Portable floor and method of manufacture and installation

Abstract

A portable floor is provided comprising a first panel board, a second panel board and a biscuit. The first panel board has a plurality of first panel sides, where one of the first panel sides includes a first panel slot. The second panel board has a plurality of second panel sides, where one of the second panel sides includes a second panel slot. The biscuit inserted into the first panel slot and the second panel slot.

Description

FIELD OF THE INVENTION

The present invention relates generally to a portable floor and a method of creating and installing the portable floor.

BACKGROUND OF THE INVENTION

Conventional portable floors tend to be complicated to install and manufacture, and require numerous, bulky pieces. Thus, there is a need for a simple, light weight portable floor that is easy to manufacture.

SUMMARY OF THE INVENTION

In accordance with the present invention, a floor panel is provided comprising a panel board and a biscuit. The panel board has a top surface, a bottom surface, and a plurality of sides. One side of the panel board includes a first slot and a second side includes a second slot. The biscuit is attached to the first slot or the second slot.

In accordance with the present invention, a portable floor is provided comprising a first panel board, a second panel board and a biscuit. The first panel board has a plurality of first panel sides, where one of the first panel sides includes a first panel slot. The second panel board has a plurality of second panel sides, where one of the second panel sides includes a second panel slot. The biscuit is inserted into the first panel slot and the second panel slot.

In accordance with the present invention, a method is provided, comprising the steps of locking a tongue of a first interlocking panel into a groove of a second interlocking panel to form a row of interlocking panels, attaching the row of interlocking panels to a surface of a substrate, locking a tongue of a third interlocking panel to a groove of a fourth interlocking panel to form a second row of interlocking panels, attaching the second row of interlocking panels to the surface of the substrate adjacent the first row of interlocking panels, wherein the substrate, first row of interlocking panels and second row of interlocking panels forms a floor panel, trimming a groove from the first interlocking panel, trimming a tongue from the second interlocking panel, trimming a groove from the third interlocking panel, trimming a tongue from the fourth interlocking panel, and carving a slot on a side of the floor panel.

Other systems, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an implementation of the invention and, together with the description, serve to explain the advantages and principles of the invention. In the drawings,

FIG. 1 depicts a top perspective view of one embodiment of a floor panel, in accordance with the present invention;

FIG. 2 depicts a bottom perspective view of the floor panel shown in FIG. 1;

FIG. 3 depicts a top view of one embodiment of a biscuit, in accordance with the present invention;

FIG. 4 depicts a top view of another embodiment of a biscuit in the unlocked position, in accordance with the present invention;

FIG. 5 depicts a top view of the biscuit shown in FIG. 3 in the locked position;

FIG. 6 depicts a top perspective view of an interlocking panel, in accordance with the present invention;

FIG. 7 depicts a front view of the interlocking panel shown in FIG. 6;

FIG. 8 depicts a front view of two interlocking panels with the tongue of one panel inserted into the groove of the second panel, in accordance with the present invention;

FIG. 9 depicts a perspective view of two interlocking panels shown in FIG. 8;

FIG. 10 depicts a front view of the two interlocking panels shown in FIG. 8 with the panels in the locked position;

FIG. 11 depicts a perspective view of three interlocking panels attached to a substrate, in accordance with the present invention;

FIG. 12 depicts a perspective view of nine interlocking panels attached to a substrate, in accordance with the present invention;

FIG. 13 depicts a perspective view of the nine interlocking panels attached to the substrate shown in FIG. 12 with the edges of the panels trimmed;

FIG. 14 depicts a perspective view of two floor panels and a transition, in accordance with the present invention;

FIG. 15 depicts a perspective view of the transition shown in FIG. 14;

FIG. 16 depicts a cross-sectional view of the transition attached to the two floor panels shown in FIG. 14;

FIG. 17 depicts a perspective view of a U-bolt connecting two floor panels, in accordance with the present invention;

FIG. 18 depicts a perspective view of one embodiment of a locking mechanism in the unlocked position;

FIG. 19 depicts the locking mechanism shown in FIG. 18 in the locked position; and

FIG. 20 depicts a perspective view of a portable floor, in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to implementations consistent with the present invention as illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same or like parts.

FIG. 1 depicts one embodiment of a floor panel 100. Floor panel 100 includes a panel board 110 with slots 120 carved into each side 130 of the panel board 110, a number of biscuits 140 inserted into some of the slots 120, and a number of support blocks 170 under the panel board 110. Although depicted with three slots 120 in each side 130 of the floor panel 100, one skilled in the art will appreciate that any number of slots 120 can be carved into each side 130 of the floor panel 100 without departing from the scope of the invention.

Biscuits 140 are inserted into the slots 120 to ensure that adjacent floor panels 100 are aligned. Biscuits 140 may be made of any rigid material, such as wood, plastic or metal. Biscuit 140 may be a single piece, as depicted in FIG. 3. Alternatively the biscuit may include two pieces, such as a Simplex biscuit 150. FIG. 4 depicts the Simplex biscuit 150 in the unlocked position, and FIG. 5 depicts the Simplex biscuit 150 in the locked position. Each 1/2 Simplex biscuit 160 is inserted into the corresponding slots 120 of adjacent floor panels 100 so that the Simplex biscuits 150 not only align the floor panels, but also lock the floor panels 100 together. Floor panel 100 is shown with three single-piece biscuits 140 on one side, one 1/2 Simplex biscuit 160 and two empty slots 120 on the second side, three empty slots 120 on the third side, and one 1/2 Simplex biscuit 160 and two single-piece biscuits 140 on the fourth side. One skilled in the art, however, will recognize that any combination of biscuits can be used between the floor panels 100 without departing from the scope of the invention. For example, floor panel 100 may include three single-piece biscuits 140 on one side, three empty slots 120 on the opposite side, and three 1/2 Simplex biscuits 160 in the remaining slots.

The biscuits may be attached to the slots 120 by any means known in the art. For example, the biscuits may be glued into the slots 120 or may include barbs to frictionally hold the biscuit in the slot 120.

Support blocks 170 are attached to the bottom of the floor panel 100 to allow a user to run cables under the portable floor. The support blocks 170 also provide additional support for the flooring, and distribute the weight across each floor panel 100. Although depicted with nine support blocks 170, one skilled in the art will appreciate that any number of support blocks 170 can be attached to each floor panel 100 without departing from the scope of the invention.

FIGS. 6-11 illustrate one method of constructing a floor panel 100 in accordance with the present invention. An interlocking panel 600, depicted in FIG. 6, is used to construct the surface of a floor panel 100 in accordance with the present invention. One example of such an interlocking panel is provided by Kährs. Other examples of interlocking panels are described in U.S. Pat. Nos. 6,606,834; 6,588,166; 6,532,709; 6,510,665; and 6,516,579.

Interlocking panel 600 includes a top surface 610 having a desired flooring finish, for example as illustrated with a hardwood floor finish. Interlocking panel 600 also includes a tongue 620 along one end of the panel, and a groove 630 along the opposite end of the panel. As depicted in FIGS. 8 and 9, the tongue 620 of one interlocking panel 600 can be placed into the groove 630 of another interlocking panel 600 so that when the interlocking panels 600 are aligned as depicted in FIG. 10, the panels 600 lock together.

In the present invention, a number of interlocking panels 600 are locked together to form one row of panels 1100. For example, as depicted in FIG. 11, three interlocking panel 600 are locked together to form the row of panels 1100. Although depicted with three interlocking panels 600, one skilled in the art will appreciate that any number of interlocking panels 600 can be locked together to form the row of panels 1100 without departing from the scope of the invention. The row of panels 1100 is attached onto a substrate 1110, for example by gluing the row 1100 onto the substrate 1110. The substrate 1110 is made of a rigid material, such as a particle board, plywood, luaun, or any other type of wood. Preferably, the substrate 1110 will be made of a light-weight material to reduce the weight of the floor panel 100 to make it easier to handle. For example, the substrate 1110 may be made of a 1/8 inch featherply.

Additional rows of panels 1100 are attached to cover the surface of the substrate 1110, as illustrated in FIG. 12. The edges 1120 of the rows of panels 1100 are trimmed to remove the outer tongues 1130 and grooves 1140, and form a rectangular panel board 110, as depicted in FIG. 13. Slots 120 are carved into the sides 130 of the panel board 110, and biscuits are attached to the slots 120, as described above. Support blocks 170 are also attached to the bottom of the panel board 110 by any conventional means, such as by nailing or gluing the support blocks 170 to the panel board 110, to form the floor panel 100 of the present invention.

Two floor panels 100 are attached by inserting a single-piece biscuit 140 in a first floor panel into the corresponding empty slot 120 of a second floor panel, and by locking one 1/2 Simplex biscuit 160 in the first floor panel into the corresponding 1/2 Simplex biscuit 160 in the second floor panel, as depicted in FIG. 14. In addition, a transition 1400 can be used to further lock together two floor panels 100 along the outer edge of the final flooring. Transition 1400 includes prongs 1410 that can be inserted into holes 1420 drilled into two support blocks 1430 of adjacent floor panels 100, as shown in detail in FIG. 14. FIG. 16 illustrates a cross-section through the prong 1410 of the transition 1400 after the transition 1400 is inserted into the blocks 1430 of adjacent floor panels 100. Alternatively, a U-bolt 1700 can be placed through holes in adjacent floor panels 100 to lock adjacent panels 100 together along the outer edge of the final floor, as illustrated in FIG. 17.

FIG. 18 depicts one embodiment of a locking mechanism to hold the transition 1400 onto the panel board 110. The locking mechanism includes a first part 1800 and a second part 1810. The first part 1800 includes a recess 1820 between two walls 1830, and the second part includes a prong 1840. The prong 1840 of the second part 1810 engages the recess 1820 of the first part 1800 to lock the transition 1400 onto the panel board 110, as depicted in FIG. 19. Although depicted with the first part 1800 attached to the panel board 110 and the second part 1810 attached to the transition 1400, one skilled in the art will appreciate that the first and second parts may be switched.

The locking mechanism may be attached to the transition 1400 and the panel board 100 by any means known in the art. For example, screws 1850 may be used to attach the first part 1800 and the second part 1810 to the panel board 110 and the transition 1400.

One skilled in the art will appreciate that the methods described above to attach the panel boards 110 together or to attach the transitions 1400 to the panel boards 110 may be used in various combinations without departing from the scope of the invention. For example, biscuits 140 and/or Simplex biscuits 150 may be used to attach transitions 1400 onto the panel boards 110. Similarly, locking mechanism 1800, 1810 may be used to hold the panel boards 110 together. Moreover, a combination of biscuits, Simplex biscuits and locking mechanisms may be used to attach the various pieces together.

After all floor panels are attached and locked together with transitions 1400, additional transitions 1440 are attached around the floor panels to create a portable floor 2000, as illustrated in FIG. 20. Although depicted with four floor panels 100, one skilled in the art will appreciate that any number of floor panels can be attached together to form the portable floor without departing from the scope of the invention.

While various embodiments of the present invention have been described, it will be apparent to those of skill in the art that many more embodiments and implementations are possible that are within the scope of this invention. Accordingly, the present invention is not to be restricted except in light of the attached claims and their equivalents.

Claims

1. A portable floor, comprising.

a first panel board having a plurality of first panel sides, wherein one of the plurality of first panel sides includes a first panel slot;

a second panel board having a plurality of second panel sides, wherein one of the plurality of second panel sides includes a second panel slot;

a first 1/2 Simplex biscuit inserted into the first panel slot;

a second 1/2 Simplex biscuit inserted into the second panel slot, wherein the first 1/2 Simplex biscuit locks into the second 1/2 Simplex biscuit;

a transition; and

a locking mechanism between the transition and the panel board, wherein the locking mechanism attaches the transition to the panel board.

2. The portable floor of claim 1, further comprising:

a first support block attached to the bottom of the first panel board; and

a second support block attached to the bottom of the second panel board.

3. The portable floor of claim 1, wherein the one of the plurality of first panel sides includes a third panel slot and the one of the plurality of second panel sides includes a fourth panel slot, the portable floor further comprising:

a biscuit inserted into the third panel slot and the fourth panel slot.

4. The portable floor of claim 1, wherein a second one of the plurality of first panel sides includes a third panel slot, the portable floor further comprising:

a third panel board having a plurality of third panel sides, wherein one of the plurality of third panel sides includes a fourth panel slot; and

a biscuit inserted into the third panel slot and the fourth panel slot.

5. A portable floor, comprising.

a first panel board having a plurality of first panel sides, wherein one of the plurality of first panel sides includes a first panel slot;

a second panel board having a plurality of second panel sides, wherein one of the plurality of second panel sides includes a second panel slot;

a first 1/2 Simplex biscuit inserted into the first panel slot; and

a second 1/2 Simplex biscuit inserted into the second panel slot, wherein the first 1/2 Simplex biscuit locks into the second 1/2 Simplex biscuit.

6. The portable floor of claim 5, further comprising:

a first support block attached to the bottom of the first panel board, wherein the first support block includes a first hole;

a second support block attached to the bottom of the second panel board, wherein the second support block includes a second hole;

a transition;

a first prong attached to the transition, wherein the first prong is insertable into the first hole of the first support block; and

a second prong attached to the transition, wherein the second prong is insertable into the second hole of the second support block.

7. The portable floor of claim 5, wherein a second one of the plurality of first panel sides includes a third panel slot, the portable floor further comprising:

a transition having a fourth panel slot; and

a biscuit inserted into the third panel slot and the fourth panel slot.

8. The portable floor of claim 5, wherein a second one of the plurality of first panel sides includes a third panel slot, the portable floor further comprising:

a transition having a fourth panel slot;

a first 1/2 Simplex biscuit inserted into the third panel slot; and

a second 1/2 Simplex biscuit inserted into the fourth panel slot, wherein the first 1/2 Simplex biscuit locks into the second 1/2 Simplex biscuit.

9. The portable floor of claim 5, wherein the one of the plurality of first panel sides includes a third panel slot and the one of the plurality of second panel sides includes a fourth panel slot, the portable floor further comprising:

a biscuit inserted into the third panel slot and the fourth panel slot.

10. The portable floor of claim 5, wherein a second one of the plurality of first panel sides includes a third panel slot, the portable floor further comprising:

a third panel board having a plurality of third panel sides, wherein one of the plurality of third panel sides includes a fourth panel slot; and

a biscuit inserted into the third panel slot and the fourth panel slot.

11. A portable floor, comprising.

a first panel board having a plurality of first panel sides, wherein one of the plurality of first panel sides includes a first panel slot;

a second panel board having a plurality of second panel sides, wherein one of the plurality of second panel sides includes a second panel slot; and

a biscuit inserted into the first panel slot and the second panel slot.

12. The portable floor of claim 11, further comprising:

a transition; and

a locking mechanism between the transition and the panel board, wherein the locking mechanism attaches the transition to the panel board.

13. The portable floor of claim 11, further comprising:

a first support block attached to the bottom of the first panel board, wherein the first support block includes a first hole;

a second support block attached to the bottom of the second panel board, wherein the second support block includes a second hole;

a transition;

a first prong attached to the transition, wherein the first prong is insertable into the first hole of the first support block; and

a second prong attached to the transition, wherein the second prong is insertable into the second hole of the second support block.

14. The portable floor of claim 11, wherein a second one of the plurality of first panel sides includes a third panel slot, the portable floor further comprising:

a transition having a fourth panel slot; and

a biscuit inserted into the third panel slot and the fourth panel slot.

15. The portable floor of claim 11, wherein a second one of the plurality of first panel sides includes a third panel slot, the portable floor further comprising:

a transition having a fourth panel slot;

a first 1/2 Simplex biscuit inserted into the third panel slot; and

a second 1/2 Simplex biscuit inserted into the fourth panel slot, wherein the first 1/2 Simplex biscuit locks into the second 1/2 Simplex biscuit.

16. The portable floor of claim 11, wherein the one of the plurality of first panel sides includes a third panel slot and the one of the plurality of second panel sides includes a fourth panel slot, the portable floor further comprising:

a biscuit inserted into the third panel slot and the fourth panel slot.

17. The portable floor of claim 11, wherein a second one of the plurality of first panel sides includes a third panel slot, the portable floor further comprising:

a third panel board having a plurality of third panel sides, wherein one of the plurality of third panel sides includes a fourth panel slot; and

a biscuit inserted into the third panel slot and the fourth panel slot.

18. A method, comprising the steps of.

carving a slot on a side of the floor panel;

inserting a biscuit to the slot; and

attaching a supporting block to the bottom of the floor panel.

19. A floor panel, comprising:

a panel board having a top surface, a bottom surface, and a plurality of sides, wherein a first of the plurality of sides includes a first slot and a second of the plurality of sides includes a second slot; and

a biscuit inserted to the first slot.

20. The floor panel of claim 19, further comprising: a 1/2 Simplex biscuit inserted to the second slot.

21. The floor panel of claim 19, further comprising:

a 1/2 Simplex biscuit inserted to the second slot.