] The invention additionally includes a stair nose assembly
600 (FIGS. 33A and 34). In a first embodiment, the stair nose
assembly 600 can be formed by joining a T molding (such as
T-molding 6, 220, 255, 400, or T/End molding 104) with a structure
(such as end moldings 10 and 230). The joint formed at the junction
between the T-molding and the additional structure can be
maintained by any means discussed herein, such as adhesive/glue or
other chemical or mechanical element. By forming the elements of
stair nose assembly 600 with matching decor, a uniform appearance
can be achieved.
[0131] Preferably, however, stair nose assembly 600 is a unitary
structure, sold as a single unit, consisting of a first section
601, and a second section 602, manufactured as a single structure.
Typically, the stair nose assembly 600 includes a core 603 and a
covering 604, which are selected from the cores and covering
materials discussed elsewhere herein. In one embodiment, the stair
nose assembly 600 is provided with cuts 605A-C which permit the
stair nose assembly 600 to be used for other purposes after being
separated at cuts 605A-C. For example, dividing at cut 605A
produces an end molding 10, while dividing at cut 605B produces
both an end molding 10 and a T-molding 6. Dividing at cut 605A and
605C can produce an element which can be used as a quarter round or
shoe molding 606 (FIG. 33B).
[0132] An alternate stair nose assembly 610 can be formed by
forming a carpet reducer 611, substantially similar to the carpet
reducer 7, having a groove 612 in a lower surface thereof. By
joining a stair nose attachment 613, by inserting a tongue 614
thereof into the groove 612, the stair nose assembly 610 can be
formed. Similarly, stair nose assembly can be manufactured as a
single piece by joining the carpet reducer 611 to stair nose
attachment prior to adding the decorative surface thereof, or by
forming the stair nose assembly 610 as a unitary structure,
allowing for removal of stair nose attachment 613 at installation,
at, for example, cut 615. When removed, stair nose attachment 613
can be used as a shoe molding or quarter round molding.
[0133] Each of the stair nose assemblies 600 and 610 can be affixed
directly to the subfloor with a mechanical, chemical or other
attachment means as discussed herein. Alternatively, a track may be
used to secure the stair nose assemblies 600 and 610.
[0134] One preferred method for forming a generic molding element
650 is shown in FIGS. 35-37. By this method, individual pieces are
separately manufactured and held together in place by the covering
material. In a first step, two end moldings 650A and 650B, a carpet
reducer part 605C and a hard surface reducer part 605D are milled
or otherwise shaped from a core material (as disclosed herein) and
held together (FIG. 36). This can be accomplished by, for example,
using a clamp, other mechanical elements or a glue (sufficient to
hold the pieces together until the covering is applied). Once the
pieces are held together cuts 611-613 can be made, and thereafter,
a covering 654 (as discussed herein) is applied. Through this
method, the covering 654 (and optionally the glue) holds the
generic molding element 650 together.
[0135] The molding of the invention can be produced by forming the
generic structure, and providing cuts therein, before affixing the
covering thereto. In one embodiment, the separable parts are
completely removed from each other and can be held in place by a
clamp or a mold, until the covering is affixed thereto.
[0136] In another embodiment, the covering can be affixed to the
generic structure prior to the separable elements being formed.
Typically, the cuts are formed in the underside of the structure,
as the upper surface of the generic structure has the covering
thereon.
[0137] In one embodiment, the invention uses a paper (with or
without hard particles--e.g., having a Moh's hardness of at least
about 4 or 6, preferably at least about 7, therein, which can be
alpha-aluminum (alumina), silicon carbide, diamond, cerium oxide,
zirconium oxide, and/or glass beads), and once printed, is
impregnated with a thermosetting resin. The impregnated paper is
then further combined with other layers and elements to form a
laminate which can be bonded to a core material.
[0138] Suitable core materials include one or more of wood,
fiberboard, such as high density fiberboard (HDF) or medium density
fiberboard (MDF), polymer (thermosetting and thermoplastic),
flaxboard, stone (e.g., ceramic, marble, slate), cardboard,
concrete, gypsum, high density fiber reinforced plaster, veneers
such as plywood, oriented strand board, cores made from particles
(including discrete pieces of polymer or wood, which can be in the
form of chips, curls, flakes, sawdust, shavings, slivers, stands,
wavers, wood flour, wood wool and/or fibers), and other structural
materials, such as metals (e.g., brass, aluminum, steel, copper,
composites, composites or alloys). In some embodiments, the core
material can be foamed (either open cell or closed cell), such as
polyurethane. In still further embodiments, the core is made as a
composite from multiple materials (such as those listed above),
either as a heterogeneous mass, multiple layers or defined
sections, e.g., upper and lower veneers covering a core of
particles. Any of the above materials may also be provided with
antistatic or antibacterial properties, e.g., by the inclusion of
silver flakes, powders or particles, carbon black, ceramics, or
other metals or alloys. Preferred plastics include extrudable
and/or moldable thermosetting and thermoplastic resins, the latter
including high density olefins and polyvinylchloride.
[0139] This laminate may also be covered with other types of
coverings, such as foils (such as metal, paper or thermoplastic
foils), paints or a variety of other decorative elements,
including, but not limited to wood veneer, ceramic, metal, vinyl or
other decorative materials.
[0140] In anther embodiment, the decor is provided on the core
material itself, i.e., without the paper layer, e.g., as described
by, e.g., U.S. Pat. No. 6,465,046 (herein incorporated by reference
in its entirety). In one embodiment, the core is optionally
provided with a primer and/or a base color, on which the decorative
pattern or display is printed or otherwise generated. While the
term "pattern" is used herein, it is to be understood that
"pattern" need not be or include any repeating units, thus
"pattern" is simply a visual and/or textual display. Once the decor
is complete, the printed decor can be covered with a wear layer,
thereby giving the decor abrasion and/or scratch resistance. The
wear layer can be provided in the form of a sheet of
alpha-cellulose which is bonded to the core, or it can be applied
in a liquid form, and is typically provided with hard particles as
described herein. The wear layer can include melamine-formaldehyde,
urea-formaldehyde, maleamid, lacquers, acrylic resins, and/or
urethanes.
[0141] Often, the result of the printing process of the invention
resembles a natural or synthetic object, such as wood or wood tiles
or boards, ceramic (e.g., tiles), stone (including marble and
granite, such as tiles), or fantasy patterns (i.e., those not found
in nature), including a monochromatic or random field.
[0142] Moreover, the invention can have a texture which enhances
the pattern of an underlying printed image. Such texturing can be
created to be "in register" with, offset from, or to contrast with
the image of the paper sheet. Such texturing may be created by
physical pressing, e.g., embossing (as taught by U.S. application
Ser. No. 10/440,317 (filed May 19, 2003), U.S. Pat. No. 7,003,364,
and WO9731775 and WO9731776) or chemically created (as taught by
U.S. Pat. No. 6,991,830). The texture can be selected by the
installer to enhance (e.g., match or contrast with) any texture of
adjacent or included surfaces. The texture may also be provided on
the decor such that features of the texture extend from a flooring
element onto and possible completely across the adjacent flooring
elements, which texture may, or may not coincide with the
underlying decor. Each of the documents discussed in this paragraph
are incorporated herein in its entirety.
[0143] The invention is typically used in the construction of a
surface, such as a top for a counter or table, floor, ceiling, or
wall. Such surfaces are often found in residential structures
(e.g., single and multi-family houses, condominiums, townhomes,
co-operatives, apartments, and lobbies of such buildings),
commercial structures (e.g., retail stores, strip malls, shopping
malls, office buildings, hotels, restaurants, supermarkets, banks,
churches, airports and other transit stations), public structures
(e.g., stadiums and arenas, schools, museums, theaters, post
offices, hospitals, courthouses and other government buildings), as
well as industrial structures (e.g., manufacturing plants, mills,
and warehouses) and surfaces of vehicles (e.g., ships. trains,
aircraft, public and private busses, cars and other motor
vehicles).
[0144] It should be apparent that embodiments other than those
specifically described above may come within the spirit and scope
of the present invention. Hence, the present invention is not
limited by the above description.
* * * * *