U.S. patent application number 16/691881 was filed with the patent office on 2021-08-12 for systems and methods related to natural wood products.
The applicant listed for this patent is Custom Finish Wood Flooring LLC. Invention is credited to Robert L. Peterson.
Application Number | 20210246666 16/691881 |
Document ID | / |
Family ID | 1000005553037 |
Filed Date | 2021-08-12 |
United States Patent
Application |
20210246666 |
Kind Code |
A1 |
Peterson; Robert L. |
August 12, 2021 |
Systems and Methods Related to Natural Wood Products
Abstract
Systems and methods directed to the art of installing flooring
include untreated flooring planks having a hardwood top surface
delivered to a jobsite and including improved thickness tolerances
and/or top surface comparative coefficients of friction.
Inventors: |
Peterson; Robert L.;
(Elkhorn, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Custom Finish Wood Flooring LLC |
Whitewater |
WI |
US |
|
|
Family ID: |
1000005553037 |
Appl. No.: |
16/691881 |
Filed: |
November 22, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
15436004 |
Feb 17, 2017 |
10501943 |
|
|
16691881 |
|
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|
62297205 |
Feb 19, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04F 15/02038 20130101;
E04F 2201/023 20130101; E04F 2201/0107 20130101; E04F 15/04
20130101 |
International
Class: |
E04F 15/02 20060101
E04F015/02; E04F 15/04 20060101 E04F015/04 |
Claims
1. A natural wood product comprising: a first substantially planar,
mechanically treated first outer surface; a second substantially
planar, mechanically treated first outer surface; wherein the
static friction coefficient of the first outer surface against the
second outer surface is about 0.15 to about 0.30.
2. The natural wood product of claim 1, wherein the static friction
coefficient of the first outer surface against the second outer
surface is about 0.15 to about 0.25.
3. The natural wood product of claim 1, wherein the mechanical
treatment is at least one of: planing sanding, scraping, and
brushing.
4. The natural wood product of claim 1, the wood product comprising
solid hardwood.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S. patent
application Ser. No. 15/436,004, filed Feb. 17, 2017, entitled
"Systems and Methods for Installing Flooring," which claims the
benefit of now expired U.S. Provisional Patent Application Ser. No.
62/297,205, filed 19 Feb. 2016, entitled "Systems and Methods for
Installing Natural Wood Flooring," both of which are incorporated
herein by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] Systems and methods according to the present invention
relate generally to building construction materials and
construction methods, and more particularly to flooring systems
employing natural wood, either solid natural wood or including a
natural wood veneer.
[0003] Presently, most hardwood (e.g., oak, maple, hickory, etc.)
flooring provided to a jobsite for either do-it-yourselfers or even
professional installers suffers from at least one of two
deficiencies, namely, surface height variation and/or finish.
Either of these deficiencies can lead to further required
expenditures to complete a uniform installation.
[0004] A deficiency of surface height variation is indicated by
adjacent boards forming an offset lip defined by a height
difference between an untreated top surface of one board and an
untreated top surface of an adjacent board. Such lips may be caused
by a variation in overall plank thickness of adjacent boards and/or
variation of partial plank thicknesses caused by mating constructs
(e.g., tongue and groove, overlapping, or click) of adjacent
boards.
[0005] A deficiency in finish may be indicated by relatively rough
surfaces having a noticeably high coefficient of friction, as
further explained below, or stained and/or protected surfaces. A
problem with stained flooring presented to a jobsite is that there
is a chance that the stain shade of presented stained flooring may
not match existing stained flooring. A problem with protected
flooring is that a desired sheen may not have been achieved.
[0006] To accommodate prior flooring exhibiting thickness
variation, flooring installers would normally secure flooring
planks to flooring joists or underlayment. Immediately after
securing the flooring planks, offset lips at one or more places
along the exposed flooring surface are usually detected. To
substantially eliminate the offset lips, significant surface
treatment, such as sanding, was required.
[0007] Significant surface treatment (e.g. sanding) was also used
to accommodate prior flooring planks exhibiting undesirable rough
surface characteristics. Regarding stain color and protectant
sheen, if the product delivered to a jobsite does not meet
expectations, either additional finishing efforts were required, or
entirely new product would need to be ordered, thus causing delay
in job completion.
[0008] Accordingly, the art of flooring installation, and
especially flooring installation adjoining a preexisting wood floor
at a jobsite, could benefit from systems and methods related to
supplying untreated (e.g., unstained) but more precise flooring
planks with hardwood top surfaces.
SUMMARY OF THE INVENTION
[0009] The present invention relates to improved systems and method
related to supplying and installing hardwood flooring planks to
address one or more problems experienced heretofore with prior
flooring planks provided to a jobsite and/or to provide alternative
advantages as described herein.
[0010] According to an aspect of an embodiment of a flooring system
according to the present invention, the system includes a plurality
of planks including at least a first plank and a second plank. The
first plank has a length, a bottom surface and an untreated
hardwood plank top surface disposed opposite the bottom surface and
separated therefrom by a first plank thickness. The first plank may
also include a first plank tongue extending along and perpendicular
to the first plank length, the tongue having a tongue top surface
and a tongue bottom surface. The second plank has a length, a
bottom surface and an untreated hardwood top surface disposed
opposite the bottom surface and separated therefrom by a second
plank thickness. The second plank may include structure to mate
with the first plank, such as a groove extending along and
perpendicular to the second plank length, the groove having a
groove top surface and a groove bottom surface. The groove may be
configured to receive the first plank tongue, wherein when the
tongue and groove, or other mating structure, are mated, the
maximum distance between the first plank top surface and the second
plank top surface (such as along mating top surface edges) defines
a differential height, which is preferably less than or equal to
0.50 mm, more preferably less than or equal to 0.30 mm, and most
preferably less than or equal to 0.25 mm. The planks may be solid
hardwood or engineered hardwood, or the untreated hardwood top
surface may be a veneer, such as applied to an engineered
substrate.
[0011] According to another aspect of an embodiment of a flooring
system according to the present invention, the first plank further
has a first flange height extending from the tongue top surface to
a nearest edge of the first plank untreated hardwood top surface
and a second flange height extending from the tongue bottom surface
to the nearest edge of the first plank untreated hardwood top
surface. The second plank further has a first tab height extending
from the groove top surface to a nearest edge of the second plank
untreated hardwood top surface; and a second tab height extending
from the groove bottom surface to the nearest edge of the second
plank untreated hardwood top surface. If the first plank thickness
is greater than the second plank thickness, any difference between
the first tab height and the first flange height is preferably less
than or equal to 0.50 mm, more preferably less than or equal to
0.30 mm, and most preferably less than or equal to 0.25 mm. If the
second plank thickness is greater than the first plank thickness,
any difference between the second tab height and the second flange
height is preferably less than or equal to 0.50 mm, more preferably
less than or equal to 0.30 mm, and most preferably less than or
equal to 0.25 mm.
[0012] According to still another aspect of an embodiment of a
flooring system according to the present invention, the top
surfaces of the two planks are preferably mechanically treated to
provide a relative static friction coefficient of the first plank
untreated hardwood top surface against the second plank untreated
hardwood top surface of preferably about 0.15 to about 0.30, and
most preferably about 0.15 to about 0.25.
[0013] According to yet another aspect of an embodiment of a
flooring system according to the present invention, at least one of
the first plank untreated hardwood top surface and the second plank
untreated hardwood top surface comprises mechanical treatment, such
as at least one of planing, sanding, scraping, and brushing.
[0014] According to an aspect of an embodiment of a method
according to the present invention, such method includes the steps
of obtaining a flooring system according to the present invention
and delivering the flooring system to a jobsite. The method may
further include the steps of mating the first plank tongue and the
second plank groove and securing the first plank and the second
plank to a subfloor, preferably prior to any chemical treatment of
the top plank surfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a top plan view of a conventional hardwood plank
floor terminating along a carpeted edge.
[0016] FIG. 2 is a cross-sectional view taken along line 2-2 of
FIG. 1.
[0017] FIG. 3 is a cross-sectional elevation view taken from FIG.
2.
[0018] FIG. 4A is a first alternative cross-sectional elevation
view taken from FIG. 3.
[0019] FIG. 4B is a second alternative cross-sectional elevation
view taken from FIG. 3.
[0020] FIG. 4C is a third, substitute cross-sectional elevation
view taken from FIG. 3 featuring planks according to the present
invention rather than conventional planks.
[0021] FIG. 5 is an elevation diagram of an experimental setup.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] Although the disclosure hereof is detailed and exact to
enable those skilled in the art to practice the invention, the
physical embodiments herein disclosed merely exemplify the
invention which may be embodied in other specific structures. While
the preferred embodiment has been described, the details may be
changed without departing from the invention, which is defined by
the claims.
[0023] Turning now to the Figures, a first embodiment 100 of a
hardwood plank flooring surface is shown, formed by a plurality of
planks 110. The hardwood plank may be solid hardwood (i.e.,
harvested from a tree having broad leaves, producing a fruit or
nut, and going dormant in the winter, such as alder, oak, cherry,
maple, birch, etc.) or a hardwood veneer may form a surface
thereof. For a number of various reasons, it may be desirable to
longitudinally expand the flooring surface in a direction at least
substantially parallel with a length 110a of the flooring planks
110 and/or laterally expand the flooring surface in a direction at
least substantially parallel with a width 110b of the flooring
planks 110. Alternatively or additionally, it may be desirable to
install an entirely new flooring surface after removing the
existing surface 100.
[0024] FIG. 2 is a cross-sectional view taken through a plurality
of planks 110 of an installed, finished floor. With reference also
to FIG. 3 as a close-up view of FIG. 2, the planks 110 are usually
fastened or adhered to a sub-floor 120, such as plywood, which is
in turn secured to a floor joist 30. Alternatively, the planks 110
may be secured directly to the floor joist 130. Alternatively, the
planks 110 may be secured to a different substrate, such as a
concrete floor (not shown). The planks 110 may include several
features known in the art to assist in installation, such as
tongue-and-groove joints 140 and base surface kerfs 150. Each plank
110 generally includes a length 110a and width 110b, as mentioned
above, but further includes a thickness 110c, the thickness 110c
extending between and including a bottom surface 112 and an
untreated hardwood top surface 114. While lengths 110a may vary
from plank to plank, or be provided as substantially similar,
preferred widths 110b are preferably about 25 millimeters (about
one inch) to about 410 millimeters (about 16 inches). The top
surface 114 may be formed of the same material that comprises the
remainder of the plank 110 (e.g., hardwood) or the surface 114 may
be provided as a laminate layer of an operable thickness. Preferred
plank thicknesses 110c are between about 6.3 millimeters (about 1/4
inch) and about 51 millimeters (about two inches). Mating
tongue-and-groove joints 140 may be provided along the length 110a
and may also be provided along the width 110b of the planks 110.
Each joint 140 may be formed by mating structure on adjacent planks
110, including a longitudinal rib or tongue 142 formed on a first
plank 110 and a longitudinal slot or groove 144 formed into a
second, adjacent plank 110.
[0025] In an installed and finished floor, it is preferable to have
the mating portions of top surfaces 114 of adjacent planks 110 form
an at least substantially continuous or even flooring surface, as
seen in FIG. 3. An acceptable finished floor usually includes a
minimal difference between finished heights of adjacent planks 110.
It is estimated that a completed floor having a maximum height
difference between adjacent plank top surfaces 114 over a majority
of the floor of 0-0.5 millimeters is preferred, with less than 0.3
millimeters is more preferred, and less than 0.25 millimeters being
most preferred.
[0026] As mentioned above, conventional flooring planks provided to
a jobsite generally have undesirable variations that may lead to
costly efforts to produce an acceptable flooring surface. For
instance, prior planks 110' have been previously delivered to a
jobsite and installed. After installation, however (and with
reference to FIG. 4A) it has been noticed that a joint lip 300 may
be created, having a differential height 302 (measured between
adjacent plank top surfaces 114 of greater than is desirable, such
as greater than 0.5 millimeters. In the depicted situation, though
the tongue 142 and groove 144 are aligned when the bottom plank
surfaces 112 are placed against the subfloor 120 or other
supporting surface, the overall plank heights (or thicknesses)
110c' are different, thereby causing the differential height 302.
The overall plank height 110c' may be measured at least
substantially perpendicular to the subfloor 120 or perpendicular to
the general expanse of the floor, up to a topmost edge 304 (or
otherwise thickest portion) of the respective plank 110'. The
topmost edge 304 may be provided at a seam formed by the top
surfaces 114 of the two planks 110' or may be spaced therefrom.
Though shown herein as having a squared-off corner 304 forming the
lip 300, the corner (or other topmost part) 304 may be set back
towards a medial longitudinal axis of a plank by some modification
of the plank, such as by chamfering or distressing one or both
longitudinal edges of the plank.
[0027] The displacement 302 between top surfaces 114 of adjacent
planks 110 may be affected by differences in plank thickness 110c,
but may be more substantially affected by variations in height
differences between a top plank surface 114 and a joining
structure, such as a corresponding mating tongue 142 or groove 144.
Turning now to FIG. 4B, it can be seen that a top surface 142a of a
tongue 142 is forced or rests against a top surface 144a of a
groove 144, and a flange height 310 measured between the tongue top
surface 142a and the topmost point 304 is greater than a tab height
312 measured between the groove top surface 144a and the plank top
surface 114, thereby causing an undesirable lip 300 at a
differential height 302. While it is shown that the flange height
310 is measured from the tongue top surface 142a, it could instead
be measured from a bottom surface 142b of the tongue 142 (see 310'
in FIG. 4C) and compared to a tab height 312 measured from a bottom
surface 144b of the groove 144 (see 312' in FIG. 4C), if such
bottom surfaces 142b,144b were forced or rested against each
other.
[0028] FIG. 4C depicts a preferred embodiment 210 of planks
according to the present invention. A plurality of planks 210 is
provided to a jobsite. The planks 210 are produced to a tight
tolerance to ensure minimal variance to minimize any sort of lip
300 as described previously. Thus, the topmost point 304 of a first
plank 210 is, upon installation, disposed preferably no more than
0.50 millimeters above the top surface 214 of the adjacent plank
210. In the depiction shown, the top surface 214 of the left plank
210 is horizontally level with the topmost point 304 of the right
plank 210, thereby eliminating any lip 300. Thus, for a plurality
of provided planks 210, a lip 300 of less than 0.5 millimeters is
preferably provided along an entire length of engagement between
any two of the plurality of planks 210. Such lesser lip 300 may be
provided by ensuring that the plank thicknesses 210c are less than
0.5 millimeters different. If a first plank 210 at a joint 240
provides a tongue 242, and that plank thickness 210c is greater
than the thickness 210c of the adjoining plank 210, by more than
0.5 millimeters, a lesser lip 300 may still be achieved by ensuring
that the tab height 312 is not greater than or less than the flange
height 310 by more than 0.5 millimeters. If a second plank 210 at a
joint 240 provides a groove 244, and that plank thickness 210c is
greater than the thickness 210c of the adjoining plank 210, by more
than 0.5 millimeters, a lesser lip 300 may still be achieved by
ensuring that the tab height 312' is not greater than or less than
the flange height 310' by more than 0.5 millimeters. More generally
speaking, if upon installation a tongue top surface 242a engages a
groove top surface 244a, then the absolute value of the flange
height 310 minus the tab height 312 is preferably less than 0.5
millimeters. Alternatively or additionally, if upon installation a
tongue bottom surface 242b engages a groove bottom surface 244b,
then the absolute value of the flange height 310' minus the tab
height 312' is preferably less than 0.5 millimeters. Though
described with respect to a tongue-and-groove mating structure, it
is to be understood that the goal of the present invention may also
be achieved with other mating structures, such as an overlap or a
click mating structure. In the event of other mating structures
used, corresponding flange and tab heights 310,312 may be defined
with relation to mating structure of adjacent planks 110, where
such mating structure impedes relative movement of such planks 110
in a direction that is generally parallel to the thickness 110c of
the planks 110.
[0029] Mechanical surface treatment of planks to be provided to a
jobsite according to the present invention preferably includes
smoothing out the planks (e.g., planing, sanding, etc.) to a
desired smoothness to ease finishing treatment requirements. As
used herein, "untreated" should be understood to mean that although
a surface of a plank has undergone mechanical treatment (e.g.,
planning, sanding, scraping, brushing), it is provided as a bare
hardwood surface, which has not received chemical treatment, such
as staining, sealing, painting. A desired smoothness has been
discovered to be indicated by static coefficient of friction
determined by experiments conducted according to FIG. 5. A first
plank 410 having a length 410a is placed on a horizontal surface
434 and a second plank 510 is placed on top of the first plank 410,
with the top surfaces 414,514 in contact (i.e., the second plank
510 was placed face down). The first plank 410 is then slowly
elevated to determine at what angle 430 the length 410a of the
first plank 410 is positioned with respect to the horizontal
surface 434 (and/or measuring a height 432 of the length 410a from
the horizontal surface 434) when the second plank 510 begins to
move, thus indicating a component of the force of gravity
overcoming any static friction force (F.sub.s) between the two
planks. While tests were run firstly with smaller experimental
pieces, first planks having a mass of greater than 0.5 kilograms
seemed to demonstrate more consistent results.
[0030] To calculate the static friction forces (F.sub.s), the known
formula of F=ma (force equals mass times acceleration) may be used.
The mass was measured, and the acceleration used can be an amount
of the force of gravity. Accordingly, the fraction of the
gravitational acceleration moving in the direction of the first
plank 410 is equal to the sine of the angle 430 at which the second
plank 510 begins moving along the first plank 410. The sine of the
angle 430 may also be calculated by finding the quotient of the
height 432 divided by the length 410a. Thus, the static friction
force (F.sub.s) may be calculated by multiplying the measured mass
(in kilograms) by gravitational acceleration (9.81 m/s.sup.2) and
the quotient of the height 432 divided by the length 410a,
illustrated in the following equation:
F.sub.s=m*g*(height/length)
[0031] To calculate desired coefficients of static friction, the
height 432 of the first plank 410 at which the second plank 510
plank begins to slide is divided by a horizontal distance 436
measured along the horizontal surface 434 to the ends of the first
plank 410. Alternatively, knowing the length 410a of the first
plank 410, the horizontal distance 436 may be calculated by finding
the square root of the difference between the length 410a squared
and the height 432 squared.
[0032] The average results of the experiments run are shown in the
following table:
TABLE-US-00001 Horizontal Length Height Distance Planks Mass (410a)
(432) (436) F.sub.s Coeff. Prior Art 688 g 2.00 m 0.62 m 1.90 m
2.09N 0.32 According to 630 g 2.00 m 0.46 m 1.95 m 1.42N 0.24 this
invention
Thus, it can be concluded that a coefficient of static friction
between two planks delivered to a jobsite according to the present
invention is preferably in the range of about 0.15 to less than
about 0.30, and more preferably in the range of about 0.15 to less
than about 0.25, when measured and calculated as described
herein.
[0033] Additionally or alternatively, one or more other surface
treatments (in addition to or alternatively to sanding/planing) may
be undertaken on the top surface 114 of a plank 110 according to
the present invention. A plank 110 may be provided with a varying
thickness across its width 110b, such as with hand scraping, or
imitation thereof. The top surface 114 may be distressed, such as
by striking the surface 114 with various implements to create
dents, dings, or other impressions. The top surface 114 may be
brushed, such as with a wire brush sander.
[0034] To produce planks according to the present invention, tight
production control may be used, including sharp tools and
post-production inspection. Planks including one or more features
as disclosed herein may then be collected for delivery to a
jobsite. The collection may be simply stacking a plurality of
planks on a vehicle and transporting them to a jobsite, or may
further include bundling and/or packaging the planks. Packaging of
the planks may make delivery to a jobsite more efficient.
Preferably, the one or more features included in planks according
to the present invention (the tolerances and variances (including
coefficient of friction)) can be observed by comparing any two of
the plurality of planks delivered to a jobsite. Planks according to
the present invention provided to a jobsite and thereafter
installed provide easier finishing, requiring generally only
buffing, and chemical treatment, such as stain application, and/or
other fluid protective application (e.g., polyurethane, tung oil,
etc.).
[0035] As used herein, the phrase "provided to a jobsite" or
"delivered to a jobsite" indicates that the material so provided is
intended to be installed at the jobsite (e.g., in the room,
building, or on the property parcel) in the state provided, without
further modification. Any additional treatment of the material
(e.g. intentional modification of plank top surfaces 114) is then
undertaken after the material is installed (e.g. buffing, staining,
and/or protecting).
[0036] The foregoing is considered as illustrative only of the
principles of the invention. Furthermore, since numerous
modifications and changes will readily occur to those skilled in
the art, it is not desired to limit the invention to the exact
construction and operation shown and described. While the preferred
embodiment has been described, the details may be changed without
departing from the invention, which is defined by the claims.
* * * * *