Modular flooring system

Abstract

A modular wood flooring system comprising a plurality of multi-layer flooring sections, provided in pre-measured sectional units and adapted for rapid installation is disclosed. Each flooring section includes a resilient bottom layer, an intermediate sub-floor layer, and a top wood flooring layer. The ends of adjoining sections are staggered to avoid the appearance of a straight line seam. Each flooring section further includes a top edge portion adapted with a recessed latching mechanism to allow the sections to be mechanically connected. A first flooring section is adapted with a male latch member and a second flooring section is adapted with a female latch receiving member for receiving the male latch member of an adjoining first flooring section. The latching mechanism is recessed into an opening formed in the intermediate plywood sub-floor layer and configured so as to be generally flush therewith to permit the latch to be covered by a portion of wood flooring laterally projecting from an adjacent flooring section. The latching mechanism is manually configurable between latched and un-latched configurations without requiring tools.

Description

MODULAR FLOORING SYSTEM CROSS REFERENCE TO RELATED APPLICATIONS

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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

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COPYRIGHT NOTICE

A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyrights rights whatsoever.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to flooring systems, and more particularly to a sectional made-to-measure engineered wood flooring system having a plurality of pre-assembled wood flooring sections adapted with mechanical latching mechanisms for rapid and efficient installation.

2. Description of Related Art

Wood flooring is a popular floor covering choice for homes, commercial environments, and public facilities. There are many types, sizes, colors, application methods, and the variety of wood floor species currently on the market. Wood flooring material is commonly available in solid wood, engineered wood, and acrylic impregnated forms. Solid wood flooring comprises a single piece of wood from top to bottom and is available in a variety of species, stains and finishes. Engineered wood flowing consists of layers of wood pressed together, with the grains running in different directions, and is typically available in 3 and 5 ply. Because the grains run in different directions, engineered wood flowing is more dimensionally stable than solid wood. Acrylic impregnated wood flowing is fabricated by a process where acrylics are injected into the wood itself, creating a super-hard, extremely durable floor. This type of flooring is often used in commercial installations, like shopping malls and restaurants, however, they are right at home in busy households as well.

Installation of wood flooring is typically a time consuming process that generates substantial wood flooring waste product. Wood flooring is typically installed plank by plank in a time consuming process that and generates approximately 10%-15% waste as planks are cut and trimmed to fit the space. In addition, job site conditions often require the installation of a plywood sub-floor and sound attenuating underlayment. Underlayment is typically required for installation of laminate flooring or engineered real wood flooring. The function of underlayment is to absorb some of the minor imperfections in the sub-floor, and to help deaden sound when walking on the floor. Accordingly, the underlayment reduces overhead sound in rooms below the flooring in addition to lessening the affects of sub-floor imperfections. The sound reducing quality is especially true of cork underlayment. Accordingly, wood flooring installation is a costly, time consuming, and wasteful process.

As a result of the recognized disadvantages associated with conventional wood flooring systems, the background art reveals a number of attempts to improve the efficiency of conventional wood flooring systems and installation techniques. For example, U.S. Pat. No. 1,045,219, issued to Tramill, discloses a portable sectional elevated floor that may be disposed compactly for transportation and quickly assembled. U.S. Pat. No. 1,778,352, issued to Bruce, discloses short pieces of flooring formed into unitary blocks that are installed and connected using spline and groove structures. U.S. Pat. No. 1,925,070, issued to Livezey, discloses wood block flooring laid on a plastic cement sub-floor. U.S. Pat. No. 2,652,753, issued to Smith, discloses intermeshing sectional matting adapted for forming ground level platforms and walkways.

The background art further reveals attempts directed to providing sectional flooring systems. For example, U.S. Pat. No. 4,289,420, issued to Davis, discloses a wooden mat assembly for construction of temporary roadway surfacing. The wooden mat assembly is formed from interlocking mats, each mat being formed from a plurality of layers or boards, each layer being formed from boards parallel to each other and perpendicular to boards forming the adjacent layer, the layers being fastened together at points of intersection by screw shank nails or other fastening means.

U.S. Pat. No. 4,538,392, issued to Hamar, discloses portable sectionalized flooring suitable for a basketball court or the like is assembled from a plurality of separate floor sections arranged in rows with each section composed of interengaged tongue and groove strips defining the floor surface, spaced stringers extending transversely of such strips and an underlayment interposed between the strips and stringers. The sections are adapted with interlocking finger joints and secured by latch devices.

U.S. Pat. No. 4,988,131, issued to Wilson, discloses, interlocking sections for portable floors and the like. The interlocking members latch a male member and a female member fitting into recesses along the edges of the floor section. A release mechanism, actuated by an Allen key wrench, has a cam member which engages springs to release the male locking member.

U.S. Pat. No. 5,987,839, issued to Hamar, discloses a method and apparatus for the construction of a two-layer flooring system formed by interlocking both the ends and sides of a plurality of mat units. Each of the mat units includes two layers of boards, and includes end locking tabs extending beyond the edge of the first layer and corresponding end locking slots, formed by offsetting selected boards.

The references disclosed in the background art include complex sectional flooring systems that fail to adequately address problems existing in the art. More particularly, the flooring systems of the background art fail to provide a modular sectional flooring system wherein each section is comprised of sub-floor and underlayment layers and adapted with a simple mechanical latching mechanism to allow for sections to be quickly and easily installed and secured. Accordingly, there exists a need for an improved sectional wood flooring system that overcomes the limitations and disadvantages present in the art.

BRIEF SUMMARY OF THE INVENTION

The present invention overcomes the limitations and disadvantages in the art by providing a modular wood flooring system comprising a plurality of multi-layer flooring sections, provided in pre-measured sectional units each including a resilient bottom layer, an intermediate sub-floor layer, and a top wood flooring layer. The ends of adjoining sections are preferably staggered to avoid the appearance of a straight line seam. Each flooring section further includes a laterally projecting edge portion adapted with a recessed latching mechanism to allow the sections to be mechanically connected. More particularly, a first flooring section is adapted with a male latch member and a second flooring section is adapted with a female latch member for receiving the male latch member of an adjoining first flooring section. The latching mechanism is recessed into an opening formed in the intermediate plywood sub-floor layer and configured so as to be generally flush therewith to permit the latch to be covered by a portion of wood flooring laterally projecting from an adjacent flooring section. The latching mechanism is manually configurable between latched and un-latched configurations without requiring tools.

Accordingly, it is an object of the present invention to provide an improved modular flooring system that may be fabricated in made-to-order dimensional specifications for rapid installation with little or no waste.

Another object of the present invention is to provide such a flooring system wherein each section comprises a multi-layer configuration including a resilient underlayment layer, an intermediate plywood sub-floor layer, and a top wood flooring layer.

Still another object of the present invention is to provide such a flooring system adapted with a mechanical latching mechanism to facilitate rapid mechanical connection of adjoining sections.

These and other objects are met by the present invention which will become more apparent from the accompanying drawing and the following detailed description of the drawings and preferred embodiments.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is an exploded plan view showing a plurality of modular wood flooring sections in separated relation;

FIG. 2 is a plan view showing the modular wood flooring sections shown in FIG. 1 in a joined configuration;

FIGS. 3 and 4 are end views of sections in the separated and joined configurations respectively;

FIG. 5 is an exploded perspective view showing modular flooring sections having an alternate staggered end configuration in a separated configuration;

FIG. 6 is a perspective view thereof with the sections in a joined configuration;

FIG. 7 is an exploded perspective view of the mechanical latching mechanism formed by a male latching member on a first flooring section and a female latch receiving member on a second flooring section;

FIG. 8 is a side sectional view of the mechanical latching mechanism in the un-latched configuration;

FIG. 9 is a side sectional view thereof depicting the male latching member pivoting from the un-latched configuration; and

FIG. 10 is a side sectional view thereof depicting the mechanical latching mechanism in the latched configuration.

DETAILED DESCRIPTION OF THE INVENTION

With reference now to the drawings, FIGS. 1-10 depict a preferred embodiment of a sectional wood flooring system, generally referenced as 10, in accordance with the present invention. As best illustrated in FIGS. 1-4, wood flooring system 10 comprises a plurality of multi-layer flooring sections, referenced as 12a-12i adapted for installation in covering relation with an underlying surface in interlocking mating relation. Each flooring section 12, has opposing ends that are either linear or staggered depending on the intended placement of the sections. For example, sections 12a, 12b, 12c, 12g, 12h, and 12i, each have a linear end and an opposing staggered end. The linear edge is intended for placement adjacent to a wall while the staggered end is intended for interlocking adjoining relation with similarly staggered end formed by an adjacent section to avoid the appearance of a straight line seam. Similarly, sections 12d, 12e, 12f, have opposing ends that are terminate in a staggered configuration and are thus intended for installation in an intermediate position. In a typical installation flooring system 10 is installed in a residential or commercial building in covering relation with an otherwise unfinished concrete floor. Flooring sections are preferably fabricated in accordance with the dimensional specifications for a particular job to allow for the fabrication, shipment, and installation of a wood floor that precisely fits a space without requiring significant cutting or trimming. In a preferred embodiment, sections are fabricated of uniform width and varying lengths to allow a floor to be formed to fit most common room sizes. For example, sections may me dimensioned each with a width of 2 feet, and lengths of 1 foot, 3 feet, and 5 feet respectively thereby allowing for combinations to provide a wide variety of dimensions.

In a preferred embodiment, each flooring section 12 includes a resilient bottom layer 14, an intermediate sub-floor layer 16, a top wood flooring layer 18, and a latching mechanism 20. Resilent bottom layer 14 preferably comprises cork, however, any suitable resilient underlayment is considered within the scope of the present invention. As noted herein above, the resilient underlayment 14 absorbs minor imperfections in the supporting unfinished concrete floor, and helps deaden sound. Intermediate sub-floor layer 16 preferably comprises plywood of suitable thickness (e.g. nominal ½″ or ¾″ thickness) and provides a structure suitable for attachment to resilient bottom layer 14 on the bottom surface thereof and the wood flooring layer 20 18 on the top surface thereof. Upper wood floor layer 18 may comprise any suitable laminate or engineered wood flooring.

FIGS. 5 and 6 depict alternately shaped modular wood flooring sections, generally referenced as 12j and 12k. Each flooring section 12 includes a resilient bottom layer 14, an intermediate sub-floor layer 16, a top wood flooring layer 18, and a latching mechanism 20. As discussed in more detail below, intermediate sub-floor layer 16 has a lateral edge 17 that projects outward from the corresponding lateral edge of the upper wood flooring layer 18. Projecting lateral edge 17 is adapted with an upwardly projecting tongue 19 and mechanical latching hardware, generally referenced as 20, as best seen in FIG. 6. More particularly, intermediate sub-floor layer 16 has an edge portion 17 adapted with mechanical latching hardware, namely a latch mechanism 20 that functions to fix adjoining sections in the installed position. In addition, edge portion 17 is further adapted with an upwardly projecting tongue 19 configured for mating tongue and groove connection to a groove 15 defined in the undersurface of an overlapping edge portion of an upper layer 18 from an adjacent section.

As best seen in FIGS. 7-10, each latch mechanism comprises a male latch member 22 and a female latch receiving member 24, each of which are receivably disposed within corresponding openings formed within intermediate plywood layer 16 as best illustrated in FIG. 3. Male latch member 22 includes a latch housing 26 adapted with resilient side wall clips 28 that engage intermediate plywood layer 16 and provide for secured snap fit engagement therewith. Latch housing 26 further includes latch 30 secured thereto in pivotal relation therewith by a pivot pin 32 insertedly received within an aperture 33 on the proximal end thereof. Latch 30 further includes an intermediate body portion having first and second projecting anchors, referenced as 34 and 36, that function to engage portions of the latch mechanism in the latched configuration. In addition, latch 30 includes a distal end portion forming a resilient clip 38 that functions to retain latch 30 in either the unlatched configuration depicted in FIG. 8 or the latched configuration shown in FIG. 10. It should be noted that male latch member, including latch housing 26 and latch 30 are generally flush (or slightly recessed) relative to the top surface of intermediate plywood layer 16j so as to enable a projecting portion of wood flooring from and adjacent section to project thereover in covering relation therewith so as to conceal latch mechanism 20 in the finished installation. Female latch receiving member 24 comprises a latch receiving housing received within an opening formed in intermediate plywood layer 16k. Female latch receiving member 24 includes resilient side wall clips 25 that engage intermediate plywood layer 16k and provide for secured snap fit engagement therewith. In an alternate embodiment, latch members 22 and 24 may be secured to intermediate plywood layer 16 by fasteners. As illustrated in FIG. 1, sections are configured with either one or two latch members. For example, section 12a, which is intended for installation with one end up against a wall includes a single male latch member, whereas section 12d which is an intermediate section includes a male latch member at one end and a female latch receiving member at the other end. An advantage of the he latch mechanism disclosed herein is the ability to configure the latch between latched and unlatched configurations without the use of special tools.

As best illustrated in FIGS. 8-10, latching mechanism functions to secure adjoining flooring sections once said sections are placed in adjacent relation by pivoting latch member 30 from the unlatched configuration shown in FIG. 8, upward as illustrated in FIG. 9, and into a latched configuration in engagement with female latch receiving member 24 as seen in FIG. 10. As illustrated in FIG. 10, once in the latched configuration the entire latching mechanism is recessed into openings formed in the intermediate plywood sub-floor layers and configured so as to be generally flush therewith to permit latching mechanism 20 to be covered by a portion of wood flooring laterally projecting from an adjacent flooring section.

In addition, a significant aspect of the present invention includes providing a latching mechanism is manually configurable between latched and un-latched configurations without requiring tools. More particularly, the resilient distal end 38 of latch member 30 may be disengaged from latch housing 26 and moved from the unlatched configuration to the latched configuration manually without the need for tools. Similarly, the resilient distal end 38 of latch member 30 may be disengaged from female latch receiving member 24 and moved from the latched to the unlatched configuration manually without the need for tools.

The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to a person skilled in the art.

Claims

1. A modular flooring system comprising:

a plurality of modular flooring sections, including first and second connectable flooring sections, each of said flooring sections having at least one end terminating in staggered configuration;

said first and second flooring sections each including a resilient layer, an intermediate rigid layer, and a top wood floor layer;

said intermediate rigid layer having a lateral edge portion projecting beyond the corresponding lateral edge of said top wood floor layer;

said lateral edge portion of said first flooring section including a male latch mechanism;

said lateral edge portion of said second flooring section including a female latch receiving mechanism;

said first and second flooring sections connectable in end to end relation and selectively secured by engagement of said male latch mechanism on said first flooring section with said female latch receiving mechanism on said second flooring section.

2. A modular flooring system according to claim 1, wherein said lateral edge portion projecting beyond the corresponding lateral edge of said top wood floor layer further includes a raised tongue.

3. A modular flooring system comprising:

a plurality of modular flooring sections, including first and second connectable flooring sections, each of said flooring sections having opposing side edges and opposing ends with at least one end terminating in staggered configuration;

each flooring section including a resilient layer, an intermediate rigid layer, and a top wood floor layer, said an intermediate rigid layer having a projecting lateral side edge extending beyond the corresponding lateral side edge of said top wood floor layer and adapted with at least one latch mechanism and an upwardly projecting raised tongue, said top wood floor layer having a projecting opposing lateral side edge extending beyond the corresponding lateral side edge of said intermediate rigid layer, said projecting opposing lateral side edge having an undersurface defining a recessed groove;

said first and second flooring sections connectable in end-to-end relation and selectively secured by engagement of said at least one latch mechanism on said first flooring section with said at least one latch mechanism on said second flooring section.

4. A modular flooring system according to claim 3, further including a third connectable flooring section having opposing side edges and opposing ends, said third flooring section disposed in adjacent side-by-side relation with said first flooring section such that said projecting lateral side edge of said third flooring section is disposed in overlapping relation with said projecting lateral side edge of said intermediate rigid layer of said first floor section such that the recessed groove defined on the undersurface thereof engages the tongue defined on said first flooring section so as to secure said third flooring section relative to said first flooring section.

5. A modular flooring system according to claim 3, wherein said latch mechanism comprises a male latch member receivably disposed within a corresponding opening defined in said intermediate rigid layer of said first flooring section, and a female latch receiving member receivably disposed within a corresponding opening defined in said intermediate rigid layer of said second flooring section.

6. A modular flooring system according to claim 5, wherein said male latch member is pivotally adjustable between an unlatched configuration to a latched configuration without the use of tools.

7. A modular flooring system according to claim 6, wherein said male latch member comprises a latch secured in pivotal relation with said flooring section by a pivot pin inserted through a proximal end thereof, an intermediate body portion having first and second projecting anchors for engaging portions of said female latch receiving member in the latched configuration, and a distal end portion forming a resilient clip for retaining that functions to retain said latch in either latched or unlatched configurations.