GB2374879A

GB2374879A - Portable outdoor flooring assembly

Info

Publication number: GB2374879A
Application number: GB0205335A
Authority: GB
Inventors: Michael Francis Scullion; Graham Davis
Original assignee: Individual
Current assignee: Individual
Priority date: 2001-03-09
Filing date: 2002-03-07
Publication date: 2002-10-30
Also published as: GB0205335D0; GB0105803D0

Abstract

A floor panel 2 comprises at least two side surfaces having co-operating interlocking formations 3, 4 thereon allowing the panel to be releasably connected to adjacent panels to form a floor assembly(, Fig 1). The interlocking formations may comprise spaced locking projections with corresponding spaced locking apertures similar to a jigsaw puzzle. Alternatively the interlocking formations may be of tongue and groove type (22, Fig 12) or may comprise a plurality of male members 3 which are receivable in corresponding female members 4. In the latter embodiment male members 3 can be arranged beneath an outwardly extending lip 5 to co-operate with female receiving members 4. The panels can be secured with respect to the ground using projections integrally formed on the base of the panel, or alternatively by using separate spiked pegs (38, Fig 15).

Description

PORTABLE OUTDOOR FLOORING ASSEMBLY The present invention relates to a portable flooring assembly for use outdoors and in particular a portable flooring assembly for use in an awning of a caravan or beneath a tent.

It is known to provide a thin flexible ground sheet to cover the ground beneath a tent or an awning of a caravan in order to provide a dry and mud free floor surface. While such a ground sheet does protect the user from moisture from the ground and prevents the floor of the awning from becoming muddy or slippery, such prior art ground sheets provide poor insulation properties and the are susceptible to damage from rocks or other sharp objects that may exist on the ground surface therebeneath or from objects placed upon the groundsheet, particularly when it is positioned on soft ground. Where a person sleeps directly on the groundsheet, the cold damp ground therebeneath can result in substantial loss of body heat and unevenness or sharp objects in the ground can cause discomfort.

The portable flooring assembly of the present invention overcomes the disadvantages of the prior art ground sheets by providing a smooth, even floor surface with good thermal insulation properties.

According to the present invention there is provided a portable flooring assembly for use outdoors, said flooring assembly comprising a plurality of releasably interconnectable floor panels, each floor panel having an upper surface, a lower surface and a plurality of side surfaces, at least two side surfaces of each floor panel having c-operating interlocking formations thereon permitting each panel to be releasably connected to one or more similar adjacent panels. Preferably each floor panel has four sides. While it is

envisaged that co-operating interlocking formations may be provided on only two opposite side surfaces of each floor panel in a preferred embodiment of the invention said interlocking formations are provided on/in each side surface of each floor panel. The interlocking formations are preferably integrally formed with each floor panel.

The interlocking formations may comprise spaced locking fingers and corresponding spaced locking apertures such as that provided on a jig-saw puzzle or may comprise an interlocking tongue and groove arrangement, an elongate groove being provided along at least a portion of a first side of each floor panel and a corresponding elongate tongue being provided along at least a portion of a second side, opposing said first side, of each floor panel.

Alternatively, the interlocking formations may comprise a plurality of elongate male connecting members being receivable in a plurality of elongate female receiving apertures or bores. Preferably each floor panel has four sides and a plurality of male connecting apertures are provided on two adjacent sides of each floor panel while a plurality of female receiving apertures are provided on the two remaining sides of each panel. Preferably each elongate male connecting member extends in a vertical direction and said corresponding female receiving apertures or bores have a vertically aligned central axis.

Preferably each elongate male connecting member extends upwardly from an outwardly projecting portion or extension extending from a side of the floor panel and comprises an upwardly extending stud extending from the upper face of said outwardly projecting portion. Preferably each female receiving aperture is provided in a further outwardly projecting portion or extension of said panel, extending from a side of each floor panel adjacent an upper edge thereof. Each of said female receiving apertures may narrow towards a central region thereof and each downwardly extending stud may have a

necked portion such that the stud is a press fit into the corresponding aperture and is retained therein. Alternatively, each male connecting member may have a circumferential projection adjacent an upper end thereof to retain each male connecting member in a corresponding female receiving aperture.

Preferably each outwardly projecting portion having male connecting members provided thereon extends from a side of each floor panel adjacent the mid-point thereof while each outwardly projecting portion provided with female receiving apertures extends from a side of each floor panel adjacent the upper edge thereof, such that the outwardly projecting portions provided with female receiving apertures of a first panel can overlie an outwardly projecting portion provided with corresponding male connecting members on a side of a second floor panel, with the upwardly extending studs of the male connecting members inserted through respective female receiving apertures, when said first and second floor panels lie alongside one another with their upper surface aligned in a common plane.

Securing pegs may be provided to secure the flooring assembly to the ground, apertures being provided in one or more of the floor panels, preferably adjacent the comer portions of the flooring assembly, for receiving the securing pegs. Preferably each aperture is tapered or has a countersunk portion adapted to receive the head of a securing peg, such that the securing pegs, when inserted into the apertures, do not extend above the surface of the flooring assembly, avoiding any trip hazard that might be formed if the securing pegs extend above the surface of the flooring assembly. Formations may be formed in the upper surface of each securing peg adapted to receive a peg removal tool to allow the securing pegs to be removed when the flooring assembly is to be dismantled.

At least one projection may be provided on the lower surface of each floor panel, said at least one projection, in use, being forced into the ground beneath the panel in order to prevent movement of the panel with respect to the ground. Preferably a plurality of such projections is provided on the lower surface of each floor panel, each projection comprising a downwardly extending spike or stud. Each such projection may be formed integrally with each panel or may be removably mounted on the underside of each panel.

Threaded apertures may be provided in the lower surface of each panel into which a correspondingly threaded portion of a spike or stud might be screwed. This would allow the spikes or studs to be removed when the floor panels are to be placed on a hard surface.

Preferably the lower surface of each floor panel may have a series of substantially vertical or inclined integrally formed ribs thereon, extending downwardly therefrom. Such ribs provide increased grip, resisting movement of the floor panels on the ground surface therebeneath, and advantageously provide air spaces beneath the panels providing improved insulation, reducing any build up of damp beneath the panels and reducing damage to vegetation beneath the floor panels, for example where the floor panels are laid on a grass surface. Apertures may be formed in the upper surface of each floor panel, provided between adjacent pairs of said ribs.

The upper surface of each floor panel may have a roughened or textured finish in order to provide improved grip for persons walking thereon.

Each floor panel is preferably formed from a substantially rigid plastic material having good thermal insulating properties and may be formed by an injection moulding process.

According to a further aspect of the invention there is provided a floor panel for a portable flooring assembly for use outdoors, said floor panel having an upper surface, a lower surface and a plurality of side surfaces, at least two side surfaces of the floor panel having co-operating interlocking formations thereon permitting the panel to be releasably connected to one or more similar adjacent panels.

The present invention will now be described further, by way of example, with reference to the accompanying drawings, in which :- Fig. 1 is a plan view of a portable modular flooring assembly according to a second embodiment of the present invention; Fig. 2 is a perspective view of a single floor panel forming the flooring assembly shown in Fig. 1; Fig. 3 is a plan view of the floor panel of Fig 2; Fig 4 is a side elevation of the floor panel of Fig 2; Fig 5. is a detail view of an edge of the floor panel of Fig. 2 showing the interconnecting formations; Fig 6. is a view of the underside of the floor panel of Fig. 2; Fig 7. is a plan view of a further embodiment of a portable modular flooring assembly according to the present invention; Fig. 8 is an end view of the floor panel of Fig. 7; Fig 9. is a plan view of a further modified embodiment of a portable modular flooring assembly according to the present invention; Fig. 10 is an end view of the floor panel of Fig. 9 Fig 11. is a plan view of a yet further embodiment of a portable modular flooring assembly according to the present invention;

Fig. 12 is a perspective view of a single floor panel of the flooring assembly shown in Fig. 11; Fig 13. is a detail view of the co-operating formations allowing adjacent panels of the flooring assembly of Fig. 11 to be interconnected; Fig. 14 is detail view of an alternative embodiment of the c-operating formations allowing adjacent floor panels to be interconnected; Fig. 15 is a sectional view through a floor panel showing a securing peg for securing the flooring assembly to the ground; Fig. 16 is a plan view of the securing peg shown in Fig. 15; Fig. 17 is a perspective view of a tool for removing the securing peg shown in Figs. 15 and 16.

A first embodiment of the invention is shown in Figs. 1 to 6, wherein a portable modular flooring assembly 1 comprises a plurality of releasably interconnectable plastic floor panels 2 joined together by means of male and female interlocking formations 3,4 integrally formed on the sides of each panel.

As can be seen from Figs. 1 to 6, each floor panel 2 has four sides, two adjacent sides each having an outwardly extending lip 5 thereon, each lip 5 having three downwardly extending studs 3 integrally formed thereon, as shown more clearly in Fig. 5. The two remaining sides of each floor panel 2 each have three female receiving members 4 integrally formed thereon. As shown more clearly in Fig. 5, each female receiving member 4 comprises a vertically extending receiving aperture 7, formed in an outwardly projecting portion 8 extending from the side of the floor panel, for receiving one of said downwardly extending studs 3 therein. Each receiving aperture 7 narrows towards a central region thereof and each downwardly extending stud 3 has a

corresponding necked portion 9 such that each stud 3 is a press fit into a corresponding aperture 7 and is retained therein.

The outwardly projecting lip portions 5 on which the studs 3 are formed extend from adjacent sides of the floor panel 2 adjacent the upper edge thereof while the outwardly projecting portion 8 of each female receiving member 4 extends from a side of the floor panel 2 adjacent the lower edge thereof, such that each outwardly projecting lip portion 5 can overlie the outwardly projecting portions 8 of respective female receiving members 4 on one side of a second floor panel, with the downwardly extending stud 3 thereof inserted through the receiving aperture 7 of the respective female receiving member 4, when said first and second floor panels lie alongside one another with their upper surface aligned in a common plane.

The interlocking formations 3,4 allow panels to be easily connected together, the downwardly extending studs 3 on a side of a first panel being pushed vertically into corresponding receiving apertures 7 on a side of a second, already laid, panel as said first panel is placed alongside said second panel. Since the studs 3 and receiving apertures 7 are vertically aligned they cannot be inadvertently pulled apart by forces acting in the plane of the floor panels 2.

As shown in Fig. 6, the lower surface of each floor panel 2 comprises a plurality of diagonally extending ribs or ridges 10. The ribs 10 help to provide improved grip in order to resist movement of the floor panels 2 on the ground, especially where the floor panels 2 rest on a soft surface. Furthermore, the gaps 11 between the ribs 10 form ventilation spaces beneath the floor panels 2, providing improved insulation, reducing the build up of moisture beneath the floor panels 2 and reducing the damage to vegetation beneath the floor

panels 2, particularly where the floor panels 2 are laid upon a grass covered surface.

While in Fig. 1 an array of 16 interconnected floor panels 2 is shown, any number of floor panels may be joined together depending on the area of the surface which is required to be covered by the flooring assembly. For use in an awning of a caravan or under a tent floor panels of 200mm by 200mm may be used. Such panels can be easily stored when not in use by stacking. If required, in order to prevent any movement of the flooring assembly, conventional tent pegs can be inserted through one of more of the receiving apertures 7 of the female receiving members 4 on the outermost sides of the flooring panels 2 adjacent the edges of the flooring assembly.

In the embodiment shown in Fig. 7, each panel 100 has a plurality of elongate rectangular apertures 101 formed therethrough, said apertures 101 being arranged in rows parallel to a pair of opposed sides of the panel 100.

Between each row of apertures, extending from the lower surface of the panel 100, is provided a pair of downwardly and outwardly diverging ribs 102 extending across the width of the panel parallel to said opposed pair of sides of the panel. The lower end of each rib terminates in a foot portion, upon which, in use, the panel rests. The ribs 102 and apertures 101 provide ventilation beneath the panel 100 to reduce damage to grass upon which the panel may be placed and to provide an insulating air gap beneath the panel 100.

As in the embodiment shown in Figs. 3 to 6, two adjacent sides of the panel 100 are provided with an outwardly extending lip 105 thereon, each lip 105 having three downwardly extending studs 106 integrally formed thereon, as shown more clearly in Fig. 8. The two remaining sides of each floor panel

100 each have three female receiving members 107 integrally formed thereon having apertures therein adapted to receive the studs of an adjacent panel.

The upper surface of the panel, between the apertures 101, is provided with a plurality of raised projections, formed integrally with the panel, in order to produce a non-slip surface.

A modification of the embodiment of Figs. 7 and 8 is shown in Figs. 9 and 10 wherein two adjacent sides of each floor panel 200 are provided an outwardly projection portion 201 spaced below the upper surface of the panel 200, said projecting portions 201 having a plurality of upwardly extending studs 202 formed thereon extending from the upper face of said outwardly projecting portion 201. A plurality of female receiving apertures 204 are provided on the two remaining sides of each panel. Each stud 202 extends in a vertical direction and said corresponding female receiving apertures 204 have a vertically aligned central axis. Each stud 202 has a circumferential projection 203 adjacent an upper end thereof to retain the stud 202 in a corresponding female receiving aperture of an adjacent panel.

A further embodiment of the invention is shown in Fig. 11, wherein the portable modular flooring assembly 21 comprises a plurality of releasably interconnectable polypropylene floor panels 22,26 arranged in offset or staggered rows, each panel 22,26 having co-operating interlocking tongue and groove formations 23 on a pair of opposed sides thereof such that each panel 22,26 in each row is releasably connected to a portion of a side of two adjacent panels in each row adjacent thereto by means of a slide fit. Edging strips 24,25 are connected to the interlocking formations on the outer side edge of each outermost row of panels.

In an further alternative embodiment (not shown) the floor panels comprising each outermost row have interlocking formations on only one side thereof, allowing the panels to be connected to the panels in an adjacent row, the outermost side surface of each panel being free from interlocking formations and presenting a smooth outer surface, removing the need for the edging strips.

As shown in Fig. 11, in order that the overall flooring assembly presents a square or rectangular profile, the end panels 26 in each alternate row are half the width of the remaining panels 22. In a typical application, for use on the ground underneath the awning of a caravan, the larger full width panels 22 are 18" (45.72 cm) square while the half width panels 26 are 18" (45.7cm) by 9" (22.86cm) and both the full width 22 and half width panels are 1/4" (6.3 mm) to 3/8" (9.5 mm) thick. When disassembled the panels 22,26 can be stacked and easily stored away in a container in a caravan or other vehicle.

As shown in Fig. 12, each panel 22,26 comprises a planar substantially rectangular or square tile having an upper surface 27, a lower surface 28 and four side surfaces 29,30, 31,32. An elongate groove 33 is provided along a first side 30 of the panel and a correspondingly shaped elongate tongue 34 is provided on a second side 31, opposite said first side 30, such the panel can be interlockingly connected to adjacent panels. The rounded tongue 34 shown in Figs. 12 and 13 permits adjacent panels to be slid together.

Although a slide fit is preferred, as it provides a strong connection between adjacent panels, it is envisaged that the panels might be snap fitted together.

By aligning the panels in offset rows, with their first 30 and second sides 31 (i. e. the side having respective tongue 34 and groove 33 formations thereon) respectively aligned in each row, the tongue 34 on one panel can

interconnect with a portion of the groove 33 on two adjacent panels in an adjacent row. In this way a substantially rigid floor assembly is formed from a plurality of individual floor panels.

Fig. 14 shows a further alternative embodiment of the invention. In this embodiment the cross sections of the elongate tongue 36 and corresponding elongate groove 35 are different from that shown in Figs. 12 and 13. The height section of the groove 35 gradually increases from the side surface 30 of the panel 22 towards the base of the groove 35 while the height of the tongue 36 increases from the side surface 31 the panel 22 to the outer end of the groove in the form of a dovetail joint, allowing adjacent panels to be slid together.

In order to resist movement of the flooring assembly on the ground, securing pegs are inserted into the ground through one or more of the floor panels, preferably through panels adjacent the end of each row of panels in the flooring assembly. As shown in Fig. 15, tapered apertures 37 are provided in at least some of the floor panels 22, tapering from the upper surface 27 to the lower surface 28 of the panel. Correspondingly tapered securing pegs 38 can be inserted through the tapered apertures 37 to fix the flooring assembly in place, the securing pegs 38 being driven into the ground beneath the flooring panels until the upper 39 surface of the securing peg 38 is level with the upper surface 27 of the flooring panel into which it is fitted. An aperture 30 is provided in the upper surface 39 of the securing peg 38 leading to recess 41 in the head of the securing peg 38. As well as securing the flooring assembly in place, the securing pegs 38 may also serve to secure a portion of the awning to the flooring assembly.

A peg removal tool 41, shown in Fig. 17 can be used to remove the securing peg 38 from panels when the flooring assembly is to be dismantled. The peg removal tool 41 comprises an elongate shaft 42 having a handle 43 at one end and a T-shaped peg engaging portion 44 at the opposite end thereof. In order to remove a securing peg 38, the T-shaped peg engaging 44 portion is placed into the aperture 40 of a peg 38 and the tool 41 is twisted through approximately 900 so that the peg engaging portion 44 is positioned in the recess 41 in the head of the peg 38. With the peg engaging portion 44 in this position the peg 38 can be removed by pulling on the handle 43 of the peg removal tool 41.

In addition to, or instead of, the use of securing pegs, the undersides of some or all of the floor panels may be provided with a pattern of ground engaging projections (not shown) in order to prevent movement of the panels with respect to the ground therebeneath. The projections may be integrally formed with the panels and may be pyramid shaped or may comprise spikes.

Alternatively the projections may comprise removable studs, removably mounted in apertures in the underside of each panel such that they cab be removed when the floor panels are to be placed on hard ground. The apertures in the underside of each panel might be threaded to receive correspondingly threaded portions of each stud, allowing the studs to be screwed into the underside of each panel.

The upper surface of each floor panel may have a roughened, textured or patterned surface finish to provide a non-slip surface for persons walking thereon, for example the upper surface of each floor panel may have a pattern of raised squares thereon.

The flooring assembly can be easily adapted to cover different areas of the ground by simply interconnecting more or less floor panels.

The floor panels may be coloured to match the colouring of the awning or tent with which they are to be used.

Claims

CLAIMS 1. A portable flooring assembly for use outdoors, said flooring assembly comprising a plurality of releasably interconnectable floor panels, each floor panel having an upper surface, a lower surface and a plurality of side surfaces, at least two side surfaces of each floor panel having co- operating interlocking formations thereon permitting each panel to be releasably connected to one or more similar adjacent panels.
2. A portable flooring assembly as claimed in claim 1, wherein each floor panel has four sides.
3. A portable flooring assembly as claimed in claim 1 or 2, wherein said interlocking formations are provided on/in each side surface of each floor panel.
4. A portable flooring assembly as claimed in any preceding claim, wherein the interlocking formations are integrally formed with each floor panel.
5. A portable flooring assembly as claimed in any preceding claim, wherein the interlocking formations comprise spaced locking fingers and corresponding spaced locking apertures such as that provided on a jig- saw puzzle.
6. A portable flooring assembly as claimed in any of claims 1 to 4, wherein the interlocking formations comprise an interlocking tongue and groove arrangement, an elongate groove being provided along at least a portion of a first side of each floor panel and a corresponding elongate tongue

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being provided along at least a portion of a second side, opposing said first side, of each floor panel.
7. A portable flooring assembly as claimed in any of claims 1 to 4, wherein the interlocking formations comprise a plurality of elongate male connecting members being receivable in a plurality of elongate female receiving apertures or bores.
8. A portable flooring assembly as claimed in claim 7, wherein each floor panel has four sides and a plurality of male connecting apertures are provided on two adjacent sides of each floor panel while a plurality of female receiving apertures are provided on the two remaining sides of each panel.
9. A portable flooring assembly as claimed in claim 8, wherein each elongate male connecting member extends in a vertical direction and said corresponding female receiving apertures or bores have a vertically aligned central axis.
10. A portable flooring assembly as claimed in claim 9, wherein each elongate male connecting member extends upwardly from an outwardly projecting portion or extension extending from a side of the floor panel and comprises a upwardly extending stud extending from the upper face of said outwardly projecting portion.
11. A portable flooring assembly as claimed in claim 9 or 10, wherein each female receiving aperture is formed in an outwardly projecting portion or extension extending from a side of each floor panel.

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12. A portable flooring assembly as claimed in claim 11, wherein each of said female receiving apertures narrow towards a central region thereof and each downwardly extending stud has a necked portion such that the stud is a press fit into the corresponding aperture and is retained therein.
13. A portable flooring assembly as claimed in claim 11, wherein each male connecting member may have a circumferential projection adjacent an upper end thereof to retain each male connecting member in a corresponding female receiving aperture.
14. A portable flooring assembly as claimed in any of claims 11 to 13, wherein each outwardly projecting portion having male connecting members formed thereon extends from a side of each floor panel from a position below the upper edge thereof while the outwardly projecting portion formed with female receiving apertures therein extends from a side of each floor panel adjacent the upper edge thereof, such that each outwardly projecting portion on a side of a first floor panel can overlie the outwardly projecting portions of respective male connecting members on one side of a second floor panel, with the upwardly extending studs of the outwardly extending portion inserted through corresponding female receiving apertures receiving members, when said first and second floor panels lie alongside one another with their upper surface aligned in a common plane.
15. A portable flooring assembly as claimed in any preceding claim, wherein securing pegs are provided to secure the flooring assembly to the ground, apertures being provided in one or more of the floor panels, preferably adjacent the corner portions of the flooring assembly, for receiving the securing pegs.

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16. A portable flooring assembly as claimed in claim 15, wherein each aperture is tapered or has a countersunk portion adapted to receive the head of a securing peg, such that the securing pegs, when inserted into the apertures, do not extend above the surface of the flooring assembly, avoiding any trip hazard that might be formed if the securing pegs extend above the surface of the flooring assembly.
17. A portable flooring assembly as claimed in claim 16, wherein formations are formed in the upper surface of each securing peg adapted to receive a peg removal tool to allow the securing pegs to be removed when the flooring assembly is to be dismantled.
18. A portable flooring assembly as claimed in any preceding claim, wherein at least one projection is provided on the lower surface of each floor panel, said at least one projection, in use, being forced into the ground beneath the panel in order to prevent movement of the panel with respect to the ground.
19. A portable flooring assembly as claimed in claim 18, wherein a plurality of projections are provided on the lower surface of each floor panel, each projection comprising a downwardly extending spike or stud.
20. A portable flooring assembly as claimed in claim 19, wherein each such projection is formed integrally with each panel.
21. A portable flooring assembly as claimed in claim 19, wherein each such projection is removably mounted on the underside of each panel.

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22. A portable flooring assembly as claimed in any preceding claim, wherein each floor panel has a series of integrally formed elongate ribs thereon.
23. A portable flooring assembly as claimed in any preceding claim, wherein the upper surface of each floor panel has a roughened or textured finish in order to provide improved grip for persons walking thereon.
24. A portable flooring assembly as claimed in any preceding claim, wherein each floor panel is formed from a substantially rigid plastic material having good thermal insulating properties, formed by an injection moulding process.
25. A floor panel for a portable flooring assembly for use outdoors, said floor panel having an upper surface, a lower surface and a plurality of side surfaces, at least two side surfaces of the floor panel having co-operating interlocking formations thereon permitting the panel to be releasably connected to one or more similar adjacent panels.
26. A portable flooring assembly as described herein with reference to the accompanying drawings.
27. A floor panel as described herein with reference to the accompanying drawings.