DROP DECK FLOORING PANEL

Abstract

A drop deck flooring panel includes a top surface of the panel and a bottom surface of the panel opposite the top surface of the panel. The top surface includes a plurality of raised surface features forming channels and a plurality of holes residing within the channels. The bottom surface of the panel includes a plurality of ribs corresponding to the plurality of raised surface features, where the plurality of holes traverse the top surface and the bottom surface. The channels are configured to direct water away from a topmost surface of the plurality of raised surface features, where the plurality of holes serve as drainage for the water.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a non-provisional patent application claiming priority to copending U.S. provisional patent application Ser. No. 63/749,050, which was filed on Jan. 24, 2025, by Mark Cesari and Chris Brozina for “Drop Deck Flooring Panel”, which is hereby incorporated by reference.

BACKGROUND

Technical Field

The present invention relates to flooring systems, and more particularly to modular flooring systems with interlocking panel assemblies.

Background Art

Modular flooring systems may be used for entertainment events, sporting events, disaster relief efforts, and other activities. Known flooring systems, however, often require numerous tools and fasteners (e.g., screws and bolts) to connect the flooring panels, causing the assembly and disassembly of the flooring panels to be time-consuming. The known flooring panels may damage the surface on which they sit due to the trapping of moisture under the flooring panel or a lack of air flow through the underside of the flooring panel. The known flooring panels may also allow water to reside on the surface, such that the water creates a slipping hazard.

SUMMARY

In accordance with one embodiment of the invention, a drop deck flooring panel includes a top surface of the panel and a bottom surface of the panel opposite the top surface of the panel. The top surface includes a plurality of raised surface features forming channels and a plurality of holes residing within the channels. The bottom surface of the panel includes a plurality of ribs corresponding to the plurality of raised surface features, where the plurality of holes traverse the top surface and the bottom surface. The channels are configured to direct water away from a topmost surface of the plurality of raised surface features, where the plurality of holes serve as drainage for the water.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing features of embodiments will be more readily understood by reference to the following detailed description, taken with reference to the accompanying drawings, in which:

FIG. 1 illustrates a top isometric view of a drop deck panel.

FIG. 2 illustrates a bottom isometric view of a drop deck panel.

FIG. 3 illustrates a top orthogonal view of a drop deck panel.

FIG. 4A illustrates a bottom orthogonal of a drop deck panel.

FIG. 4B illustrates a right orthogonal view of a drop deck panel.

FIG. 4C illustrates a left orthogonal view of a drop deck panel.

FIG. 4D illustrates a front orthogonal view of a drop deck panel.

FIG. 4E illustrates a back orthogonal view of a drop deck panel.

FIG. 5 illustrates a close-up, top cross-sectional isometric view of the drainage holes of the drop deck panel.

FIG. 6 illustrates a close-up, bottom isometric view of the drainage holes.

FIG. 7 illustrates a close-up, top cross-sectional isometric view of a drainage hole.

FIG. 8 illustrates a close-up isometric view of a corner of the drop deck panel.

FIGS. 9 and 10 illustrate a top isometric view and a bottom perspective view, respectively, of a pair of drop deck panels coupled in a top-to-bottom configuration.

FIGS. 11 and 12 illustrate close-up, top cross-sectional isometric views of a pair of drop deck panels coupled in a top-to-bottom configuration.

FIG. 13 illustrates an isometric view of a pair drop deck panels coupled in a bottom-to-bottom configuration.

FIG. 14 illustrates a close-up, cross-sectional view of a coupling of a pair of drop deck panels in a bottom-to-bottom.

FIG. 15 illustrates a set of drop deck panels coupled in a checkerboard configuration.

FIG. 16 illustrates a set of drop deck panels coupled in a staggered configuration.

FIG. 17 illustrates a set of drop deck panels coupled in a hatch pattern.

FIG. 18 illustrates a close-up view of a lock direction indication.

FIGS. 19 and 20 illustrate a top isometric view and a side view, respectively, of a drop deck panel transition piece.

FIGS. 21A and 21B illustrate top isometric exploded views of a panel assembly that includes a cam lock.

FIG. 21C illustrates a cross-sectional isometric view of a receptacle portion of the cam lock.

FIG. 21D illustrates a cross-sectional isometric view of a latch portion of the cam lock.

FIG. 21E illustrates an isometric cross-sectional view of the cam lock in situ.

FIG. 21F illustrates a cross-sectional bottom isometric close-up view of first and second panels coupled by the cam lock.

FIG. 21G illustrates a top isometric cross-sectional close-up view of first and second panels coupled by the cam lock.

FIGS. 22A and 22B illustrate top isometric views of tongue and groove locking mechanisms in a panel.

FIG. 22C illustrates an isometric close-up view of the female portion of the tongue and groove locking mechanism.

FIG. 22D illustrates an isometric close-up view of the male portion of the tongue and groove locking mechanism.

FIG. 22E illustrates an isometric cross-sectional view of the tongue and groove locking mechanism with the male and female portions coupled.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

Discussed herein are embodiments of a flooring system with interlocking panels. The flooring system may include a plurality of drop deck panels. The top surface of a drop deck panel includes surface features that form channels through which water may traverse and reduce the risk of a slipping hazard. The top surface further includes one or more drainage holes that may also serve as screw holes for screws to couple the drop deck panel to another component. A pair of drop deck panels may be stacked in a top-to-bottom manner or a bottom-to-bottom manner to form a stronger structure than a single drop deck panel. Other advantages may also be realized from the implementation of one or more of the embodiments.

Reference in this specification to “one embodiment,” “an embodiment,” “an exemplary embodiment,” “some embodiments,” or “a preferred embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not other embodiments. In general, features described in one embodiment might be suitable for use in other embodiments as would be apparent to those skilled in the art.

References to “top” and “bottom” are used herein to indicate relative orientation for ease of description only and are not to be limiting as absolute positions of components.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, elements, and/or components, but do not preclude the presence or addition of one or more other features, elements, components, and/or groups thereof.

The Figures use the following reference numerals:

• • 100 drop deck panel
  • 100a first drop deck panel
  • 100b second drop deck panel
  • 102 raised surface features of panel 100
  • 102b raised surface features of second panel 100b
  • 104 ribs of panel 100
  • 104a ribs of first panel 100a
  • 104b ribs of second panel 100b
  • 106a ribs of holes of first panel 100a
  • 106b holes of second panel 104b
  • 110B channels of second panel 100b
  • 106 holes of panel 100
  • 108 cut-away feature of panel 100
  • 110 channels of panel 100
  • 120 long axis of panel 100
  • 122 short axis of panel 100
  • 702 beam
  • 1402 screw
  • 1802 lock direction indication
  • 1902 transition piece
  • 1904 cut-away feature of transition piece 1902
  • 2002 space beneath transition piece 1902
  • 2100 cam lock
  • 2101 receptacle portion of cam lock 2100
  • 2102 latch portion of cam lock 2102
  • 2104 receiver of receptacle portion 2101
  • 2105 latch of latch portion 2102
  • 2106 opening in latch portion 2102
  • 2107 hex wrench
  • 2200 tongue and groove locking mechanism
  • 2201 male portion of tongue and groove locking mechanism 2200
  • 2202 female portion of tongue and groove locking mechanism 2200
  • 2205 bottom surface of female portion 2202
  • 2206 bottom of male portion 2201
  • 2207 top of male portion 2201
  • 2208 Top Surface of Female Portion 2202

FIGS. 1 and 2 illustrate a top isometric view and a bottom isometric view, respectively, of a drop deck panel 100. FIGS. 3 through 4E illustrate a top orthogonal view, a bottom orthogonal view, a right orthogonal view, a left orthogonal view, a front orthogonal view, and a back orthogonal view, respectively, of a drop deck panel. In one example embodiment, a drop deck panel 100 is 4 feet along the short axis 122 and 8 feet along the long axis 120. The long axis 120 and the short axis 122 are substantially perpendicular to each other. The top surface of the panel 100 (see FIGS. 1 and 3) includes a plurality of raised surface features 102. In one embodiment, the topmost surface of the raised surface features is approximately 1/16-inch above the surface of the panel 100. The raise surface features form channels 110 (see FIG. 5) on the top surface of the panel 100 through which water may traverse, which assists in directing water away from the topmost surface of the panel 100. The raised surface features 102 further avoid any “sink marks” from a mold from interfering with the topmost surface of the panel 100. The bottom surface of panel 100 (see FIGS. 2 and 4) includes a plurality of ribs 104 that correspond to channels 110 on the top surface. The ribs 104 are configured flush with the bottommost surface of the panel 100 such that the ribs 104 contact the ground, which provides more stability when the panel 100 is installed.

The panel 100 includes a plurality of holes 106 (see FIGS. 3 and 4), residing within the channels 110, through which water may traverse the panel 100. In one example embodiment, the holes 106 are located approximately every 12 inches along the long axis 120 and every 20 inches along the short axis 122. Water may be directed away from the topmost surface of the panel 100, through the channels 110, through the holes 106, and to the ground on which the panel 100 sits. The holes 106 further allow air to traverse through the panel 100 to the ground below, reducing damage to any grass on the ground. The raised surface features 102 may be textured to further reduce the risk of slippage. FIG. 5 illustrates a close-up, top cross-sectional perspective view of the drainage holes 106 of the drop deck panel 100. FIG. 6 illustrates a close-up, bottom perspective view of the drainage holes 106. FIG. 7 illustrates a close-up, top cross-sectional perspective view of a drainage hole 106. The holes 106 may serve the dual purpose of being screw holes. In any of the holes 106, a screw may be inserted to couple the panel 100 to a component beneath the panel 100. For example, the panel 100 may be coupled to a beam 702 of a scaffolding structure (see FIG. 7). The number of holes 106 may be configured such that more holes 106 exist than required to serve as screw holes, thus ensuring that holes 106 will be available to serve as drainage. Optionally, plugs (not shown) may be inserted into one or more holes 106 to prevent walking hazards for high-heeled shoes.

FIG. 8 illustrates a close-up perspective view of a corner of the drop deck panel 100. In one embodiment, one or more corners of the panel 100 includes a cut-away feature 108, such that, when four panels are coupled corner to corner, the corners of the four panels form an additional drainage hole.

FIGS. 9 and 10 illustrate a top perspective view and a bottom perspective view, respectively, of a pair of drop deck panels coupled in a top-to-bottom configuration. FIGS. 11 and 12 illustrate close-up, top cross-sectional perspective views of a pair of drop deck panels coupled in a top-to-bottom configuration. In one example embodiment, a pair of drop deck panels 100A-100B may be coupled, or stacked, such that the ribs 104A on the bottom surface of a first panel 100A reside within the channels 110B formed by the raised surface features 102B of a second panel 100B. Although only a pair of panels 100A-100B are shown, additional panels 100 may be coupled/stacked to either panel 100A or 100B. The top-to-bottom configuration of panels 100A-100B allows a set of panels to be transported with less sliding and/or requiring less strapping to hold in place, which provides greater safety in the transport of the panels.

FIG. 13 illustrates a perspective view of a pair drop deck panels coupled in a bottom-to-bottom configuration. FIG. 14 illustrates a close-up, cross-sectional view of a coupling of a pair of drop deck panels in a bottom-to-bottom. In one embodiment, a pair of drop deck panels 100A-100B may be coupled such that the ribs 104A of a first panel 100A abuts the ribs 104B of a second panel 100B. As shown in FIG. 14, the ribs 100A and 100B are aligned such that one or more of the holes 106A of the first panel 100A abut one or more holes 106B of the second panel 100B. A screw 1402 may be inserted through the holes 106A-106B to couple the first and second panels 100A-100B. When coupled in this manner, the first and second panels 100A-100B provide a thicker and stronger panel. The coupling of the first and second panels 100A-100B also forms an enclosed structure, which may be desirable if the panels are to rest on soft ground, such as grass or sod. Further, plugs (not shown) may be inserted into the holes 106A and 106B, in which screws are not inserted, to prevent water from entering the enclosed structure and/or to prevent walking hazards for high-heeled shoes. Optionally, the panels 100A-100B may also be welded together to fully seal the panel combination.

A set of drop deck panels may be coupled in a variety of configurations. For example, FIG. 15 illustrates a set of drop deck panels coupled in a checkerboard configuration. FIG. 16 illustrates a set of drop deck panels coupled in a staggered configuration. FIG. 17 illustrates a set of drop deck panels coupled in a hatch pattern.

FIG. 18 illustrates a close-up view of a lock direction indication. In one embodiment, a lock direction indication 1802 may be included on the top surface of the drop deck panel 100. The lock direction indication 1802 may be placed proximate to one or more of the cam locks (not shown). A cam lock may lock using either a clockwise or counterclockwise turn, depending on the configuration of the cam lock installation. By including the lock direction indication 1802, safety is improved by reducing a risk of a cam lock being turned in the unlock direction when a locking direction is intended.

FIGS. 19 and 20 illustrate a top perspective view and a side view, respectively, of a drop deck panel transition piece. In one embodiment, the thickness of the drop deck panel 100 is greater than a standard ¾-inch plywood, commonly used in conjunction with a flooring system. To prevent the transition between a ¾-inch plywood and the drop deck panel 100, a transition piece 1902 that includes an inclined surface on at least a portion of the top side of the transition piece 1902 may be coupled to the plywood. The inclined surface includes a higher end that is proximate to the panel 100 and a lower end that is distal from the panel 100. As shown in FIG. 20, an edge of a piece of the plywood (not shown) would reside within the space 2002. The transition piece 1902 would be coupled to the edge of the plywood, such as via screws. The transition piece 1902 includes a cut-away feature 1904 at its bottom side that corresponds to features at an edge of the panel 100. For example, the male portions 2201 of the tongue and groove locking mechanism 2200 (described further below) may reside within the cut-away feature 1904. The transition piece 1902, coupled to the plywood, would be positioned to abut the panel 100 such that a topmost surface of the transition piece 1902 is flush with the top surface of the panel 100. The inclined surface of the transition piece 1902 provides a transition between the top surface of the panel 100 to the top surface of the plywood, thus reducing the risk of a tripping hazard. By use of the transition piece 1902, no modifications to the plywood or the panel 100 is required.

FIGS. 21A-21G illustrate a cam lock 2100 for coupling a plurality of panels. FIGS. 21A and 21B illustrate top isometric views of a panel 100 that includes a plurality of cam locks 2100. Two cam locks 2100 reside in each of the long sides of the panel 100, while one cam lock 2100 reside in each of the short sides of the panel 100. FIG. 21C illustrates a cross-sectional isometric view of the receptacle portion 2101 of the cam lock 2100. FIG. 21D illustrates a cross-sectional isometric view of a latch portion 2102 of the cam lock 2100. FIG. 21E illustrates an isometric cross-sectional view of the cam lock 2100 in situ. FIG. 21F illustrates a cross-sectional bottom isometric close-up view of a plurality of panels coupled by the cam lock 2100. FIG. 21G illustrates a top isometric cross-sectional close-up view of a plurality of panels coupled by the cam lock 2100. The cam lock 2100 includes a receptacle portion 2101 and a latch portion 2102. The receptacle portion 2101 and the latch portion 2102 are positioned on opposite sides of the panel 100. The receptacle portion 2101 includes a receiver 2104. The latch portion 2102 of the cam lock 2100 includes a latch 2105 that may be rotated by inserting a tool (e.g., hex wrench 2107, see FIG. 21E) into an opening 2106 in the latch portion 2102. The latch 2105 may be rotated to protrude beyond the housing of the latch portion 2102 and engage the receiver 2104 of the receptacle portion 2101, thus placing the cam lock 2100 in a locked position.

FIGS. 22A-22E illustrate a tongue and groove locking mechanism 2200 for coupling a plurality of panels. FIGS. 22A and 22B illustrate top isometric views of tongue and groove locking mechanisms in a panel 100. FIG. 22C illustrates an isometric close-up view of a female portion 2202 of a tongue and groove locking mechanism 2200. FIG. 22D illustrates an isometric close-up view of a male portion 2201 of a tongue and groove locking mechanism 2200. FIG. 22E illustrates an isometric cross-sectional view of the tongue and groove locking mechanism 2200 with the male and female portions 2201-2202 coupled. As illustrated in FIGS. 22A and 22B, the front side and the right side of the panel 100 includes female portions 2202 of the tongue and groove locking mechanism 2200 and the receptacle portions 2101 of cam locks 2100. The back side and the left side of the panel 100 includes male portions 2201 of the tongue and groove locking mechanism 2200 and the latch portions 2102 of cam locks 2100.

Referring to FIGS. 21A-21G and FIGS. 22A-22D, the first and second panels 100A and 100B may each be the panel 100. To couple the first panel 100A to the second panel 100B, the male portion 2201 in the first panel 100A is pressed into the female portion 2202 in the second panel 100B, such that the male portion 201 in the first panel 100A resides within the female portion 2202 in the second panel 100B. The cam lock 2100 is then placed into the locked position. To place the cam lock 2100 in a locked position, the latch 2105 of the cam lock 2100 in the first panel 100A is rotated to engage the receiver 2104 of the receptacle portion 2101 in the second panel 100B. The cam lock 2100 in the locked position prevents the decoupling of the panels 100A and 100B due to movements along the axes 120 and 122. The engagement of the male portion 2201 and the female portion 2202 of the tongue and groove locking mechanism 2200 prevents the decoupling of the panels 100A and 100B due to up and down movements of the panels 100A and 100B. Referring to FIG. 22E, when a load is applied to the top surface of the first panel 100A, the first panel 100A moves downward. The downward movement of the first panel 100A is limited by the engagement of the bottom 2206 of the male portion 2201 with the bottom surface 2205 of the female portion 2202. When the load is then removed from the first panel 100A, the first panel 100A moves upward. The upward movement of the first panel 100A is limited by the engagement of the top 2207 of the male portion 2201 with the top surface 2208 of the female portion 2202. Similarly, when a load is applied to the top surface of the second panel 100B, the second panel 100B moves downward. The downward movement of the second panel 100B is limited by the engagement of the top surface 2208 of the female portion 2202 with the top 2207 of the male portion 2201. When the load is then removed from the second panel 100B, the second panel 100B moves upward. The upward movement of the second panel 100B is limited by the engagement of the bottom surface 2205 of the female portion 2202 with the bottom 2206 of the male portion 2201. To decouple the first panel 100A and the second panel 100B, the cam lock 2100 is placed into an unlocked position, where the latch 2105 of the latch portion 2102 in the first panel 100A is rotated to disengage from the receiver 2104 of the receptacle portion 2101 in the second panel 100B. The first and second panels 100A-100B are then separated to decouple the male portion 2201 of the tongue and groove locking mechanism 2200 in the first panel 100A from the female portion 2202 of the tongue and groove locking mechanism 200 in the second panel 100B.

Various embodiments of the present invention may be characterized by the potential claims listed in the paragraphs following this paragraph (and before the actual claims provided at the end of this application). These potential claims form a part of the written description of this application. Accordingly, subject matter of the following potential claims may be presented as actual claims in later proceedings involving this application or any application claiming priority based on this application. Inclusion of such potential claims should not be construed to mean that the actual claims do not cover the subject matter of the potential claims. Thus, a decision to not present these potential claims in later proceedings should not be construed as a donation of the subject matter to the public.

The embodiments of the invention described above are intended to be merely exemplary; numerous variations and modifications will be apparent to those skilled in the art. All such variations and modifications are intended to be within the scope of the present invention as defined in any appended claims.

Claims

1. A flooring panel, comprising:

a top surface of the panel, comprising: a plurality of raised surface features forming channels; and a plurality of holes residing within the channels; and

a bottom surface of the panel opposite the top surface of the panel, comprising: a plurality of ribs corresponding to the plurality of raised surface features, wherein the plurality of holes traverse the top surface and the bottom surface.

2. The flooring panel of claim 1, wherein the channels are configured to direct water away from a topmost surface of the plurality of raised surface features, wherein the plurality of holes serve as drainage for the water.

3. The flooring panel of claim 1, further comprising one or more lock rotation indications for one or more cam locks.

4. The flooring panel of claim 1, further comprising a transition piece coupled to an abutting piece of plywood and abutting an edge of the flooring panel.

5. The flooring panel of claim 1, further comprising:

a front side comprising a female portion of at least one first tongue and groove locking mechanism and a receptable portion of one or more first cam locks;

a back side opposite the front side, comprising a male portion of at least one second tongue and groove locking mechanism and a latch portion of one or more second cam locks;

a right side opposite the left side, comprising a female portion of at least one third tongue and groove locking mechanism and a receptable portion of one or more third cam locks; and

a left side comprising a male portion of at least one fourth tongue and groove locking mechanism and a latch portion of one or more fourth cam locks.

6. The flooring panel of claim 1, further comprising a transition piece abutting a side of the flooring panel, the transition piece comprising:

a top side and a bottom side opposite the top side; and

an inclined surface on at least a portion of the top side, wherein a higher end of the inclined surface being proximate to the flooring panel and a lower end of the inclined surface being distal from the flooring panel.

7. The flooring panel of claim 6, wherein the transition piece further comprises a cut-away feature at the bottom side of the transition piece, wherein one or more features residing at a side of the flooring panel resides within the cut-away feature.

8. A flooring system, comprising:

a first panel, comprising: a first top surface of the first panel, comprising: a first plurality of raised surface features forming first channels; and a first plurality of holes residing within the first channels; and a first bottom surface of the first panel opposite the first top surface of the first panel, comprising: a first plurality of ribs corresponding to the first plurality of raised surface features, wherein the first plurality of holes traverse the first top surface and the first bottom surface; and

a second panel, comprising: a second top surface of the second panel, comprising: a second plurality of raised surface features forming second channels; and a second plurality of holes residing within the second channels; and a second bottom surface of the second panel opposite the second top surface of the second panel, comprising: a second plurality of ribs corresponding to the second plurality of raised surface features, wherein the second plurality of holes traverse the second top surface and the second bottom surface,

wherein the first panel and the second panel are coupled.

9. The flooring system of claim 8, wherein the first panel and the second panel are coupled, such that the first plurality of ribs reside within the second channels.

10. The flooring system of claim 9, wherein the first panel and the second panel are coupled, such that the first plurality of ribs abut the second plurality of ribs, wherein one or more screws are inserted into the first plurality of holes and the second plurality of holes.