EP2853636B1

EP2853636B1 - Modular flooring system

Info

Publication number: EP2853636B1
Application number: EP13192260.1A
Authority: EP
Inventors: Chuchen Lin
Original assignee: Huidong Meixin Plastic Lumber Products Manufacturing Co Ltd
Current assignee: Huidong Meixin Plastic Lumber Products Manufacturing Co Ltd
Priority date: 2013-09-27
Filing date: 2013-11-11
Publication date: 2016-09-14
Anticipated expiration: 2033-11-11
Also published as: EP2853636A2; KR101602807B1; WO2015043039A1; CN103850418B; KR20150035373A; EP2853636A3; AU2013254967B1; CN103850418A; CN103758323A; CN103758324A

Description

Technical Field

The present embodiments generally relate to a modular flooring system that provides flooring using wood panels or artificial wood panels over a plastic base.

Description of Related Art

The request for outdoor wooden or artificial wooden floors is constantly on the rise. The main zones of use are swimming pool areas, gardens, open spaces of public venues, and many private places. Various outdoor wooden flooring systems are known in the prior art. These outdoor wooden flooring systems usually use many keels and the boards are fixed to the keels via locking units. The locking units are fixed both the boards and the keels via screws. It need professional person to install the flooring system.
CN 201424781Y discloses a combined environment-friendly flooring system comprising floor modules and a cushion securely connected with the floor modules. The cushion is comprised of a plurality of subunit connected to each other. The floor thus can be assembled as desired into different shape and size.
Thus, a need exists for a simple modular flooring system that is versatile and interchangeable to adapt quickly to different sized spaces and over different types of hard surfaces.

BRIEF SUMMARY OF THE INVENTION

An object of the present invention is to provide a modular flooring system which is easy to install and suitably robust.
A modular flooring system for installation over a surface, the modular flooring system includes a plurality of bases, a plurality of removable clips and a plurality of boards. All the bases are interlocked to form a substructure storey. The plurality of removable clips is configured for removably connecting to one of the plurality of interlocking bases to forme a middle storey. Each board is configured to removably connect at lest two removable clips while the at least two removable clips are engaged with at least one of the plurality of bases. The plurality of boards forms a top storey.
Each base defines a plurality of open areas, and a plurality of hooks is secured to each inner perimeter which defines the open area. Each removable clip includes a clip base, at least one pair of grippers, and a plurality of connecting rods. The clip base has a bottom side and a top side. Each gripper extends from the top side of the clip base, and a first gripper of each pair of grippers attaches to the clip base on a side opposite a second gripper. The plurality of connecting rods extends from the bottom side of the clip base, and each connecting rod is configured to engage one of the hooks. Each board is formed to slide within the pairs of grippers for a secure engagement while the at least two removable clips are engaged with at least one of the plurality of bases.
As an embodiment of the present invention, each base further includes an outer frame, a plurality of spacers, a plurality of inner frames, a plurality of tubes, a plurality of support members, and at least a pair of locking means which include a male locking means and a female locking means. The outer frame has a center point, the outer frame is convex polygon shaped with an even number of edges. And the outer frame is formed in a frame plane. Each spacer extends from the outer frame towards the center point. Each inner frame has an outer perimeter and an inner perimeter, and each inner frame is circular shaped, or elliptical shaped, or convex polygon shaped with an even number of edges. The plurality of tubes is formed in the edges/edge of each inner frame, and each tube includes a foot portion extending at an angle of 70∼90 degrees from the frame plane. The foot portion supports the outer frame apart from the surface. The support member connects a tube from an inner frame to a tube of an adjacent inner frame, and two tubes of a part of the plurality of inner frames connect to at least one spacer. The male locking means and female locking means are formed on each of at least four sides of the outer frame opposite the plurality of spacers, and the male locking means and the female locking means are in a spaced apart relationship from each other on a side. The plurality of hooks is secured to each inner perimeter of each inner frame.
As an embodiment of the present invention, each board includes a board top having a first width, a board bottom having a second width, a first groove and a second groove. The second width is shorter than the first width. The first groove is formed between the board top and the board bottom, on a first side, and the second groove is formed between the board top and the board bottom on an opposite side of the board. Each groove extends the length of the board for engagement with the pairs of grippers.
Preferably, each board defines a plurality of board holes extending the length of the board without penetrating the groove, the board top, or the board bottom.
Preferably, the second width is at least 10 percent less than the first width.
Preferably, the plurality of hooks is formed in a C-shape, and wherein each C-shaped hook is secured to the inner perimeter of the inner frames and each hook is secured at a midpoint of the hook.
Preferably, each connecting rod of the removable clip comprises a ridge for locking into one of the hooks.
Preferably, the connecting rods are formed in a diamond pattern to enable orientation of the boards in two directions.
Preferably, each gripper has a lip for securing the board to the removable clip and wherein the lips of each pair of grippers face each other.
Preferably, a slot is formed in the clip base and a fang securing mechanism is removably insertable into the slot. The fang securing mechanism has fangs for penetrating the board when a load is applied to the board.
Preferably, the top side of the clip base of each removable clip defines a plurality of holes capable of receiving the plurality of connecting rods of another removable clip, and the bottom side of the clip base of each removable clip defines at least two grooves capable of receiving the at least one pair of grippers of another removable clip when the connecting rods of the removable clip are inserted in the another removable clip.
Preferably, the spacers and the inner frames are formed from an identical material as the outer frame.
Preferably, each of the bases is a molded component with an ability to withstand temperatures from -17,8 degrees Celsius to 48,9 degrees Celsius (0 degrees Fahrenheit to 120 degrees Fahrenheit) without breaking.
Preferably, the outer frame comprises from 1 spacer to 32 spacers extending toward the center point in the frame.
Preferably, per inner perimeter of each inner frame includes from 2 to 8 hooks.
The surface can be concrete, a hard packed dirt, or another even solid surface.
Preferably, each outer perimeter of each inner frame can includes from 2 support members to 8 support members.
Preferably, each base includes 4 removable clips to 16 removable clips.
Preferably, each base includes a first message board, and each clip base includes a second message board.
The modular flooring system of the present invention is modular, quick and easy to install, take apart, and rebuild if a portion becomes broken. The height of the flooring system is easy to adjust by using two or more overlapped removable clips.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of one of the base of the system.
FIG. 2 is a side view of the base.
FIG. 3 is a top view of two bases according to the embodiments.
FIG. 4 is a bottom view of the base.
FIG. 5 is a top view of a removable clip usable in the system.
FIG. 6 is a bottom view of a removable clip usable in the system.
FIG. 7 is a side view of a removable clip usable in the system.
FIG. 8 is a detail cut view of two removable clips fixed together usable in the system.
FIG. 9 is an end view of a board according to the embodiments.
FIG. 10 is side view of a fang securing mechanism according to the embodiments.
FIG. 11 is a detail cut view of a portion of the interlocking impact resistant semirigid base with clips and boards attached forming The modular flooring system.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is further described in detail with the reference of the attached drawings and the specific embodiments.
The present embodiments relate to a quick interlocking modular flooring system that has a plurality of interlocking bases, a plurality of clips that removably engage each base and a plurality of boards attachable to the removable clips mounted to the bases. The bases are interlocked to form a substructure storey, the removable clips engaged with the bases form a middle storey, and the boards removably connected to the clips form a top storey. A benefit of this invention is that the system is modular, quick and easy to install, take apart, and rebuild if a portion becomes broken.
The boards are preferably artificial wood panels. The bases and the removable clips are preferably be formed from recycled plastics, like recycled plastic milk bottles, such as polyethylene or polypropylene. The base can be made from alpha olefin homopolymers, or blends of alpha olefin homopolymers with copolymers. The base can also be made from copolymers of alpha olefins that are crosslinked. And each base can be a one piece structure.
Preferably, the bases have the ability to withstand loads up to 300 pounds without deforming, and can bend up to an angle of 20 percent from a base plane without breaking. As a result, the bases and the removable clips can provide an even durable support over a concrete, a hard packed dirt, or another even solid surface.
Referring to FIG. 1 to FIG. 10, a modular flooring system according to an exemplary embodiment is illustrated. The modular flooring system can use a plurality of bases 12, a plurality of removable clips 50, and a plurality of boards 62.
As shown in FIGS. 1, 2, 3 and 4, each base 12 can be molded or pressure formed into a shape that has an outer frame 14 with a center point 16. In the embodiment, the outer frame 14 is shaped substaintially square with four edges/sides and formed in a frame plane. The outer frame 14 has a first side 18 opposite a second side 20, and a third side 22 opposite a fourth side 24 positioned around the center point. The third and fourth sides are connected to and formed between the first and second sides.
In other embodiments, the outer frame can be any of convex polygon shaped with an even number of edges.
A plurality of spacers (such as those labeled 26a, 26b, 26ae, 26af in FIG. 1) extends from the outer frame 14 towards the center point 16. The spacers are preferably made from the same material as the outer frame 14, such as a flexible plastic or plastic mixed with rubber.
A plurality of inner frames (such as those labeled 28a, 28b, 281, and 28d in FIG. 1) is connected to the spacers within the outer frame 14. Each inner frame defines an open area in its center, and has an outer perimeter (such as that labeled 30a in FIG. 1) and an inner perimeter (such as that labeled 32a in FIG. 1). The outer perimeters are depicted as the outside of each inner frame. The inner perimeters are depicted on the inside of each inner frame.
In the embodiment, the inner frames are shaped substaintially square. Four tubes (such as those labeled 40a, 40b, 40c, and 40d in the inner frame 28a in FIG. 1) are formed at each corner of each inner frame. The tubes can have an inner diameter of 1,27 cm (0.5 inches) for receiving screws. In other embodiments, two to eight tubes can be used per inner frame, these tubes can be arranged centrosymmetric, or axisymmetric
As shown in FIG. 1, the inner frame 28a has tubes 40a-40d and the inner frame 28b has tubes 40e-40h.
Adjacent inner frames are connected with each other via a plurality of support members (such as those labeled 44w, 44x, 44y, 44z in FIG. 1). All the inner frames are preferably arranged in lines and rows. One to four support members can extend from each tube. For example, the inner frame 28a has tube 40d with support member 44w extending from it towards a tube of inner frame 281. The inner frame 28a has tube 40c with support member 44x extending from it towards a tube of inner frame 281 that is different from the tube to which support member 44w connects. The inner frame 28b has a tube 40h with a support member 44y extending towards a tube 40aw of an inner frame 28d. The inner frame 28b has a tube 40g with a support member 44z extending from it in parallel to support member 44y towards a different tube of the same inner frame 28d.
A first message board 90 is defined on the upper surface of each base. The message board can support printed text or contain embossed text, images, logos or an emergency message. In the embodiment, four adjacent support member extend toward each other to form a board in the upper surface of one base to form the first message board 90.
In other embodiments, the inner frames can be circular shaped, or elliptical shaped, or any of convex polygon shaped with an even number of edges.
In the embodiment, the spacers are used for connecting the outer frame with the adjacent inner frames, in other embodiments, the spacers can connect from a tube of one inner frame to a tube of an adjacent inner frame.
A plurality of hooks is secured to each inner perimeter of each inner frame. In the embodiment, the hooks are C-shaped, and each hook is secured at a midpoint of the hook, with the open ends of the C-shape all oriented towards a center of the inner frame. The midpoint of one hook can be arranged to the middle of one side of an inner frame, or to one conner of an inner frame.
In the embodiment, four hooks are depicted in each inner frame, and formed in a diamond pattern. As shown in FIG. 1, the inner frame 28a has hooks 46a, 46c and 46d are labeled.
In other embodiments, from 2 hooks to 8 hooks can be used per inner perimeter of each inner frame, and these hooks are preferably arranged in a diamond pattern. In other embodiments, the hooks can be mounted in at least two of the four corners of one or all of the inner frames. When the inner frames are circular shaped, or elliptical shaped, or other convex polygon shaped with six or eight edges, the hooks are preferably arranged in a diamond pattern.
A plurality of male locking means (such as those labeled 48a and 48h in FIG. 1) and a plurality of female locking means (such as those labeled 49a and 49h in FIG. 1) are shown formed on each side of the outer frame opposite the plurality of spacers. The male and female locking means are in a spaced apart relationship from each other on a side of the frame.
FIG. 2 is a side view of the base. In FIG. 2, the base 12 is shown with the fourth side 24 of the outer frame. Each of the plurality of tubes can have a foot portion (such as those labeled 42aa, 42z, 42w in FIG. 2) extending at an angle 70 degrees to 100 degrees from a frame plane 25. In the embodiment, the foot portion extends at 90 degrees from the frame plane 25 on a side opposite the side shown in FIG. 1. The foot portions is configured for supporting the frame apart from a surface 8.
In this side view, male locking members 48c and 48d and female locking members 49c and 49d can be seen. The locking members can be configured to receive opposing locking members from another base.
FIG. 3 is a top view of two bases according to the exemplary embodiment. The base 12b is shown interlocking with the base 12a. In this example, the base 12b uses its male locking members to engage the female locking member of base 12a. Base 12b simultaneously uses its female locking members to engage male locking members of base 12a. This secure interlock enables the system to be highly durable.
In other embodiments, when the outer frame has another shape of convex polygons, such as hexagon with six edges. Each edge of the outer frame can arrange one or two pairs of a male locking member and a female locking member. When the outer frame is shaped like a octagon having eight edges, four of the eight edges can arrange one or two pairs of a male locking member and a female locking member.
FIG. 4 is a bottom view of one of the base 12 with the foot portions 42a-42an. The first side 18, the second side 20, the third side 22 and the fourth side 24 are also shown.
Referring to FIGs. 5 to 7, a removable clip 50 according to an exemplary embodiment is shown. FIG. 5 is a top view of the removable clip 50. FIG. 6 is a bottom view of the removable clip 50. FIG. 7 is a side view of the removable clip 50. The removable clip 50 is used to connect one of the bases.
The removable clip 50 includes a clip base 52 with a bottom side 54 and a top side 56. A pair of grippers 58a and 58b extend from the top side 56 of the clip base 52. The first gripper 58a attaches to the clip base 52 on a side opposite a second gripper 58b. In the embodiment, the pair of grippers 58a and 58b each have a lip 55a and 55b for securing a single board to the removable clip 50. Understandably, the lips of the pair of grippers face each other.
In other embodiments, each removable clip 50 can have two or more pairs of grippers extend from two sides of the clip base for securing a single board to the removable clip. Two or more pairs of grippers may hold the single board more tightly than one pair of grippers.
The removable clip 50 has a plurality of connecting rods 60a, 60b, 60c and 60d extending from the clip base 52 on the bottom side 54. Each connecting rod is configured to engage one of the hooks. Each connecting rod preferably has a ridge. Ridge 61 a is on rod 60a, ridge 61b is on rod 60b, and ridge 61c is on rod 60c for locking into or engaging one of the hooks. The connecting rods can be oriented in a diamond pattern to enable orientation of the boards in two directions. The connecting rods can be separated by an angle from 80 degrees to 120 degrees.
A second message board 92 can be formed in the clip base 52. The message board can support printed text or contain embossed text, images, logos or an emergency message.
Furthermore, the top side 56 of the clip base of each removable clip 50 defines a plurality of holes 51 a, 51b, 51c and 51 d capable of receiving the plurality of connecting rods of another removable clip when the connecting rods of the another removable clip are inserted in the removable clip 50 as shown in FIG. 8. The bottom side 54 of the clip base of each removable clip 50 defines two grooves 57a and 57b capable of receiving the pair/pairs of grippers of another removable clip when the connecting rods of the removable clip are inserted in the another removable clip. A benefit of this structure is that the whole height of the flooring system can be adjusted by using two or more removable clip overlapped together.
Also shown in FIG. 5 is a slot 96 which can receive a device for providing a penetrating grip into a board held by the grippers of a clip attached to a base.
FIG. 9 is an end view of a board from the plurality of boards according to the exemplary embodiment. Each board of the system can have an identical length, and each board is formed to slide within the grippers of a clip for a secure engagement with the clip while the clip is engaged with the base.
In this embodiment, each board 62a of the plurality of boards has a board top 68 having a first width 70 and a board bottom 74 having a second width 76. The second width is preferably at least 10 percent less than the first width, thus that the grippers and the clips can be hide under the board top 68.
A first groove 78a is formed on one side of the board between the board top 68 and the board bottom 74. A second groove 78b is formed on the opposite side of the board between the board top and the board bottom. Each groove extends the length of the board for engagement with the pair of grippers.
Each board defines a plurality of board holes 94 formed in the board 62a extending the entire length of the board without penetrating the groove, board top or board bottom. As a result, the weight of each board is more light.
FIG. 10 shows a fang securing mechanism according to the exemplary embodiment. The fang securing mechanism 98 can be removably inserted into the slot 96, shown in FIG. 5. Fangs 100a-100c penetrate the board when a load is applied to the board, which can be up to 1000 pounds. The fang securing mechanism can have a thickness from 0.2 millimeters to 0.4 millimeters and a length from 1 millimeter to 4 millimeters.
FIG. 11 shows a portion of the base with removable clips and boards attached forming the modular flooring system. The modular flooring system 10 is over one base 12a supporting two removable clips 50a and 50b, with each removable clip supporting a single board 62a and 62b. The pair of grippers 58a and 58b can hold board 62a to the removable clip 50a and the pair of grippers can engage each groove 78a and 78b of the board 62a.
The pair of grippers 58c and 58d can hold board 62b to the removable clip 50b and the pair of grippers can engage each groove 78c and 78d of the board 62b.
In embodiments, the spacers can have a length fromk 1,27 cm to 3,175 mm (0.05 inches to 0.125 inches). The spacers and the inner frames can be formed from an identical material as the frame. The base can be a molded component with an ability to withstand temperatures from -34,4 degrees Celsius to 65,6 degrees Celsius (30 degrees Fahrenheit to 150 degrees Fahrenheit) without breaking. The surface can be concrete, hard packed dirt, or another even, solid surface.
In embodiments, from 1 spacer to 32 spacers can be connected to the frame and extend toward the center point in the frame. From 2 support members to 8 support members can extend from each outer perimeter of each square.
In embodiments, 2 male locking members and 2 female locking members can be used per side of the outer frame. In embodiments, from 4 removable clips to 16 removable clips per base can be used.
In other embodiments, the outer frame and the spacers of the base may be omitted. The base may be a plane defining a plurality of open areas without penetrating each other. And the plurality of hooks is secured to each inner perimeter which defines one open area.
In installation, an even number of bases may be interlocked to form a square. Then 4 to 16 removable clips may be inserted in each base. Finally, four boards may slide within the pairs of grippers of the removable clips from a side of each base.
In disassembly, the boards can be pulled out upwardly, the removable clips may be pulled out from the bases at the same time. Then, the removable clips can be removed from the boards. Finally, the bases can be separated by unlocking the male and female locking members. Thus, it is very easy to install and disassemble the flooring assembly. Most grown-up and even teenagers can do it alone.
The above description is only a preferable embodiment of the present invention. It should be noted that: for those skilled in this field, more modifications and improvements can be made wihout departing from the scope of the invention as defined by the claims

Claims

A modular flooring system for installation over a surface comprising:
a plurality of bases (12) for being interlocked to form a substructure storey;

a plurality of removable clips (50) for removably connecting to one of the plurality of interlocking bases (12), the plurality of removable clips (50) forming a middle storey; and

a plurality of boards (62), each board configured to removably connect at least two removable clips (50) while the at least two removable clips (50) are engaged with at least one of the plurality of bases (12), characterized in that each base (12) comprises:
a plurality of open areas defined therein; and

a plurality of hooks (46a, 46c, 46d) secured to each inner perimeter which defines a corresponding open area;

each removable clip (50) comprises:
a clip base (52) with a bottom side (54) and a top side (56);

at least one pair of grippers (58a, 58b), each gripper extending from the top side (56) of the clip base (52), wherein a first gripper (58a) of each pair of grippers (58a, 58b) attaches to the clip base (52) on a side opposite a second gripper (58b); and

a plurality of connecting rods (60a, 60b, 60c, 60d) extending from the bottom side (54) of the clip base (52), each connecting rod configured to engage one of the hooks (46a, 46c, 46d); and

each board (62) is formed to slide within the pairs of grippers (58a, 58b) for a secure engagement while the at least two removable clips (50) are engaged with at least one of the plurality of bases (12).
The modular flooring system of claim 1, characterized in that each base (12) further comprises:
an outer frame (14) with a center point (16), the outer frame (14) is convex polygon shaped with an even number of edges, and wherein the outer frame (14) is formed in a frame plane (25);

a plurality of spacers (26a, 26b, 26ae, 26af), each spacer extending from the outer frame (14) towards the center point (16);

a plurality of inner frames (28a, 28b, 281, 28d) configured in the outer frame (14), each inner frame having an outer perimeter (30a) and an inner perimeter (32a), wherein each inner frame is circular shaped, or elliptical shaped, or convex polygon shaped with an even number of edges;

a plurality of tubes (40a, 40b, 40c, 40d) formed in the edges/edge of each inner frame, each tube comprising a foot portion (42aa, 42z, 42w) extending at an angle of 70∼100 degrees from the frame plane (25), wherein the foot portion (42aa, 42z, 42w) supports the outer frame (14) apart from the surface;

a plurality of support members (44w, 44y, 44z), each support member connecting a tube (40d) from an inner frame (28a) to a tube of an adjacent inner frame (281), and wherein two tubes of a part of the plurality of inner frames connect to at least one spacer (26a, 26b, 26ae, 26af); and

a male locking means (48a, 48h) and a female locking means (49a, 49h) formed on each of at least four sides of the outer frame (14) opposite the plurality of spacers (26a, 26b, 26ae, 26af), wherein the male locking means (48a, 48h) and the female locking means (49a, 49h) are in a spaced apart relationship from each other on a side;
wherein the plurality of hooks (46a, 46c, 46d) is secured to each inner perimeter (32a) of each inner frame (28a, 28b, 281, 28d).
The modular flooring system of claim 1, characterized in that each board (62) comprises:
a board top (68) having a first width (70);

a board bottom (74) having a second width (76), with the second width (76) shorter than the first width (70); and

a first groove (78a) formed between the board top (68) and the board bottom (74), on a first side, and a second groove (78b) formed between the board top (68) and the board bottom (74) on an opposite side of the board (62), wherein each groove (78a, 78b) extends the length of the board for engagement with the pairs of grippers (58a, 58b).
The modular flooring system of claim 3, characterized in that further comprising a plurality of board holes (94) formed in the boards extending the length of the boards without penetrating the groove (78a, 78b), the board top (68), or the board bottom (74).
The modular flooring system of claim 3, characterized in that the second width (76) is at least 10 percent less than the first width (70).
The modular flooring system of claim 1, characterized in that the plurality of hooks (46a, 46c, 46d) are formed in a C-shape, and wherein each C-shaped hook is secured to the inner perimeter (32a) of the inner frames (28a) and each hook is secured at a midpoint of the hook.
The modular flooring system of claim 1, characterized in that each connecting rod (60a, 60b, 60c, 60d) of the removable clip (50) comprises a ridge for locking into one of the hooks (46a, 46c, 46d).
The modular flooring system of claim 1, characterized in that the connecting rods (60a, 60b, 60c, 60d) are formed in a diamond pattern to enable orientation of the boards in two directions.
The modular flooring system of claim 1, characterized in that each gripper (58a, 58b) has a lip (55a, 55b) for securing the board to the removable clip (50) and wherein the lips (55a, 55b) of each pair of grippers face each other.
The modular flooring system of claim 1, characterized in that comprising a slot (96) formed in the clip base (52) and a fang securing mechanism (98) removably insertable into the slot, wherein the fang securing mechanism (98) has fangs (100a, 100b, 100c) for penetrating the board when a load is applied to the board.
The modular flooring system of claim 1, characterized in that the top side (56) of the clip base (52) of each removable clip (50) defines a plurality of holes (51a, 51b, 51c, 51d) capable of receiving the plurality of connecting rods of another removable clip (50), and the bottom side (54) of the clip base (52) of each removable clip (50) defines at least two grooves (57a, 57b) capable of receiving the at least one pair of grippers of another removable clip (50) when the connecting rods of the removable clip are inserted in the another removable clip.
The modular flooring system of claim 2, characterized in that the spacers (26a, 26b, 26ae, 26af) and the inner frames (28a, 28b, 281, 28d) are formed from an identical material as the outer frame (14).
The modular flooring system of claim 1, characterized in that each of the bases (12) is a molded component with an ability to withstand temperatures from -17,8 degrees Celsius to 48,9 degrees Celsius (0 degrees Fahrenheit to 120 degrees Fahrenheit) without breaking.
The modular flooring system of claim 1, characterized in that the outer frame (14) comprises from 1 spacer to 32 spacers extending toward the center point (16) in the frame.