Floor covering transition device
The present invention provides a transition device assembly for transitioning between a first floor covering and a second floor covering that includes an elongated T-shaped member, a covering and an elongated base. The elongated T-shaped member has an upper portion and a base portion. The covering is attached to the elongated T-shaped member and covers a top and each side of the upper portion of the T-shaped member. The elongated base has a substantially flat portion and a longitudinally extending upwardly opening channel for receiving the base portion of the elongated T-shaped member. There may also be a notch in each end of the covering and the elongated T-shaped member to accommodate a doorstop. Alternatively, the covering also extends beyond the ends of the elongated T-shaped member and has a notch in each end of the extended covering to accommodate a doorstop.
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This application is a continuation-in-part of and claims priority based on U.S. patent application Ser. No. 10/684,984 filed Oct. 14, 2003, which is a continuation of and claims priority to U.S. patent application Ser. No. 10/202,231 filed Jul. 24, 2002 that issued as U.S. Pat. No. 6,662,518 B1 on Dec. 16, 2003, all of which are incorporated herein by reference.
FIELD OF THE INVENTIONThe present invention relates generally to the field of wall to wall carpeting techniques, and more particularly to floor covering transition device for use between a section of carpet and another floor covering.
BACKGROUND OF THE INVENTIONCarpet installation and replacement in dwellings, such as homes and apartment units can be a very expensive proposition. This is primarily due to the fact that adjoining pieces of carpet within a room or between rooms must match. In other words, all the pieces of carpet must come from the same dye lot. Otherwise, a person will be able to visually detect that the pieces of carpet do not match. This problem drastically increases the cost of carpet replacement because all the carpet has to be replaced rather than only those pieces or rooms that need new carpet. One attempt to solve this problem has been the replacement of a section of carpet with a wood floor looking laminate product (or sheet vinyl). For example, the carpet in a hallway is replaced with the wood floor looking laminate product. As a result, the carpet in the rooms adjoining the hallway, such as bedrooms, does not have to match each other. The biggest drawback of this type of installation is that it is substantially more expensive than a conventional installation. Moreover, this approach also does not allow the possibility of installing carpet in a living room and dining room independent of one another.
There is, therefore, a need for a transition device that can be installed between two floor coverings to separate areas and allows the use of different carpet dye lots or the installation of new carpet next to old carpet.
SUMMARY OF THE INVENTIONThe present invention provides a transition device that can be installed between two pieces of flooring material or floor covering to separate areas, such as rooms, closets and hallways, in a typical dwelling. The present invention is particularly applicable for use in apartment units to provide eye-appealing, fashionable accents to the finished appearance of the apartment unit. By separating the different rooms and isolatable floor areas, different dye-lots and even different colors can be combined in the same unit, a practice that has previously been impractical. The ability to mix colors, dye-lots and new carpet with old carpet allows the installer to use a much lower priced segment of the carpet mills inventory stock known as “short-rolls” or remnants. Typically, this carpet was difficult for the mills to get rid of and is priced at less than half the normal cost of full rolls of carpet.
The finished initial installation also gives the management companies the option of replacing partial units or isolated rooms or areas in an apartment unit. This has been impractical previous to the development of the present invention due to the fact that carpeting is manufactured in dye lot increments and generally carpets that come from different dye lots cannot be combined. Consequently, if a single room needs to be replaced in a unit, normally replacement of the carpet within the entire unit is ordered so that all the carpet will match. As a result, management companies are able to save money and time as compared to a conventional carpet installation. This is possible due to the fact that the present invention allows the use of short rolls and remnants for these installations, which can be bought at significant discounts from standard carpet at full-roll pricing. Even if short rolls and/or remnants are not used, the savings of doing only part of a unit, versus a complete unit are significant. Moreover, the transition devices of the present invention provide a new visual appearance for apartment units in a business where there is very little opportunity to differentiate product, namely the unoccupied apartment unit that is being marketed. The apartment units all look very much the same, especially when it comes to the flooring products.
More specifically, the present invention provides a transition device assembly that includes an elongated T-shaped member, a covering and an elongated base that have a combined height to provide a transition between a first floor covering and a second floor covering. The elongated T-shaped member has an upper portion and a base portion. The covering is attached to the elongated T-shaped member and covers a top and each side of the upper portion of the T-shaped member. The elongated base has a substantially flat portion and a longitudinally extending upwardly opening channel for receiving the base portion of the elongated T-shaped member. In one case, there is also a notch in each end of the covering and the elongated T-shaped member to accommodate a doorstop. In another case, the covering also extends beyond the ends of the elongated T-shaped member and has a notch in each end of the extended covering to accommodate a doorstop. In another case, there are no notches and the bottom of the doorstop is removed as part of the installation.
In addition, the present invention provides a system for transitioning between a first floor covering and a second floor covering that includes an elongated T-shaped member, a covering and an elongated base. The elongated T-shaped member has an upper portion and a base portion. The covering is attached to the elongated T-shaped member and covers a top and each side of the upper portion of the T-shaped member. The elongated base is attached to a floor having a substantially flat portion and a longitudinally extending upwardly opening channel for receiving the base portion of the elongated T-shaped member. The first floor covering is attached to the floor and extends underneath one side of the upper portion of the elongated T-shaped member. The second floor covering is attached to the floor and extends underneath the other side of the upper portion of the elongated T-shaped member. The elongated base, elongated T-shaped member and the covering have a combined height to provide a transition between the first floor covering and the second floor covering. In one case, there is also a notch in each end of the covering and the elongated T-shaped member to accommodate a doorstop. In another case, the covering also extends beyond the ends of the elongated T-shaped member and has a notch in each end of the extended covering to accommodate a doorstop. In another case, there are no notches and the bottom of the doorstop is removed as part of the installation.
Moreover, the present invention provides a method for manufacturing a device for transitioning between a first floor covering and a second floor covering. An elongated T-shaped member having an upper portion and a base portion is fabricated and a covering is attached to the elongated T-shaped member such that the covering covers a top and each side of the upper portion of the T-shaped member. An elongated base is also fabricated and has a substantially flat portion and a longitudinally extending upwardly opening channel for receiving the base portion of the elongated T-shaped member. The elongated base, elongated T-shaped member and the covering have a combined height to provide a transition between a first floor covering and a second floor covering. In one case, a notch is also cut in each end of the covering and the elongated T-shaped member to accommodate a doorstop. In another case, the covering also extends beyond the ends of the elongated T-shaped member and a notch is cut in each end of the extended covering to accommodate a doorstop.
In addition, the present invention provides a transition device assembly that includes an elongated T-shaped semi-flexible member and two or more bases. The elongated T-shaped semi-flexible member has an upper portion and a base portion. The two or more bases have a substantially flat portion and an upwardly extending opening channel for receiving the base portion of the elongated T-shaped member. The two or more bases and elongated T-shaped semi-flexible member provide a transition between a non-linear first floor covering and a corresponding second floor covering.
Other features and advantages of the present invention will be apparent to those of ordinary skill in the art upon reference to the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGSThe above and further advantages of the invention may be better understood by referring to the following description in conjunction with the accompanying drawings, in which:
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts, which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not limit the scope of the invention.
The present invention provides a transition device that can be installed between two pieces of flooring material or floor covering to separate areas, such as rooms, closets and hallways, in a typical dwelling. The present invention is particularly applicable for use in apartment units to provide eye-appealing, fashionable accents to the finished appearance of the apartment unit. By separating the different rooms and isolatable floor areas, different dye-lots and even different colors can be combined in the same unit, a practice that has never been viewed favorably by apartment owners or managers previously. The ability to mix colors and dye-lots allows the installer to use a much lower priced segment of the carpet mills inventory stock known as “short-rolls” or remnants. Typically, this carpet was difficult for the mills to get rid of and is priced at less than half the normal cost of full rolls of carpet.
The finished initial installation also gives the management companies the option of replacing partial units or isolated rooms or areas in an apartment unit. This has been impractical previous to the development of the present invention due to the fact that carpeting is manufactured in dye lot increments and generally carpets that come from different dye lots cannot be combined. Consequently, if a single room needs to be replaced in a unit, normally replacement of the carpet within the entire unit is ordered so that all the carpet will match. As a result, management companies are able to save money and time as compared to a conventional carpet installation. This is possible due to the fact that the present invention allows the use of short rolls and remnants for these installations, which can be bought at significant discounts from standard carpet at full-roll pricing. Even if short rolls and/or remnants are not used, the savings of doing only part of a unit, versus a compete unit are significant. Moreover, the transition devices of the present invention provide a new visual appearance for apartment units in a business where there is very little opportunity to differentiate product, namely the unoccupied apartment unit that is being marketed. The apartment units all look very much the same, especially when it comes to the flooring products.
For example,
Seaming the two pieces of carpet together 102 and 104 is a labor intensive and “tricky” proposition. More specifically, two pieces of carpet 102 and 104 are seamed together by overlapping the edges of the carpet 102 and 104 leaving about 2 inches of excess carpet at the middle of the doorway. A chalk line is then snapped on the back of the overlapped carpet edges and a straight edge is trimmed to ensure a straight seam. The straight edges are overlapped and a row cutter is used to cut the bottom piece. The edge of the top piece is used as a guide in cutting the seam to fit. A length of seaming tape 106 is cut and centered under the seam. The adhesive side of the tape 106 must be facing up and the carpet seams must butt up against each other. A seaming iron is then used to melt the adhesive by slowly pulling the iron down the tape 106. Once the adhesive is melted, the carpet edges are immediately pressed together over the tape 106. The seam should then be rolled over with a seam rolling tool.
Now referring to
Referring now to the present invention as illustrated in
Transition devices 200, which may be simulated wood-plank insert pieces, are glued down throughout the entire unit after the old carpet is removed. Note that the transition devices 200 may also be used in new installations. The normal locations for the transition devices 200 are usually identical to those where regular seams go in a conventional installation. That would usually include all standard doors leading from one carpeted area to another and other strategic spots that create practical separation of carpets. These spots would include the beginning of a hallway leading to bedrooms and a prominent transition piece between the living room and dining room whenever possible. Note that the transition devices 200 can be used with other floor coverings, such as tile, wood or vinyl.
Now referring to
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Similarly,
The elongated core 320, 322 and 342 can be made from wood, plywood, compressed fiberboard, pressboard, fiberglass, foam, metal or other suitable material. The elongated core 320, 322 and 342 are typically ⅜″ thick and either 5″ wide or 7″ wide depending on where they are installed. In addition, the edges between the top 304, 324 and 344 and the opposing sides 308, 328 and 348 of the elongated core 302, 322 and 342 can be square or rounded. Likewise, the elongated core's 302, 322 and 342 cross section can be substantially rectangular or trapezoidal.
The covering 312, 332 and 352 can be patterned vinyl, vinyl pieces, laminate, ceramic, plastic, synthetic imitation material or other decorative and wear-resistant material. The covering 312, 332 and 352 is preferably at least 1/16 inch thick to provide durability. In the case of transition device 320, the covering 332 should extend at least ½ inch underneath the elongated core 322. For example, the covering 312, 332 and 352 can be made from the same durable sheet vinyl that typically goes into the kitchens and bathrooms of many standard apartment units. The wood plank styles of the sheet vinyl look surprisingly like real wood plank.
The transition devices 300, 320 and 340 that are to be used in doorways can be cut to the exact width of the door casings (universal standard sizes most often found are 24, 30 and 32 inches). The short side dimension of these transition devices 300, 320 and 340 is usually 5 inches. The transition devices 300, 320 and 340 that are used to separate living rooms from dining rooms usually have short side dimensions of 7 inches and are specially manufactured to whatever lengths are required. Special alterations can be easily made on site, as the material is easily cut with a small hand held saw.
The present invention allows installers to be issued the correct amount of the pre-manufactured transition devices 300, 320 and 340 when they pick up the carpet for the installation. Large inventories of the most common sized transition devices 300, 320 and 340 can be maintained at the carpet warehouse. For example, there are three common door sizes that occur more often than any others. A variety of other common sized transition devices 300, 320 and 340 that are used in non-door applications can also be stocked.
The transition device 300, 320 and 340 are also very inexpensive (under one dollar including labor) to manufacture. Moreover, installation of the transition devices 300, 320 and 340 may be faster than seaming two pieces of carpet together.
In door applications, the doorstop 122 (
Now referring to
A transition device assembly in accordance with another embodiment of the present invention will now be discussed in reference to
Referring now to
As will be described below in reference to
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Referring now to
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The elongated T-shaped member 812 has an upper portion 818 and a base portion 820. The elongated T-shaped member 812 can be made from vinyl, plastic, rubber, composite materials, wood or metal. The upper portion 818 forms a downwardly shaped arc and is semi-flexible. The arced shape combined with a semi-flexible material allows the transition device assembly 800 to provide a substantially level, smooth or gradual transition between the two pieces of carpet 802, 804 with minimal or no gaps. In addition, the base portion 820 may have one or more longitudinally extending ridges or ribs (not shown) along each side of the base portion 820 that provide a more secure fit with the channel 832 of the elongated base 816. A friction fit, glue, a combination of glue and friction can be used to secure the base portion 820 in the channel 832 of the elongated base 816. Note that a friction fit allows the invention to be reused (e.g., snap in, pull out when new carpet is installed and snap back in).
The covering 814 is attached to the elongated T-shaped member 812 and tightly covers a top 822 and each side 824 of the upper portion 818 of the elongated T-shaped member 812. As shown, the covering 814 also covers portions of a bottom 826 of the upper portion 818 of the elongated T-shaped member 812. The covering 814 can be made from sheet vinyl, laminate and one or more vinyl pieces. In addition, the covering is typically decorative (e.g., wood-grain, slate, etc.) and wear-resistant. The covering is typically attached to the elongated T-shaped member 812 with double face tape, glue, staples, nails, screws, tacks or a combination thereof. In one case, there is also a notch (not shown) in each end of the covering 814 and the elongated T-shaped member 812 to accommodate a doorstop (not shown). In another case, the covering 814 also extends beyond the ends of the elongated T-shaped member 812 and has a notch (not shown) in each end of the extended covering (not shown) to accommodate a doorstop (not shown). Alternatively, there are no notches and the bottom of the doorstop (not shown) is removed as part of the installation.
The elongated base 816 is attached to the floor 810 with glue, masonry nails, screws or other fasteners (e.g., masonry nail 828). The elongated base 816 has a substantially flat portion 830 and a longitudinally extending upwardly opening channel 832 for receiving the base portion 820 of the elongated T-shaped member 812. Tack strip 834 is attached to the floor 810 via masonry nails 836. Tack strip 838 is attached to the base portion 820 via masonry nails 828. Note that the base portion 820 may also extend underneath tack strip 834 and padding 804. Carpet 802 is attached to the floor 810 via tack strip 834 and extends underneath one side of the upper portion 818 of the elongated T-shaped member 812. Similarly, carpet 806 is attached to the floor 810 via tack strip 838 and extends underneath one side of the upper portion 818 of the elongated T-shaped member 812. The elongated base 816, elongated T-shaped member 812 and the covering 814 have a combined height to provide a transition between the two pieces of carpet 802 and 806.
Referring now to
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In door applications, the doorstop 122 (
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The standard door transition devices/assemblies are produced and installed so that they appear to be cut around the doorstop pieces. Slots are cut into the elongated core before the covering is attached so that the installer can easily cut to the shape of the doorstop piece at the job site. The width of the door jam pieces is 5 inches, which corresponds to the normal width of standard door jams. After installation, the transition device/assembly should appear as if it was custom fitted to the door jam it is secured to. As for the ⅜ inch thickness, this elevation from the floor that the transition devices is glued to provide an edge that tack strip can be installed along. Once the tack strip is down, the carpet in the room can be stretched over the pins and the resulting edge can be tucked into the slot between the tack-strip and the transition piece. The finished transition piece and the carpet on either side of it will end up creating a level surface with no dip or raised edge that could create a tripping hazard.
Referring now to
For example, living room/dining room transition pieces can be enhanced by creating “L” combinations or installing angled transition devices/assemblies. The separation between the living room and dining room is where the most creativity can be used on the transition devices/assemblies. These transition devices/assemblies are usually in excess of 8 to 10 feet long and are preferably 7 inch wide if possible. Additionally, these transition devices/assemblies are usually in close proximity to the kitchen. When a new kitchen floor is installed with the identical wood plank patterned sheet vinyl that is used to wrap the transition devices/assemblies, the total effect is enhanced.
Non-doorway transition devices/assemblies are normally cut to final size at the job site. When the transition device/assembly is not located at a conventional doorway, its width and length are determined by the opening it is being installed into. Normally 7 inch pieces are more dramatic, but the wall space that the transition device/assembly abuts to may not be sufficient to accept a full 7 inch piece. In that case, a 5 inch transition device/assembly would have to be used instead.
Now referring to
Transition device assembly 1518 includes an elongated T-shaped semi-flexible member (between end points 1542 and 1544) and two or more bases 1520-1540 (indicated by the dashed lineds). The elongated T-shaped semi-flexible member (between end points 1542 and 1544) has an upper portion and a base portion as previously described. The two or more bases 1520-1540 have a substantially flat portion and an upwardly extending opening channel for receiving the base portion of the elongated T-shaped member (between end points 1542 and 1544). The two or more bases 1520-1540 and elongated T-shaped semi-flexible member (between end points 1542 and 1544) provide a transition between a non-linear first floor covering and a corresponding second floor covering. In other words, transition device assembly 1518 can be used to create arcs, circles and other non-linear floor patterns.
The embodiments and examples set forth herein are presented to best explain the present invention and its practical application and to thereby enable those skilled in the art to make and utilize the invention. However, those skilled in the art will recognize that the foregoing description and examples have been presented for the purpose of illustration and example only. The description as set forth is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching without departing from the spirit and scope of the following claims.
Claims
1. A transition device assembly comprising:
- an elongated T-shaped member having an upper portion and a base portion;
- a covering attached to the elongated T-shaped member and covering a top and each side of the upper portion of the T-shaped member;
- an elongated base having a substantially flat portion and a longitudinally extending upwardly opening channel for receiving the base portion of the elongated T-shaped member; and
- wherein the elongated base, elongated T-shaped member and the covering have a combined height to provide a transition between a first floor covering and a second floor covering.
2. The transition device assembly as recited in claim 1, wherein the elongated T-shaped member is semi-flexible.
3. The transition device assembly as recited in claim 1, wherein the upper portion of the elongated T-shaped member comprises a downwardly shaped arc.
4. The transition device assembly as recited in claim 1, wherein the base portion has one or more longitudinally extending ridges along each side of the base portion.
5. The transition device assembly as recited in claim 1, wherein the elongated T-shaped member has a cross section substantially as shown in FIG. 5.
6. The transition device assembly as recited in claim 1, wherein the elongated T-shaped member comprises vinyl, plastic, rubber, fiberglass, composite materials, wood and metal.
7. The transition device assembly as recited in claim 1, further comprising a notch in each end of the elongated T-shaped member, the covering and the elongated base to accommodate a doorstop.
8. The transition device assembly as recited in claim 1, wherein the covering is decorative and wear-resistant.
9. The transition device assembly as recited in claim 1, wherein the covering also covers portions of a bottom of the upper portion of the elongated T-shaped member.
10. The transition device assembly as recited in claim 1, wherein the covering comprises sheet vinyl, laminate, plastic, ceramic or one or more vinyl pieces.
11. The transition device assembly as recited in claim 1, wherein the covering is attached to the elongated member with double face tape, glue, staples, nails, screws, tacks or a combination thereof.
12. The transition device assembly as recited in claim 1, wherein the longitudinally extending upwardly opening channel is disposed substantially along a longitudinal center line of the substantially flat portion.
13. The transition device assembly as recited in claim 1, wherein the longitudinally extending upwardly opening channel is disposed between a longitudinal center line and a longitudinal edge of the substantially flat portion.
14. The transition device assembly as recited in claim 1, wherein the longitudinally extending upwardly opening channel is disposed substantially along a longitudinal edge of the substantially flat portion.
15. The transition device assembly as recited in claim 1, wherein the base portion of the elongated T-shaped member is secured within the channel of the elongated base with a friction fit, glue or a combination thereof.
16. The transition device assembly as recited in claim 1, wherein the first and second floor coverings comprise carpet, tile, wood, vinyl or laminate.
17. The transition device assembly as recited in claim 1, wherein the transition is substantially level, smooth or gradual.
18. The transition device assembly as recited in claim 1, further comprising a notch in each end of the elongated T-shaped member and the covering to accommodate a doorstop.
19. The transition device assembly as recited in claim 1, wherein the covering extends beyond the ends of the elongated T-shaped member.
20. The transition device assembly as recited in claim 19, further comprising a notch in each end of the extended covering to accommodate a doorstop.
21. A system comprising:
- an elongated T-shaped member having an upper portion and a base portion;
- a covering attached to the elongated T-shaped member and covering a top and each side of the upper portion of the T-shaped member;
- an elongated base attached to a floor having a substantially flat portion and a longitudinally extending upwardly opening channel for receiving the base portion of the elongated T-shaped member;
- a first floor covering attached to the floor and extending underneath one side of the upper portion of the elongated T-shaped member;
- a second floor covering attached to the floor and extending underneath the other side of the upper portion of the elongated T-shaped member; and
- wherein the elongated base, elongated T-shaped member and the covering have a combined height to provide a transition between the first floor covering and the second floor covering.
22. The system as recited in claim 21, wherein the first and second floor coverings are carpet and further comprising a first pad disposed between the first floor covering and the floor and a second pad disposed between the second floor covering and the floor.
23. The system as recited in claim 21, wherein the first and second floor coverings are attached to the floor using strips.
24. The system as recited in claim 21, wherein the first or second floor coverings extend over the substantially flat portion of the elongated base.
25. The system as recited in claim 21, further comprising a notch in each end of the elongated T-shaped member and the covering to accommodate a doorstop.
26. The system as recited in claim 21, wherein the covering extends beyond the ends of the elongated T-shaped member.
27. The system as recited in claim 26, further comprising a notch in each end of the extended covering to accommodate a doorstop.
28. A method for manufacturing a device for transitioning between a first floor covering and a second floor covering comprising the steps of:
- fabricating an elongated T-shaped member having an upper portion and a base portion;
- attaching a covering to the elongated T-shaped member such that the covering covers a top and each side of the upper portion of the T-shaped member;
- fabricating an elongated base having a substantially flat portion and a longitudinally extending upwardly opening channel for receiving the base portion of the elongated T-shaped member; and
- wherein the elongated base, elongated T-shaped member and the covering have a combined height to provide a transition between a first floor covering and a second floor covering.
29. The method as recited in claim 28, further comprising the step of cutting a notch in each end of the elongated T-shaped member and the covering to accommodate a doorstop.
30. The method as recited in claim 28, wherein the covering extends beyond the ends of the elongated T-shaped member.
31. The method as recited in claim 30, further comprising the step of cutting a notch in each end of the extended covering to accommodate a doorstop.
32. A transition device assembly comprising:
- an elongated T-shaped semi-flexible member having an upper portion and a base portion;
- two or more bases having a substantially flat portion and an upwardly extending opening channel for receiving the base portion of the elongated T-shaped member; and
- wherein the two or more bases and elongated T-shaped semi-flexible member provide a transition between a non-linear first floor covering and a corresponding second floor covering.
Type: Application
Filed: Aug 25, 2005
Publication Date: Dec 22, 2005
Applicant: Arbor Contract Carpet (Irving, TX)
Inventor: Paul Devereux (Irving, TX)
Application Number: 11/211,307