SMART FLOORING SYSTEM

Abstract

Some novel features pertain to a floor coupling structure that includes a first portion, a second portion extending from a first end of the first portion, the second portion for coupling to a first plank portion of a floor plank; and a third portion extending from a second end of the first portion, the third portion for coupling to a second plank portion of the floor plank. In some implementations, the first portion, the second portion and the third portion are a single piece. In some implementations, the floor coupling structure further includes a side protrusion and side slot, the side slot configured to couple to another protrusion of a first coupling structure, the side protrusion configured to coupled to another side slot of a second coupling structure. In some implementations, the second portion is a first coupling portion and the third portion is a second coupling portion.

Description

CLAIM OF PRIORITY

The present application claims priority to U.S. Provisional Application No. 61/654,525, titled “Smart Flooring System”, filed Jun. 1, 2012, which is hereby expressly incorporated by reference herein.

BACKGROUND

1. Field of Invention

At least one feature pertains to a smart flooring system and apparatus.

2. Background of Invention

Wood flooring is a very common flooring material in homes. In addition to being a very practical material, wood is also very aesthetically pleasing. Wood flooring can come in many styles, sizes, shapes, and types.

There are generally two types of wood flooring, solid wood and engineered wood. Solid wood, which is also called hardwood, is flooring material made from a single piece of timber. In contrast, engineered wood is made of multiple layers of materials. Specifically, engineered wood has several layers, including a top layer and a core layer. The top layer is sometimes referred to as the lamella layer. The top layer is the layer that is visible. The core layer is the layer underneath the top layer and is usually invisible once the engineered wood flooring is installed. Laminate wood flooring is an example of an engineered wood.

FIG. 1 illustrates a top view of a portion of a typical wood floor after installation. As shown in this figure, the wood floor 100 is made of at least several planks of wood 110a-m. These planks of woods 110a-m can be either solid wood or engineered wood. As shown in FIG. 1 the planks of wood 110a-m are installed on the floor in a staggered manner. Staggering the placement of the wood planks helps prevent the wood planks from moving after installation.

FIG. 2 illustrates a side view of a portion of a typical wood floor after installation. As shown in this figure, the wood floor 200 is installed over a foundation 210. In some instances, the foundation 210 is a concrete foundation. However, the foundation 210 can be any surface that a wood floor can be installed on. The wood floor 200 includes four wood planks 220-250. These four wood planks 220-250 are interconnected to each other side by side.

As shown in FIG. 2, each wood plank 220-250 has a male portion and a female portion. The wood planks 220-250 are interconnected to each other through these male and female portions. For example, the female portion of wood plank 220 is connected to the male portion of wood plank 230. Additionally, the female portion of wood plank 230 is connected to the male portion of wood plank 240. Finally, the female portion of wood plank 240 is connected to the male portion of wood plank 250. To secure the wood floor 200 to the foundation 210 some sort of glue may be applied between the foundation 210 and the base of the wood planks 220-250. Alternatively, or in conjunction, the wood planks 220-250 may be securely attached to the foundation 210 by driving a nail through each wood plank 220-250.

The downside to the above conventional method is that it is a very permanent installation. In order words, it's an installation process that cannot be undone without taking apart the entire wood floor. Through the course of normal use, a wood floor will go through wear and tear. In some instances, certain portions of the wood floor may even get damaged. For example, one of the planks may get scratched or cracked. Because the wood planks are glued and/or nailed to the foundation and interlocked to each other, it's not possible to simply replace the damaged plank. Instead, the entire wood floor would need to be replaced. This is not practical and not cost effective, especially if the damage is minor or localized.

Consequently, what is needed is a method/system for flooring that is easy to install, cost effective, easy to replace and repair.

SUMMARY

Various features relate to a smart flooring system and apparatus.

A first example provides a floor coupling structure that includes a first portion, a second portion extending from a first end of the first portion, the second portion for coupling to a first plank portion of a floor plank; and a third portion extending from a second end of the first portion, the third portion for coupling to a second plank portion of the floor plank.

According to an aspect, the first portion, the second portion and the third portion are a single piece.

According to one aspect, the floor coupling structure further includes a side protrusion and side slot, the side slot configured to couple to another protrusion of a first coupling structure, the side protrusion configured to coupled to another side slot of a second coupling structure.

According to an aspect, the first portion is a base portion configured to be positioned on a floor.

According to one aspect, the first portion is a base portion configured to be positioned on a wall. In some implementations, the second portion is a first coupling portion and the third portion is a second coupling portion.

A second example provides an apparatus that includes a base portion configured to be positioned on a floor, a first portion extending from a first end of the base portion, the first portion for coupling to a first plank portion of a floor plank, and a second portion extending from a second end of the base portion, the second portion for coupling to a second plank portion of the floor plank.

According to an aspect, the first portion includes a first end member and a second end member, wherein the second portion comprises a third end member and a fourth end member. In some implementations, the first end member of the first portion is for coupling to the first plank portion of the floor plank. In some implementations, the third end member of the second portion is for coupling to the second plank portion of the floor plank. In some implementations, the first end member of the first portion is a living hinge. In some implementations, the apparatus is for coupling to another apparatus. In some implementations, the another apparatus includes another base portion, another first portion extending from another first end of the another base portion, the another first portion for coupling to another first plank portion of another floor plank; and another second portion extending from another second end of the another base portion, the another second portion for coupling to another second plank portion of the another floor plank. In some implementations, the another first portion comprises another first end member and another second end member, wherein the another second portion comprises another third end member and another fourth end member. In some implementations, the second end member of the first portion is for coupling to the another fourth end member of the another second portion.

According to one aspect, the first portion includes a male portion for coupling to the first plank portion of a floor plank, wherein the first plank portion is a first female portion, wherein the second portion includes another male portion for coupling to the second plank portion of the floor plank, wherein the second plank portion is a second female portion.

According to an aspect, the base portion, the first portion and the second portion is a single piece.

According to one aspect, the base portion, the first portion and the second portion are made of Polypropylene (“PP”).

According to an aspect, the floor plank is a wood floor plank.

According to one aspect, the base portion comprises at least one channel.

DRAWINGS

Various features, nature and advantages may become apparent from the detailed description set forth below when taken in conjunction with the drawings in which like reference characters identify correspondingly throughout.

FIG. 1 illustrates a conventional flooring system.

FIG. 2 illustrates an exemplary novel flooring system.

FIGS. 3-4 illustrate an exemplary sequence for installing coupling structures and planks

FIGS. 5-7 illustrate an exemplary sequence for installing coupling structures, planks and replacing/repairing a plank.

FIG. 8 illustrates exemplary coupling structures.

FIG. 9 illustrates an exemplary coupling structure.

FIG. 10 illustrates an exemplary combination of a plank and a coupling structure.

FIG. 11 illustrates a view of an exemplary combination of a plank and a coupling structure.

FIG. 12 illustrates a view of an exemplary combination of a plank and a coupling structure.

FIG. 13 illustrates a view of an exemplary combination of a plank and a coupling structure.

FIG. 14 illustrates a closeup view of two coupling structures coupled at a coupling point/region.

FIG. 15 illustrates yet another exemplary combination of a plank and a coupling structure.

FIG. 16 illustrates an exemplary sequence for installing coupling structures and planks.

FIG. 17 illustrates another exemplary sequence for installing coupling structures and planks.

FIG. 18 illustrates an exemplary combination of coupling structures and planks.

FIG. 19 illustrates another exemplary combination of coupling structures and planks.

FIG. 20 illustrates an exemplary side view of a plank.

FIG. 21 illustrates an exemplary plan view (e.g., bottom view) of a plank.

DETAILED DESCRIPTION

The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention.

Overview

Some novel features pertain to a floor coupling structure that includes a first portion, a second portion extending from a first end of the first portion, the second portion configured for coupling to a first plank portion of a floor plank; and a third portion extending from a second end of the first portion, the third portion configured for coupling to a second plank portion of the floor plank. In some implementations, the first portion, the second portion and the third portion are a single piece. In some implementations, the floor coupling structure further includes a side protrusion and side slot, the side slot configured to couple to another protrusion of a first coupling structure, the side protrusion configured to coupled to another side slot of a second coupling structure. In some implementations, the first portion is a base portion configured to be positioned on a floor. In some implementations, the first portion is a base portion configured to be positioned on a wall. In some implementations, the second portion is a first coupling portion and the third portion is a second coupling portion.

Exemplary Flooring Structure

FIGS. 3-4 illustrate an embodiment of a wood flooring system that can be used. As shown in FIG. 3, the wood flooring system 300 includes several coupling structures 310-340. The coupling structures 310-340 are positioned on the foundation 350 in an interlocking manner. Each coupling structure 310-340 has a first interlocking portion and a second interlocking portion. In some embodiments, the first interlocking portion is a male interlocking portion (e.g., male coupling portion) and the second interlocking portion is a female interlocking portion (e.g., female coupling portion).

As shown in FIG. 3, the female interlocking portion of coupling structure 310 is connected to the male interlocking portion of coupling structure 320. Similarly, the female interlocking portion of coupling structure 320 is connected to the male interlocking portion of coupling structure 330, and the female interlocking portion of coupling structure 330 is connected to the male interlocking portion of coupling structure 340. Once the coupling structures 310-340 of the wood floor system 300 are positioned into place, then a wood floor can be installed on top of it.

FIG. 4 illustrates a wood floor system after the installation of the wood floor. As shown in this figure, the wood floor system 300 includes coupling structures 310-340 and wood planks 410-440. Each wood plank is coupled to a respective coupling structure. For instances, wood plank 410 is coupled to coupling structure 310, wood plank 420 is coupled to coupling structure 320, wood plank 430 is coupled to coupling structure 330, and wood plank 440 is coupled to coupling structure 340.

Examples of coupling portions (e.g., male and female coupling portions) will be further described in at least FIG. 10.

Different embodiments may use different types of wood planks. Some embodiments may use solid wood planks, engineered wood planks or any combination thereof. In addition, each coupling structure of the wood floor system may be installed on the foundation 350 in a staggered manner.

Utilizing this system has several advantages over conventional flooring. First, it is very easy to install. Unlike conventional flooring, no glue or nails are required to securely fasten the floor system to the foundation. This is because in some embodiments, the coupling structures are made of plastic, which has a higher coefficient of friction than wood. As a result, the floor system is less likely to move, even without the glue or nails. Thus, by taking away the glue and nails, this system in some embodiments is much easier to install then conventional flooring. In addition, one advantage of bypassing the use of glue and/or nails is that they don't produce as much noise after installing. Wood tends to expand and contract with different temperatures and pressure condition. When conventional flooring is used with glue and/or nails, the contraction and expansion of the wood causes friction and noise. Under the novel flooring system, the expansion and contraction of the wood does not cause as much noise, if any, since the flooring system is able to move, expand, and/or contract separately from the wood, and/or foundation. Moreover, when all the coupling structures and planks are coupled together, it essentially forms one strong structure/structural piece that is very unlikely to move (e.g., due to the combined weight of the structure/structural piece).

Second, the coupling structure acts as a padding and/or insulator for the floor. Depending on the material that is used as the coupling structure, the coupling structure adds another layer between the foundation and the wood floor. This extra layer can provide extra cushioning and/or insulation from the heat or cold temperature that might radiate from or to the foundation. In some instances, the coupling structure may also provide ventilation of the floor.

Third, because there is no glue or nails that permanently affix the wood planks, the floor can be easily removed, replaced or fixed without having to take apart the entire floor. An example of how to replace a wood plank will be further described below.

FIGS. 5-7 illustrate a sequence of how a wood flooring system allows for the replacement of a wood plank. As shown in FIG. 5, the wood flooring system 500 includes several wood planks and coupling structures. As illustrated in this figure, the wood plank 510 is damaged (e.g., deep scratch). In some embodiments, when the wood plank 510 is damaged, the wood plank 510 is simply detached from its corresponding coupling structure 520. Different embodiments may remove the wood plank 510 differently. In some implementations, the wood plank 510 may need to be broken in order to be removed.

FIG. 6 illustrates the wood flooring system after the damaged wood plank 520 has been removed. As shown in this figure, all of the other coupling structures and wood planks from the wood flooring system 500 are still in place, including the coupling structure 520.

FIG. 7 illustrates the wood flooring system after a replacement wood plank has been installed. As shown in the figure, a wood plank 700 has been installed in the wood flooring system 500 and is coupled of the coupling structure 520. The wood plank 700 replaces the wood plank 510 that was damaged and removed from the wood flooring system.

Thus, it is apparent that the above flooring system is advantageous and superior to what is currently being used in homes and/or offices. In addition to being cost effective, replaceable and repairable, the above flooring system is also very easy to install, thereby foregoing the need to hire professional installers.

FIGS. 3-7 illustrate a few examples of how a coupling structure of a floor system may be designed. However, different embodiments may use different designs.

FIG. 8 illustrates other examples of coupling structure designs that may be used in the floor system of the present invention. In some embodiments, the coupling structure may include hollow channels 800, which allow air to circulate in the coupling structure. These channels may help with the insulation of the floor as well as help provide a softer feel or spring like feel to the floor. In some embodiments, these channels may also help ventilate the floor and help in the drying of the floor (e.g., when liquid is spilled). In some implementations, the channels may be cavities in a base portion of the coupling structure. These hollow channels (e.g., cavities) may be located in any of the coupling structures described in the present application.

In addition to the channels, different embodiments of the coupling structures may use different combinations of male and female locking/coupling mechanisms (e.g., coupling portions) to securely couple the coupling structures to either the wood planks and/or other coupling structures.

The embodiments shown in FIG. 8 are merely conceptual illustrations of different embodiments of coupling structures and are not intended to be exact representations of the coupling structures, including the different combinations male and female locking mechanisms. Although some embodiments may use the above configuration as exactly shown.

Having described a coupling structure in general, a specific embodiment will now be described.

FIG. 9 illustrates an embodiment of a coupling structure used in floor system of the present invention. As shown in FIG. 9, the coupling structure 900 includes a first portion 910, a second portion 920 and a third portion 930. In some embodiments, the first portion 910, the second portion 920 and the third portion 930 are a single piece. In other embodiments, the first portion 910, the second portion 920 and the third portion 930 are at least two different pieces. In some implementations, the second portion 920 is a first coupling portion 920. In some implementations, the first coupling portion 920 is a male coupling portion. In some implementations, the third portion 930 is a second coupling portion 930. In some implementations, the second coupling portion 930 is a female coupling portion configured to receive a male coupling portion.

As shown in FIG. 9, the second portion 920 includes a first member 940 and a second member 950. The third portion 930 includes a third member 960 and a fourth member 970.

The first member 940 is for coupling to a first portion of a wood floor plank (not shown). The second member 950 is for coupling to a corresponding member of another coupling structure that is adjacent to the right of the coupling structure 900. In some embodiments, the corresponding member is similar to the fourth member 970.

The third member 960 is for coupling to a second portion of a wood floor plank (not shown). The fourth member 970 is for coupling to a corresponding member of yet another coupling structure that is adjacent to the left of the coupling structure 900. In some embodiments, the corresponding member is similar to the second member 950.

As further shown in FIG. 9, the first portion 910 includes several channels 980a-c. In some embodiments, these channels 980a-c allow air to circulate underneath the coupling structure and/or provide some insulation.

Having described a specific embodiment of a coupling structure, another specific embodiment will now be described.

FIG. 10 illustrates a side view of an embodiment of a floor system of the present invention. As shown in FIG. 10, the floor system 1000 includes a coupling structure 1010 and a plank 1020. In some embodiments, the plank 1020 is a wood floor plank. The plank 1020 includes a first plank portion/slot 1030 and a second plank portion/slot 1040. The first and second plank portions/slots 1030-1040 may be slots and/or grooves in the side of the plank 1020. Different implementations may use different shapes for the slots and/or grooves.

The coupling structure 1010 includes a first portion 1050, a second portion 1060 and a third portion 1070. In some embodiments, the first portion 1050, the second portion 1060 and the third portion 1070 are a single piece. In other embodiments, the first portion 1050, the second portion 1060 and the third portion 1070 are at least two different pieces. In some implementations, the second portion 1060 is a first coupling portion 1060. In some implementations, the first coupling portion 1060 is a male coupling portion. In some implementations, the third portion 1070 is a second coupling portion 1070. In some implementations, the second coupling portion 1070 is a female coupling portion configured to receive a male coupling portion.

As shown in FIG. 10, the second portion 1060 (e.g., first coupling portion) includes a first member 1062 and a second member 1064. In some implementations, the second member 1064 is an upper coupling portion (e.g., top coupling portion). The third portion 1070 (e.g., second coupling portion) includes a third member 1072 and a fourth member 1074. In some implementations, third member 1072 is hinge (e.g., living hinge). In some implementations, the fourth member 1074 is base coupling portion. In some implementations, the base coupling portion of a first coupling structure is configured to be coupled to an upper coupling portion of a second coupling structure.

The first member 1062 (e.g., first plank coupling member/portion) is configured for coupling to the first plank portion 1030 of the floor plank 1020. The first member 1062 may have one or more beveled corner in some implementations. In some implementations, the one or more beveled corners allow the plank 1000 to more easily couple to the coupling structure 1010. The second member 1064 is configured for coupling to a corresponding member of another coupling structure (e.g., second coupling structure) that is adjacent to the right of the coupling structure 1010. In some embodiments, the corresponding member is similar to the fourth member 1074. In other words, in some implementations, the second member 1064 is configured to be coupled to a fourth member of another coupling structure.

As further shown in FIG. 10, the second member 1064 has a T-shape and includes a channel 1066. The T-shape of the second member 1064 allows the second member (and consequently the coupling structure 1010) to securely couple to another coupling structure (e.g., second coupling structure), without the second member 1064 of the coupling structure 1010 sliding out. In some embodiments, the channel 1066 allows a user to visually see the center of the second member 1064. The usefulness of the channel 1066 will further be described below in FIG. 14.

The third member 1072 (e.g., second plank coupling member/portion) is configured for coupling to the second plank portion 1040 of the floor plank 1020. In some embodiments, the third member 1072 is a living hinge, which allows the third member 1072 to flexibly move and/or pivot about a base. The fourth member 1074 is configured for coupling to a corresponding member of yet another coupling structure that is adjacent to the left of the coupling structure 1010. In some embodiments, the corresponding member of the other coupling structure (e.g., second coupling structure) is similar to the second member 1064. More specific examples of the use multiple coupling structures (e.g., first and second coupling structures) and multiple planks (e.g., first and second planks) will be further described in FIGS. 16-17.

FIGS. 11-13 illustrate different angled views of an embodiment of the floor system of FIG. 10. Specifically, FIGS. 11-13 illustrate the coupling structure 101 and the plank 1020 from different views/perspectives.

FIG. 14 illustrates a close up view of how two coupling structures can be coupled to each other. As shown in FIG. 14, a first coupling structure 1410 and a second coupling structure 1420 are coupled to each other. The first coupling structure 1410 includes a first member 1430 and a second member 1440. In some implementations, the first member 1430 and the second member 1440 are part of a first coupling portion of the first coupling structure 1410. The second coupling structure 1420 includes a third member 1450 and a fourth member 1460. In some implementations, the third member 1450 and the fourth member 1460 are part of a second coupling portion of the second coupling structure 1420.

The third member 1450 is a living hinge in some embodiments. The living hinge can move flexibly and/or pivot about a base.

As illustrated in FIG. 14, the second member 1440 and the fourth member 1460 are coupled to each other, which effectively couples the first coupling structure 1410 and the second coupling structure 1420 together. The second member 1440 has a T-shape. In some embodiments, the T-shape of the second member 1440 (e.g., upper coupling portion) is configured to allow the second member 1440 to securely latch/couple/lock to the fourth member 1460 (e.g., base coupling portion).

In some embodiments, a pin, nail or screwdriver may also be used to further secure the second member 1440 to the fourth member 1460. To help in the alignment of the pin, nail and/or screwdriver, a channel 1442 located on the second member 1440 may be used to indicate where to insert the pin, nail and/or screwdriver.

In other embodiments, the coupling structure may include more than one living hinge. FIG. 15 illustrates a coupling structure 1500 that includes two living hinges 1510-1520. As shown in this figure, the living hinges 1510-1520 are used to couple the coupling structure 1500 to a plank 1020. In some implementations, the living hinges 1510-1520 may be configured to couple to slots (e.g., first and second portions/slot 1030-1040) in the side (e.g., first side, second side) of the plank 1020. In some implementations, each hinge is flexible and may pivot about a base. Moreover, each living hinge may be offset from a y-axis.

FIG. 15 illustrates a close up view section 1530, which shows a close up view of the living hinge 1510. As shown in this figure, the living hinge 1510 is off by angle of θ degrees from a y-axis. Different embodiments may use living hinges with different degrees. In some embodiments, a first living hinge may have a first offset degree, while a second living hinge may have a second offset degree.

FIG. 16 illustrates an exemplary method for installing a floor system in some implementations. As shown in FIG. 16, a first coupling structure 1602 is provided. In some implementations, the first coupling structure is one of the coupling structures (e.g., coupling structures 310, 900, 1010, 1500) described in the present disclosure. The first coupling structure 1602 includes a first coupling portion 1620 and a second coupling portion 1622. In some implementations, the first coupling portion 1620 is similar and/or the same as the coupling portion 1070 of FIG. 10. In some implementations, the second coupling portion 1622 is similar and/or the same as the coupling portion 1060 of FIG. 10.

Next, a second coupling structure 1604 is provided. The second coupling structure 1604 includes a third coupling portion 1630 and a fourth coupling portion 1632. In some implementations, the third coupling portion 1630 is similar and/or the same as the coupling portion 1070 of FIG. 10. In some implementations, the fourth coupling portion 1632 is similar and/or the same as the coupling portion 1060 of FIG. 10.

The second coupling structure 1604 is coupled to the first coupling structure 1602. As shown in FIG. 2, the second coupling portion 1622 is coupled to the third coupling portion 1630. Different implementations may couple the second coupling structure 1604 to the first coupling structure 1602 differently. For example, in some implementations, the second coupling structure 1604 may be clipped and/or slid into a portion of the first coupling structure 1602. For example, the second coupling portion 1622 is coupled to the third coupling portion 1630. Although not shown, additional coupling structures (e.g., third coupling structure, fourth coupling structure) may be provided to cover a portion or all of a floor and/or wall.

Once a desired number of coupling structures are provided and coupled to each other, one or more planks may be provided. In some implementations, the first plank is one of the planks (e.g., planks 220, 700, 1020) described in the present disclosure. As shown in FIG. 16, a first plank 1610 is provided and coupled to the first coupling structure 1602. Next, a second plank 1612 is provided and coupled to the second coupling structure 1604. Although not shown, additional planks (e.g., third plank, fourth plank) may be provided and coupled to additional coupling structures. In some implementations, the design of the planks provides pressure at the coupling points/joints of the coupling structures, thereby providing additional secure coupling between coupling structures. This ensures that the coupling structures do not separate or come apart in some implementations. It should be noted that the order in which the planks and/or coupling structures are coupled (e.g., attached) together in FIG. 16 is merely exemplary. In some implementations, the order/sequence can be different, depending on the preference of the person installing the coupling structures and/or planks, and/or depending on the layout of the room/floor/wall. In some implementations, the installation of the coupling structures and/or planks may be from left to right or right to left.

In some implementations, one or more the planks may include a protrusion and slot. In some implementations, the protrusion may be referred to as a tongue. In some implementations, the slot may be referred to as a groove. These protrusions and slots may provide additional coupling points/regions to further ensure a secure and reliable fit of the planks in some implementations.

FIG. 17 illustrates an example of a sequence of coupling structures and planks that includes a protrusion and slot being installed. Specifically, FIG. 17 illustrates an exemplary sequence for installing a first coupling structure 1702, a second coupling structure 1704, a first plank 1710, and a second plank 1712. The second coupling structure 1704 is coupled to the first coupling structure 1702. The first plank 1710 is coupled to the first coupling structure 1702 and the second plank 1712 is coupled to the second coupling structure 1704.

As shown in FIG. 17, the second coupling structure 1704 is provided (e.g., put on a floor), and then the first coupling structure 1702 is coupled to the second coupling structure 1702. The first coupling structure 1702 includes a first coupling portion 1740 and a second coupling portion 1742. In some implementations, the first coupling portion 1740 is similar and/or the same as the coupling portion 1070 of FIG. 10. In some implementations, the second coupling portion 1742 is similar and/or the same as the coupling portion 1060 of FIG. 10.

The second coupling structure 1704 includes a third coupling portion 1730 and a fourth coupling portion 1732. In some implementations, the third coupling portion 1730 is similar and/or the same as the coupling portion 1070 of FIG. 10. In some implementations, the fourth coupling portion 1732 is similar and/or the same as the coupling portion 1060 of FIG. 10.

FIG. 17 illustrates that the second coupling portion 1742 of the first coupling structure 1702 is coupled to the third coupling portion 1730 of the second coupling structure 1704. Next, the second plank 1712 is provided and coupled to the second coupling structure 1704. Once the second plank 1712 is coupled, the first plank 1710 is provided and coupled to the first coupling structure 1710. Although not shown, additional coupling structures (e.g., third coupling structure, fourth coupling structure) and additional planks (e.g., third plank, fourth plank) may be provided. In some implementations, the design of the planks provides pressure at the coupling points/joints (e.g., region where coupling portions meet) of the coupling structures, thereby providing additional secure coupling between the coupling structures. This ensures that the coupling structures do not separate or come apart in some implementations. It should be noted that the order in which the planks and/or coupling structures are coupled (e.g., attached) together in FIG. 17 is merely exemplary. In some implementations, the order/sequence can be different, depending on the preference of the person installing the coupling structures and/or planks, and/or depending on the layout of the room/floor/wall. In some implementations, the installation of the coupling structures and/or planks may be from left to right or right to left.

The first plank 1710 includes a first protrusion 1720 and a first slot 1722. The second plank 1712 includes a second protrusion 1724 (e.g., tongue) and a second slot 1726 (e.g., groove). The protrusions and slots are located on the side of the planks. As shown in FIG. 17, the first plank 1710 is coupled to the second plank 1712. Specifically, the first slot 1722 of the first plank 1710 is coupled to the second protrusion 1724 of the second plank 1712. In some implementations, the first slot 1722 (e.g., groove) is configured to receive the second protrusion 1724 (e.g., tongue).

As mentioned above, the slots (e.g., groove0 are located on the side of the planks. However, in some implementations, the slots may be located on a different side/portion of the planks. For example, the slots may be located on the bottom portion of the planks, as illustrates in FIG. 18. As shown in FIG. 18, the first plank 1802 and the second plank 1804 each includes several slots. Specifically, the first plank 1802 includes a first bottom slot 1810, a second bottom slot 1812, and a third bottom slot 1814. The second plank 1812 includes a fourth bottom slot 1820, a fifth bottom slot 1822, and a sixth bottom slot 1824. FIG. 18 illustrates that the bottom slots traverse the length of the planks. However, in some implementations, the bottom slots may traverse the width of the planks. In some implementations, some bottom slots may traverse the length of the planks while other bottom slots may traverse the width of the planks. In addition, some or all of the bottom slots may traverse part of the length and/or width of the planks. In some implementations, some or all of the bottom slots may traverse the plank diagonally (e.g., 45 degrees). Different implementations may use different number of bottom slots.

In some implementations, the bottom slots allow for the easy removal of the plank, should the plank need to be repaired/removed. Specifically, in some implementations, the bottom slots allow the planks to be easily cracked/broken, thus facilitating the removal of the plank. This may be done in case a plank needs to be repaired/replaced. The bottom slots provide one or more weak points in the plank, and when substantial pressure is applied (e.g., by using a chisel, hammer), the plank may crack/break along the bottom slot(s), and thereby allows the plank to be easily separated and removed from the other planks and/or coupling structures.

In some implementations, a plank may include bottom slots, side slots and side protrusions. FIG. 19 illustrates an example of planks that includes such bottom slots, side slots and side protrusions. Specifically, FIG. 19 illustrates a first coupling structure 1902, a second coupling structure 1904, a first plank 1910, and a second plank 1912. The second coupling structure 1904 is coupled to the first coupling structure 1902. The first plank 1910 is coupled to the first coupling structure 1902 and the second plank 1912 is coupled to the second coupling structure 1904.

The first plank 1910 includes a first protrusion 1920 and a first slot 1922. The second plank 1912 includes a second protrusion 1924 and a second slot 1926. The protrusions and slots are located on the side of the planks. As shown in FIG. 19, the first plank 1910 is coupled to the second plank 1912. Specifically, the first slot 1922 of the first plank 1910 is coupled to the second protrusion 1924 of the second plank 1912. In some implementations, the first slot 1922 is configured to receive the second protrusion 1924.

FIG. 19 also illustrates that the first plank 1902 includes a first bottom slot 1930, a second bottom slot 1932, and a third bottom slot 1944. The second plank 1912 includes a fourth bottom slot 1940, a fifth bottom slot 1942, and a sixth bottom slot 1944. FIG. 19 illustrates that the bottom slots traverse the length of the planks. However, in some implementations, the bottom slots may traverse the width of the planks. In some implementations, some bottom slots may traverse the length of the planks while other bottom slots may traverse the width of the planks. In addition, some or all of the bottom slots may traverse part of the length and/or width of the planks. In some implementations, some or all of the bottom slots may traverse the plank diagonally (e.g., 45 degrees). Different implementations may use different number of bottom slots.

FIGS. 20-21 illustrate a side view and plan view of an exemplary plank in some implementations. Specifically, FIGS. 20-21 illustrates a first plank 2010 that includes a first protrusion 2020, a first slot 1922, a first bottom slot 2030, a second bottom slot 2032, and a third bottom slot 2044. FIG. 21 illustrates that the bottom slots traverse the length of the plank. However, in some implementations, the bottom slots may traverse the width of the planks. In some implementations, some bottom slots may traverse the length of the planks while other bottom slots may traverse the width of the planks. In addition, some or all of the bottom slots may traverse part of the length and/or width of the planks. In some implementations, some or all of the bottom slots may traverse the plank diagonally (e.g., 45 degrees). Different implementations may use different number of bottom slots.

One or more of the components and functions illustrated in FIGS. 1-21 may be rearranged and/or combined into a single component or embodied in several components without departing from the invention.

Different embodiments may use different materials for the coupling structure/floor coupling structure. For example, some embodiments may use Polypropylene (“PP”), Polyethylene (“PE”), Polyvinyl chloride (“PVC”) or any other hard or soft plastics. In addition, some embodiments may use an alloy, such as aluminum, a metal, or rubber as the coupling structure. A combination or mixture of any of the above materials may also be used. For example, different portions/members of the coupling structure may have different materials in some embodiments.

Different embodiments may manufacture the coupling structure differently. Some embodiments may use extrusion or molding to manufacture the coupling structure. In addition, some embodiments, may apply some sort of padding between the foundation and the coupling structure. The padding may be any soft material, including a soft plastic or rubber. The padding material may add an insulating layer to the floor system. The padding material may also provide a leveling mechanism for the coupling structure, in some embodiments. Although, the above floor system is described for a wood floor, the above system can also be applied to other types of flooring materials. In some embodiments, the floor system may be applied to carpet and tiles. It should also be noted that the above apparatus, system, coupling structures and/or planks can be used and/or applied to walls in some implementations.

While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention is not be limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those ordinarily skilled in the art. For example, the size and dimensions are merely examples.

Claims

1. An apparatus comprising:

a base portion configured to be positioned on a floor;

a first portion extending from a first end of the base portion, the first portion for coupling to a first plank portion of a floor plank; and

a second portion extending from a second end of the base portion, the second portion for coupling to a second plank portion of the floor plank.

2. The apparatus of claim 1, wherein the first portion comprises a first end member and a second end member, wherein the second portion comprises a third end member and a fourth end member.

3. The apparatus of claim 2, wherein the first end member of the first portion is configured for coupling to the first plank portion of the floor plank.

4. The apparatus of claim 3, wherein the third end member of the second portion is configured for coupling to the second plank portion of the floor plank.

5. The apparatus of claim 3, wherein the first end member of the first portion is a living hinge.

6. The apparatus of claim 2, wherein the apparatus is configured for coupling to another apparatus.

7. The apparatus of claim 6, wherein the another apparatus comprises:

another base portion;

another first portion extending from another first end of the another base portion, the another first portion is configured for coupling to another first plank portion of another floor plank; and

another second portion extending from another second end of the another base portion, the another second portion is configured for coupling to another second plank portion of the another floor plank.

8. The apparatus of claim 7, wherein the another first portion comprises another first end member and another second end member, wherein the another second portion comprises another third end member and another fourth end member.

9. The apparatus of claim 7, wherein the second end member of the first portion is configured for coupling to the another fourth end member of the another second portion.

10. The apparatus of claim 1, wherein the first portion includes a male portion configured for coupling to the first plank portion of a floor plank, wherein the first plank portion is a first female portion, wherein the second portion includes another male portion configured for coupling to the second plank portion of the floor plank, wherein the second plank portion is a second female portion.

11. The apparatus of claim 1, wherein the base portion, the first portion and the second portion is a single piece.

12. The apparatus of claim 1, wherein the base portion, the first portion and the second portion are made of Polypropylene (“PP”).

13. The apparatus of claim 1, wherein the floor plank is a wood floor plank.

14. The apparatus of claim 1, wherein the base portion comprises at least one channel.

15. A floor coupling structure comprising:

a first portion;

a second portion extending from a first end of the first portion, the second portion configured for coupling to a first plank portion of a floor plank; and

a third portion extending from a second end of the first portion, the third portion configured for coupling to a second plank portion of the floor plank.

16. The floor coupling structure of claim 15, wherein the first portion, the second portion and the third portion are a single piece.

17. The floor coupling structure of claim 15 further comprising a side protrusion and side slot, the side slot configured to couple to another protrusion of a first coupling structure, the side protrusion configured to coupled to another side slot of a second coupling structure.

18. The floor coupling structure of claim 15, wherein the first portion is a base portion configured to be positioned on a floor.

18. The floor coupling structure of claim 15, wherein the first portion is a base portion configured to be positioned on a wall.

19. The floor coupling structure of claim 15, wherein the second portion is a first coupling portion and the third portion is a second coupling portion.

20. The floor coupling structure of claim 19, wherein the first coupling portion is a female coupling portion and the second coupling portion is a male coupling portion.