U.S. patent application number 11/997101 was filed with the patent office on 2008-09-11 for interlocking member.
This patent application is currently assigned to Granbay Holdings Pty Ltd.. Invention is credited to Shaun Nolan.
Application Number | 20080216435 11/997101 |
Document ID | / |
Family ID | 37682928 |
Filed Date | 2008-09-11 |
United States Patent
Application |
20080216435 |
Kind Code |
A1 |
Nolan; Shaun |
September 11, 2008 |
Interlocking Member
Abstract
A member such as a board (10) configured to interlock with
similar such boards, typically for use as flooring. The board (10)
comprises an elongate body (11) having first and second opposed
faces (13, 15) and two longitudinal sides (17, 19). A first locking
portion (12) is provided at one longitudinal side (17) and a second
locking portion (22) is provided at the other longitudinal side
(19). The first locking portion (21) comprises a tongue (23)
presenting a convex face (33), and the second locking portion (22)
comprises a groove (41) for receiving the tongue (23) of a similar
board disposed adjacent thereto. The groove (41) has a face
incorporating a concave portion (49) for receiving the convex face
(33) of the tongue (23), whereby interaction between the convex and
concave portions (33, 49) serves to draw the tongue (23) of one
board into the groove (41) of another board upon relative angular
movement between the two boards towards a position whereby they are
in side-by-side relation. The first locking portion (21) further
comprises a first interlocking element configured as a further
groove (38) disposed between the tongue (23) and the second face
(15) of the body (11). Additionally, the second locking portion
(22) further comprises a second interlocking element configured as
a rib (61) disposed between the groove (41) and the second face
(15) of the body (11). The rib (61) and groove (38) of adjacent
boards are adapted to interlock when the two boards are in
side-by-side relation.
Inventors: |
Nolan; Shaun; (Scarborough,
AU) |
Correspondence
Address: |
MERCHANT & GOULD PC
P.O. BOX 2903
MINNEAPOLIS
MN
55402-0903
US
|
Assignee: |
Granbay Holdings Pty Ltd.
Scarborough
AU
|
Family ID: |
37682928 |
Appl. No.: |
11/997101 |
Filed: |
July 28, 2006 |
PCT Filed: |
July 28, 2006 |
PCT NO: |
PCT/AU2006/001063 |
371 Date: |
January 28, 2008 |
Current U.S.
Class: |
52/588.1 |
Current CPC
Class: |
E04F 2201/0153 20130101;
E04F 13/08 20130101; E04F 2201/07 20130101; E04F 15/02
20130101 |
Class at
Publication: |
52/588.1 |
International
Class: |
E04F 15/14 20060101
E04F015/14 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 28, 2005 |
AU |
2005904035 |
Jan 30, 2006 |
AU |
2006900424 |
Feb 15, 2006 |
AU |
2006100114 |
Claims
1. A coupling for interlocking two members each having first and
second opposed faces, the coupling comprising a first locking
portion provided on one member and a second locking portion
provided on the other member, wherein the first locking portion
comprises a male portion configured as a tongue, the male portion
having a section presenting a convex face, and the second locking
portion comprises a female portion configured as a groove for
receiving the male portion, the female portion having a face
incorporating a concave section for receiving the convex face of
the male portion, whereby interaction between the convex face and
concave section serves to draw the male portion into the female
portion upon relative angular movement between the two members
towards an interlocked position, and wherein the first locking
portion further comprises a first interlocking element disposed
between the male portion and the second face of the first member,
and the second locking portion further comprises a second
interlocking element disposed between the female portion and the
second face of the second member, the first and second interlocking
elements being adapted to interlock when the two members are in the
interlocked condition.
2. A coupling according to claim 1 wherein the convex face is
asymmetrical to thereby define a cam surface.
3. A coupling according to claim 2 wherein the convex face
comprises a plurality of segments disposed angularly one with
respect to another.
4. A coupling according to claim 1, 2 or 3 wherein the section of
the male portion presenting the convex face comprises a lobe.
5. A member comprising an elongate body having first and second
opposed faces and two longitudinal sides, a first locking portion
provided at one longitudinal side and second locking portion
provided at the other longitudinal side, wherein the first locking
portion comprises a male portion configured as a tongue, the male
portion having a section presenting a convex face, and the second
locking portion comprises a female portion configured as a groove
for receiving the male portion of a similar member disposed
adjacent thereto, the female portion having a face incorporating a
concave section for receiving the convex face of the male portion,
whereby interaction between the convex face and concave section
serves to draw the male portion of one member into the female
portion of another member upon relative angular movement between
the two members towards a position whereby they are in side-by-side
relation and wherein the first locking portion further comprises a
first interlocking element disposed between the male portion and
the second face of the body, and the second locking portion further
comprises a second interlocking element disposed between the female
portion and the second face of the body, the first and second
interlocking elements of adjacent members being adapted to
interlock when the two boards are in side-by-side relation.
6. A member according to claim 5 wherein the first face has two
opposed edges from which the longitudinal sides extend at
respective junctions therebetween.
7. A member according to claim 5 wherein said relative angular
movement between the boards is about a fulcrum defined by
engagement between one junction of one member and the adjacent
junction of the other member.
8. A member according to claim 5, wherein the section presenting
the convex face extends towards the first face.
9. A member according to claim 8 wherein the section presenting the
convex face is provided on the side of the male portion closer to
the first face of the board, and the concave section is provided in
the side of the female portion closer to the first face.
10. A member according to claim 5 wherein the section presenting
the convex face comprises a plurality of segments disposed one
adjacent another.
11. A member according to claim 10 wherein the segments are
disposed angularly to define facets and edges between adjacent
facets
12. A member according to claim 5 wherein the first and second
interlocking elements define two interlocking surfaces adapted to
co-operate for frictional engagement therebetween to provide an
interlocking action.
13. A member according to claim 12 wherein the first and second
interlocking elements preferably comprise a further groove defining
one of the interlocking surfaces and a matching rib defining the
other of the interlocking surfaces, the rib being adapted to be
snugly received in the further groove with the two interlocking
surfaces in frictional engagement.
14. A member according to claim 5 wherein the first locking portion
further comprises a first abutment face extending from the first
face and a second abutment face extending from the second face, the
second abutment face being offset inwardly with respect to the
first abutment face, the male portion extending outwardly from the
two abutment faces.
15. A member according to claim 14 wherein the second abutment face
is raked inwardly.
16. A member according to claim 5 wherein the second locking
portion further comprises a third abutment face extending from the
first face and a fourth abutment face extending from the second
face, the fourth abutment face being offset with respect to the
third abutment face in the outward direction, the female portion
extending inwardly from the two abutment faces.
17. A member according to claim 16 wherein the third abutment face
is raked inwardly.
18. A member according to claim 5 wherein the groove has a wall on
the opposed side thereof to said concave section, said wall having
at least a section thereof adjacent the outer end of the groove
raked away from said concave section.
19. A member according to claim 1 wherein at least one void is
defined between the tongue and the groove of two interconnected
boards.
20. A board comprising an elongate body having first and second
opposed faces and two longitudinal sides, a first locking portion
provided at one longitudinal side and second locking portion
provided at the other longitudinal side, wherein the first locking
portion comprises a male portion configured as a tongue, the male
portion having a section presenting a convex face, and the second
locking portion comprises a female portion configured as a groove
for receiving the male portion of a similar board disposed adjacent
thereto, the female portion having a face incorporating a concave
section for receiving the convex face of the male portion, whereby
interaction between the convex face and concave section serves to
draw the male portion of one board into the female portion of
another board upon relative angular movement between the two boards
towards a position whereby they are in side-by-side relation and
wherein the first locking portion further comprises a first
interlocking element disposed between the male portion and the
second face of the body, and the second locking portion further
comprises a second interlocking element disposed between the female
portion and the second face of the body, the first and second
interlocking elements of adjacent boards being adapted to interlock
when the two boards are in side-by-side relation.
21. A board comprising an elongate body having first and second
opposed faces and two longitudinal sides, the first face having two
opposed edges from which the longitudinal sides extend at
respective junctions therebetween, a first locking portion provided
at one longitudinal side and second locking portion provided at the
other longitudinal side, wherein the first locking portion
comprises a male portion configured as a tongue, the male portion
presenting a convex face extending towards the first face and the
second locking portion comprises a female portion configured as a
groove for receiving the male portion of a similar board disposed
adjacent thereto, the female portion having a face incorporating a
concave portion for receiving the convex face of the male portion,
whereby interaction between the convex face and concave portion
serves to draw the male portion of one board into the female
portion of another board upon relative angular movement between the
two boards towards a position whereby they are in side-by-side
relation, said relative angular movement being about a fulcrum
defined by engagement between one junction of one board and the
adjacent junction of the other board, and wherein the first locking
portion further comprises a first interlocking element disposed
between the male portion and the second face of the body, and the
second locking portion further comprises a second interlocking
element disposed between the female portion and the second face of
the body, the first and second interlocking elements of adjacent
boards being adapted to interlock when the two boards are in
side-by-side relation
22. A board comprising an elongate body having first and second
opposed faces and two longitudinal sides, a first locking portion
provided at one longitudinal side and second locking portion
provided at the other longitudinal side, wherein the first locking
portion comprises a male portion configured as a tongue, the male
portion having a section presenting a convex face, and the second
locking portion comprises a female portion configured as a groove
for receiving the male portion of a similar board disposed adjacent
thereto, the female portion having a face incorporating a concave
section for receiving the convex face of the male portion, whereby
interaction between the convex face and concave section serves to
draw the male portion of one board into the female portion of
another board upon relative angular movement between the two boards
towards a position whereby they are in side-by-side relation and
wherein the first locking portion further comprises a first
interlocking element disposed between the male portion and the
second face of the body, wherein the section presenting the convex
face comprises a plurality of segments disposed one adjacent
another.
23. A board according to claim 22 wherein the segments are disposed
angularly to define facets and edges between adjacent facets.
24. A member comprising an elongate body having first and second
opposed faces and two longitudinal sides, the first face having two
opposed edges from which the longitudinal sides extend at
respective junctions therebetween, a first locking portion provided
at one longitudinal side and second locking portion provided at the
other longitudinal side, wherein the first locking portion
comprises a male portion configured as a tongue, the male portion
comprising a lobe section presenting a cam face extending towards
the first face and the second locking portion comprises a female
portion configured as a groove for receiving the male portion of a
similar member disposed adjacent thereto, the female portion having
a face incorporating a receiving portion for receiving the lobe
section of the male portion, whereby interaction between the cam
face and the receiving portion serves to draw the male portion of
one member into the female portion of another member upon relative
angular movement between the two members towards a position whereby
they are in side-by-side relation, said relative angular movement
being about a fulcrum defined by engagement between one junction of
one member and the adjacent junction of the other member, and
wherein the first locking portion further comprises a first
interlocking element disposed between the male portion and the
second face of the body, and the second locking portion further
comprises a second interlocking element disposed between the female
portion and the second face of the body, the first and second
interlocking elements of adjacent boards being adapted to interlock
when the two members are in side-by-side relation.
25. A member comprising an elongate body having first and second
opposed faces and two longitudinal sides, a first locking portion
provided at one longitudinal side and second locking portion
provided at the other longitudinal side, wherein the first locking
portion comprises a male portion configured as a tongue, the male
portion having a lobe section presenting a cam face, and the second
locking portion comprises a female portion configured as a groove
for receiving the male portion of a similar member disposed
adjacent thereto, the female portion having a face incorporating a
receiving section for receiving the cam face of the male portion,
whereby interaction between the cam face and receiving section
serves to draw the male portion of one member into the female
portion of another member upon relative angular movement between
the two members towards a position whereby they are in side-by-side
relation, and wherein the cam face comprises a plurality of
segments disposed one adjacent another.
26. A coupling for interlocking two members each having first and
second opposed faces, the coupling comprising a first locking
portion provided on one member and a second locking portion
provided on the other member, wherein the first locking portion
comprises a male portion configured as a tongue, the male portion
having a lobe section presenting a cam face, and the second locking
portion comprises a female portion configured as a groove for
receiving the male portion, the female portion having a face
incorporating a receiving section for receiving the cam face of the
male portion, whereby interaction between the cam face and
receiving section serves to draw the male portion into the female
portion upon relative angular movement between the two members
towards an interlocked position, and wherein the cam face comprises
a plurality of segments disposed angularly one adjacent
another.
27.-29. (canceled)
Description
FIELD OF THE INVENTION
[0001] This invention relates to coupling for interlocking two
members and also to members incorporating such couplings. The
invention is concerned particularly, although not solely, with a
coupling for interlocking boards, as well as with a board
configured to interlock with another similar such board.
[0002] The invention has been devised particularly, although again
not necessarily solely, as a board for flooring, and also as a
board for cladding for walls (both interior and exterior walls) and
ceilings as well as partitioning.
BACKGROUND ART
[0003] Floor boards of the tongue-and-groove type are well known.
Such boards are assembled to provide strip flooring by fitting
boards together, involving installing one board in position and
then sliding a neighbouring board laterally into position so that
the tongue of one board engages in the groove of the other board.
The boards can be fixed in position in any suitable way, typically
by nailing and/or gluing.
[0004] Tongue-and-groove flooring is advantageous in that the
connection between neighbouring floor boards accommodates relative
movement arising through expansion and shrinkage of the boards. A
further advantage of tongue-and-groove flooring is that the floor
boards can be made from any appropriate timber, including hardwoods
and soft woods. This allows the floor boards to be of solid
(one-piece) construction, configured as planks of timber.
[0005] There is, however, a deficiency with tongue-and-groove
flooring in that shrinkage of the floor boards can result in
unsightly gaps between the boards. Further, the boards can warp,
providing a "cupping" effect which again can be unsightly.
[0006] In recent times, there has been a trend towards flooring
systems involving panels that can be interlocked. The panels may be
fixed in portion in any suitable way, typically by nailing, gluing
and/or floating between. Typically, such panels are of composite
construction, comprising a core and a laminate applied to the core
to provide a robust yet decorative floor surface. Typically, the
core is made of a relatively soft material such as MDF, HDF or the
like. The panels are adapted to interlock, with each panel being
provided with an interlocking male portion configured as a tongue
and a matching interlocking female portion configured as a groove.
The arrangement is such that the panels can be interlocked one to
another with a snap action to resist lateral separation between the
panels (which could otherwise lead to unsightly gaps). Such panels
do, however, rely upon the relative softness of the core material
in which the female portion is formed, to yield to allow entry of
the respective male portion for locking engagement therewith. For
this reason, the panels need to be of the composite construction
incorporating the soft core, and cannot be of solid (one-piece)
timber.
[0007] It would be advantageous for there to be a board which can
interlock with a corresponding board without the boards necessarily
having to be of composite construction incorporating softer core
material.
DISCLOSURE OF THE INVENTION
[0008] According to a first aspect of the invention there is
provided a coupling for interlocking two members each having first
and second opposed faces, the coupling comprising a first locking
portion provided on one member and a second locking portion
provided on the other member, wherein the first locking portion
comprises a male portion configured as a tongue, the male portion
having a section presenting a convex face, and the second locking
portion comprises a female portion configured as a groove for
receiving the male portion, the female portion having a face
incorporating a concave section for receiving the convex face of
the male portion, whereby interaction between the convex face and
concave section serves to draw the male portion into the female
portion upon relative angular movement between the two members
towards an interlocked position, and wherein the first locking
portion further comprises a first interlocking element disposed
between the male portion and the second face of the first member,
and the second locking portion further comprises a second
interlocking element disposed between the female portion and the
second face of the second member, the first and second interlocking
elements being adapted to interlock when the two members are in the
interlocked condition.
[0009] Preferably, the convex face is asymmetrical to thereby
define a cam surface. The convex face may comprise a plurality of
segments disposed angularly one with respect to another. The
section of the male portion presenting the convex face may comprise
a lobe.
[0010] According to a second aspect of the invention there is
provided a member comprising an elongate body having first and
second opposed faces and two longitudinal sides, a first locking
portion provided at one longitudinal side and second locking
portion provided at the other longitudinal side, wherein the first
locking portion comprises a male portion configured as a tongue,
the male portion having a section presenting a convex face, and the
second locking portion comprises a female portion configured as a
groove for receiving the male portion of a similar member disposed
adjacent thereto, the female portion having a face incorporating a
concave section for receiving the convex face of the male portion,
whereby interaction between the convex face and concave section
serves to draw the male portion of one member into the female
portion of another member upon relative angular movement between
the two members towards a position whereby they are in side-by-side
relation and wherein the first locking portion further comprises a
first interlocking element disposed between the male portion and
the second face of the body, and the second locking portion further
comprises a second interlocking element disposed between the female
portion and the second face of the body, the first and second
interlocking elements of adjacent members being adapted to
interlock when the two boards are in side-by-side relation.
[0011] According to a third aspect of the invention there is
provided a board comprising an elongate body having first and
second opposed faces and two longitudinal sides, a first locking
portion provided at one longitudinal side and second locking
portion provided at the other longitudinal side, wherein the first
locking portion comprises a male portion configured as a tongue,
the male portion having a section presenting a convex face, and the
second locking portion comprises a female portion configured as a
groove for receiving the male portion of a similar board disposed
adjacent thereto, the female portion having a face incorporating a
concave section for receiving the convex face of the male portion,
whereby interaction between the convex face and concave section
serves to draw the male portion of one board into the female
portion of another board upon relative angular movement between the
two boards towards a position whereby they are in side-by-side
relation and wherein the first locking portion further comprises a
first interlocking element disposed between the male portion and
the second face of the body, and the second locking portion further
comprises a second interlocking element disposed between the female
portion and the second face of the body, the first and second
interlocking elements of adjacent boards being adapted to interlock
when the two boards are in side-by-side relation.
[0012] Preferably, the first face has two opposed edges from which
the longitudinal sides extend at respective junctions
therebetween.
[0013] Preferably, said relative angular movement between the
boards is about a fulcrum defined by engagement between one
junction of one board and the adjacent junction of the other
board,
[0014] Preferably, the first surface of the board presents an
exposed surface, which in the case of a floor board would be the
upper surface and in the case of cladding would be the visible
surface.
[0015] Preferably, the section presenting the convex face extends
towards the first face.
[0016] Preferably, the section presenting the convex face is
provided on the side of the male portion closer to the first face
of the board, and the concave section is provided in the side of
the female portion closer to the first face.
[0017] The section presenting the convex face comprises a plurality
of segments disposed one adjacent another. In this way, the section
presents a multi-faceted surface. The multi-faceted surface may
have a camming effect as it interacts with the concave section to
draw the male portion into the female portion.
[0018] Preferably, the first and second interlocking elements
define two interlocking surfaces adapted to co-operate for
frictional engagement therebetween to provide an interlocking
action.
[0019] The first and second interlocking elements preferably
comprise a further groove defining one of the interlocking surfaces
and a matching rib defining the other of the interlocking surfaces,
the rib being adapted to be snugly received in the further groove
with the two interlocking surfaces in frictional engagement.
[0020] Preferably, the first interlocking element comprises the
further groove and the second interlocking element comprises the
rib, the further groove being located adjacent and parallel to the
male portion and the rib being located adjacent and parallel to the
female portion.
[0021] The first locking portion may further comprise a first
abutment face extending from the first face and a second abutment
face extending from the second face, the male portion extending
outwardly from the two abutment faces. The second abutment face may
be offset inwardly with respect to the first abutment face.
[0022] The second locking portion may further comprise a third
abutment face extending from the first face and a fourth abutment
face extending from the second face, the female portion extending
inwardly from the two abutment faces. The fourth abutment face may
be offset with respect to the third abutment face in the outward
direction.
[0023] With this arrangement, when two boards according to the
invention are interconnected, the respective first and third
abutment faces, and also the respective second and fourth abutment
faces, are in abutting relationship.
[0024] Preferably, the first and second interlocking elements
provide engagement between abutting second and fourth abutment
faces of interlocking boards.
[0025] Preferably, the male portion and female portion are
configured to define one or more voids therebetween. The voids are
useful in accommodating variations in the dimensional
characteristics of the male and female portions and for also
accommodating any excess glue used for the purposes of gluing the
male portion into position in the female portion.
[0026] The second locking portion may incorporate a channel to
receive fastening elements such as nails, staples or the like.
Additionally, or alternatively, the channel may receive an
adhesive, such as a "wet glue".
[0027] The interlocking connection between the boards may
accommodate some angular misalignment between adjoining boards
(such as in circumstances which the substrate on which the boards
are installed is not entirely level) without adversely affecting
the interlocking action. Such misalignment may comprise both
positive curvature and negative curvature.
[0028] This may be accomplished by provision of raking on one of
the longitudinal sides adjacent the first face. Further, there may
also be raking on a section of the side of the groove adjacent the
second face, said section being adjacent the open end of the
groove.
[0029] Weather guard strips, which can be either fixed or
removable, may also be provided.
[0030] According to a fourth aspect of the invention there is
provided a member comprising an elongate body having first and
second opposed faces and two longitudinal sides, the first face
having two opposed edges from which the longitudinal sides extend
at respective junctions therebetween, a first locking portion
provided at one longitudinal side and second locking portion
provided at the other longitudinal side, wherein the first locking
portion comprises a male portion configured as a tongue, the male
portion comprising a lobe section presenting a cam face extending
towards the first face and the second locking portion comprises a
female portion configured as a groove for receiving the male
portion of a similar member disposed adjacent thereto, the female
portion having a face incorporating a receiving portion for
receiving the lobe section of the male portion, whereby interaction
between the cam face and the receiving portion serves to draw the
male portion of one member into the female portion of another
member upon relative angular movement between the two members
towards a position whereby they are in side-by-side relation, said
relative angular movement being about a fulcrum defined by
engagement between one junction of one member and the adjacent
junction of the other member, and wherein the first locking portion
further comprises a first interlocking element disposed between the
male portion and the second face of the body, and the second
locking portion further comprises a second interlocking element
disposed between the female portion and the second face of the
body, the first and second interlocking elements of adjacent boards
being adapted to interlock when the two members are in side-by-side
relation.
[0031] According to a fifth aspect of the invention there is
provided a member comprising an elongate body having first and
second opposed faces and two longitudinal sides, a first locking
portion provided at one longitudinal side and second locking
portion provided at the other longitudinal side, wherein the first
locking portion comprises a male portion configured as a tongue,
the male portion having a lobe section presenting a cam face, and
the second locking portion comprises a female portion configured as
a groove for receiving the male portion of a similar member
disposed adjacent thereto, the female portion having a face
incorporating a receiving section for receiving the cam face of the
male portion, whereby interaction between the cam face and
receiving section serves to draw the male portion of one member
into the female portion of another member upon relative angular
movement between the two members towards a position whereby they
are in side-by-side relation, and wherein the cam face comprises a
plurality of segments disposed one adjacent another.
[0032] According to a sixth aspect of the invention there is
provided a coupling for interlocking two members each having first
and second opposed faces, the coupling comprising a first locking
portion provided on one member and a second locking portion
provided on the other member, wherein the first locking portion
comprises a male portion configured as a tongue, the male portion
having a lobe section presenting a cam face, and the second locking
portion comprises a female portion configured as a groove for
receiving the male portion, the female portion having a face
incorporating a receiving section for receiving the cam face of the
male portion, whereby interaction between the cam face and
receiving section serves to draw the male portion into the female
portion upon relative angular movement between the two members
towards an interlocked position, and wherein the cam face comprises
a plurality of segments disposed angularly one adjacent
another.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The invention will be better understood by reference to the
following description of specific embodiments thereof as shown in
the accompanying drawings in which:
[0034] FIG. 1 is an end view of a floor board according to a first
embodiment;
[0035] FIG. 2 is a fragmentary view (on an enlarged scale) of a
first longitudinal side of the floor board;
[0036] FIG. 3 is a fragmentary view (on an enlarged scale) of a
second longitudinal side of the floor board;
[0037] FIG. 4 is a fragmentary perspective view illustrating a
floor boards according to the embodiment being positioned for
locking connection one to the other;
[0038] FIG. 5 is an underside perspective view of the arrangement
shown in FIG. 4;
[0039] FIG. 6 is a fragmentary perspective view illustrating the
two floor boards in the interlocked condition;
[0040] FIGS. 7 to 11 are a series of schematic end views
illustrating two floor boards according to the embodiment
undergoing interconnection;
[0041] FIGS. 12 to 16 are fragmentary views showing on a larger
scale the interconnections between the two floor boards illustrated
in FIGS. 7 to 11;
[0042] FIG. 17 is a fragmentary view (on an enlarged scale) of the
interconnection between the two floor boards;
[0043] FIG. 18 is a fragmentary view of a first longitudinal side
of a floor board according to a second embodiment;
[0044] FIG. 19 is a fragmentary view of a second longitudinal side
of the floor board according to the second embodiment;
[0045] FIG. 20 is a view similar to FIG. 18 but with several angles
identified;
[0046] FIG. 21 is a view similar to FIG. 19 but with a further
angle identified;
[0047] FIG. 22 is a fragmentary view of the tongue on the first
longitudinal side, illustrated on an enlarged scale;
[0048] FIG. 23 is a fragmentary view of the interconnection between
two floor boards according to the second embodiment;
[0049] FIG. 24 is a view similar to FIG. 23, with the exception
that there is a positive curvature between the two interconnected
floor boards;
[0050] FIG. 25 is also a view similar to FIG. 23, with the
exception that there is a negative curvature between the two
interconnected floor boards;
[0051] FIG. 26 is an end view of a floor board according to a third
embodiment;
[0052] FIG. 27 is a fragmentary view (on an enlarged scale) of a
first longitudinal side of the floor board according to the third
embodiment;
[0053] FIG. 28 is a fragmentary view (on an enlarged scale) of a
second longitudinal side of the floor board according to the third
embodiment; and
[0054] FIG. 29 is an end view of two floor boards according to the
third embodiment connected together.
BEST MODE(S) FOR CARRYING OUT THE INVENTION
[0055] The embodiments shown in the drawings are each directed to a
floor board 10 configured to interlock with other similar such
boards in order to provide strip flooring.
[0056] Referring to FIGS. 1 to 17, floor boards 10 according to the
first embodiment each comprise an elongate body 11 having a first
face 13, a second face 15, a first longitudinal side 17 and a
second longitudinal side 19. The first face 13 and the first
longitudinal side 17 intersect at junction 18. Similarly, the first
face 13 and the second longitudinal side 19 intersect at junction
20.
[0057] When the floor board 10 is installed in position to provide
flooring, the second face 15 is disposed downwardly (and so will
hereinafter be referred to as the lower face 15) and the first face
13 is disposed upwardly to define the floor surface (and so will
hereinafter be referred to as the upper face 13).
[0058] A first locking portion 21 extends along the first
longitudinal side 17 of the body 11 and a second locking portion 22
extends along the second longitudinal side 19.
[0059] In this embodiment, the floor board 10 is formed of a single
piece of timber, in which case the first and second locking
portions 21, 22 are integral with the body. In this regard, the
floor board 10 is produced by milling (or otherwise machining) a
piece of timber to form the body 11 having the upper and lower
faces 13, 15 as well as the two locking portions 21, 22.
[0060] The first locking portion 21 comprises a male portion
configured as a tongue 23. The first locking portion 21 further
comprises an upper abutment face 24 and a lower abutment face 25,
from which the tongue 23 extends outwardly. The upper abutment face
24 extends downwardly from upper face 13, and the lower abutment
face 25 extends upwardly from lower face 15. The lower abutment
face 25 is offset inwardly with respect to the upper abutment face,
as best seen in FIG. 1.
[0061] The tongue 23 has an upperside 26 and an underside 27 which
merge at smooth transitional edge 29 extending longitudinally along
the body 11.
[0062] The upperside 26 includes a straight section 31 and an
arcuate section 33 of convex configuration. Thus the arcuate
section 33 provides a lobe section presenting a convex face. The
convex face is asymmetrical and as such constitutes a cam face. The
straight section 31 extends from the upper abutment face 24 in a
downward direction to intersect with the arcuate section 33, as
shown in the drawings.
[0063] The underside 27 of the tongue 23 includes a straight
section 35 and a curved section 37. The straight section 35 extends
from the lower abutment face 25 to merge with the arcuate section
37 which terminates at the edge 29 where it merges smoothly with
the arcuate section 33 at the transitional edge 29, as shown in the
drawings.
[0064] The lower abutment face 25 at the first locking portion 21
extends downwardly from the underside 27 of the tongue 23 to the
lower face 15 of the body.
[0065] The first locking portion 21 further comprises a groove 38
in the lower abutment face 25 adjacent to the underside 27 of the
tongue 23. The groove 38 has a longitudinal extent parallel to the
tongue 23. The groove 38 is configured as a channel having straight
side sections 39 extending inwardly from the abutment face 25 and
an arcuate inner end section 40. Side section 39a is co-planar with
the underside 27 of the tongue 23 to merge seamlessly therewith.
Side section 39b intersects with the abutment face 25 at junction
39c which is chamfered. An external locking corner 60 is defined at
the intersection of side section 39b and abutment face 25.
[0066] Side section 39c defines an interlocking surface 62, the
purpose of which will be explained later.
[0067] The portion 25a of the lower abutment face 25 below the
groove 38 is raked inwardly somewhat.
[0068] The second locking portion 22 comprises a female portion
configured as a groove 41. The second locking portion 22 further
comprises an upper abutment face 42 and a lower abutment face 43
from which the groove 41 extends inwardly. The lower abutment face
43 is offset outwardly with respect to the upper abutment face 42,
as best seen in FIG. 1. The groove 41 has an upper wall 44, a lower
wall 45 and an inner wall 46. The upper wall 44 of the groove 41
incorporates an outer straight section 47 extending inwardly from
the upper abutment face 42, an arcuate section 49 and an inner
section 51 adjacent the inner wall 46. The outer section 47 extends
inwardly towards the lower wall 45, and intersects with the arcuate
section 49. The inner section 51 is small in comparison to sections
47, 49 of the upper wall 44 and defines a shoulder 53 adjacent the
inner wall 46.
[0069] The arcuate section 49 is of concave configuration for
co-operation with the convex arcuate section 33 of the tongue, as
will be explained in more detail later.
[0070] The lower wall 45 has a straight section 45a parallel to the
faces 13, 15, and a convex section 45b which intersects with inner
wall 46. It extends beyond the upper confines of the groove 41 as
defined by the upper abutment face 42 and outwardly to the lower
abutment face 43. The lower wall 45 incorporates a channel 55
extending longitudinally with respect to the body 11, the channel
55 being located in the exposed section 57 of the lower wall 45
beyond the upper confines of the groove 41.
[0071] The lower abutment face 43 at the second locking portion 22
extends downwardly from the lower wall 45 of the groove 41 to the
lower face 15 of the body.
[0072] The second locking portion 22 further comprises a rib 61
configured and dimensioned to be snugly received in the groove 38
of an adjoining board, with a void 72 defined therebetween. The rib
61 has a longitudinal extent parallel to the groove 41. The rib 61
has two straight side sections 63 and an arcuate outer end section
65. Side section 63a is co-planar with the lower wall 45 of the
groove 41 to merge seamlessly therewith. Side section 63b
intersects with the lower abutment face 43. An internal locking
corner 70 is defined at that intersection.
[0073] Side section 63b defines a further interlocking surface 64,
the purpose of which will also be explained later.
[0074] While not shown in the drawings, the junctions 18, 20
between the first face 13 and the respective upper abutment faces
24, 42 can be profiled if desired, such as by incorporation of a
chamfer at each junction.
[0075] As alluded to above, the board 10 according to the
embodiment is adapted to interlock with similar such boards to
provide strip flooring. In this regard the first and second locking
portions 21, 22 cooperate to provide a coupling for interconnecting
the boards. The manner in which the boards interlock will now be
described, with reference to FIGS. 7 to 16 of the drawings, in
which two boards 10a and 10b according to the embodiment are
illustrated. The description will be made with reference to board
10a already being in an installed position such that its lower face
15 is supported on a substrate (not shown). The substrate can be of
any appropriate form according to the installation site. The
substrate may, for example, comprise a continuous surface such as
concrete or plywood panelling, or subfloor framing such as timber
joists.
[0076] With floor board 10a in position with its second locking
portion 22 exposed, floor board 10b is presented to floor board 10a
at an angle of about 20.degree. to the horizontal, as illustrated
in FIG. 7. The tongue 23 of floor board 10b is inserted into the
groove 41 of floor board 10a, with the arcuate section 33 of the
tongue upperside 26 contacting the curved transition section 50 of
the upper wall 44 of the groove 41, and the curve section 37 of the
tongue underside 27 contacting the lower wall 45 of the groove. The
downward inclination of the straight section 31 on the tongue
upperside 26 provides the necessary clearance with respect to the
groove upper wall 44 when the floor board 10b is in the tilted
condition.
[0077] The two floorboards 10a, 10b are also in contact at or
closely adjacent junctions 18, 20. This contact provides a fulcrum
80 about which floorboard 10b can be rotated to lock the two boards
together, as will be explained below.
[0078] Floor board 10b is then progressively tilted downwardly and
pushed towards floor board 10a, thereby causing the tongue 23 to
slide along the upper and lower walls 44, 45 of the groove, as
illustrated in FIGS. 7 to 16. As the tongue 23 further enters the
groove 41, the convex section 33 on the tongue moves into
engagement with the concave section 49 on the upper wall 44 of the
groove. Co-operation between the convex section 33 of the tongue 23
and the concave section 49 of the groove 41 produces a cam effect
which causes the tongue to be drawn further into the groove 41 as
the floor board 10b continues to be tilted downwardly. With this
arrangement, the tongue 23 and groove 41 mechanically interlock,
establishing a "knuckle joint" connection therebetween.
[0079] As board 10b approaches the position where it is almost
resting on the substrate, the groove 38 on floor board 10b moves
into registration with the rib 61 on floor board 10a, as
illustrated in FIGS. 10 and 15. Upon movement of floor board 10b
into its final position on the substrate, as illustrated in FIGS.
11 and 16, the cam effect between the tongue 23 and the groove 41
draws the tongue fully into the groove and also draws the groove 38
into full engagement about the rib 61. Further, the external corner
60 moves into engagement with the internal corner 70, as shown in
FIGS. 16 and 17. As the corners 60, 70 move into engagement, the
interlocking surface 62 on the first locking portion 21
frictionally engages against the further interlocking surface 64 on
the second locking portion 22
[0080] When the groove 38 has fully received the rib 61, as shown
in FIGS. 11 and 16, the external corner 60 locks into the internal
corner 70, with the interlocking surfaces 62, 64 in compressive
engagement.
[0081] The lower abutment face 25 on floor board 10b is brought
into contact with the lower abutment face 43 on floor board 10a as
the tongue 23 is drawn fully into the groove 41. Similarly, the
upper abutment face 24 of floor board 10b is brought into
compressive contact with the upper abutment face 42 of floor board
10a.
[0082] Engagement between the groove 38 and rib 61, or more
particularly the external and internal corners 60, 70, has the
effect of drawing the boards 10a, 10b into planar alignment on the
substrate to correct any warpage in the boards.
[0083] When the boards 10a, 10b are interlocked, the raked portion
25a of the lower abutment face 25 can co-operate with abutment face
43 to define a wedge-shaped space 71. The space 71 can accommodate
some expansion and contraction between the interlocked boards, as
well as accommodating some over-centering movement between the two
boards without disrupting the integrity of interlocking
therebetween in circumstances where the substrate on which the
boards are laid is not entirely level.
[0084] The interlocking connection between the two floor boards
10a, 10b draws the boards together into abutting relationship at
the respective abutment faces. Further, in the interlocking
condition there are various interfaces of contact between the
tongue 23 and the groove 41. Specifically, the convex section 33 on
the upperside 26 of the tongue 23 is in contact with the concave
section 49 of the upper wall 44 of the groove 41. Additionally, the
straight section 35 of the underside 27 of the tongue 23 is in
contact with the bottom wall 45 of the groove 41. Further, there is
an interlocking action between corners 60, 70.
[0085] The various forces involved in establishing and maintaining
the two boards in the interlocked condition will be explained with
reference to FIG. 17. There are three primary forces, a first
acting along line X-X, a second acting along line Y-Y and a third
acting along line Z-Z.
[0086] The first force, which acts along line X-X, is a compressive
force established by compression between fulcrum 80 and the
interlocked corners 60, 70.
[0087] The second force, which acts along line Y-Y is a tension
force which holds the tongue 23 in tension within the locking
groove 41. The tension arises through compressive contact between
the boards at abutment faces 24, 42 and 25, 43, and engagement of
the tongue 23 in groove 41 at mating arcuate sections 33, 49. The
third force, which acts along line Z-Z, is a compressive force
established between fulcrum 80 and contact between the tongue 23
and groove 41 at the interface between mating convex section 33 and
concave section 49. The axis Z-Z is normal to a tangent at the two
mating arcuate sections 33, 49.
[0088] The interlock between the two boards 10a, 10b serves to
assist in transferring load (such load arising, for example, from
the application of weight to the upper surface 15) from one board
to the other board. Load transfer is assisted by the offset
relationship between the contacting abutment faces 24, 42, a
consequence of which is that the tongue underside 27 presents a
significant load bearing area on the lower wall 45 of the groove
41. Load transfer is also assisted by interaction between the rib
61 and the groove 38 in which it is received, as well as
compression between contacting abutment faces 24, 42 and 25,
43.
[0089] In some applications, the boards 10a and 10b (as well as
other similar boards installed to provide flooring) are in a
"floating" arrangement, whereby they are not fixed to the substrate
and also not fixed to one another (apart from being interlocked by
way of the first and second locking portions 21, 22).
[0090] There are, however, many applications where the floor boards
would be nailed to the substrate. The board 10 according to the
embodiment is particularly suitable for this purpose, as the
channel 55 in the exposed section 57 of the lower wall 45 of the
groove 41 can receive fixings such as nails or staples, thereby
allowing the boards to be nailed in place by way of a "secret
fixing" process. The heads of the fixings can be accommodated
entirely within the channel 55. Alternatively, the fixings may be
installed such that they are slightly proud of the surface of the
lower wall 45, thereby providing some frictional engagement with
the tongue of the adjacent board as the tongue is being introduced
into the groove. The fixings are not so proud as to prevent entry
of the tongue but rather allow the tongue to enter, with the
underside 27 of the tongue being scored by the heads of the
fixings. This scoring action the tongue to enter the groove and
also provides some frictional engagement on the tongue to assist in
maintaining it in position within the groove.
[0091] The channel 55 is so positioned relative to the upper
abutment face 42 that the latter can be used as a guide for a gun
employed to drive fixings into the floor board. The gun can be
positioned against the abutment face 42 and then moved along that
face, driving fixings at necessary intervals into the floor board
through the channel 55.
[0092] In other applications, glue can be used in fixing the boards
together. The glue can be either a "wet" glue or a "dry" glue.
[0093] If a wet glue is used to fix the boards together, the glue
can be applied into the channel 55. It is particularly convenient
to apply the glue into the channel 55 by way of a wiping process.
Once the wet glue has been introduced into the channel 55, the
tongue 23 of the next board can then be inserted and the board
installed.
[0094] Where a dry glue is used, it is typically applied to both
the tongue 23 and the groove 41. In this regard, a layer of dry
glue is applied to the straight section 35 of the tongue underside
27 and the lower wall 45 of the groove 41 inwardly of the channel
55.
[0095] It is a particular feature of the interlocking connection
between the two boards that voids exist between the tongue 23 and
the groove 41 when the tongue is fully accommodated within the
groove. The voids comprise void 73 defined between the junction
between the lower wall 45 and the inner wall 46 of the groove 41
and also the curved section 37 of the underside 27 of the tongue.
The void 73 accommodates variations in machining of the boards, and
also expansion and contraction between the boards without
disrupting the integrity of the interconnection therebetween, as
well as accommodating any surplus glue which might be present at
the interconnection following installation of the boards. The
ability to accommodate surplus glue is particularly advantageous,
as it prevents the surplus glue being expelled from the junction
between the boards and possibly contaminating the floor surface. It
also prevents any confined glue from developing a "hydraulic
effect" which might either oppose full entry of the tongue 23 into
the groove 41 or develop a force which might cause the tongue to
partially retreat from the groove and therefore develop a gap
between the interconnected boards.
[0096] In the installation process illustrated in FIGS. 7 to 16,
the tongue 23 of the particular board 10b being laid was presented
to the groove 41 of the previously-laid board 10a. However, the
configuration of the first and second locking portions 21, 22 is
such that the installation process can be varied, with the groove
41 of a board being laid being presented to the tongue 23 of a
previously-laid board.
[0097] Referring now to FIGS. 18 to 25, the floor boards 10
according to the second embodiment are each similar in many
respects to the floor boards according to the first embodiment and
similar reference numerals are used to identify similar parts.
[0098] It is a particular feature of the interlocking connection
that it can accommodate some angular misalignment between adjoining
boards in circumstances where the substrate is not entirely level,
without adversely affecting the interlocking action between the
boards. Where there is no angular misalignment, the angle .sigma.
defined between the first faces 13 of adjacent boards 10 is
180.degree., as shown in FIG. 23. Where there is angular
misalignment, it may comprise what is referred to as positive
deviation or negative deviation. Positive deviation is angular
misalignment in which the angle .sigma. defined between the first
faces 13 of adjacent boards 10 less than 180.degree., as shown in
FIG. 24. Negative deviation is angular misalignment in which the
angle .sigma. defined between the first faces 13 of adjacent boards
10 greater than 180.degree., as shown in FIG. 25. Typically, the
interlocking connection of this embodiment can accommodate positive
deviation of up to 30 mm over a 1 metre span and negative deviation
of 15 mm over a 1 metre span.
[0099] The ability to accommodate angular misalignment is provided
by inward raking of the lower abutment face 25 of the first locking
portion 21 as identified by angle .phi. in FIG. 21, and also by
inward raking of the upper abutment face 42 of the second locking
portion 22 as identified by angle .alpha. in FIG. 20. In this
embodiment, angle .phi. is about 15.degree. and angle .alpha. is
about 3.degree.. Further, the lower wall 45 of the groove 41 is
configured to accommodate the angular misalignment. Specifically,
that section 45c of the lower wall 45 extending beyond the plane of
the upper abutment face 42 is raked downwardly, as identified by
angle .beta. in FIG. 20. In this embodiment, angle .beta. is about
2.degree..
[0100] In this second embodiment, there are also some differences
from the first embodiment in respect of the configuration of the
tongue 23 and the grove 41. Specifically, in this embodiment, the
lobe section 33 of the tongue 23 presents a cam surface comprising
a plurality of straight segments 91 disposed in an angular
arrangement, as best shown in FIG. 22. In this way, the cam face
comprises a plurality of facets 93 and edges 95 between adjacent
facets The multi-faceted cam face presented by the lobe section 33
of the tongue 23 provides a camming effect as it interacts with
section 49 of the groove 41 to draw the tongue 23 into the groove
41. The edges 95 grip against section 49 of the groove 41 during
the camming action to assist in drawing the tongue 23 into the
groove 41.
[0101] Further, in this embodiment, the lower wall 45 of the groove
41 has an inner section 45d which is disposed inwardly of the raked
section 45c and which extends to the inner wall of the groove. The
inner section 45d is substantially straight. The junction between
the straight inner section 45d and the raked outer section 45c is
identified in the drawings by reference numeral 45e. With is
arrangement, the lower wall 45 of this embodiment does not
incorporate the straight and convex sections 45a, 45b of the first
embodiment. This configuration assists in accommodating angular
misalignment between adjacent boards as previously described and
also increases the size of void 73.
[0102] Still further, the configuration of the upper wall 44 of the
grove 41 is different. Specifically, there is a flank section 48
between the outer straight section 47 and the arcuate section 49.
The presence of the flank section 48 produces a void 75 which
assists in accommodating expansion and contraction between the
boards without disrupting the integrity of the interconnection
therebetween.
[0103] Still further, in this embodiment, the area of the underside
27 of the tongue 23 where the straight section 35 merges with the
curved section 37 defines a heel 36. The heel 36 contacts the lower
wall 45 of the groove 41 in the region of the junction 45e when the
tongue 23 is accommodated within the groove.
[0104] With this embodiment, an effective interconnection can be
established between adjacent boards even in circumstances of
angular misalignment involving either positive or negative
curvature, as previously explained. Regardless of whether there is
angular misalignment as shown in FIGS. 24 and 25, or no angular
misalignment as shown in FIG. 23, the adjacent board 10 abut at the
junctions 18, 20 which define fulcrum 80 and remain in such
abutment. In each case, there is contact between the interlocked
boards at contact points a, b, c and d, as shown in FIGS. 23 to 25.
Further, there is also contact at contact point e in the negative
deviation condition, as shown in FIG. 25. It is contact between the
boards at the various contact points that provides the integrity of
the interconnection.
[0105] Any expansion and contraction between the interconnected
boards 10 is accommodated within the interconnection without
disrupting the integrity of the interconnection. The voids 72, 73
and 75 assist in accommodating the expansion and contraction.
[0106] Referring now to FIGS. 26 to 29, the floor boards 10
according to the third embodiment are each similar in many respects
to the floor boards according to the first embodiment and so
similar reference numerals are used to identify similar parts.
[0107] In this third embodiment, the first locking portion 21
comprises a male portion configured as a tongue 23, as was the case
in the first embodiment. In this embodiment, however, the first
locking portion 21 does not further comprise a groove but rather a
rib 101 on the lower abutment face 25 adjacent to the underside 27
of the tongue 23.
[0108] The second locking portion 22 comprises a female portion
configured as a groove 41, as was the case in the first embodiment.
In this embodiment, however, the second locking portion 22 does not
further comprise a rib but rather a groove 103 configured and
dimensioned to be snugly the rib 101 of an adjoining board, as
illustrated in FIG. 29. The rib 101 and groove 103 cooperate to
provide interlocking surfaces which frictionally engage, as was the
case with the first embodiment.
[0109] In the embodiments described, the boards are constructed of
solid timber. It should be appreciated that the boards can be of
any appropriate construction, including: timber, bamboo and other
natural organic materials; composite materials (such as laminate on
substrate); and BSB ("bamboo strand board").
[0110] While the embodiments have been described in relation to a
board for strip flooring, it should be understood that a board
according to the invention may be used for various other
applications, including cladding for partitioning, interior and
exterior walls, and as ceiling boards.
[0111] Where boards according to the invention are used in exterior
applications, there may be provision to incorporate weather seals
at the junctions therebetween.
[0112] Further, the invention may have application to members other
than boards. One such application may be in coupling frame elements
together, such as in building trusses.
[0113] Modifications and improvements can be made without departing
from the scope of the invention.
[0114] Throughout the specification, unless the context requires
otherwise, the word "comprise" or variations such as "comprises" or
"comprising", will be understood to imply the inclusion of a stated
integer or group of integers but not the exclusion of any other
integer or group of integers.
* * * * *