AU2020103145A4

AU2020103145A4 - A combination flooring mallet and tapping block or mallet block

Info

Publication number: AU2020103145A4
Application number: AU2020103145A
Authority: AU
Inventors: Gregory Robert Ceglarski; Corrine Marie Chapman
Original assignee: Vallina Pty Ltd Trading As Scribed Flooring
Current assignee: Vallina Pty Ltd Trading As Scribed Flooring
Priority date: 2019-12-03
Filing date: 2020-10-30
Publication date: 2021-01-07
Anticipated expiration: 2028-10-30

Abstract

A mallet block for tapping floorboards during installation. The mallet has feet protruding from the base of the mallet and thus is at a pre-determined distance from the floor at which the mallet face strikes the floorboard to avoid any impact damage to crucial parts of the interlocking edges of the floorboards. 1/6 20a 22a 10 16a 012 12a 18a Figure 1 14 10 16 18 12b 22 Figure 2 20

Description

A mallet block for tapping floorboards during installation. The mallet has feet protruding from the base of the mallet and thus is at a pre-determined distance from the floor at which the mallet face strikes the floorboard to avoid any impact damage to crucial parts of the interlocking edges of the floorboards.

1/6

20a

22a 10

16a 012

12a

18a Figure 1

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16 18

12b

22 Figure 2 20

A COMBINATION FLOORING MALLET AND TAPPING BLOCK OR MALLET BLOCK.

FIELD OF THE INVENTION This invention relates to the floor repair, installation and refurbishment industry. In particular, it concerns a combination flooring mallet and tapping block, henceforth referred to as a mallet block, for tapping together floorboards which typically include interlocking side edges and are adhered by adhesive to a building floor. Specifically, the invention eliminates the need for a separate hammer or mallet normally required when using conventional prior art floorboard tapping or knocking blocks. An advantage of the invention is that it can also be used on floating floor applications wherein floorboards are not adhered to a floor.

BACKGROUND OF THE INVENTION The utilization of factory machined floorboards with specially adapted interlocking side edges that are bonded with adhesive to an existing floor is common practice to the floor installation and refurbishment industries. Invariably, the relevant prior art concerns new floorboards which must be firmly tapped and fitted closely together with specially adapted tools. These include floor knocking or tapping blocks and tools used to strike them such as mallets and dead blow hammers. An important fact is that floorboards come in various sizes, widths and thicknesses and floor installers presently need to carry a number of differently sized and specialized tools to knock tongue and groove or any generation of interlocking edged floorboards together. These boards are usually struck just above the tongue or any interlocking edge members to avoid damaging them. This often involves the necessity of keeping a set of different types of tapping blocks and hammers which can be expensive. While care and experience is usually required in using these specialized tools, adhesive is often accidently smeared on the upper or finished surfaces of the floorboards during installation. This may often be simply due to the number of tools involved which can come into contact with the adhesive being applied to the floor. In particular, the bases of prior art knocking or flooring blocks are commonly in contact with the adhesive bed which greatly increases the chances of accidently touching the exposed or finished surface of a floorboard with it. Flooring adhesives have to be by their nature strong and chemically resilient. They are usually petro-chemically based and industrial solvents such as toluene and acetone are commonly involved. Unfortunately, when they are used to remove any accidently smeared adhesive, these solvents are able to easily damage the outer or finished layers of the floorboards. Very often floorboards are also of expensive or rare timbers which may have to be significantly sanded back to remove the accidently smeared adhesive. To further add to the problem, some prior art floorboards have printed or laminated surfaces which are not only damaged by strong chemicals but cannot be sanded back to their base layers.

While it is an object of the present invention to seek to eliminate or ameliorate one or more of the problems of the prior art, it is a particular object to provide a solution for installing floor boards which not only seeks to introduce a more efficient installation methodology but also reduces the number of requisite tools and the chances of accidentally damaging or smearing floor boards with adhesive.

SUMMARY OF THE INVENTION

In a broad aspect, the invention resides in a combination mallet and tapping block or mallet block for the installation of flooring comprising: a block base having a gripping handle and at least one side comprising a mallet face adapted for striking floorboards the base further including a plurality of floor engaging feet; wherein in use, by means of the gripping handle, floorboards to be adhered to a floor on an adhesive bed can be firmly tapped into place using the mallet face without need for a separate striking tool, and wherein the feet pre-determine a distance of the base from the floor to clear the adhesive bed and at which the mallet face strikes the floorboard to avoid damaging any interlocking side edges of the floorboard and/or accidentally smearing the floorboard with adhesive.

Preferably, the base is a rectangular block of polypropylene or other inert or dense plastic. Suitably, the gripping handle is mounted on the top of the base.

In a preferred example, the gripping handle is mounted in an off center position on top of the base to enable by a wrist twist to strike a side edge or an end of a floorboard with the mallet face in an arcuate and pivotal motion while maintaining a corner of the mallet block against the side edge or the end of a floorboard as a pivot.

Suitably, one side of the base comprises the mallet face; however two or more sides of the base can also be mallet faces.

Preferably, the floor engaging feet can be completely retracted into the base so as to use the mallet block on floating floor installations wherein floorboards are installed without any adhesive and which floorboards include a locking system.

In a particular application, when used on a floating floor of tongue and groove floorboards adhered together with adhesive on top of the grooves, retracting the feet completely within the base eliminates the possibility of damage to any type or style of floor underlay.

In addition, by completely retracting the feet within the base wherein they do not protrude from the top of the base, the risk of injury or catching on anything while using the mallet block is also prevented.

In a preferred example, the plurality of floor engaging feet are comprised of threaded studs located in threaded holes in the base wherein the protrusion of the studs from the bottom of the base can be adjusted by screwing the studs in or out of the threaded holes.

Suitably, the distance the studs protrude from the bottom of the base is adjusted according to the thickness of the floorboards being laid and/or location of tongues or grooves or side-edge shoulders of the floorboards with which the mallet face is brought into contact.

In the alternative, the floor engaging feet are not adjustable but are fixed protrusions of the base designed for use with floorboards of a predetermined thickness and edge configuration.

In another aspect, the invention resides in a method of use of the mallet block as herein before described to lay interlocking side edged floorboards including the steps of:

adjusting, where present, any adjustable feet to prevent the mallet block from coming into contact with adhesive applied to the floor and wherein the mallet face is also at a desired height to avoid damage to when tapping an interlocking side edge of a floorboard;

using the handle to slide the mallet block against the side edge and

striking the side edge with the mallet face in an arcuate and pivotal motion using a corner of the mallet block in contact with the floor board as a pivot,

wherein the tapped floorboard is interlocked with an adjacent and previously laid floorboard.

In a further aspect, the invention resides in a method of use of the mallet block as claimed in any of the preceding claims to close gaps between the ends of floorboards including the steps of:

adjusting ,where present, any adjustable feet to prevent the mallet block from coming into contact with adhesive applied to the floor and wherein the mallet face is also at a desired height to avoid damage to when tapping an end of a floorboard;

using the handle to slide the mallet block against previously laid floorboards and

striking the end of a floorboard with the mallet block wherein a gap between the said end and an end of a previously laid floorboard is able to be closed.

In yet a further aspect, the invention resides in a method of use of the mallet block as herein before described on floating floor installations wherein the floor engaging feet are completely retracted into the base and the mallet block is used to tap together floorboards installed without adhesive and wherein the floorboards include a locking system.

The invention can also be used on floating floors where the floor boards are glued together but not to the floor itself.

While the invention eliminates the need for a separate hammer or mallet normally required when using prior art tapping or knocking blocks, the mallet block can still be used in the conventional manner of a prior art knocking or tapping block which is struck with a hammer or mallet or in fact another mallet block as herein described.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the present invention is understood reference is made to the accompanying drawings wherein:

FIG. 1 and FIG. 2 are perspective drawings of a preferred mallet block of the invention.

FIGURES 3 to 6 are orthographic views of the mallet block of FIG. 1 and FIG. 2.

FIG. 7 shows the mallet block used on a tongue and groove floorboard with feet raising it clear of an adhesive layer.

FIG.8 is a cutaway view of a stud foot of the mallet block.

FIG. 9 shows the mallet block used to tap floorboards together.

FIG.10 shows the mallet block used to align the ends of floorboards.

DETAILED DESCRIPTION

Figures and 2 show perspective drawings of a preferred combined mallet and tapping block or mallet block 10 for the installation of flooring typically involving floorboards adapted to be adhered to the floor on a bed of glue.

Figures 3 to 6 are orthographic views of the mallet block 10 to provide a better understanding of the parts wherein the same numbering system has been maintained throughout. The mallet block 10 comprises a block base12 having a gripping handle 14. There is least one mallet face 12a adapted for tapping floorboards (not shown in this view). The base 12 further includes a plurality of floor engaging feet 16, 18, 20, 22. By gripping the handle 14, floorboards can be firmly tapped into place using an arcuate and wrist twisting action with the mallet face(refer Fig.9)The protruding feet prevent the base from coming into contact with the adhesive layer applied to the floor to substantially reduce or avoid the chances of smearing the floor boards accidentally with the mallet block. The feet 16, 18, 20, 22 protruding from the base 12 also pre-determine a distance from the floor at which the mallet face 12a strikes the floorboard to avoid any impact damage to crucial parts of the interlocking edges of the floorboards (refer Fig.7). As shown, the base 12 is a rectangular block of polypropylene or it can be another inert or dense plastic or timber or metal. The gripping handle 14 is mounted on the top of the base 12. Suitably, one or more sides of the base comprise the mallet facel2a. In this example, the plurality of floor engaging feet 16-22 are threaded studs located in threaded holes 16a, 18a, 20a, 22a in the base 12 wherein the protrusion of the studs from the bottom of the base 12b can be adjusted by screwing the studs 16-22 in or out of the threaded holesl6a-22a. In this case the feet are long grub screws which can be driven by a Torx or Allen key either manually or with a cordless screw driver. The distance the studs protrude from the bottom 12b of the base is adjusted according to the thickness of the floorboards being laid and/or location of tongues or grooves or side edge shoulders of the floorboards with which the mallet face 12a is brought into contact (refer Fig.7). In the alternative, the floor engaging feet are not adjustable but are permanent protrusions or fixtures of the base designed for use with floorboards of a predetermined thickness and edge configuration.

Figure 7 shows the mallet block 10 used on a tongue and groove floorboard 30 with feet raising it clear of an adhesive layer 36 and wherein the distance the studs 16, 18 protrude from the bottom 12b of the base 12 is adjusted to according to the thickness of the floorboard 30 and the location of the side-edge shoulder 30a of the floorboard with which the mallet face 12a is brought into contact.

The process of using the invention may be generally described in the following terms. The adjustable feet 16, 18 ( 20, 22 obscured from view) can be wound up or down in the base 12 to ensure the base 12b of the mallet block is clear of the glue layer 36 when the flooring 30 is being laid on the glue bed 36. The mallet block 10 is adjusted in height to sit exactly above the tongue 30a of the board 30. Once adjusted to the correct height the mallet block is then used to strike the side edge shoulder 30b of the board without having to use a hammer.

Figure 8 is a cutaway view of a threaded foot or stud 16 of the mallet block 10. Stud 16 and the other feet (not shown) screw in and out of threaded holes 16a ( others not shown) in the base 12.

Figure 9 shows the mallet block 10 of Figures 1 and 2 used to tap tongue and groove or any generation of interlocking floor boards 30, 32 together with a wrist-operated striking action, as shown by arrow 35. The technique employed is by maintaining contact with the board 30 with one corner of the mallet block 12c as a pivot and impacting the side edge 30b of the board with the mallet face 12a of the mallet block 10. This technique prevents damage to the tongue (not shown in detail) and face of the board 30 which must be kept intact for joining it to the next board to be laid (not shown). As hereinbefore described, the gripping handle 14 is preferably mounted in an off center position on top of the base 12 to enable by twisting the wrist to strike a side edge or an end of a floorboard with the mallet face 12a in a substantially arcuate and pivotal motion while maintaining a corner 12c of the base against the side edge 30b of the floorboard as a pivot.

Figure 10 shows another way the mallet block 10 can be used to strike the end 40a of a floorboard 40 to close gap 51 between floorboard 40 and previously laid floorboard 50. This is done by maintaining contact with floorboards 46, 48 with the side or mallet face 12a and sliding the mallet block 10 back and forth while tapping the end 40a of the floorboard 40 with base 12 to close gap 51.

As previously described, preferably the floor engaging feet can be retracted into the base so as to use the mallet block on floating floor installations wherein the floorboards are installed without any adhesive and which floorboards include a locking system.

The floor engaging feet can preferably be retracted into the base when used on a floating floor of tongue and groove floorboards adhered together with adhesive on top of the grooves to eliminate the possibility of damage to any type or style of floor underlay. More preferably the floor engaging feet can be completely retracted into the base wherein they do not also protrude from the top of the base to prevent the risk of injury or catching on anything while using the mallet block.

As previously also mentioned, while the invention eliminates the need for a separate hammer or mallet normally required when using prior art tapping or knocking blocks, the mallet block of the present invention can still be used in the conventional manner as a knocking or tapping block which is struck with a hammer or of necessity another mallet block of the invention.

It will of course be realized that while the foregoing has been given by way of illustrative example of this invention and the best method of its utility known to and fully described by the inventor, all such further and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as herein set forth.

In the specification the terms "comprising" and "containing" shall be understood to have a broad meaning similar to the term "including" and will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. This definition also applies to variations on the terms "comprising" and "containing" such as "comprise", "comprises", "contain" and "contains". It will also be understood that references to integers or elements defined in the singular likewise will also apply to their plural case and vice versa.

Claims

1. A combination mallet and tapping block or mallet block for the installation of flooring comprising: a block base having a gripping handle and at least one side comprising a mallet face adapted for striking floorboards the base further including a plurality of floor engaging feet; wherein in use, by means of the gripping handle, floorboards to be adhered to a floor on an adhesive bed can be firmly tapped into place using the mallet face without need for a separate striking tool, and wherein the feet pre-determine a distance of the base from the floor to clear the adhesive bed and at which the mallet face strikes the floorboard to avoid damaging any interlocking side edges of the floorboard and/or accidentally smearing the floorboard with adhesive.

2. The mallet block of claim 1 wherein the base is a rectangular block of polypropylene or other inert or dense plastic.

3. The mallet block of claim 1 wherein the gripping handle is mounted on top of the base.

4. The mallet block of claim 1 wherein the gripping handle is mounted in an off center position on top of the base to enable by a wrist twist to strike a side edge or an end of a floorboard with the mallet face in an arcuate and pivotal motion while maintaining a corner of the mallet block against the side edge or the end of a floorboard as a pivot.

5. The mallet block of claim 1 wherein one or more sides of the base are also mallet faces.

6. The mallet block of claim 1 wherein the floor engaging feet can be completely retracted into the base so as to use the mallet block on floating floor installations wherein floorboards are installed without any adhesive and wherein the floorboards include a locking system.

7. The mallet block of claim 1 wherein the floor engaging feet can be retracted into the base when used on a floating floor of tongue and groove floorboards adhered together with adhesive on top of the grooves to eliminate the possibility of damage to any type or style of floor underlay.

8. The mallet block of claim 1 wherein the floor engaging feet can be completely retracted into the base wherein they do not also protrude from the top of the base to prevent the risk of injury or catching on anything while using the mallet block.

9.The mallet block of claim 1 wherein the plurality of floor engaging feet are comprised of threaded studs located in threaded holes in the base wherein the protrusion of the studs from the bottom of the base is adjusted by screwing the studs in or out of the threaded holes.

1.The mallet block of claim 1 wherein the distance the floor engaging feet protrude from the bottom of the base is adjusted according to the thickness of the floorboards being laid and/or location of tongues or grooves or side-edge shoulders of the floorboards with which the mallet face is brought into contact.

11. The mallet block of claim 1 wherein the floor engaging feet are not adjustable but are fixed protrusions of the base designed for use with floorboards of a predetermined thickness and edge configuration.

12. A method of use of the mallet block as claimed in any of the preceding claims to lay interlocking side edged floorboards including the steps of:

using the handle to slide the mallet block against the side edge and

13. A method of use of the mallet block as claimed in any of the preceding claims to close gaps between the ends of floorboards including the steps of:

14. A method of use of the mallet block as claimed in any of the preceding claims in floating floor installations wherein the floor engaging feet are retracted into the base and the mallet block is used to tap together floorboards installed without adhesive and wherein the floorboards include a locking system.

15. A method of use of the mallet block as claimed in any of the preceding claims wherein the floor engaging feet are retracted into the base and the mallet block is used to tap together a floating floor of tongue and groove floorboards adhered together with adhesive on top of the grooves to eliminate the possibility of damage to any type or style of floor underlay.

16. A method of use of the mallet block as claimed in any of the preceding claims wherein the floor engaging feet are completely retracted into the base wherein they do not protrude from the top of the base to prevent the risk of injury or catching on anything while using the mallet block.

17. A method of use of the mallet block as claimed in any of the preceding claims wherein the mallet block is used as a conventional knocking or tapping block which is struck with a hammer or mallet or another mallet block as herein described.