Wood Floor Gap Jack
A flooring installation tool for closing gaps between wooden floorboards by straightening bowed floorboards or bending straight floorboards installed on a sub floor. The main components are: a base, a threaded rod, a main nut, a pushing foot, a push plate; and a pull plate. The tool base is affixed to or abuts a building structure with the pushing foot abutting a bowed floorboard to be installed. The main nut is turned; linear force is exerted closing gaps between the floorboard being installed and a previously installed floorboard. The push plate when placed between the pushing foot and floorboard allows fastening of floorboard in-line with the exerted linear force. To install the last floorboard the pull plate is placed under the base hooking on the edge of the floorboard exerting linear force between the wall and last floorboard closing gaps between floorboards. The pushing foot swivels to self align.
The invention relates to tools and methods to close gaps between wooden floorboards by straightening bowed floorboards or bend straight floorboards during installation by forcing abutting edges of individual pieces of flooring into proper position till they can be fastened in place to the sub floor.
BACKGROUND OF THE INVENTIONTongue and grove natural wood flooring inside homes has been and will probably always be desired for the durability and beauty of natural wood. Unsightly gaps, loose fitting floorboards, and runs of floorboards that are not straight result if floorboards are not abutted tightly when fastened in place, all of which diminish the durability and beauty of a natural wood floor.
Presently wooden tongue-and-grove floorboards inside homes are typically installed on top of plywood sub floors. The installation process is to secure a first row of floorboards to the plywood sub floor parallel to a starting wall in a room; one floorboard at a time is installed secured to the sub floor tightly abutting a previously installed floorboard. When securing floorboards to a sub floor it is a common practice to use nails or staples as fasteners to secure the floorboard in place to the sub floor. Tongue and grove floorboards have tongue-and-grove edges. When nailing or stapling a floorboard in place the fastener is driven on the tongue edge of the floorboard above the tongue on an angle into the sub floor. The driving force and angle of the fastener when securing the floorboard to the sub floor drives the floorboard being installed into a tighter abutment with a previously installed floorboard. As each new piece of floorboard is installed the grove edge of the new piece of floorboard is abutted to the tongue edge of a previously installed floorboard. The design of the tongue-and-grove edges is to have the grove of the new piece of floorboard being installed to conceal the fastener in the previously installed floorboard. This method has the floorboards secured in place with one edge of the floorboard's grove held by the tongue of an abutting secured floorboard and on the tongue edge secured with fasteners. The flooring is installed from the base of a starting wall to the base of a finishing wall.
One of the problems for the installers of tongue-and-grove wooden floorboards is a gap between floorboards during installation. Due to the nature of wood cutting new wooden floorboards often warp in the horizontal plane forming a flat curved board. A new floorboard that is warped when abutted against a previously installed straight floorboard leaves a gap between the abutting edges. As the floor is installed piece by piece from the base of the starting wall to the base of the finishing wall gaps that are not closed add up, the floorboards as a group are no-longer, tight, parallel or straight. The same problem exists if the previously installed floorboard is warped and the new floorboard to be installed is straight or also warped. When installing a new piece of floorboard to abut a previously installed floorboard the driving force of nailing or stapling a new floorboard in place may not be sufficient to abut the new piece of floorboard tight to eliminate a gap between floorboards.
It is possible when installing wooded floorboards to close gaps between wooden floorboards by straightening bowed floorboards or bending straight floorboards to abut a previously installed floorboard. Several devices have been developed over the years to accomplish this task. All of them suffer some deficiencies making them impractical to use when installing floorboards on top of sub floor.
Examples of four prior art methods of flooring jacks such as: The “FLOOR CLAMP” U.S. Pat. No. 10,061, issued 1853, uses a screw to exert force and clamps over the top of a floor joist. The “FLOOR-CLAMPS” U.S. Pat. No. 136,428 issued 1873, uses rack and pinion to exert force and straddles a floor joist clamping to the floor joist. The “CLAMPING DEVICE FOR CONSTRUCTING FLOORING, DECKING AND THE LIKE”, U.S. Pat. No. 3,143,335, issued 1964, uses hydraulics to exert force and rests on top of a floor joist clamping to the floor joist. The “FLOOR JACK”, U.S. Pat. No. 6,962,179, issued in 2005, uses leverage to exert force and has a spur that is driven into the top of a floor joist. These devices require access to the floor joist. Modern present construction methods concealed the floor joists below the sub floor. These devices will not work to install floorboards on top of a plywood sub floor.
The prior art method of flooring jacks used by the “TOOL FOR REMOVING LATERAL DEFLECTION IN A WOOD PLANK”, U.S. Pat. No. 4,821,784, issued in 1989, uses leverage to exert force on a floorboard and a fastener member for engaging a fixed flat surface, such as plywood. This device suffers from several problems making its use impractical. When used to install a floorboard on top of a plywood sub floor the device does not provide clearance to fasten the floorboard to the sub floor in-line with the device's exerted force holding the board in place. When installing a floorboard that is bowed out at the end it requires exerting force and securing the floorboard at the very end of the floorboard. Exerting force to a floorboard in one spot and fastening it in another spot will not secure the floorboard as required. The tool's foot that exerts force on a floorboard if not positioned exactly perpendicular to a floorboard only abuts the floorboard at the edge of the foot causing damage to the floorboard. Another problem is the large size of the device combined with the lateral swing of the long leverage handle making the device unusable when installing the last several rows of floorboards in rooms with walls and in confined areas, such as closets.
The prior art method of flooring jacks used by the “FLOORING INSTALLATION TOOL”, U.S. Pat. No. 5,964,450 issued 1999 uses a jack, such as a trailer-tongue jack, to exert force; the device slides on a standard 2.times.4 board. This device suffers from several problems making its use impractical. When used to install a floorboard on top of a plywood sub floor the device does not provide clearance to fasten the floorboard to the sub floor in-line with the device's exerted force holding the board in place. Another problem is the device is long, heavy, and difficult to use being attached on an 8-foot long 2.times.4 board. An installer would need a vehicle capable to move an 8 foot long 2.times.4 board to bring the device to the job site. The tool's foot that exerts force on a floorboard if not positioned exactly perpendicular to a floorboard only abuts the floorboard at the edge of the foot causing damage to the floorboard.
There is a product on the market made by Powernail Co. called Powerjack™. The Powerjack comes in two models both using a ratcheting mechanism to exert force model 100 and model 200. The Powerjack model 200 is mounted to the sub floor with screws it has a foot to exert linear force to a floorboard to move the floorboard into place. This device when used to install a floorboard on top of a plywood sub floor does not provide clearance to fasten the floorboard to the sub floor in-line with the exerted force holding the board in place. Another problem is the length of the tool; the rack for the ratcheting mechanism extends trough the tool past the front on one end and past the back on the other end. The length of the device prevents the device from being used to install the last several rows of floorboards. The rack for the ratcheting mechanism protruding past the back of the device prevents abutting the back of the device against a fixed object limiting device use. The tool's foot that exerts force on a floorboard if not positioned exactly perpendicular to a floorboard only abuts the floorboard at the edge of the foot causing damage to the floorboard. The device using a ratcheting mechanism can not accurately push the floorboard into position; one click on the ratchet less is not enough movement of the floorboard and one click more over moves the floorboard. The Powerjack model 100 is for installing the last few rows of floorboards. The device hooks on the floorboard to be installed with the device's foot pushing on the wall. If the wall in not perfectly parallel to the floorboard being install the device exerts linear force on the floorboard off to one side of the device. The model 100 also uses a ratcheting mechanism, which can not accurately push the floorboard into position. The device can be used to install floorboards not close to a wall by abutting the foot to a board fastened to the sub floor. With the device hooked on the floorboard the tool does not provide clearance to fasten the floorboard to the sub floor in-line with the exerted force holding the board in place. The Powerjack requires two separate tools to install a complete wooden floor the model 100 for the last few floorboards and the model 200 for the main body of the floor.
SUMMARY OF THE INVENTIONThe invention comprises a flooring installation tool for closing gaps between wood floorboards by straightening bowed floorboards or bending straight floorboards. The tool exerts linear force on the edge of a floorboard to be installed, closing gaps between a previously installed floorboard and a new floorboard to be installed. Once the gap between floorboards is closed the floorboard being installed is then secured in place to the sub floor with staples or nails.
Turning the tool's main threaded nut on the tool's main threaded rod caused the tool's pushing foot to move forward. When the tool's pushing foot moves forward the tool in total becomes longer, expanding. This develops linear force between the tool's base plate and the tool's pushing foot.
If the tool is not held in place perpendicular to an object the pushing foot swivels laterally self aligning the front face of the pushing foot keeping it parallel to the object.
The main nut is turned with a standard wrench or a ratcheting wrench. The tool is inherently self-locking that will not release exerted linear force till the main nut is backed off.
In use there are two different ways the tool can be used to applying linear force to move a bent floorboard straight as follows. Either the pushing foot moves forward or the base plate moves backwards.
The “first way the tool is used to apply linear force” is with the tool held in place with the tool's pushing foot abutting a floorboard that is to be installed and fastened to a sub floor. The tool is held in place by screwing or nailing the base plate to the sub floor or with the back of the tool abutting a fixedly in place object. A building wall, a board screwed to the sub floor or a board placed between the tool and a fixedly in place object are options to abut the back of the tool against. The main nut on the tool is turned to move in the forward direction moving the tool's pushing foot forward increasing the length of the tool. With the tool's base plate being held in place the tool's pushing foot with linear force pushes on the floorboard moving the floorboard. The main nut on the tool is to be turned till the floorboard is abutting tightly to a previously installed floorboard and gaps between floorboards are closed. The floorboard is then fastened in place to the sub floor with nails or staples. The main nut on the tool is turned in the opposite direction till the pushing foot is back at the starting position; the tool is removed for reuse. When using the tool in this way the tool's pushing foot can be used to push directly on the floorboard or on an object placed between the pushing foot and the floorboard such as the tool's pushing plate or a block of wood.
The “second way the tool is used to apply linear force” is with the tool's pushing foot abutting a fixedly in place object and the base plate abutting a floorboard that is to be installed and fastened to a sub floor. A building wall, a board screwed to the sub floor or a board placed between the tool's pushing foot and a fixedly in place object are options to abut. The main nut on the tool is turned to move in the forward direction moving the tool's base plate backwards increasing the length of the tool. With the tool's pushing foot abutting a stationary object the tool's base plate with linear force pushes on the floorboard moving the floorboard. The main nut on the tool is to be turned till the floorboard is abutting tightly to a previously installed floorboard and gaps between floorboards are closed. The floorboard is then fastened in place to the sub floor with nails or staples. The main nut on the tool is turned in the opposite direction till the pushing foot is back at the starting position; the tool is removed for reuse. When using the tool in this way the tool's base plate can be used to push directly on the floorboard or on an object placed between the base plate and the floorboard such as the tool's accessory pushing plate, the tool's accessory pulling plate or a block of wood.
When installing a wooden floorboard that is bowed exerting linear force to the floorboard will bend and straighten the floorboard. When bending and straightening a floorboard the strongest point to fasten the floorboard to the sub floor is in-line with the applied linear force forcing the floorboard straight. The tool's push plate is an independent part of the tool to be used in conjunction with the tool providing clearance to fasten a floorboard in-line with the applied linear force. When used the tool's push plate follows as described in “first way the tool is used to apply linear force” above with the push plate inserted between the pushing foot and the floorboard. The back end of the push plate is placed on the sub floor abutting the tools pushing foot. The tool's push plate front end's low profile abuts a tongue and grove floorboard to be installed on the tongue side of the floorboard below the tongue and above the sub floor. The nut on the tool is turned exerting linear force to the floorboard by way of the push plate straightening the floorboard and closing gaps between floorboards. The push plate provides clearance necessary to hand nail or to use a floorboard nailing tool or floorboard stapler tool to fasten the floorboard in-line with the applied linear force.
Installing a floorboard having an outward bend at the end of the floorboard is a difficult bow to straighten and secure. To straighten and fasten this type of bowed floorboard requires clearance necessary to: hand nail or to use a floorboard nailing tool or floorboard stapler tool to fasten the floorboard at the very end of the floorboard in-line with the applied linear force. This is accomplished using the tool with the tool's push plate as described above.
The tool itself is compact in size to be used up-to the last two floorboards to be installed. The tool's pull plate is an independent part of the tool to be used in conjunction with the tool to straighten or bend the last two floorboards to be installed. The pull plate is to be placed on top of the next to last floorboard being installed. The tool is placed on top of the pull plate with the tool's pushing foot abutting scrap pieces of floorboards stacked between the wall and pushing foot. The front of the pull plate hooks over the board to be installed. The main nut on the tool is turned to move in the forward direction moving the tool base plate backwards increasing the length of the tool. When the tool increases in length it exerts linear force between the tool, the wall and the back of the pull plate pulling the new floorboard being installed tight to a previously installed floorboard. The main nut on the tool is to be turned till the floorboard is abutting tightly to a previously installed floorboard and gaps between floorboards are closed. The floorboard is then fastened in place.
Typically when a wooden tongue and grove floor is install a ½″ to ¾″ gap is left between the flooring and the wall for expansion. The tool's pull plate requires less than the normal expansion gap between the last floorboard and the wall. The pull plate is to be placed on top of the last board being installed. The pull plate is to be placed on top of the last floorboard being installed. The front of the pull plate hooks over the floorboard to be installed. The tool's pull plate is placed against the wall to distribute the force of the tool. The tool is placed on top of the pull plate with the tool's pushing foot abutting the tool's pull plate. The main nut on the tool is turned to move in the forward direction moving the tool's base plate backwards increasing the length of the tool. When the tool increases in length it exerts linear force between the tool, the pull plate against the wall and the back of the pull plate pulling the new floorboard being installed tight to a previously installed floorboard. The main nut on the tool is to be turned till the floorboard is abutting tightly to a previously installed floorboard and gaps between floorboards are closed. The floorboard is then fastened in place.
The key to the success of this invention unlike prior art designs are: the push plate provides clearance necessary to hand nail or to use a floorboard nailing tool or floorboard stapler tool to fasten the floorboard in-line with the applied linear force which is the strongest holding point to secure a floorboard in place, the compact size of the invention allows use up to the last two floorboards and with the pull plate the tool is used for the last two rows of floorboard requiring only one tool to do the job of two tools, the invention's pushing foot swivels laterally to be parallel with the floorboard distributing the linear force across the face of the pushing foot so as not to damage the floorboard as do misaligned tools that push with a corner of their pushing foot, the invention is inherently self locking not requiring locking mechanisms to be held in position and the invention positions with linear accuracy not incrementally.
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When installing a new floorboard that is warped when abutted against a previously installed straight floorboard it leaves a gap between the abutting edges. The instant invention is used in several different ways to move and straighten a new warped wooden unsecured floorboard to close a gap between the abutting edges of the new warped floorboard and the previously secured in place installed straight floorboard.
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The follow illustrates different methods using the instant invention when installing a wooden tongue and grove floor to straighten a bowed bent wooden floorboard that is to be installed and secured in place.
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Although the invention has been described herein primarily as a flooring installation tool, it will be understood that the flexible arrangement of the invention allows its use in other applications as well. With the tool attached to a sub floor exerting linear force on the bottom wooded plate of a studded interior wall being installed during construction of a building to straighten or hold the studded wall in place. The tool can also be used for leveling with the tool placed under an object with the tool held in place in the vertical position the linear force of the tool can lift to raise or level an object such as a window frame.
Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. References herein to details of the illustrated embodiments are not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention. Various modifications and alterations in the disclosed invention and methods will be apparent to those skilled in the art of the foregoing description which does not depart from the spirit of the invention and are within the scope of the invention without departing from the concept thereof.
Claims
1.) A flooring installation tool for removing or adding lateral deflection to a wooden floorboard to close gaps between adjacent floorboards by exerting linear force to the edge of a floorboard, comprising:
- a.) a base plate, said base plate having front end and back end, said base plate has a first leg and second leg the length of the said base plate, said legs each having a foot the length of said legs, said legs are parallel and spaced apart sufficient to fit a pushing foot in-between, the top of the said base plate is slotted to allow a bolt to pass through connecting the tool's pushing foot to a pushing bracket, said slot's length provides for linear travel of the tool's said pushing foot, the top of said base plate has a turned up back flange on the back end, said base plate has a turned up front flange on the front end, said feet on the bottom of said first and second legs have holes to secure the base plate to a sub floor with screws or nails,
- b.) a main threaded rod, said main threaded rod is attached to said base plate said back and said front flange,
- c.) a main threaded nut, said main threaded nut is on the said main threaded rod between said base plate said turned up back flange on the said back end and said base plate said turned up front flange on said front end,
- d.) a washer, said washer is slid in front of said threaded main nut on said main threaded rod,
- e.) a pushing bracket, said pushing bracket has a top side and a bottom side, said pushing bracket having a hole in the top side is slid onto the said main threaded rod in front of said washer, said pushing bracket has a hole in the bottom side,
- f.) a spring, said spring is of sufficient size to fit over the said threaded main rod, said spring is slid in-front of said pushing bracket on said main threaded rod, said spring has a front end and a back end, said spring length and tension is such as to press on said pushing bracket's front side, said spring maintains pressure on said pushing bracket front side, pressure on said pushing bracket maintains pressure on said washer, said washer in turn maintains pressure on said main nut, said back end of said spring abuts the said pushing bracket front side, said front end of said spring abuts said base plate front flange,
- g.) a pushing foot, said pushing foot has a top side and a front side, said top side has a hole in it and connects it to said pushing bracket with a bolt,
- h.) a bolt, said bolt connects said pushing bracket to said pushing foot through said slot in said base plate,
- i.) a front nut, said front nut is screwed on the said main threaded rod in front of said base plate said turned up front flange on said front end,
- j.) a back nut, said back nut is screwed on the said main threaded rod behind the said base plate said turned up back flange on said back end,
- k.) a snap ring, which snaps on the main threaded nut to hold a wrench in place.
- l.) a pull plate having a front end and a back end; said front end is formed with a turned down flange, said back end is formed with a turned up flange.
- m.) a push plate which has a front end and a back end said front end has a low profile to abut a tongue and grove floorboard on the tongue edge of the floorboard below or even with the top of the tongue allowing clearance to fasten the floorboard directly in-line with applied linear force.
2.) The flooring installation tool of claim 1, the assembled tool with said pushing foot resting closest to said base plate back end is the starting position for using the tool. The tool's said main nut is turned on said main threaded rod in the direction to move said main nut towards said base plate front end. The said main nut moves forward exerting linear force on said washer. The said washer moves forward exerting linear force on said pushing bracket. Said pushing bracket, said bolt and said pushing foot being all connected as one all move towards said base plate front end. Said spring between said pushing bracket and inside of said the base plate turned up front flange compresses said spring. The total length of the tool increases as measured from said base plate back end to said pushing foot front side.
3.) The flooring installation tool of claim 1, the assembled tool with said pushing foot resting forward and outwardly in relation to said base pate front end is in the finish position when using the tool. Said main nut is turned on said main threaded rod in the direction to move said nut towards said base plate back end. Said spring being in the compressed state exerts linear force on said pushing bracket. Said pushing bracket, said bolt and said pushing foot being all connected as one all move towards said base plate back end. Said pushing bracket exerts linear force on said washer moving said washer towards said base plate back end. Said washer exerts linear force on said main nut. The total length of the tool decreases as measured from said base plate front end to said pushing foot front side.
4.) The flooring tool of claim 1, by placing said pushing foot front side abutting an object and said base plate back end placed abutting a different object turning said main nut in the direction to increase the total length of the tool exerts linear force in both directions on both objects moving either said pushing foot or said base plate whichever is abutting the object with the least resistance and will move the object with the least resistance.
5.) The flooring tool of claim 1, by fixedly attaching the said base plate to a part of a building structure such as the sub floor with screws or nails through said mounting holes with said pushing foot placed abutting the edge of a unsecured wooden floorboard to be installed turning of said main nut in the forward direction increase the total length of the tool, the pushing foot exerts linear force moving the unsecured floorboard being installed to a tight abutment to a previously installed floorboard straightening or bending the unsecured floorboard closing gaps between the floorboards.
6.) The flooring tool of claim 1, by abutting the said base plate back end against a stationary object such as a building wall or a board secured to the sub floor, with said pushing foot placed abutting the edge of a unsecured wooden floorboard to be installed turning of said main nut in the forward direction increase the total length of the tool the pushing foot exerts linear force moving the unsecured floorboard being installed to a tight abutment to a previously installed secured floorboard straightening or bending the unsecured floorboard closing gaps between the floorboards.
7.) The flooring tool of claim 1, by abutting the said pushing foot against a stationary object such as a building wall or a board secured to the sub floor, with said base plate back end placed abutting the edge of a unsecured wooden floorboard to be installed turning of said main nut in the forward direction increase the total length of the tool the base plate back end exerts linear force moving the unsecured floorboard being installed to a tight abutment to a previously installed secured floorboard straightening or bending the unsecured floorboard closing gaps between the floorboards.
8.) The flooring tool of claim 1, placing said accessory pull plate on top of a unsecured floorboard to be installed with the said turned down flange facing downward hooking over the tongue edge of the unsecured floorboard exerting linear force on the said pull plate back end turned up flange in the direction to move the unsecured floorboard being installed to a tight abutment to a previously installed secured floorboard will straighten or bend the unsecured floorboard being installed to close gaps between the floorboards. To exert linear force on said pull plate with the tool in the starting position said base plate is placed on top of said pull plate with said base plate back end abutting said pull plate back end turned up flange said pushing foot is placed abutting a stationary object such as a building wall. Turning said main nut in the forward direction exerts linear force on the stationary wall and exerts linear force on the pull plate, since the wall is fixed in place the pull plate moves pulling the unsecured floorboard being installed to a tight abutment to a previously installed secured floorboard straightening or bending the unsecured floorboard being installed to close gaps between the floorboards.
9.) The flooring tool of claim 1, said accessory push plate flat front end has a low profile to abut a tongue and grove floor board resting on a sub floor on the tongue side of the floorboard below or even with the top of the tongue of the floorboard and above the sub floor. With said push plate's flat front end abutting a floorboard to be installed below or even with the top of the tongue of the floorboard, exerting linear force on the back end of the said push plate said push plate moves forward moving the unsecured floorboard being installed to a tight abutment to a previously installed secured floorboard straightening or bending the unsecured floorboard being installed to close gaps between the floorboards. Said push plate provides clearance necessary to hand nail or to use a standard floorboard fastening tool to fasten the floorboard directly in-line with the applied linear force. To exert linear force on said push plate with the tool in the starting position said tool is secured in place to the sub floor with nails or screws. The push plate is placed with the back end abutting the tool's said pushing foot and the push plate's front end abutting an unsecured floor board below or even with the top of the tongue of the floorboard. Turning said main nut in the forward direction exerts linear force on the push plate.
10.) The flooring tool of claim 1, in which said main nut is to be turned with any appropriate device.
11.) The flooring tool of claim 1, in which said main nut is to be turned with a ratcheting wrench.
12.) The flooring tool of claim 1, in which said spring maintains pressure providing enough resistance for a ratcheting wrench to work as intended.
13.) The flooring tool of claim 1, in the alternate in which said washer and main nut are one piece.
14.) The flooring tool of claim 1, in which said pushing foot laterally swivels self-aligning the front face of said pushing foot to be parallel to an object it is abutted against eliminating damage caused by pushing with a misaligned tool pushing with only the corner of the pushing foot.
15.) The flooring tool of claim 1, in which said main nut has a snap ring on the back end to hold a wrench in place.
16.) The flooring tool of claim 1, in which the main nut and main threaded rod are inherently self-locking in position.
17.) The flooring tool of claim 1, in which said main nut positions with linear precision not incrementally.
18.) The flooring installation tool of claim 1, in the alternate the tool's said main nut in the alternate is fixedly to the main threaded rod, said pushing bracket in the alternate has a threaded hole that the main threaded rod is threaded in. Turning said main threaded nut turns said main threaded rod moving said pushing bracket forward. Said pushing bracket, said bolt and said pushing foot being all connected as one all move towards said base plate front end. Said spring between said pushing bracket and inside of said the base plate turned up front flange compresses said spring. The total length of the tool increases as measured from said base plate back end to said pushing foot front side.
Type: Application
Filed: Jan 31, 2008
Publication Date: Aug 6, 2009
Inventor: Joseph Louis Mirocha (Homer Glen, IL)
Application Number: 12/023,989