AU2013204045A1

AU2013204045A1 - Modular Flooring System

Info

Publication number: AU2013204045A1
Application number: AU2013204045A
Authority: AU
Inventors: Graham Hossack
Original assignee: POLY PAVE AUSTRALIA Pty Ltd
Current assignee: POLY PAVE AUSTRALIA Pty Ltd
Priority date: 2013-01-31
Filing date: 2013-04-11
Publication date: 2014-08-14
Also published as: WO2014117219A1

Abstract

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Description

MODULAR FLOORING SYSTEM TECHNICAL FIELD [0001] The present invention relates to a modular flooring system and particularly to a modular flooring system allowing relocation if necessary. BACKGROUND ART [0002] Modular flooring systems are available. The majority of modular flooring systems available are formed from a number of components having edge connections allowing connection of adjacent components together. This typically involves careful and complete alignment in order to form the floor, increasing the precision required and also the time required for assembly and disassembly. [0003] It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country. SUMMARY OF INVENTION [0004] The present invention is directed to a modular flooring system, which may at least partially overcome at least one of the abovementioned disadvantages or provide the consumer with a useful or commercial choice. [0005] With the foregoing in view, the present invention in one form, resides broadly in a modular flooring system including i. a number of perimeter components, each having a substantially planar portion with a shaped rebate formed thereinto with at least one shaped opening associated therewith, ii. a number of base components, each base component abutting at least one adjacent perimeter component or an adjacent base component along each edge thereof, each base component having a substantially planar portion with a shaped rebate formed thereinto with at least one shaped opening associated therewith, each shaped opening having a. a portion of first dimension and b. an opposed portion of second dimension smaller than the first dimension, and iii. at least one key having a planar body portion and at least two lugs, each lug having a neck portion extending perpendicularly to the body portion of the key and an enlarged head extending radially beyond the neck portion to define an abutment shoulder spaced from the body such that during assembly, the perimeter components surround abutting base components and a key is located such that the enlarged head portion of the lugs extends through the portion of first dimension of a shaped opening whereupon rotation of the key moves the neck portion into the portion of second dimension and the abutment shoulder abuts a surround of the portion of second dimension preventing removal of the key from the opening unless the key is first rotated thus locking the modular flooring system together in a releasable manner. [00061 The modular flooring system of the present invention is directed towards providing a modular floor of high durability which is relocatable if desired but capable of permanent or semipermanent fixing to a support surface if required. Normally, the modular flooring system of the present invention is located on a support surface which can be any type including finished or unfinished, level or of variable height. It is anticipated that the modular flooring system of the present invention can be used for example outdoors on a grass or similar surface as well as indoor on any form of flooring whether provided with cushioning between the support surface and the modular flooring of the invention or not. [00071 The modular flooring system of the preferred embodiment may be used to provide traction or grip on what would otherwise be a slippery surface. The upper surface of the modular flooring system of the preferred embodiment can be designed according to required characteristics for example cushioning, high grip, hard wearing, flexible or the like. It is particularly preferred that the components used in the modular flooring of the present invention can have additional surface treatments applied thereto or can have different materials either mounted relative to the components or moulded integrally with the components in order to provide the required characteristics. [0008] The features of the modular flooring system of the preferred embodiment will allow drainage to occur beneath the modular floor in order to allow for over surface flow of water or other liquids without the water or other liquid flowing on the modular floor surface. [0009] Still further, the modular flooring system of the present invention includes or allows an amount of flex due to the particular design of the support for the modular flooring system providing each component with rigidity and with flexibility of the flooring system provided through the key is connecting the components allowing a small amount of articulation between the components, when assembled. [0010] The modular flooring system of the present invention includes a number of perimeter components. Typically the perimeter components are provided in order to define a border for the modular flooring system. There can be any number of perimeter components. Further, the perimeter components can have any shape. According to the preferred embodiment however there are typically two configurations of perimeter components namely an L-shaped perimeter component and a straight perimeter component. [0011] The L-shaped perimeter components will typically be provided as corners whether the comers provided are internal corners or external corners. An L-shaped perimeter component will normally have two portions at an angle to one another. When used in the present specification, the term "internal comer" means that the two portions are at an angle to one another with the base components provided on the side of the perimeter component which has greater than 1800 separation between the two portions and the term "external comer" means that the two portions are at an angle to one another with the base components provided on the side of the perimeter component which has less than 180' separation between the two portions. [0012] Any other shape perimeter component can be provided including arcuate but rectilinear perimeter components are preferred. [0013] The perimeter components, regardless of configuration normally have a set of similar features. Normally, the perimeter components include a substantially planar base plane defined by one or more elements. Typically, at least a portion of the upper surface is generally parallel to the substantially planar base plane. [0014] The upper surface of the perimeter components or at least a portion thereof will typically be substantially planar. Recesses or depressions may be formed into the upper surface. Preferably, one or more openings may be present within each of the recesses or depressions if provided. [0015] According to a particularly preferred embodiment, a regular array of recesses or depressions is provided across the upper surface of the base components and at least a portion of the upper surface of the perimeter components. [0016] According to the most preferred embodiment, the recesses are rectangular in shape and approximately 1 to 2 mm in depth. [00171 Preferably, the substantially planar base plane is defined by a number of individual elements or feet. The underside of the perimeter components is typically configured as a grid. Generally speaking, there are three parts to any grid namely, a face or tile shape, edges and _r vertices. Each face or tile shape is a two dimensional shape enclosed by one or more edges. Each edge is a one dimensional line segment ending at two vertices. In some circumstances there are no vertices (such as a circular tile shape) but this is uncommon in modular systems. [00181 Preferably, the underside of the substantially planar base plane is formed from a plurality of feet which extend from arch supports located along each edge of each face or tile shape. As outlined above, any face or tile shape can be used but preferably, the tile shape will be rectangular. Therefore, the underside of the substantially planar base plane is divided into a number of rectangles with a leg with a foot at each vertex of each rectangular tile shape and an arch extending between one leg and the leg provided at each of the surrounding nine vertices. [0019] Each leg preferably extends substantially perpendicularly to the upper surface of the component with a leg normally located at each vertex. Clearly, the smaller the size of the face or tile shape in the grid, means that there are more tile shapes provided and therefore more legs. The more legs that are provided, the more rigid to the component will be and the fewer legs that are provided, the more flexible the component will be. [0020] If the grid provided is a regular, rectangular grid, normally one or more arch supports will be aligned to form one or more channels on the underside of each component. These channels space the underside of the component from the surface except for the contact points at the feet and still support the component as well is providing strength and the desired rigidity depending on the number of tile shapes in the grid. [0021] Preferably, each component of the modular flooring system will be a moulded plastic material giving the components high-strength and also a degree of rigidity. [0022] Each comer of each component preferably has a shaped to rebate formed thereinto with at least one shaped opening associated with each rebate. Typically, the rebate is formed to accept a portion of the at least one key and each at least one shaped opening functions to receive a portion of the at least one key. [0023] The shape of the rebate formed into each component will vary according to a variety of factors such as the shape of the key and the shape of the component. However, according to the preferred embodiment, the modular flooring system of the present invention is rectilinear and therefore, the components are generally rectangular or have planar side edges. Further, according to the preferred embodiment, the key is generally circular which means that the rebate is either circular or at least partially circular.

[00241 Returning to the two preferred configurations of perimeter components namely, L shaped and straight, the perimeter components will typically be wedge shaped in cross-section with a first portion in which the upper surface is generally parallel to the substantially planar base plane and a second portion which is angled relative to the first portion and generally angled towards the planar base plane. A shaped and/or finished outer edge can be provided in order to minimise any stubbing which may occur. [0025] In the straight configuration, normally the rebates will be provided on the inner corners of the straight perimeter component (on the comers of the first portion) and will generally be quadrant shaped. [0026] In relation to the L-shaped perimeter component the features will generally be similar to those in the straight perimeter component but with two portions angled relative to one another. In this configuration, typically a rebate is located at an outer end of each arm, and a further rebate is provided at the corner where the edges of each of the two arms meet. In an external comer configuration, the rebate will normally be provided at an internal corner and in an internal corner configuration, the rebate will normally be provided at an external corner. [00271 Preferably, the rebate at each end in this configuration will be substantially quadrant shaped. The corner rebate however is typically also sector shaped but preferably the rebate will be formed of a 2700 sector. Normally, a shaped opening is provided in each 90' quadrant of the rebate and therefore, a single quadrant shaped rebate will normally have one shaped opening and a 270' rebate will normally have three shaped openings therein. [0028] The rebate will normally have a particular shape as well of a particular cross sectional shape. The rebate will normally have an outer portion at a particular depth and an internal portion at an increased depth. In cross-section, the rebate will preferably have a stepped appearance with an outer portion into which the shaped openings are formed and an inner portion at a lower level. It is preferred that the inner portion or second rebate will also have a particular cross-sectional shape in which a central portion is raised above a deeper outer, annular ring. Normally, an opening is formed through the raised central portion. As will be clear to a person skilled in the art, depending on how many components are located adjacent one another to form the floor, a number of different portions will form the rebate. The configuration of the rebate provided on each component will therefore preferably correspond to the configuration is formed on each of the other components such that when the components abut one another during assembly, a generally circular rebate is formed.

[00291 The modular flooring system of the present invention also includes a number of base components with each base component abutting at least one adjacent perimeter component or an adjacent base component along each edge and each base component having at least one shaped rebate formed thereinto. Generally, each of the base components are formed in a manner which is the same as the perimeter components but instead of having an angled portion to create the wedge shaped appearance of the perimeter components, the base components are typically of the same thickness across the length and breadth. [0030] Generally, each of the base components will be rectangular but any shape may be provided. It has however been found that a regular shape and in particular a tessellate shape provides the greatest number of variations in shape which can be formed using the base components. [00311 Preferably, each of the base components is provided with a rebate at each comer thereof (if the base component has a corner). The rebates do not have to be located at the corner thereof but can be located alternatively along an edge which will in use, but an adjacent edge and therefore, allow a key to lock the respective base components to one another. Accommodation can be provided wherein a rebate is provided at at least some of the comers and at least some of the edges. [0032] According to the invention, at least one and normally a plurality of keys are provided in order to releasably lock adjacent components of the flooring system together. Each key includes a planar body portion and at least two lugs. The planar body portion is circular according to a preferred embodiment of the present invention but any other shape may be used. [00331 Preferably, one or more openings are provided in an upper surface of the planar body portion to facilitate attachment or engagement of a tool with the key. The one or more openings can be formed into or completely through the planar body portion. Further, a rebate or shoulder may be associated with any one or more of the openings in order to allow the tool to hold or engaged the body to facilitate removal of the key in particular. [0034] One or more edge protrusions may be provided extending from an edge of the planar body portion in order to provide visual and/or audible and/or tactile feedback of the locking/unlocking of the key to a user. Typically, the edge protrusions extend laterally from the edge of the body portion. The edge protrusions may be of any shape such as triangular or pointed or rounded for example. [0035] Each of the lugs has a neck portion extending perpendicularly to the body portion of the key and an enlarged head extending radially beyond the neck portion to define an abutment shoulder spaced from the body portion of the key. The lugs are typically solid for strength purposes. Normally, there are at least three and preferably four lugs on each key and all lugs typically extend on the same side of the planar body portion of the key. However, the number of lugs will typically depend upon the shape of the base components and therefore, the number of vertices or edges of the base components. [00361 The neck of each lug is typically an elongate post or similar extending from an underside of the body portion. Normally, the neck extends substantially perpendicularly to the underside of the body portion. Typically, the neck is substantially cylindrical but other shapes can be provided. However the substantially cylindrical neck is preferred for the lack of corners which allows rotation of the key with the lugs minimising any catching. [00371 The enlarged head of each lug normally extends in each direction radially from the neck. Therefore, the head will normally be substantially circular when viewed from above (or below). The difference in dimension of the neck and the enlarged head forms a radial abutment shoulder substantially parallel to the underside of the body but spaced therefrom. [00381 The enlarged head may taper inwardly from an outer limit of the abutment shoulder in order to assist with assembly and allow at least a degree of self-location or self-orientation of the enlarged head with the shaped opening into which it is inserted in use. [00391 The enlarged head of the lug and a shaped opening preferably engage one another in order to lock the base components relative to one another and to lock the perimeter components with the base components. Typically, the key will operate to lock the components relative to one another against lateral movement. [0040] The rotation of the key during the locking may also draw the key downward or into the rebate in order to perform a more secure attachment. This can be accomplished by angling the surrounds of the shaped opening. [0041] The shaped opening provided in the components of the modular flooring system of the present invention will typically be substantially peanut shaped, or having two enlarged portions with a narrowed intervening linking portion between the two enlarged portions. According to a preferred embodiment, a first enlarged portion of the shaped opening is provided which is larger than the dimension of the enlarged head of the lug. Normally, the first enlarged portion of the shaped opening corresponds in shape to the shape of the lug and this allows insertion and removal of the enlarged head of the lug from the shaped opening.

0 [00421 The other of the two enlarged portions, the second enlarged portion will typically be smaller than the dimension of the enlarged head of the lug. Preferably, the periphery of the second enlarged portion provides an abutment area for the abutment shoulder in order to prevent removal of the lug from the shaped opening after the rotation until the enlarged head is aligned with the first enlarged portion. [0043] The second enlarged portion can be of any shape and size provided that it is smaller than the enlarged head. For example, the second enlarged portion of the shaped opening may be equal to the dimension of the linking portion but preferably, it is slightly larger than the linking portion and also slightly larger than the dimension of the neck of the lug. [0044] The intervening linking portion will typically be smaller in dimensions than both enlarged portions. The intervening linking portion or the transition between the intervening linking portion and each of the enlarged portions preferably provides tactile and/or audible feedback on the position or location of the neck portion of the lug within shaped opening. [0045] The intervening linking portion is approximately the same dimension as the neck of the lug but it may be slightly larger or smaller (providing a smaller dimension intervening portion requires that the neck and/or the surrounds of the intervening linking portion be slightly deformable in order to allow passage of the neck). [0046] A fastener may be provided in order to more permanently fix the modular flooring system of the present invention to a supporting surface. Where this is required, a fixing ring may be provided as an additional component in the system of the present invention. Typically, the fixing ring includes an annular body with an opening there through. The opening and the opening surround normally provides a seat for the head of the fastener and into which the head can be received. Normally, the upper surrounds of the opening a tapered inwardly and downwardly to receive the head of the fastener. [00471 Normally, the fixing ring is made of metal. Preferably, the fixing ring is located in the second rebate of the components of the flooring system and will typically function to temporarily hold the adjacent components together before the key is used to lock the components relative to one another. [0048] A depending lip or rim is normally provided on an underside of the fixing ring around the outside of the fixing ring. The depending lip or ring will normally be received in a channel between the raised central portion and the rebate having a shaped opening therein.

[00491 A fastener is normally driven through the fixing ring whilst the ring is located in position which holds the components together and then the key is used to both cover the fastener and further lock the components relative to one another to form the modular flooring system. [0050] The various components of the system of the present invention will normally be manufactured of a plastic material, normally a rigid plastic material although any overmoulded or attached layer can be manufactured of a suitable material to provide the characteristics desired. Although plastics are preferred materials for their availability and ease of working, it is clear that alternative materials may be used such as for example a rubber or rubber substitute for nonslip layers or over moulding. Still further, the rigid plastic material preferably used for the various components of the system could be replaced either partially or totally with alternative materials having the same (or superior) properties or material characteristics such as composite materials, woodfibre materials, fibreglass materials or the like. [0051] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention. [0052] The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge. BRIEF DESCRIPTION OF DRAWINGS [00531 Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows: [0054] Figure 1 is an isometric view of a portion of a modular flooring system according to a preferred embodiment of the present invention. [0055] Figure 2 is an isometric view of the portion illustrated in Figure 1 with elastomer moulded over the base components according to a preferred embodiment of the present invention. [00561 Figure 3 is an isometric view of the portion illustrated in Figure 1 with an EVA layer fixed directly to the base components to provide a cushioned modular floor according to a a IV preferred embodiment of the present invention. [00571 Figure 4 is an isometric view of a modular flooring system according to a preferred embodiment of the present invention. [0058] Figure 5 is an isometric view of the flooring system illustrated in Figure 4 from below. [0059] Figure 6 is a partially exploded isometric view of the flooring system illustrated in Figure 4. [0060] Figure 7 is a view from below of a corner portion of the modular flooring system illustrated in Figure 4 in the locked condition. [0061] Figure 8 is a sectional side view along line A-A of the configuration illustrated in Figure 7. [0062] Figure 9 is a detailed view of the portion illustrated in Figure 8 and designated "Detail A". [0063] Figure 10 is a view from below of a corner portion of the modular flooring system illustrated in Figure 4 in the unlocked condition. [0064] Figure 11 is a sectional side view along line B-B of the configuration illustrated in Figure 7. [0065] Figure 12 is a detailed view of the portion illustrated in Figure 8 and designated "Detail B". [0066] Figure 13 is a detailed isometric view of embodiment illustrated in Figure 4 with the key removed from the modular floor system. [00671 Figure 14 is a isometric view of the key illustrated in Figure 13 from below. [0068] Figure 15 is an isometric view of the configuration illustrated in Figure 13 with the position of the fixing ring illustrated. [0069] Figure 16 is a sectional side view of the configuration illustrated in Figure 15. DESCRIPTION OF EMBODIMENTS 1[ 1 [00701 According to a particularly preferred embodiment of the present invention, a modular flooring system is provided. [00711 The modular flooring system 10 of the preferred embodiment illustrated in the accompanying Figures includes a number of perimeter components 11, each having a substantially planar inner portion 12 with a shaped rebate 13 formed thereinto with at least one shaped opening 14 located within the shaped rebate 13. [0072] The preferred embodiment also includes a number of base components 15, each base component 15 abutting at least one adjacent perimeter component 11 or an adjacent base component 15 along each edge thereof as illustrated best in Figures 4 and 6. Each base component 15 has a substantially planar body with a shaped rebate 13 formed thereinto with at least one shaped opening 14 located within with the rebate 13. [0073] Each shaped opening 14 has a portion of first dimension 16 and an opposed portion of second dimension 17 smaller than the first dimension. [0074] During assembly, the perimeter components 11 surround abutting base components 15 and are locked together using a key 18. Each key 18, a preferred embodiment of which is illustrated in Figure 14 in particular has a planar body portion 19 and a number of lugs 20, with each lug 20 having a neck portion 21 extending perpendicularly to the body portion 19 of the key 18 and an enlarged head 22 extending radially beyond the neck portion 21 to define an abutment shoulder spaced from the body 19. The enlarged head 22 illustrated is frustoconical in shape. [00751 A key 18 is located such that the enlarged head portion 22 of the lugs 20 extends through the portion of larger dimension 16 of the respective shaped openings 14 whereupon rotation of the key 18 moves the neck portion 21 into the portion of second dimension 17 and the abutment shoulder abuts a surround of the portion of second dimension 17 preventing removal of the key 18 from the opening unless the key 18 is first rotated thus locking the modular flooring system 10 together in a releasable manner. [0076] The embodiments illustrated in Figures 1 to 3 shows a 2x2 configuration with three perimeter portions and the embodiments illustrated in Figures 4 to 6 shows a 3x3 configuration with eight perimeter portions. These embodiments are for illustrative purposes only and any suitable configuration with an appropriate number of components can be used. [00771 According to the preferred embodiment illustrated, there are two configurations of perimeter components namely an L-shaped perimeter component 11' and a straight perimeter component 11". Each of the perimeter components has an outer, downwardly sloping portion 23. [0078] According to the illustrated embodiment, the L-shaped perimeter components 11' are provided as corners having two portions at an angle to one another. [00791 The perimeter components 11, regardless of configuration normally have a set of similar features. Normally, each perimeter component 11 includes a substantially planar base plane defined by one or more elements and at least a portion of the upper surface is generally parallel to the substantially planar base plane. [0080] As illustrated in Figure 1, at least a portion of the upper surface of the perimeter components 11' and the entire upper surface of the base components 11" is substantially planar. Recesses or depressions 24 are formed into the planar upper surface of each component with an opening 25 within each of the recesses or depressions 24. [0081] According to the illustrated preferred embodiment, a regular array of rectangular recesses or depressions 24 is provided across the upper surface of the base components 11" and at least a portion of the upper surface of the perimeter components 11', each recess or depression 24 being approximately 1 to 2 mm in depth. [0082] As illustrated in Figure 2, the base components 11" have a durable elastomer 26 overmolded in order to provide grip on the modular floor and minimise fatigue. The overmolding occurs through the openings 25 and recesses 24 provided with the perimeter components being left without overmoulding in order to allow water to disperse around the perimeter of the modular floor. [0083] In the embodiment illustrated in Figure 3, a layer of soft EVA foam shaped to correspond to the shape of the base components 11" is fixed directly to the base components with adhesive. An EVA foam tile 27 these fixed directly to each of the base components 11" and an EVA foam tile edge 28 is fixed directly to the planar portion of each of the perimeter components 11'. Bullnose edging 30 is provided on the EVA foam tile edge 28 which is positioned adjacent the transition between the planar portion of the perimeter component and the sloping portion 23 in order to allow the EVA foam tile edge 28 to integrate with the standard perimeter component shape without the need for new tooling. Each key 18 is also provided with an EVA foam upper 29. As illustrated, the EVA foam tiles 27 and EVA foam tile edge 28 are shaped to allow the key 18 to be inserted and removed without removal of the EVA foam from the base or perimeter components.

[00841 Preferably, the substantially planar base plane of the underside of the base or perimeter components is defined by a number of individual elements or feet as illustrated in Figure 5. The underside of each of the component is configured as a grid. Generally speaking, there are three parts to any grid namely, a face or tile shape, edges and vertices. Each face or tile shape is a two dimensional shape enclosed by one or more edges. Each edge is a one dimensional line segment ending at two vertices. [0085] Preferably, the underside of the base or perimeter components is formed from a plurality of feet which extend from arch supports located along each edge of each face or tile shape. Therefore, the underside of the substantially planar base plane of each component of the illustrated embodiment is divided into a number of rectangles with a leg with a foot at each vertex of each rectangular tile shape and an arch extending between one leg and the leg provided at each of the surrounding nine vertices. [0086] Each leg preferably extends substantially perpendicularly to the upper surface of the component with a leg normally located at each vertex. [00871 As the grid provided is a regular, rectangular grid, the arch supports will be aligned to form one or more channels on the underside of each component. These channels space the underside of the component from the surface except for the contact points at the feet and still support the component as well is providing strength and the desired rigidity depending on the number of tile shapes in the grid. [0088] Each comer of each base component 11" and each inner corner of each perimeter component 11' has a shaped rebate 13 formed thereinto with at least one shaped opening 14 associated with each rebate 13. Typically, the rebate 13 is formed to accept a portion of the body 19 of a key 18 and the shaped openings 14 function to receive a portion of the lugs 20. [0089] According to the preferred embodiment illustrated, the modular flooring system is rectilinear and therefore, the components are generally rectangular or have planar side edges. Further, according to the preferred embodiment illustrated, the key 18 is generally circular which means that the rebate 13 is partially circular such that when components are positioned adjacent one another during assembly, a circular rebate 13such as that illustrated in Figure 15 is formed.. [0090] In the straight configuration of the perimeter component 11", two rebates are provided, one on each inner comer of the straight perimeter component 11" (on the corners of the first portion) and the rebates 13 are generally quadrant shaped.

1 -r [0091] In relation to the L-shaped perimeter component 11', the features are generally be similar to those in the straight perimeter component 11" but with two arm portions angled relative to one another. In this configuration, a generally quadrant shaped rebate 13 is located at an outer end of each arm portion, and a further rebate 13 is provided at the comer where the edges of each of the two arms meet. [0092] The corner rebate is also sector shaped but the rebate is approximately a 2700 sector. [00931 Normally, one shaped opening 14 is provided in each 90' quadrant of the rebate and therefore, a single quadrant shaped rebate will normally have one shaped opening and a 270' rebate will normally have three shaped openings 14 therein. [0094] Each rebate 13 will normally have an outer portion at a particular depth and an internal portion at an increased depth. In cross-section such as is illustrated in Figure 16, the rebate 13 has a stepped appearance with an outer portion into which the shaped openings are formed and an inner portion at a lower level. It is preferred that the inner portion or second rebate will also have a particular cross-sectional shape in which a central portion is raised above a deeper outer, annular ring. Normally, an opening is formed through the raised central portion. [0095] Each of the base components 15 is provided with a rebate 13 at each corner thereof with each comer rebate being quadrant shaped. [0096] According to the preferred embodiment, a plurality of keys 18 are provided in order to releasably lock adjacent components of the flooring system together. Each key 18 includes a planar body portion 19 and four lugs 20. The planar body portion 19 of the illustrated keys 18 is circular. [00971 A number of openings 31 are provided in an upper surface of the planar body portion 19 of the key illustrated in Figure 14 to facilitate attachment or engagement of a tool with the key 18. The openings 31 are formed completely through the planar body portion 19. Further, [0100] Each of the lugs 20 has a neck portion 21 extending perpendicularly to the body portion 19 of the key 18 and an enlarged head 22 extending radially beyond the neck portion 21 to define an abutment shoulder spaced from the body portion 19 of the key 18. The illustrated lugs 20 are solid for strength purposes. [0101] The neck 21 of each lug 20 is an elongate post or similar extending from an underside of the body portion 19 substantially perpendicularly to the underside of the body 19 portion. [0102] The enlarged head 22 of each lug 20 normally extends in each direction radially from the neck 21. The head on the lugs in the illustrated embodiment are frustoconical. The difference in dimension of the neck 21 and the enlarged head 22 forms a radial abutment shoulder substantially parallel to the underside of the body but spaced therefrom. [01031 The enlarged head of the lug 20 and shaped opening 14 preferably engage one another in order to lock the base components relative to one another and to lock the perimeter components with the base components. Typically, the key 18 operates to lock the components relative to one another against lateral movement. [0104] As best illustrated in Figures 13 and 15, the shaped opening 14 provided in the components of the modular flooring system of the preferred embodiment will typically be peanut shaped, or having two enlarged portions with a narrowed intervening linking portion between the two enlarged portions. According to the preferred embodiment, a first enlarged portion 16 of the shaped opening 14 is provided which is larger than the dimension of the enlarged head 22 of the lug 20. Normally, the first enlarged portion 16 of the shaped opening 14 corresponds in shape to the shape of the lug 20 and this allows insertion and removal of the enlarged head 22 of the lug 20 from the shaped opening 14. [0105] The other of the two enlarged portions, the second enlarged portion 17 is smaller than the dimension of the enlarged head 22 of the lug 20 such that the periphery of the second enlarged portion 17 provides an abutment area for the abutment shoulder in order to prevent removal of the lug 20 from the shaped opening 14 after the rotation until the enlarged head 22 is aligned with the first enlarged portion 16. [0106] The intervening linking portion will typically be smaller in dimension than both enlarged portions. The intervening linking portion or the transition between the intervening linking portion and each of the enlarged portions will normally provide tactile and/or audible feedback on the position or location of the neck portion 21 of the lug 20 within the shaped opening 14. [01071 A fastener 32 may be provided in order to more permanently fix the modular flooring system to a supporting surface. Where this is required, a fixing ring 33 is provided as an additional component in the system of the present invention. The preferred fixing ring includes an annular body with an opening therethrough. The opening and the opening surround normally provides a seat for the head of the fastener and into which the head can be received. Normally, the upper surrounds of the opening a tapered inwardly and downwardly to receive the head of the fastener. [01081 Normally, the fixing ring is made of metal. Preferably, the fixing ring is located in the second rebate of the components of the flooring system and will typically function to temporarily hold the adjacent components together before the key is used to lock the components relative to one another. [0109] A depending lip or rim is normally provided on an underside of the fixing ring around the outside of the fixing ring as illustrated in Figure 16. The depending lip or ring is normally received in a channel between the raised central portion and the rebate having a shaped opening therein. [0110] A fastener 32 is normally driven through the fixing ring 33 whilst the ring 33 is located in position which holds the components together and then the key 18 is used to both cover the fastener 32 and further lock the components relative to one another to form the modular flooring system. [0111] The relative positions of a key (and the lugs) with a rebate with four shaped openings is illustrated in Figures 7 to 9 in the locked condition and Figures 10 to 12 in the unlocked condition. [0112] In the present specification and claims (if any), the word 'comprising' and its derivatives including 'comprises' and 'comprise' include each of the stated integers but does not exclude the inclusion of one or more further integers. [01131 Reference throughout this specification to 'one embodiment' or 'an embodiment' means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases 'in one embodiment' or 'in an embodiment' in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations. [0114] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any I / of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.

Claims

1. A modular flooring system including a number of perimeter components, each having a substantially planar portion with at least one shaped rebate formed thereinto with at least one shaped opening associated therewith, a number of base components, each base component abutting at least one adjacent perimeter component or an adjacent base component along each edge thereof, each base component having a substantially planar portion with at least one shaped rebate formed thereinto with at least one shaped opening associated therewith, each shaped opening having a portion of first dimension and an opposed portion of second dimension smaller than the first dimension, and at least one key having a planar body portion and at least two lugs, each lug having a neck portion extending perpendicularly to the body portion of the key and an enlarged head extending radially beyond the neck portion to define an abutment shoulder spaced from the body such that during assembly, the perimeter components surround abutting base components and a key is located such that the enlarged head portion of the lugs extends through the portion of first dimension of a shaped opening whereupon rotation of the key moves the neck portion into the portion of second dimension and the abutment shoulder abuts a surround of the portion of second dimension preventing removal of the key from the opening unless the key is first rotated thus locking the modular flooring system together in a releasable manner.

2. The modular flooring system as claimed in claim 1 wherein two configurations of perimeter components are provided, namely a substantially L-shaped perimeter configuration and a straight perimeter configuration.

3. The modular flooring system as claimed in claim 2 wherein the L-shaped perimeter configuration is used as a corner whether the comer is provided as an internal corner or an external corner, the L-shaped perimeter configuration having two portions at an angle to one another.

4. The modular flooring system as claimed in any one of the preceding claims wherein the perimeter components are wedge shaped in cross-section with a first portion in which the upper surface is generally parallel to a substantially planar base plane and a second portion which is angled relative to the first portion and generally angled towards the planar base plane.

5. The modular flooring system as claimed in claim 2 wherein in the straight perimeter configuration, the at least one rebate is provided on inner corners of the straight perimeter I[9/ component and are generally quadrant shaped.

6. The modular flooring system as claimed in claim 2 wherein in the L-shaped perimeter configuration at least one rebate is located at an outer end of each portion, and a further rebate is provided at a corner where edges of each of the two portions meet whether an internal corner or an external comer.

7. The modular flooring system as claimed in claim 7 wherein the at least one rebate provided at a corner is a 2700 sector shape, with a shaped opening provided in each 90' quadrant of the 270' sector shape rebate.

8. The modular flooring system as claimed in any one of the preceding claims wherein each at least one rebate have an outer portion at a particular depth and an inner portion at an increased depth giving a stepped appearance.

9. The modular flooring system as claimed in claim 8 wherein the inner portion has a central portion is raised above a deeper outer, annular ring with an opening is formed through the raised central portion.

10. The modular flooring system as claimed in any one of the preceding claims wherein each base component is of consistent thickness.

11. The modular flooring system as claimed in any one of the preceding claims wherein each of the base components is provided with a rebate at each comer thereof.

12. The modular flooring system as claimed in any one of the preceding claims wherein each of the perimeter components include a substantially planar base plane defined by one or more elements and at least a portion of the upper surface is generally parallel to the substantially planar base plane.

13. The modular flooring system as claimed in claim 12 wherein a plurality of recesses or depressions are formed into the upper surface of each component.

14. The modular flooring system as claimed in claim 13 wherein one or more openings are present within each of the recesses or depressions.

15. The modular flooring system as claimed in any one of claims 12 to 14 wherein the substantially planar base plane is defined by a number of individual elements or feet.

16. The modular flooring system as claimed in claim 15 wherein the substantially planar base plane is divided into a number of rectangular tile shapes with a leg with a foot at each vertex of each rectangular tile shape and an arch extending between one leg and a leg provided at each of the surrounding nine vertices, each leg extending substantially perpendicularly.

17. The modular flooring system as claimed in claim 15 wherein respective arches align to form one or more channels on the underside of each component.

18. The modular flooring system as claimed in any one of the preceding claims wherein each corner of each component adapted to abut another component has a shaped rebate formed thereinto with at least one shaped opening associated with each shaped rebate, the shaped rebate is formed to accept a portion of the at least one key and each at least one shaped opening functions to receive a portion of the at least one key.

19. The modular flooring system as claimed in any one of the preceding claims wherein one or more openings are provided in an upper surface of the planar body portion of the at least one key to facilitate attachment or engagement of a tool with the at least one key.

20. The modular flooring system as claimed in any one of the preceding claims wherein one or more edge protrusions are provided extending from an edge of the planar body portion of the at least one key in order to provide visual, audible and/or tactile feedback of the locking and unlocking of the at least one key to a user.

21. The modular flooring system as claimed in any one of the preceding claims wherein rotation of the at least one key during locking also draws the at least one key into the rebate in order to perform a more secure attachment.

22. The modular flooring system as claimed in any one of the preceding claims wherein each at least one shaped opening provided in a component is substantially peanut shaped, having two enlarged portions with a narrowed intervening linking portion between the two enlarged portions, a first enlarged portion of the shaped opening which is larger than the enlarged head of the lug and a second enlarged portion which is smaller than the dimension of the enlarged head of the lug.

23. The modular flooring system as claimed in claim 22 wherein the intervening linking portion is smaller in dimension than both enlarged portions.

24. The modular flooring system as claimed in any one of the preceding claims wherein a fixing ring is provided as an additional component, the fixing ring including an annular body with an opening therethrough, and located in the rebate of the components of the flooring system to temporarily hold the adjacent components together before the key is used to lock the components relative to one another.

25. The modular flooring system as claimed in claim 23 wherein a fastener is provided in order to more permanently fix the modular flooring system of the present invention to a supporting surface, the fastener extending through the fixing ring.

26. The modular flooring system as claimed in claim 23 or claim 24 wherein a depending lip is provided on an underside of the fixing ring around the outside of the fixing ring to be received in a channel in the rebate.

27. The modular flooring system as claimed in any one of the preceding claims wherein all components of the system are manufactured of a rigid plastic material.

28. The modular flooring system as claimed in any one of the preceding claims wherein one or more overmoulded or attached layers can be associated with the perimeter or base components to provide desired characteristics to the flooring system.