US20210293033A1

US20210293033A1 - Edging Forms for Producing Self-Leveling Floors and Methods of Use

Info

Publication number: US20210293033A1
Application number: US17/339,761
Authority: US
Inventors: Michael Andrew Mazzarino
Original assignee: Edgeban LLC
Current assignee: Edgeban LLC
Priority date: 2018-01-18
Filing date: 2021-06-04
Publication date: 2021-09-23
Also published as: CA3030193A1; US20190218796A1

Abstract

A method for forming a self-leveling floor includes: positioning an edging form on or adjacent to a subfloor so as to at least partially bound an area on which a self-leveling floor is to be formed, the edging form including: a body having a top face, a bottom face and a first side face that extends between the top face and the bottom face; and a plurality of spaced apart channels extending entirely through the body from the top face to the bottom face, each of the plurality of channels also passing through at least a portion of the first side face. A self-leveling flooring material is dispensed into the area in which the self-leveling floor is to be formed so that the self-leveling flooring material flows against the first side face of the body and into each of the plurality of channels.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No. 16/249,367, filed Jan. 16, 2019, which claims the benefit of Provisional Application No. 62/769,448, filed Nov. 19, 2018 and Provisional Application No. 62/618,962, filed Jan. 18, 2018, which are incorporated herein by specific reference.

BACKGROUND OF THE INVENTION

1. The Field of the Invention

The present invention relates to edging forms for producing self-leveling floors and related methods. More specifically, the present invention relates to edging forms that can be placed, used to contain a self-leveling flooring material, trimmed to a desired height, and then receive a floor covering thereon.

2. The Relevant Technology

Self-leveling cement products are often used in commercial and residential flooring industries to create a flat and smooth substrate or underlayment onto which a final flooring product can be applied. The self-leveling cement products can repair uneven, bumpy and out of level floors and can also fill in nooks and voids. Self-leveling cement products, when mixed to manufacturer's standards, have a fluid or slurry like consistency when initially mixed with water. The self-leveling cement product is then poured onto a subfloor. When mixed and installed correctly, the self-leveling cement product will flow to level and then set up and cure. The cured material becomes a hard, flat, and level surface on which a flooring product, like tile, can be installed.
Before curing, the poured self-leveling cement product can also flow into unwanted spaces if not stopped, plugged and/or contained. Unwanted spaces can include the area underneath walls, cabinets, and bathtubs and can also include opening, cutouts, and cracks, such as pipe openings, vent openings, toilet flange openings, and waste pipe penetrations, that are formed on or extend through concrete and/or wood sub-flooring. This unwanted flow of the self-leveling cement product can lead to an un-level cure of self-leveling product, extra labor and cleanup time, wasted material/money on self-leveling cement product, and poor/unsatisfactory finished product.

SUMMARY OF THE INVENTION

In a first independent aspect of the present invention, an edging form for use in forming a self-leveling floor includes:

- an elongated body having a top face, a bottom face and a first side face that extends between the top face and the bottom face, the body having a height extending between the top face and the bottom face in a range between 1 cm and 10 cm and a width in a range between 1 cm and 10 cm; and
- a plurality of spaced apart channels extending entirely through the body from the top face to the bottom face.

In one aspect, the plurality of channels also pass through a portion of the first side face.
In another aspect, the plurality of channels include:

- a primary channel that extends entirely through the body from the top face to the bottom face and is spaced apart from the first side face; and
- an access channel that extends from the first side face to the primary opening.

In another aspect, the access channel comprises a slot that is narrower than the primary channel.
In another aspect, the primary channel is cylindrical.
In another aspect, the access channel is constricted relative to the primary channel.
In another aspect, the access channel intersects with the primary channel at an angle or corner.
In another aspect, each of the plurality of channels has a transverse cross section substantially having the form of an L, J, P, T, Y or an arch.
In another aspect, the plurality of channels comprise at least 10, 20, or 30 separate channels.
In another aspect, each of the plurality of channels are spaced apart from the first side face and are completely encircled by the body.
In another aspect, the body is comprised of a polymeric foam.
In another aspect, the polymeric foam comprises polystyrene foam.
In another aspect, the polymeric foam has a density in a range between 30 kg/m³and 50 kg/m³.
In another aspect, the body is linear and has a length in a range between 0.3 meters and 3 meters.
In another aspect, at least a portion of the bottom face is disposed orthogonal to the first side face and wherein at least a portion of the top face is curved or arched.
In another aspect, at least a portion of the top face is inclined relative to the bottom face.
In another aspect, the body further comprises a second side face opposite the first side face that extends between the top face and the bottom face.
In another aspect, the top face comprises:

- a first lateral portion;
- a second lateral portion spaced apart from the first lateral portion, the first lateral portion being at an elevation above the second lateral portion when the bottom face is horizontally disposed; and
- a riser portion upwardly extending from the second lateral portion to the first lateral portion when the bottom face is horizontally disposed.

In another aspect, the first lateral portion and the second lateral portion are in parallel alignment.
In another aspect, the first lateral portion extends from the second side face and the second lateral portion extends from the first side face.
In another aspect, the plurality of spaced apart channels extending entirely through the body from the second lateral portion to the bottom face.
In another aspect, the riser portion extends perpendicular to the second lateral portion.
In another aspect, the top face comprises:

- a first lateral portion; and
- a curved riser portion downwardly projecting from the first lateral portion.

In another aspect, the body has a transverse cross section that is substantially L-shaped.
In another aspect, the body has a transverse cross section that is square or rectangular.
In another aspect, a plurality of spaced apart second channels extend entirely through the body from the top face to the bottom face, each of the plurality of second channels passing through at least a portion of the second side face.
In another aspect, a backing is secured along the second side face, the backing being more flexible than the base and being made of a different material than the base.
In another aspect, an adhesive is applied to the bottom face of the body.
In a further independent aspect of the present invention, an edging form for use in forming a self-leveling floor includes:

- an elongated body having a top face, a bottom face, and a first side face that extends between the top face and the bottom face, the body being comprised of polymeric foam; and
- a plurality of spaced apart channels extending entirely through the body from the top face to the bottom face and passing through at least a portion of the first side face.

In one aspect, the body has a height extending between the top face and the bottom face in a range between 1 cm and 10 cm and has a width in a range between 1 cm and 10 cm.
In another aspect, each of the plurality of channels comprise:

In another aspect, the access channel comprises a slot that is narrower than the primary channel.
In another aspect, the primary channel is cylindrical.
In another aspect, each of the plurality of channels has a transverse cross section substantially having the form of an L, J, P, T, Y or an arch.
In another aspect, the edging form further incudes:

- the body having a second side face opposite the first side face that extends between the top face and the bottom face; and
- a backing secured along the second side face, the backing being more flexible than the base and being made of a different material than the base.

In another aspect, the body further includes a second side face opposite the first side face that extends between the top face and the bottom face.
In another aspect, the top face includes:

In another aspect, the first lateral portion and the second lateral portion are in parallel alignment.
In another aspect, the first lateral portion extends from the second side face and the second lateral portion extends from the first side face.
In another aspect, the plurality of spaced apart channels extend entirely through the body from the second lateral portion to the bottom face.
In another aspect, the riser portion extends perpendicular to the second lateral portion.
In another aspect, the body has a transverse cross section that is substantially L-shaped.
In a further independent aspect of the present invention, an edging form for use in forming a self-leveling floor incudes:

- a body having a top face, a bottom face, an exterior side face extending between the top face and the bottom face and an interior side face extending between the top face and the bottom face, the interior side face at least partially encircling an opening extending through the body from the top face to the bottom face; and
- a plurality of spaced apart channels extending entirely through the body from the top face to the bottom face and passing through at least a portion of the exterior side face.

In one aspect, the body includes a circular ring and the opening extending through the body being circular and having an inner diameter in a range between 8 cm and 30 cm.
In another aspect, a slot extends through the body from the interior side face to the exterior side face.
In another aspect, the body is square, rectangular, or polygonal and the opening extending through the body is square, rectangular, or polygonal.
In another aspect, the body is comprised of a polymeric foam.
In another aspect, the polymeric foam comprises polystyrene foam.
In another aspect, the top face includes:

In another aspect, the first lateral portion and the second lateral portion are in parallel alignment.
In another aspect, the first lateral portion extends from the interior side face and the second lateral portion extends from the exterior side face.
In another aspect, the plurality of spaced apart channels extending entirely through the body from the second lateral portion to the bottom face.
In another aspect, the body has a transverse cross section that is substantially L-shaped.
In a further independent aspect of the present invention, a method for forming a self-leveling floor includes:

- securing an edging form to a subfloor so as to at least partially bound an area on which a self-leveling floor is to be formed, the edging form comprising:
  - a body having a top face, a bottom face and a first side face that extends between the top face and the bottom face; and
  - a plurality of spaced apart channels extending entirely through the body from the top face to the bottom face;
- dispensing a self-leveling flooring material onto the area in which the self-leveling floor is to be formed so that the self-leveling flooring material flows against the first side face or a portion of the top face of the edging form; and
- allowing the self-leveling flooring material to harden into a solid floor while the self-leveling flooring material is disposed against the first side face or the portion of the top face of the edging form.

In one aspect, the step of securing includes applying an adhesive to the bottom face of the body of the edging form.
In another aspect, applying the adhesive includes using a caulk gun to manually apply a bead of caulk to the bottom face of the body.
In another aspect, the plurality of channels also pass through at least a portion of the first side face, wherein the step of dispensing comprises the self-leveling flooring material flowing into the plurality of channels.
In another aspect, the plurality of channels are configured so that when the self-leveling flooring material cures within the plurality of channels, the edging form becomes interlocked with the cured self-leveling flooring material.
In another aspect, the step of securing includes securing the edging form to the subfloor so that the edging form spans across a doorway.
In another aspect, the step of securing includes securing the edging form to the subfloor so that the first side face and an opposing second side face of the edging form are openly and freely exposed.
In another aspect, the step of securing includes securing the edging form to the subfloor so that the self-leveling flooring material cannot flow underneath the edging form.
In another aspect the edging form is linear and the step of securing includes securing the edging form to the subfloor so that the edging form bounds at least a portion of an outer perimeter edge of the area on which a self-leveling floor is to be formed.
In another aspect, the edging form is square, rectangular, polygonal, or circular and bounds an opening extending therethrough.
In another aspect, the method includes removing a portion of the edging form projecting above the solid floor so that a remaining portion of the edging form has a top face that is flush with a top face of the solid floor.
In another aspect, the method includes applying a flooring covering over the top face of the solid floor and over the top face of the remaining portion of the edging form.
In another aspect, the flooring includes tile, carpeting, wood flooring, linoleum or vinyl flooring.
In another aspect, the method further includes:

- securing a carpet tack strip over at least a portion of the top face of the remaining portion of the edging form; and
- engaging a carpet to the track strip.

In another aspect, the step of securing a carpet tack strip over at least a portion of the top face of the remaining portion of the edging form comprises driving fasteners disposed on the tack strip into the remaining portion of the edging form.
In another aspect, the body is comprised of a polymeric foam.
In another aspect, the polymeric foam includes polystyrene foam.
In another aspect, the top face includes:

In another aspect, the self-leveling flooring material is dispensed onto the area in which the self-leveling floor is to be formed so that the self-leveling flooring material flows over the second lateral portion of the top face and against the riser portion of the top face.
In another aspect, the plurality of spaced apart channels extend entirely through the body from the second lateral portion to the bottom face.
In another aspect, the body has a transverse cross section that is substantially L-shaped.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present invention will now be discussed with reference to the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope.

FIG. 1 is a perspective view of a first edging form incorporating features of the present invention;

FIG. 2 is an exploded view of the edging form shown in FIG. 1;

FIG. 3 is a top plan view of the edging form shown in FIG. 1;

FIG. 4A is a cross-sectional side view of the edging form shown in FIG. 3 taken along line A-A;

FIG. 4B is a cross-sectional side view of an alternative embodiment of the edging form shown in FIG. 4A;

FIG. 5 is a perspective view of a second embodiment of an edging form;

FIG. 6 is an exploded view of the edging form shown in FIG. 5;

FIG. 7 is a top plan view of the edging form shown in FIG. 5;

FIG. 8 is a cross-sectional side view of the edging form shown in FIG. 7 taken along line A-A;

FIG. 9 is a top perspective view of a third embodiment of an edging form;

FIG. 10 is a bottom perspective view of the edging form shown in FIG. 9;

FIG. 11 is a top plan view of the edging form shown in FIG. 9 showing alternative embodiments of access channels;

FIG. 12 is a top plan view of the edging form shown in FIG. 9 showing alternative embodiments of channels for locking;

FIG. 13 is a top plan view of the edging form shown in FIG. 9 showing other alternative embodiments of channels;

FIG. 14 is a top perspective view of the edging form shown in FIG. 9 having alternative access channels that extend only partially through the first side face;

FIG. 15 is a bottom perspective view of the edging form shown in FIG. 14;

FIG. 16 is a cross sectional side view of an alternative edging form having the configuration of a quarter circle;

FIG. 17 is a cross sectional side view of an alternative edging form having a second side face shorter that the first side face;

FIG. 18 is a cross sectional side view of an alternative edging form having the configuration of a triangle;

FIG. 19 is a cross sectional side view of an alternative edging form having a bottom face shorter that the top face;

FIG. 20 is a cross sectional side view of an alternative edging form having a top face shorter that the bottom face;

FIG. 21 is a perspective view of a further alternative embodiment of an edging form having a configuration of a circular ring;

FIG. 22 is a perspective view of a further alternative embodiment of an edging form having a configuration of a rectangle;

FIG. 23 is a perspective view of edging forms secured to a subfloor to bound an area;

FIG. 24 is a perspective view of the assembly shown in FIG. 23 where a self-leveling flooring material is disposed within the area and a portion of the edging forms are cut down;

FIG. 25 is a perspective view of the assembly shown in FIG. 24 where the edging forms are fully cut down and a floor covering is being applied;

FIG. 26 is a perspective view of a further alternative embodiment of an edging form wherein a flexible backing strip is secured to the second side face;

FIG. 27 is a perspective view of the edging form shown in FIG. 26 applied around a column;

FIG. 28 is a top plan view of a further alternative embodiment of an edging form having channels communicating with the first side face and the second side face;

FIG. 29 is a perspective view of the assembly shown in FIG. 24 using the edging forms shown in FIG. 28;

FIG. 30 is a top perspective view of an alternative embodiment of the edging form shown in FIG. 9 having an L-shaped transverse cross section;

FIG. 31 is an elevated end view of the edging form shown in FIG. 30;

FIG. 32 is an elevated end view of an alternative design of the edging form shown in FIG. 31; and

FIG. 33 is an elevated end view of a further alternative embodiment of the edging form shown in FIG. 31.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Before describing the present disclosure in detail, it is to be understood that this disclosure is not limited to particularly exemplified structures, systems, methods, or process parameters that may, of course, vary. It is also to be understood that the terminology used herein is only for the purpose of describing particular embodiments of the present invention and is not intended to limit the scope of the invention in any manner.
All publications, patents, and patent applications cited herein, whether supra or infra, are hereby incorporated by reference in their entirety to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.
The term “comprising” which is synonymous with “including,” “containing,” or “characterized by,” is inclusive or open-ended and does not exclude additional, unrecited elements or method steps.
It will be noted that, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a “channel” includes one, two, or more channels.
As used in the specification and appended claims, directional terms, such as “top,” “bottom,” “left,” “right,” “up,” “down,” “upper,” “lower,” “proximal,” “distal” and the like are used herein solely to indicate relative directions and are not otherwise intended to limit the scope of the invention or claims.
Where possible, like numbering of elements have been used in various figures. Furthermore, multiple instances of an element and or sub-elements of a parent element may each include separate letters appended to the element number. For example, two instances of a particular element “10” may be labeled as “10A” and “10B”. In that case, the element label may be used without an appended letter (e.g., “10”) to generally refer to all instances of the element or any one of the elements. Element labels including an appended letter (e.g., “10A”) can be used to refer to a specific instance of the element or to distinguish or draw attention to multiple uses of the element. Furthermore, an element label with an appended letter can be used to designate an alternative design, structure, function, implementation, and/or embodiment of an element or feature without an appended letter. Likewise, an element label with an appended letter can be used to indicate a sub-element of a parent element. For instance, an element “12” can comprise sub-elements “12A” and “12B.”
Various aspects of the present forms and systems may be illustrated by describing components that are coupled, attached, and/or joined together. As used herein, the terms “coupled”, “attached”, and/or “joined” are used to indicate either a direct connection between two components or, where appropriate, an indirect connection to one another through intervening or intermediate components. In contrast, when a component is referred to as being “directly coupled”, “directly attached”, and/or “directly joined” to another component, there are no intervening elements present. Furthermore, as used herein, the terms “connection,” “connected,” and the like do not necessarily imply direct contact between the two or more elements.
Various aspects of the present forms, systems, and methods may be illustrated with reference to one or more exemplary embodiments. As used herein, the term “embodiment” means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments disclosed herein.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present disclosure pertains. Although a number of methods and materials similar or equivalent to those described herein can be used in the practice of the present disclosure, the preferred materials and methods are described herein.
In general, the present disclosure relates to edging forms for use in the formation of a self-leveling floor or underlayment on top of a subfloor. As described below in greater detail, the inventive edging forms can come in a variety of different configurations and sizes and when used can provide a complete sealing system for a self-leveling flooring material that is used to form the underlayment. Specifically, the edging forms can bound all or part of a perimeter of an area in which the self-leveling flooring material is dispensed for forming an underlayment and can also seal edges, fittings, drains, cutouts and other openings and/or structures within the area for the underlayment to prevent intrusion by the self-leveling flooring material.
Depicted in FIG. 1 is a first embodiment of an edging form 10A incorporating features of the present invention and which can be used to seal or bound a self-leveling flooring material. As used in the specification and appended claims, a self-leveling flooring material is a liquid or flowable material that will flow toward level under the force of gravity when poured and will cure or set to have sufficient strength properties to function as a commercial or residential floor. Commonly, the self-leveling flooring material will independently flow to level solely under the force of gravity. However, in some embodiments or uses, a trowel or other tool can be used to assist in the spreading and/or leveling of the self-leveling flooring material. The self-leveling flooring material will typically independently flow to level in a period of time less than 30 minutes and more commonly less then less than 15 minutes or 5 minutes. The self-leveling flooring material will also typically cure or set to a non-flowing state within a period of less than 72 hours and more commonly less than 48 hours or 24 hours. In one embodiment, the self-leveling flooring material is a cement based material that is purchased dry and then mixed with water to form the liquid material. However, in other embodiments, the self-leveling flooring material can comprise a polymer-based material, gypsum based material, or synthetic material. Other materials can also be used. One specific example of a self-leveling flooring material is Ardex K 15 produced by Ardex Americas.
As depicted in FIG. 2, edging form 10A comprises an elongated body 12A and an adhesive strip 14A that is secured to body 12A. Body 12A is shown having a rectangular or square transverse cross section and includes a top face 16 and an opposing bottom face 18 that extend between a first side face 20 and an opposing second side face 22. In the depicted embodiment, top face 16 and bottom face 18 are disposed in parallel alignment and opposing side faces 20 and 22 are also disposed in parallel alignment. In alternative embodiments, as discussed below in greater detail, body 12A can have a variety of other transverse cross sectional configurations and the opposing faces thereof need not be disposed in parallel alignment. Faces 16, 18, 20, and 22 extend between a first end 24 and an opposing second end 26. First end 24 terminates at an end face 28 while second end 26 terminates at an end face 30. Either of side faces 20 and 22 can be the face that comes into contact with the self-leveling flooring material during use.
Body 12A has a height H extending between top face 16 and bottom face 18, a width W extending between side faces 20 and 22, and a length L extending between end faces 28 and 30. Height H and width W are both typically at least or less than 1 cm, 2 cm, 3 cm, 4 cm, 5 cm, 7 cm, 9 cm or 10 cm or are in a range between any two of the foregoing values. For example, height H and width W are commonly in a range between 1 cm and 10 cm with between 2 cm and 8 cm or between 2 cm and 6 cm being more common. Height H and width W can be the same dimension or can be different dimensions. For example, depending on the application, height H could be larger or smaller than width W.
Length L is typically at least or less than 0.3 meters, 0.5 meters, 0.75 meters, 1 meter, 1.5 meters, 2 meters, 2.5 meters or 3 meters or in a range between any two of the forgoing values. For example, length L can be in a range between 0.3 meters and 3 meters with between 0.5 meters and 2.5 meters or between 1 meter and 2.5 meters being more common. The dimensions of the height H, width W and length L can vary depending upon the application and use preference. For example, the height H can increase as the depth of the desired underlayment increases. The width W can increase where it is needed to more securely retain body 12A to the underlying subfloor as the underlayment is curing. Thus, width W may also increase as the depth of the desired underlayment increases and/or the volume of underlayment increases. The length L can increase as the length of the underlayment increases. In one embodiment of the present invention, body 12A has a length L that is 5 feet long, a height H that is 1.5 inches tall, and a width W that is 1 inch wide.
Body 12A is typically made of a foam-based material that is liquid impermeable. The material can also be flexible. In one embodiment, the foam-based material is a polymeric foam such as polystyrene foam, ethylene-vinyl acetate foam, low-density polyethylene foam, polyurethane foam, polyethylene foam, or polyvinyl chloride foam. The polymeric foam will typically have a density of at least 30 kg/m³, 35 kg/m³, 40 kg/m³, 45 kg/m³, 50 kg/m³or 60 kg/m³or be in a range between any two of the foregoing values. Higher densities have increased strength but lower densities are typically less expensive and easier to cut. Polystyrene foam has some advantages in that it is inexpensive, lightweight, easy to form and cut and can be produced having desired compressive strength/density properties. In other embodiments, body 12A need not be made from a polymeric foam but could be made from a non-foam material such as a polymer, fiberglass, wood, rubber, or composite. Using these lateral materials would be more expensive but may have properties that are desirable for a specific application. For example, the later discussed materials may have improved strength properties that are more desirable for industrial applications.
As depicted in FIGS. 3 and 4A, extending through body 12A between top face 16 and bottom face 18 are a plurality of longitudinally spaced apart channels 32. It is noted that channels 32 are completely encircled by body 12A and are thus spaced apart from side faces 20 and 22. One of the purposes of channels 32 is to allow the user to pour a fill material, such as a self-leveling flooring material, into the plurality of channels 32 to enhance the structural properties of body 12A. Channels 32 can be formed concurrently with the formation of body 12A or can be bored, cut out or otherwise formed after body 12A is formed. During use, an upper opening of channels 32 can be manipulated to be the same level as the cured self-leveling flooring material before the fill material is poured into channels 32. For example, as discussed below in greater detail, body 12A and thus channels 32 extending therethrough can be cut down to the level of the self-leveling flooring material before filling channels 32 with the fill material. One of the benefits of channels 32 is that the fill material poured into channels 32 and allowed to cure, anchors body 12A to the underlying subfloor. That is, the fill material further secures body 12A the existing subflooring to prevent unwanted shearing. The fill material poured into the plurality of channels 32 also functions as a reinforcement for body 12A. Specifically, the fill material increases the normal stress threshold and compressive strength of body 12A for better handling the floor covering and loads that are placed thereon.
In the depicted embodiment, channels 32 have a cylindrical configuration typically having a diameter in a range between 0.3 cm and 3 cm with between 0.5 cm and 2 cm and between 0.5 cm and 1.5 cm being more common. Channels 32 are commonly spaced apart by a distance of at least or less than 1 cm, 1.5 cm, 2 cm, 3 cm, 5 cm, 8 cm, 10 cm, 15 cm, or 20 cm or in a range between any two of the foregoing values. For example, the spacing between channels 32 can be in a range between 1 cm and 20 cm with between 1 cm and 8 cm or between 1 cm and 5 cm being more common. In one embodiment, a single body 12A can have at least 10, 20, 30, 40, 50 or more channels 32 extending therethrough. As discussed below in greater detail, channels 32 need not be cylindrical but could have other configurations. For example, channels 32 could have a transverse cross section that is circular, as shown, or could be oval, square, triangular, or have other polygonal or irregular configurations.
Returning to FIG. 2, adhesive strip 14A enables body 12A to tack or otherwise secure to an existing subfloor to prevent body 12A from shearing/moving relative to the subfloor when body 12A/form 10A is blocking the self-leveling flooring material from flowing. In one embodiment, adhesive strip 14A is disposed on bottom face 18 of body 12A and comprises any type of high-strength sealant or other sealant that permanently or securely sticks to the existing subfloor on which a user applies it. Furthermore, adhesive strip 14A forms a liquid/slurry impermeable seal between body 12A and the existing subfloor. A removably cover sheet 40 is a protective sheet that can be used to cover adhesive strip 14A when form 10A is not being used. Cover sheet 40 can be any disposable, peel-able sheet.
Adhesive strip 14A can comprise as a tape-like structure having a top surface 36 and an opposing bottom surface 38. During assembly, top surface 36 of adhesive strip 14A is secured to bottom face 18 of body 12 such as by adhesive, welding, fasteners, over molding, or the like so that adhesive strip 14A is securely fixed to body 12A. Disposed on bottom surface 38 of adhesive strip 14A is an adhesive, such as a tacky adhesive used on tape, that can accomplish the above objectives. Removable cover sheet 40, such as a polymeric sheet or film, can be placed over the adhesive so that form 10A can be easily transported and handled without exposure of the adhesive. However, when it is desired to secure form 10A to a floor surface, cover sheet 40 is pulled off so as to expose the adhesive. Form 10A can then be pressed against the subfloor so that the adhesive both secures form 10A to the subfloor and provides a liquid tight seal between form 10A and the subfloor.
As shown in FIG. 4A, in one embodiment, adhesive strip 14A can be secured to bottom face 18 of body 12A so as to cover and seal closed the lower end of channels 32. In an alternative embodiment, as shown in FIG. 4B, openings 42 can be formed extending through adhesive strip 14A that are aligned with and communicate with channels 32. As such, channels 32 are openly exposed at both opposing ends so that the fill material can flow therethrough and directly contact and bind with the subfloor.
During one method of use, one or more edging forms 10A are laid out and secured to a subfloor by use of adhesive strip 14A so as to partially or completely bound an area on which a self-leveling flooring material is to be dispensed for forming a solid floor or underlayment. Next, the self-leveling flooring material is dispensed into the area, such as by pouring or pumping, so that the self-leveling flooring material fills the area to a desired level. Edging forms 10A act as dams to assist in retaining the self-leveling flooring material within the area. The self-leveling flooring material flows to level under gravity and fills in all defects formed on the subfloor.
Once the self-leveling flooring material has sufficiently cured to be stable, forms 10A are cut down, such as by using a saw, knife, or other machine, so as to leave a remaining portion of forms 10A having a top surface that is now flush with the top surface of the underlayment formed by the cured self-leveling flooring material. A fill material is then dispensed into all or at least some of channels 32 to the top surface of the remaining portions of forms 10A. The fill material is also typically a self-leveling liquid that hardens when cured. The fill material can comprise a self-leveling flooring material or can comprise some other material, such as an adhesive or binder, that flows level and cures hard. Is still another embodiment, the fill material need not be a self-leveling material. For example, it could be an adhesive or caulk that is dispensed into select channels 32 so as to fill channels 32 or to slightly overfill channel 32 and is then manually smoothed flat by removing excess fill material.
Once the fill material has sufficiently hardened, a floor covering, such as tile, vinyl, linoleum, carpet, wood flooring, or the like can be secured over both the formed underlayment and the remaining portion of forms 10A. Again, filling channels 32 with the fill material can help secure edging forms 10A to the subfloor to prevent unwanted movement thereon and also adds structural and compressive strength to each body 12A so that they can withstand the compressive forces applied thereto.
Depicted in FIG. 5 is an alternative embodiment of an edging form 10B incorporating features of the present invention. As depicted in FIG. 6, form 10B includes a body 12B and an adhesive strip 14B that is applied to body 12B. Like elements between form 10A and form 10B are identified by like reference characters. For example, body 12B includes top face 16, bottom face 18, and opposing side faces 20 and 22. However, side faces 20 and 22 can also be referred to herein as exterior side face 20 and interior side face 22. Thus, when viewed in cross section between opposing faces 20 and 22, body 12B has a square or rectangular transverse cross section. The configurations, alternatives, and dimensions associate with faces 16, 18, 20, and 22 for edging form 10A are also applicable to form 10B. Furthermore, body 12B can be made of the same materials as discussed with body 12A. Likewise, adhesive strip 14B can be made of the same materials and attached or applied to bottom face 18 the same as discussed above with regard to adhesive strip 14A and edging form 10A. A plurality of channels 32 extend through body 12B from top face 16 to bottom face 18 and can have the same dimensions, configurations, spacing and numbers as previously discussed with regard to edging form 10A. As also discussed with regard to edging form 10A, openings 42 can be formed on adhesive strip 14B that extend through adhesive strip 14B and align with channels 32 (see FIGS. 7 and 8).
However, in contrast to form 10A which is linear, form 10B is in the form of a circular ring that forms a continuous, integral loop. Specifically, exterior side face 20 is curved along its length and forms an outer perimeter having a circular configuration. In addition, interior side face 22 is curved along its length and forms an inner perimeter having a circular configuration that encircles an opening 44 extending through body 12B/form 10B. Opening 44 is circular and has an inside diameter D. As discussed below in greater detail, form 10B is configured to encircle a structure or opening so as to block or seal the self-leveling flooring material from flowing to the structure or opening. The structure or opening that form 10B encircles can be a drain fitting or opening such as a toilet opening, toilet flange, pipe, hole, cutout, electrical outlet, vent opening, water line, or any other structure or opening formed on or extending through the subfloor. Edging form 10B can be formed in a variety of different sizes depending on its application. For example, where form 10B is encircling a 1 cm diameter pipe, form 10B can be much smaller than when form 10B is encircling an opening for a toilet. In some embodiments, body 12B/edging form 10B can be formed with a diameter D that is at least or less than 5 centimeters, 10 centimeters, 15 centimeters, 20 centimeters, 25 centimeters, 30 centimeters, or 40 centimeters, or is in a range between any two foregoing values. For example, diameter D can be in range between 10 centimeters and 30 centimeters or more commonly in a range between 10 centimeters and 25 centimeters.
During one method of use, one or more edging forms 10B are laid out and secured to a subfloor by use of adhesive strip 14B so as to encircle an opening or structure on the subfloor. Forms 10B can be used in combination with or separate from edging forms 10A. For example, edging forms 10A can be used to at least partially bound an area into which self-leveling flooring material is to be dispensed for forming an underlayment while one or more forms 10B can be positioned within the area to seal structures or opening from the self-leveling flooring material. Once forms 10B are positioned, the self-leveling flooring material is dispensed into the area, such as by pouring or pumping, so that the self-leveling flooring material fills the area to a desired level. Edging forms 10B act as dams to prevent the self-leveling flooring material from accessing the structures or opening encircled by edging form 10B. That is, the self-leveling flooring material contacts and rises against exterior side face 20 but does not pass into opening 44. Again, the self-leveling flooring material typically flows to level under the force of gravity and fills in all defects formed on the subfloor.
The remaining process is the same as discussed above with regard to edging forms 10A. Specifically, once the self-leveling flooring material has sufficiently cured to be stable, edging forms 10B are cut down, such as by using a saw, knife, or other machine, so that the top surface of the remaining portion of edging forms 10B are flush with the top surface of the underlayment formed by the cured self-leveling flooring material. A fill material, as discussed above, is then dispensed into all or at least some of channels 32 to the top surface of the remaining portion of edging forms 10B.
Once the fill material has sufficiently hardened, a floor covering, such as discussed above, can be secured over both the underlayment and edging forms 10B. Again, filling channels 32 with the fill material can help secure edging forms 10B to the subfloor to prevent unwanted movement thereon and also adds structural and compressive strength to each body 12B so that they can withstand the compressive forces applied thereto.
Depicted in FIG. 9 is another alternative embodiment of an edging form 10C incorporating features of the present invention. Edging form 10C is linear like form 10A and like elements between edging forms 10A and 10C are identified by like reference characters. Edging form 10C includes an elongated body 12C having top face 16, bottom face 18, opposing side faces 20 and 22, and end faces 28 and 30. The configurations, dimensions, and alternatives associated with faces 16, 18, 20, 22, 28, and 30 as discussed with regard to body 12A are also applicable to body 12C. Likewise, the alternative materials used for forming edging form 12A are also applicable for edging form 12C.
Extending through body 12C from top face 16 to bottom face 18 are a plurality of spaced apart channels 50. However, in contrast channels 32 of body 12A where channels 32 are completely encircled by body 12A, a portion of each channel 50 extends through first side face 20 so that fluid contacting first side face 20 can flow into channels 50. More specifically, in the embodiment depicted in FIG. 9, each channel 50 comprises a primary channel 52 that extends entirely through body 12C from the top face 16 to bottom face 18 and is spaced apart from first side face 20 and second side face 22. Each primary channel 52 can have a cylindrical configuration with a circular transverse cross section or can have other configurations with other transverse cross sections including the configurations and shapes discussed above with regard to channel 32 of body 12A. Furthermore, primary channels 52 can have the same dimensions and configurations as previously discussed with regard to channels 32. Likewise, channels 50 and primary channels 52 can have the same spacing and numbers as previously discussed with regard to channels 32.
Each channel 50 also includes an access channel 54 that extends from primary channel 52 through first side face 20. In the depicted embodiment, each access channel 54 comprises a constricted slot that is narrower than primary channel 52. More specifically, access channel 52 can have a minimum width or diameter that is less than a minimum and/or maximum width or diameter of primary channel 54. For example, the minimum width of access channel 52 can be less than 0.9, 0.8, 0.6, or 0.4 times the maximum diameter of primary channel 52.
Access channel 54 can comprise a linear slot that projects perpendicular to first side face 20 and is bounded by opposing interior faces 56A and 56B. In one embodiment, at least a portion of interior faces 56A and 56B can be disposed in parallel alignment. In an alternative embodiment, as shown in FIG. 11, an access channel 54B can project from first side face 20 to primary channel 52 at an oblique angle relative to first side face 20. In another depicted embodiment, an access channel 54C is shown that curves from first side face 20 to primary channel 52. Furthermore, interior faces 56A and 56B need not be disposed in parallel alignment. By way of example and not by limitation, interior faces 56A and 56B could be disposed in planes that are converging as they extend from first side face 20 to primary channel 52, as shown by access channel 54D, or diverging as they extend from first side face 20 to primary channel 52, as shown by access channel 54E.
One of the benefits of channels 50, in contrast to channels 32, is that channels 50 are automatically self-filling with the self-leveling flooring material to proper height as the self-leveling flooring material is dispensed into the bounded area for the underlayment. That is, as discussed below in greater detail, as the self-leveling flooring material is dispensed into the area bounded for the underlayment, the self-leveling flooring material freely flows into channels 50 through access channels 54 and properly fills channels 50 to the top surface of the formed underlayment. As such, there is no need for separate filling or leveling of channels 50 with a filling material.
Another benefit of forming channels 50 so that they comprise primary channel 52 and constricted access channel 54 that extends through first side face 20 is that this configuration assists in interlocking edging form 10C with the resulting underlayment. Specifically, as discussed above, once edging form 10C is secured in position and the self-leveling flooring material is poured, the self-leveling flooring material flows through access channels 54 and into primary channels 52 where the self-leveling flooring material cures and hardens. Because of the constriction of access channels 54 relative primary channels 52, the cured flooring material within primary channels 52 cannot pass out through access channels 54. Thus, the cured flooring material interlocks edging form 10C to the underlayment to prevent unwanted separation or movement between edging form 10C and the underlayment.
It is appreciated that channels 50 can be formed in a variety of other configurations that facilitate interlocking between edging form 10C and the underlayment. By way of example and not by limitation, channels 50 can be formed with a corner, angle, arch or curve to help achieve interlocking. More specifically, as depicted in FIG. 12, a channel 50F is provided having a Y-shaped configuration. Channel 50F includes a V-shaped primary channel 52F and a linear access channel 54F that extends from first side face 20 to primary channel 52F. Angles or corners 58F are formed at the intersection between primary channel 52F and access channel 54F to facilitate the interlocking.
A channel 50G is also shown that is curved or arched along it length. The curve of channel 50G helps produce the interlocking between edging form 10C and the formed underlayment because the cured flooring material within channel 50G cannot pull out of channel 50G. In another alternative, an L-shaped channel 50H is depicted. Channel 50H includes a primary channel 52H and an access channel 54H that are both linear but that orthogonally intersect at an angle or corner 58H to help achieve interlocking.
Also depicted in FIG. 12 is P-shaped channel 501. Channel 501 includes a primary channel 521 having a semi-circular configuration and an access channel 541 that is linear and extends from first side face 20 to primary channel 521. Channels 521 and 541 intersect at an angle or corner 581 to help achieve the interlocking. In addition, primary channel 521 has a larger maximum width than access channel 541 so that the cured flooring material within primary channel 521 cannot pass through access channel 541. Further depicted in FIG. 12 is chevron or V-shaped channel 50J. Channel 50J includes a linear primary channel 52J and a linear access channel 54J that extends from first side face 20 to primary channel 52J. Channels 52J and 54J intersect at a corner 58J having an obtuse angle to help achieve interlocking. Finally, depicted in FIG. 12 is a T-shaped channel 50K. Channel 50K includes a linear primary channel 52K and a linear access channel 54K that extends from first side face 20 to centrally intersect with primary channel 52K. Channels 52K and 54K intersect at corners 58K having a right angle to help achieve interlocking. In view of the foregoing, it is appreciated channels 50 could also be formed in a variety of other configurations that would help achieve interlocking between edging form 10C and the formed underlayment.
In other embodiments, the interlocking feature can also be achieved, or at least improved, by having channels 50 extend at an oblique angle relative to first side face 20. For example, depicted in FIG. 13 is a channel SOL that is in the form of a linear slot that intersects with first side face 20 at an acute angle 0. If desired, a channel 50M in the form of a linear slot can also be formed that intersects with first side face 20 at an acute angle 0. Channels SOL and 50M are depicted as being disposed in planes that converge toward first side face 20. In an alternative embodiment, channels SOL and 50M can be configured so that they are disposed in planes that diverge toward first side face 20.
In other embodiments, however, it is not necessary for channels 50 to have an interlocking configuration as discussed above. Rather, channels 50 can be formed by simply being recessed into first side face 20. For example, as depicted in FIG. 13, channels 50N, 500 and 50P are formed recessed into first side face 20 having a semi-circular, triangular and rectangular transverse cross section, respectively. Other polygonal and irregular shapes can also be used. The channels 50N, 500 and 50P help facilitate engagement between edging form 10C and the formed underlayment.
As depicted in FIGS. 9 and 10, which are top and bottom perspective views of edging form 10C, channels 50, including primary channels 52 and access channels 54, extend entirely through body 12C from top face 16 to bottom face 18. More specifically, access channels 54 extend through first side face 20 to primary channels 52 along the full height of first side face 20 from top face 16 to bottom face 18. In alternative embodiments, however, access channels 54 need not extend along the full height of first side face 20. For example, depicted in FIGS. 14 and 15 is a top perspective view and a bottom perspective view, respectively, of body 12C having modified channels 50 formed thereon. Specifically, body 12C is formed having channels 50Q, 50R and 505 formed thereon. Channel 50Q includes a primary channel 52Q that extends entirely through body 12C from top face 16 to bottom face 18 at a location spaced apart from first side face 20 and second side face 22. However, channel 50Q comprises an access channel 54Q that does not extend the full height of first side face 20. Rather, access channel 54Q extends through first side face 20 to primary channel 52Q only through an upper portion of first side face 20 that is spaced apart from bottom face 18. Access channel 54Q also extends through top face 16 from first side face 20 to primary channel 52Q but does not extend through bottom face 18 from first side face 20 to primary channel 52Q. Access channel 54Q allows the self-leveling flooring material to automatically flow into channel 50 after the flooring material has reached a specific level.
Channel 50R also includes a primary channel 52R that extends entirely through body 12C from top face 16 to bottom face 18. However, channel 50R comprises an access channel 54R that only extends from first side face 20 to primary channel 52R at a location between and spaced apart from top face 16 and bottom face 18. In the depicted embodiment, access channel 54R comprises a cylindrical channel centrally formed on first side face 20. However, access channel 54R can have any desired transverse cross section and can be placed at other locations spaced apart from top face 16 and bottom face 18 so that access channel 54R does not pass through top face 16 or bottom face 18.
Finally, channel 505 includes a primary channel 52S that extends entirely through body 12C from top face 16 to bottom face 18. However, channel 505 comprises an access channel 54S that does not extend the full height of front face 20. Rather, access channel 54S only extends through first side face 20 to primary channel 52S through a lower portion of first side face 20 that is spaced apart from top face 16. Access channel 54S extends through bottom face 18 from first side face 20 to primary channel 52S but does not extend through top face 16 from first side face 20 to primary channel 52Q.
In the prior embodiments, each of bodies 12A-12C are described as having a square or rectangular transverse cross section that includes sides 16, 18, 20 and 22 as previously discussed. In alternative embodiments, however, each body 12 can have a variety of alternative transverse cross sectional configurations. For example, depicted in FIGS. 16-20 are end views or cross sectional side views of alternative bodies 12 that can be used as part of any of the edging forms previously or later described herein. Like elements between the bodies described in FIGS. 16-20 and bodies 12A-12C are identified by like reference characters. For example, depicted in FIG. 16 is a body 12D having bottom face 18 and first side face 20. However, top face 16 and second side face 20 have been replaced with a single curved top face 16A that extends from first side face 20 to bottom face 16. As such, body 12D has an end view or a transverse cross section with the configuration of a quarter circle. In this embodiment, channels 32 and 50 extend through body 12D from top face 16A to bottom face 18 and extend through first side face 20 as previously discussed above.
In FIG. 17, body 12E includes has a top face 16E and opposing bottom face 18 and opposing side faces 20 and 22E. In this embodiment, however, second side face 22E is shorter than first side face 20 and top face 16E extends in a curve from first side face 20 to second side face 22E. In a modified version, top face 16E could be flat, rather than curved, as designated by dash line 60. Body 12F in FIG. 18 is similar to the body 12D depicted in FIG. 16 except that instead of having a curved top face 16D, body 12F has a flat top face 16F that extends from first side face 20 to bottom face 18. As such, body 12F has an end view or a transverse cross section with the configuration of a triangle.
In FIG. 19, body 12G includes has a top face 16G and opposing bottom face 18G and opposing side faces 20G and 22. In this embodiment, although top face 16G and bottom face 18G are disposed in parallel alignment, bottom face 18G is short than top face 16G. As such, first side face 20G outwardly slopes from bottom face 18G to top face 16G. Body 12H shown in FIG. 20 is similar to the embodiment in FIG. 19 except that top face 16H is shorter than bottom face 18H so that first side face 20H slopes inwardly as it extends from bottom face 18H to top face 16H.
All of the above bodies 12D-12H are configured so that channels 32 and 50 extend therethrough from top face 16 to bottom face 18. Where channels 50 are formed, access channels 54 extend from first side face 20 to primary channels 52. All of previously discussed channels 50, primary channels 52 and access channel 54 and the alternatives thereof as discussed herein can be used with each of bodies 12D-12H.
Depicted in FIG. 21 is an edging form 10B1 having a body 12B1. Body 12B1 is in the form of a circular ring and has substantially the same configuration as body 12B depicted in FIGS. 5-8. Like elements between body 12B and body 12B1 are identified by like reference characters and thus body 12B1 includes faces 16, 18, 20 and 22 and bounds opening 44 extending therethrough. Body 12B1 can be made of the same materials and have the same configurations, dimensions, and alternatives as previously discussed herein with regard to body 12B. However, one of the distinctions between body 12B and body 12B1 is that in contrast to having channels 32 extending therethrough which are completely encircled by body 12B, body 12B1 has channels 50 extending therethrough which include primary channel 52 extending from top face 16 to bottom face 18 and access channel 54 that extends from first side face 20 to primary channel 52. Body 12B1 can be formed with any of the channels 50 or alternatives discussed herein, such as shown in FIGS. 11-15, and can be formed with any of the transverse cross sectional configurations discussed herein, such as in FIGS. 16-20. The spacing and number of channels 50 on body 12B1 can be the same as the previously discussed spacing and number of channels 32 on body 12A.
Although body 12B1 can be formed as a single, continuous, integral loop, in the depicted embodiment of FIG. 21, a slot 64 extends through body 12B1 from exterior side face 20 to interior side face 22 so that body 12B1 does not form a single, continuous, integral loop. That is, although body 12B1 has a circular ring shaped configuration with inside diameter D, body 12B1 has opposing end faces 28 and 30 that bound slot 64 therebetween. Slot 64 can be made as part of the manufacturing process. That is, in one embodiment, the interior opening 44 can be cut out with a blade or wire. For example, body 12B1 can be formed from a block of prefabricated polymeric foam or other desired material. Exterior side face 20 can be formed by using a blade or wire to cut the block into a circular configuration.
When using a saw, such as a scroll saw or band saw, the blade or wire then cuts laterally into the bock, forming slot 64, and is then used to cut out interior opening 44. The blade or wire can then pass back out of interior opening 44 through slot 64. If desired, opposing end faces 28 and 30 can be secured together such as by welding, adhesive, fastener, tape or the like so as to form a continuous loop. In other embodiments where body 12B1 is not formed by using a scroll saw or band saw, body 12B1 could be formed without the formation of slot 64. Similarly, previously discussed body 12B could be formed with slot 64 extending therethrough.
Depicted in FIG. 22 is a further alternative embodiment of an edging form 10B2 having a body 12B2 and incorporating features of the present invention. Body 12B2 is similar to body 12B1 except that body 12B2 has a rectangular looped configuration rather than a circular ring configuration. Like elements between body 12B2 and 12B1 are identified by like reference characters. Specifically, body 12B2 is in the form of a square or rectangular loop having top face 16 and opposing bottom face 18 that extend between exterior side face 20 and opposing interior side face 22. Spaced apart channels 50 extend through body 12B2 from top face 16 to bottom face 18 and also extend through at least a portion of exterior side face 20.
Exterior side face 20 forms an outer perimeter having a square or rectangular configuration while interior side face 22 forms an inner perimeter that bounds an opening 44A extending through body 10B2. Opening 44A can be square or rectangular and will commonly have a maximum width of at least or less than 10 cm, 15 cm, 20 cm, 25 cm, 30 cm, 40 cm, 50 cm or in a range between any two of the foregoing values. Opening 44A can also have a minimum width of at least or less than 5 cm, 10 cm, 15 cm, 20 cm, 25 cm, 30 cm or in a range between any two of the foregoing values. Body 12B2 is configured for encircling a rectangular air vent but can be used for encircling any type of structure or opening. Body 12B2 can be made of the same materials as previously discussed herein with regard to body 12B. Furthermore, body 12B2 can be formed with any of channels 50 or alternatives discussed herein, such as shown in FIGS. 11-15, and can be formed with any of the transverse cross sectional configurations discussed herein, such as in FIGS. 16-20. The spacing and number of channels 50 can be the same as the previously discussed spacing and number of channels 32 on body 12A.
A slot 64A extends through body 12B2 from exterior side face 20 to interior side face 22 and is bounded by opposing ends faces 28A and 30A. As previously discussed with regard to body 12B1, slot 64A can be produced by a blade or wire while removing material that forms opening 44A. However, in contrast to slot 64 which is linear, slot 64A has a substantially Z-shaped configuration which results in end face 28A forming a protrusion 66 projecting into end face 30A adjacent to interior side face 22 and end face 30A forming a protrusion 68 projecting into end face 28A adjacent to exterior side face 20. Protrusions 66 and 68 overlap so that if a lateral outside force is applied to exterior side face 20, such as when a self-leveling flooring material is pushing against exterior side face 20, protrusion 68 pushes against or is supported by protrusion 66 so as to help prevent the inward flexing or moving of body 12B2 adjacent to slot 64A. Such flexing or movement of body 12B2 could enable leaking of self-leveling flooring material into opening 44A through slot 64A which defeats the purpose of body 12B2. Slot 64 on body 12B1 can also be formed having the configuration of slot 64A to help prevent the flexing or bending of form 12B1. In other embodiments, body 12B2 can be formed without slot 64A so that body 12B2 forms a single, continuous integral loop. In still other embodiments, opposing ends faces 28A and 30A can be secured together such as by welding, adhesive, tape, fasteners or the like.
In contrast to having a circular or rectangular opening 44/44A, it is appreciated that other edging forms can also be produced in the form of a loop that encircles an opening having other configurations. For example, the opening could be triangular, oval, polygonal, irregular, or the like.
Turning to FIGS. 23-25, a method of using the various edging forms described herein and having channels 50 will now be discussed. Initially, as depicted in FIG. 23, a plurality of separate forms 10C are secured to an existing subfloor 70 so that edging forms 10C encircle an area 72 on which an underlayment, or other self-leveling floor, is to be formed. Edging forms 10C are positioned so that first side face 20 and access channels 54 of each body 12 C face area 72. Previously discussed edging forms 10C, 10B1 and 10B2 were described as not including adhesive strip 14 on bottom face 20. When produced in this configuration, an adhesive is manually applied to bottom face 20 at the time of placing forms 10C. The adhesive can comprise a sealant, caulking, construction adhesive, glue, adhesive tape, or other conventional sealants or adhesives. The adhesive commonly comes in a caulking tube and can be easily applied using a caulking gun. For example, one or more beads of caulk can be placed along the length of bottom face 20. In other embodiments, the adhesive can be applied by squeezing a tube, spraying, painting, spreading, or using some other applicator or method. Once the adhesive is applied to body 12C, body 12C is pressed against subfloor 70 so that the adhesive secures body 12C to subfloor 70 and forms a liquid tight seal therebetween. Although typically less convenient, it is also possible to apply the adhesive directly to subfloor 70 and then press body 12C onto the adhesive so as to secure body 12C to subfloor 70.
In alternative embodiments, edging forms 10C, 10B1 and 10B2 can initially be produced with and thus further comprise adhesive strip 14 formed on bottom face 20. The alternatives types, configurations, methods of attachment and use of adhesive strip 14, i.e., adhesive strip 14A and 14B, previously discussed herein are all applicable to use with forms 10C, 10B1 and 10B2 and the alternatives thereof. Where edging forms 10C include adhesive strip 14, edging forms 10C can be attached by simply removing cover strip 40 and then pressing adhesive strip 14 against subfloor 70 so that forms 10C are secured to subfloor 70 and a liquid tight seal is formed between each body 12C and subfloor 70.
As needed, edging forms 10C are cut to length and the intersecting ends are abutted at the corners to prevent leaking of the self-leveling flooring material thereat. To further help prevent unwanted leaking at the corners, an adhesive, such as discussed above, can be applied between the abutting faces to secure them together in a liquid tight engagement. Where one side of area 72 is longer than an edging form 10C, two or more edging forms 10C can be abutted end to end to form a continuous side. Again, an adhesive can be used between the abutted end faces to secure them together in a liquid tight engagement.
As depicted in FIG. 23, forms 10C are placed so that area 72 is completely encircled or bounded by forms 10C. However, this may not always be necessary. For example, in some cases an existing wall, footing, board, or other structure may form part of the perimeter boarder for area 72. In that case, edging forms 10C can be butted against the existing structure so that edging forms 10C only partially bound area 72 but all of area 72 is bounded by some structure. For example, in one method of use one or more edging forms 10C are placed across a doorway to a room while the remainder of the subfloor of the room is bounded by the walls of the room. Thus, the self-leveling flooring material can be applied over the subfloor of the room with edging form(s) 10C only extending across the doorway.
In still other applications, based on the slope of existing subfloor 70 or the intended application of the self-leveling flooring material, all of area 72 may not need to be bounded. For example, an uphill end of area 72 may not need to be bounded by an edging form 10C or other structure where the self-leveling flooring material will naturally not flow past the uphill end because of the slope of area 72.
In addition to bounding the perimeter of area 72, as necessary, locations within area 72 that need to be protected from the self-leveling flooring material or where it is desired to prevent the unwanted flowing of self-leveling flooring material are bounded or sealed off by an edging form. As previously discussed, examples of such structures or openings to be sealed off from the flooring material can include toilet flanges, air vents, wiring, outlets or other openings. As shown in FIG. 23, one or more forms 10B1 can be secured to subfloor 70 within area 72 so that the structure or opening to be sealed off from the self-leveling flooring material is disposed within opening 44 thereof. Form(s) 10B1 can be secured to subfloor 70 using the same methods as previously discussed above with regard to form 10C. During attachments to subfloor 70, opposing end faces 28 and 30 (FIG. 21) of edging form 10B1 are abutted together and can be sealed together to prevent leaking of self-leveling flooring material therethrough. In contrast to or in combination with the use of edging forms 10B1, one or more edging forms 10B2 could also be secured to subfloor 70 within area 72. In yet other applications, in contrast to or in combination with the use forms 10B1 and/or forms 10B2, areas, openings or structures within area 72 can be sealed from the self-leveling flooring material by cutting smaller sections of form 10C and securing them around the area, opening or structure. This can be done in the same way, as discussed above, that forms 10C are used to bound/seal area 72 except that first side face 20 and access channels 54 now face outward toward area 72.
Turning to FIG. 24, with the edging forms properly positioned, a self-leveling flooring material 76 is dispensed onto area 72 until self-leveling flooring material 76 reaches a desired level within area 72 for the underlayment. The dispensing of flooring material 76 can be accomplished by pouring, pumping, draining, dumping or any other dispensing method. As flooring material 76 is dispensed into area 76, flooring material 76 will naturally flow under the force of gravity into a level surface. As flooring material 76 reaches first side face 20, the edging forms prevent flooring material 76 from flowing through or under the edging forms. Accordingly, as additional quantities of flooring material 76 are dispensed into area 72, the depth of flooring material 76 increases and thus the level of flooring material rises along each first side face 20. As flooring material 76 reaches each first side face 20, flooring material 76 flows through access channels 54 and into primary channels 52. Thus, once the dispensing of flooring material 76 has stopped, the level of flooring material 76 within access channels 54 and primary channels 52 is equal to the level of flooring material 76 within area 72.
Once flooring material 76 has covered area 72 to a desired level, flooring material 76 is left to cure into a hardened state, thereby forming an underlayment 78. The edging forms are typically sized so that at least some of each edging form projects up above the top surface of underlayment 78. That is, one of the benefits of the present invention is that it is not necessary to initially design or cut the edging forms prior to dispensing of flooring material 76 so that the edging forms will match the height of the dispensed flooring material 76. Rather, once flooring material 76 has cured, the excess height of the edging forms extending above the top surface of flooring material 76 is removed. This can be accomplished by using a knife, saw blade or other trimming or cutting machines to remove the excess material. FIG. 24 shows flooring material 76 cured to form underlayment 78 and a portion of the edging forms being cut away so that a top surface 96 of remaining portion 98 of the edging forms is flush with the top surface of underlayment 78. Flooring material 76 being received and cured within channels 50 is also shown.
Producing edging forms with channels 50 that communicate with area 72 through first side face 20 achieves a number of benefits. For example, as discussed above, because channels 50 communicate with area 72 through first side face 20, channels 50 automatically fill with the same level of flooring material 76 as area 72. As such, there is no need to separately fill channels 50 with a fill material. Furthermore, having channels 50 filled to a desired height with cured flooring material 76 makes it easy to remove the excess amount of the edging forms. This is because the top surface of the cured flooring material 76 within channels 50 acts as a flat, horizontal guide along which a saw blade or knife can easily and smoothly move for cutting away the excess edging forms. In addition, as previously discussed, having flooring material 76 cured within channels 50 facilitates a secure interlocking between the cured underlayment 78 and the edging forms. As such, there is no unwanted movement of the edging forms relative to the cured underlayment 78 during cutting away of the excess edging forms, during application of the floor covering on top of underlayment 78, or after the floor covering has been applied.
Finally, channels 50 filled with cured flooring material 76 act as vertical support columns within the edging forms so that the combined edging forms and columns have sufficient compressive strength to enable the flooring material to be applied directly over the edging forms. That is, there is no need to remove the edging forms after flooring material 76 has cured. Other benefits also exist.
As depicted in FIG. 25, once all of the excess of edging forms has been removed so that the remaining portions 98 of the edging forms are now flush with underlayment 78, a floor covering can now be positioned over underlayment 78. For example, tiles 80 can now be laid and secured on top of both the edging forms and underlayment 78. Again, although the edging forms many have initially been too fragile to withstand the compressive applied through the floor covering, because of the increased compressive strength resulting from the combined edging forms and flooring material 76 cured within channels 50 thereof, tiles 80 and other floor covering can now be safely laid directly on top of the edging forms.
In addition to tile 80, carpet 82 can also be laid on top of underlayment 78 and the edging forms. Specifically, a carpet tack strip 84 can be nailed on top of edging forms 10C. Again, although edging forms 10C may not have independently been sufficiently strong to engage and support track strip 84, because of the synergistic benefits of having channels 50 filled with cured flooring material 76, the combined edging forms 10C and flooring material 76 provide sufficiently structural strength to enable tack strip 84 to be directly nailed on top of edging forms 10C. Capet 82 can then be laid over the top of underlayment 78 and secured to tack strips 84 using conventional techniques. Other flooring such as vinyl, linoleum, or wood flooring can also be secured over the top of underlayment 78 and the edging forms.
Turning to FIG. 26, a further alternative edging form 10C1 is provided. Like elements between edging form 10C and edging form 10C1 are identified by like reference characters. Edging form 10C1 includes body 12 C having channels 50 as previous discussed with regard to form 10C. Body 12C can be made of the same materials and have all of the same alternatives as previously discussed. However, form 10C1 also includes a backing strip 88 secured to and extending along second side face 22. Backing strip 88 is thinner than and more flexible than body 12C. For example, backing strip 88 can be bent over an angle of at least 90°, 180°, 270°, or 360° without failure and can also be rolled into a tube having a diameter less than 15 cm, 10 cm, or 5 cm without failure. Backing strip 88 is commonly made from a polymeric material and can comprise a polymeric film, sheet or tape. Backing strip 88 is typically attached by an adhesive but can also be attached by over molding, welding, fasteners or the like.
The function of backing strip 88 is to retain body 12C connected together when form 10C1 is bent around a radius or curvature that would typically result in the cracking and breaking/failure body 12C. For example, when body 12C is formed of a polystyrene foam, although body 12C would have some flexibility, it may fail by cracking if bent around an outside corner or around a small column. By having backing strip 88 secured to second side face 22, if edging form 10C1 is bent around a corner or small radius, as shown in FIG. 27, a crack 90 may be formed extending from each channel 50 to second side face 22 and backing strip 88. However, backing strip 88 will maintain body 12C secured together and will also act as a dam to stop flooring material 76 that may passes through cracks 90. If desired, an adhesive can be applied to a back side 92 of backing strip 88 for securing edging form 10C1, and particularly second side face 22, to an adjacent wall, column or other structure against which edging form 10C1 is being placed.
Depicted in FIG. 28 is another alternative embodiment of an edging form 10C2. Edging form 10C2 includes a body 12C2 where like elements between bodies 12C and 12C2 are identified by like reference characters. Body 12C2 is substantially the same as body 12C except that a plurality of spaced apart second channels 50 are also formed extending through body 12C2 and communicating with second side face 22. Second channels 50 communicating with second side face 22 can have the same configuration and alternatives as previously discussed with channels 50 communicating with first side face 20. Edging form 10C2 can be used as an expansion joint where large self-leveling floors are being poured. For example, as shown in FIG. 29, one or more edging forms 10C2 can be positioned within area 72 to divide area 72 into two sub-areas 72A and 72B. In this configuration, both of the opposing side faces of edging forms 10C2 are freely and openly exposed. Flooring material 76 can then be dispensed into each of sub-areas 72A and 72B so that flooring material 76 flows into channels 50 on both sides of edging form 10C2. Once flooring material 76 is cured, the excess portion of edging forms 10C and 10C2 above the level of flooring material 76 is removed and floor covering is applied in the same manner as previously discussed.
By using edging forms 10C2 as expansion joints, large self-leveling floors can be formed with minimal cracking due to expansion and contraction. As needed, edging forms 10C2 can be used to divide area 72 into as many sub-areas as needed.
Depicted in FIGS. 30 and 31 is still another alternative embodiment of an edging form 10C3. Edging form 10C3 includes a body 12C3 where like elements between bodies 12C and 12C3 are identified by like reference characters. Body 12C3 is similar to body 12C except that body 12C3 has a substantially L-shaped transverse cross section. Specifically, body 12C3 includes a top face 16J and opposing bottom face 18 that extend between a first side face 20J and second side face 22. In this embodiment, a notch 111 is formed on the top face along the length of body 12C3 so as to form the substantially L-shaped configuration. More specifically, top face 16J includes a first lateral portion 110 extending from second side face 22, a second lateral portion 112 extending from first side face 20J and a riser portion 114 extending between first lateral portion 110 and second lateral portion 112. In the depicted embodiment, first lateral portion 110 is disposed at an elevation above second lateral portion 112 when bottom face 18 is horizontally disposed. First lateral portion 110 and second lateral portion 112 are depicted as being disposed in parallel planes that both orthogonally intersect riser portion 114. That is, riser portion 114 can extend vertically up from second lateral portion 112 to first lateral portion 110 when bottom face 18 is horizontally disposed and can also extend orthogonal from bottom face 18.
In alternative embodiments, first lateral portion 110 and second lateral portion 112 need not be disposed in parallel planes. For example, one or both of portions 110 and 112 can be sloped relative to the other and/or relative to bottom face 18. For example, as shown in FIG. 31, in one embodiment, second lateral portion 112 can upwardly slope toward riser portion 114 as identified by broken line 116. Likewise, riser portion 114 can be sloped relative to first lateral portion 110 and/or second lateral portion 112.
In an alternative embodiment depicted in FIG. 32, body 12C3 again has a substantially L-shaped transverse cross section and includes top face 16J, bottom face 18 and side faces 20J and 22. In this embodiment, however, top face 16J includes first lateral portion 110, second lateral portion 112 and a riser portion 114A. In contrast to riser portion 114 which is disposed in a single plane, riser portion 114A comprises an angled shoulder portion 118 that upwardly slopes from second lateral portion 112 and an extension portion 120 that extends between shoulder portion 118 and first lateral portion 110. The formation of shoulder portion 118 reinforces body 12C3 at the intersection of second lateral portion 112 and riser portion 114A to help minimize undesired failure thereat. Shoulder portion 118 typically intersects second lateral portion 112 at an outside angle in a range between 120° and 150° but other angles can also be used. In the embodiment depicted, portions 118 and 120 are linear. However, in other embodiments, one or both of portions 118 and 120 could be curved. Furthermore, in contrast to riser portion 114A being formed in two connecting portions, riser portion 114A could also be formed with three, four, or more interconnected portions.
In still another alternative embodiment depicted in FIG. 33, body 12C3 again has a substantially L-shaped transverse cross section and includes top face 16J, bottom face 18 and opposing side faces 20J and 22. In this embodiment, however, top face 16J includes first lateral portion 110 and a riser portion 114B. Riser portion 114B has a concave curvature that extends from first side face 20J to first lateral portion 110. This configuration again reinforces body 12C3 so as to prevent failure along riser portion 114B.
Returning to FIG. 30, a plurality of spaced apart channels 50 extend through body 12C3 from top face 16J to bottom face 18 so as to communicate with first side face 20J. More specifically, channels 50 extend through body 12C3 from second lateral portion 112 to bottom face 18 and communicate with or extend through first side face 20J. As previously discussed, each channel 50 includes primary channel 52 which is extending through body 12C3 from second lateral portion 112 to bottom face 18 and access channel 54 that extends from first side face 20J to primary channel 52. All of the configurations and alternatives as previously discussed with regard to channels 50, primary channels 52 and access channel 54 are applicable to and can be incorporated into the embodiments and alternatives discussed with regard to FIGS. 30-33. For example, in the depicted embodiment, primary channel 52 is shown as having a triangular transverse cross section. In other embodiments, primary channel 52 and access channel 54 can also have the configurations as shown or discussed with regard to the embodiments in FIGS. 9-15. When applied to the embodiment depicted in FIG. 33, channels 50 and primary channels 52 extend through riser portion 114B to bottom face 18 while access channels 54 extend from first side face 20J to primary channels 42. Other properties previously discussed herein with regard to the bodies of other edge forms are also applicable to body 12C3. Such properties include but are not limited to lengths; dimensions; number, spacing and configuration of channels 50; material composition; material properties; and structural properties.
Edging forms 10C3 are used in substantially the same way as the edging forms previously discussed and the prior use disclosure is applicable to edging forms 10C3. For example, once edging forms 10C3 are secured to a subfloor and the self-leveling flooring material is dispensed, the self-leveling flooring material flows to and rises against first side face 20J. In so doing, the self-leveling flooring material also automatically flows into channels 50 as previously discussed. Once the self-leveling flooring material hardens into a solid floor or underlayment, the portion of body 12C3/edging form 10C3 projecting above the underlayment is cut flush with the top surface of the underlayment using a saw or other tool, as previously discussed. The remaining process of applying a covering, as previously discussed, can then be completed.
One of the benefits of using edging form 10C3 having the substantially L-shaped configuration, is that in some situations the self-leveling flooring material will rise above first side face 20J so as to overflow second lateral portion 112 and flow against riser portion 114. As a result, once the self-leveling flooring material has hardened to form the underlayment, the portion of edging forms 10C3 that projects above the underlayment and that needs to be removed has a decreased thickness. That is, the portion projecting above the underlayment has a thickness that extends from riser portion 114, 114A or 114B to second side face 22 as opposed to between first side face 20J and second side face 22. As such, by using edging forms 10C3 in these situations, it is significantly easier and less time consuming to remove the portion of edging forms 10C3 that projects above the underlayment. Furthermore, there is less waste and less clean up during use and a lower material cost in production.
In other alternatives, it is also appreciated that the circular, square, rectangular, and other polygonal edging forms discussed herein, such as edging forms 10B1, 10B2, 10C1 and the like previously discussed with regard to FIGS. 21-27, and alternatives discussed therewith, can also be formed having the substantially L-shaped configurations as discussed above with regard to FIGS. 30-33.
Select embodiments of edging forms and related methods described herein can achieve a number of unique benefits. For example, in some embodiments, the edging forms provide an easy and efficient way for bounding an area where a self-leveling floor is to be formed and/or sealing off areas, openings and structures where it is desired to prevent the flow of self-leveling flooring material. As a result, in some embodiments and methods a consistently level and uniform floor can be produced with decreased labor, minimal waste of material and/or minimal clean up. Furthermore, some of the edging forms are inexpensive and easy to produce, handle, cut and/or place, especially when made of a polymeric form. In addition, in some applications the inventive edging forms can be left in place with the floor covering being placed on top of them, thereby avoiding the time and mess associated with needed removal. Other benefits and advantages also exist.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

What is claimed is:

1. A method for forming a self-leveling floor comprising:

positioning an edging form on or adjacent to a subfloor so as to at least partially bound an area on which a self-leveling floor is to be formed, the edging form comprising:

a body having a top face, a bottom face and a first side face that extends between the top face and the bottom face; and

a plurality of spaced apart channels extending entirely through the body from the top face to the bottom face, each of the plurality of channels also passing through at least a portion of the first side face; and

dispensing a self-leveling flooring material into the area in which the self-leveling floor is to be formed so that the self-leveling flooring material flows against the first side face of the body and into each of the plurality of channels.

2. The method as recited in claim 1, further comprising allowing the self-leveling flooring material to harden into a solid floor while the self-leveling flooring material is disposed against the first side face and is disposed within each of the plurality of channels of the edging form.

3. The method as recited in claim 1, wherein the positioning step comprises securing the edging form to the subfloor.

4. The method as recited in claim 3, wherein the step of securing comprises applying an adhesive to the bottom face of the body of the edging form.

5. The method as recited in claim 1, wherein each of the plurality of channels comprise:

a primary channel that extends entirely through the body from the top face to the bottom face and is spaced apart from the first side face; and

an access channel that extends from the first side face to the primary opening, wherein during the dispensing step, the self-leveling flooring material flows through each access channel and into the corresponding primary channel.

6. The method as recited in claim 5, wherein the access channel comprises a slot that is narrower than the primary channel.

7. The method as recited in claim 2, further comprising removing a portion of the body projecting above the solid floor so that a remaining portion of the body has a top face that is flush with a top face of the solid floor.

8. The method as recited in claim 7, further comprising applying a flooring covering over at least a portion of the top face of the solid floor and over at least a portion of the top face of the remaining portion of the body.

9. The method as recited in claim 1, wherein the top face of the body comprises:

a first lateral portion;

a second lateral portion spaced apart from the first lateral portion, the first lateral portion being at an elevation above the second lateral portion when the bottom face of the body is positioned on the subfloor; and

a riser portion upwardly extending from the second lateral portion to the first lateral portion when the bottom face is positioned on the subfloor.

10. The method as recited in claim 9, wherein the self-leveling flooring material is dispensed into the area in which the self-leveling floor is to be formed so that the self-leveling flooring material flows over the second lateral portion of the top face and against the riser portion of the top face.

11. The method as recited in claim 10, further comprising:

allowing the self-leveling flooring material to harden into a solid floor while the self-leveling flooring material is disposed against the riser portion of the body; and

removing a portion of the body projecting above the solid floor so that a remaining portion of the body has a top face that is flush with a top face of the solid floor, the removed portion of the body comprising at least a portion of the riser portion and the first lateral portion.

12. The method as recited in claim 9, wherein the plurality of spaced apart channels extend entirely through the body from the second lateral portion to the bottom face.

13. The method as recited in claim 9, wherein the body further comprises a second side face opposite the first side face that extends between the top face and the bottom face, the method further comprising securing the second side face to a structure upstanding from the subfloor.

14. The method as recited in claim 9, wherein the body further comprises a second side face opposite the first side face that extends between the top face and the bottom face, a backing being secured along the second side face, the backing being more flexible than the body and being made of a different material than the body.

15. The method as recited in claim 1, wherein the body is comprised of a polymeric foam.

16. The method as recited in claim 15, wherein the polymeric foam comprises a polystyrene foam.

17. The method as recited in claim 1, wherein the edging form is positioned so that the edging form encircles the area in which the self-leveling floor is to be formed, the first side face of the body facing the area in which the self-leveling floor is to be formed.

18. The method as recited in claim 1, wherein the positioned edging form forms a continuous loop that encircles a second area that is separated by the edging form from the area in which the self-leveling floor is to be formed, the first side face of the body facing away from the second area.

19. A method for forming a self-leveling floor comprising:

a plurality of spaced apart channels extending entirely through the body from the top face to the bottom face;

dispensing a self-leveling flooring material so that the self-leveling flooring material flows into the area in which the self-leveling floor is to be formed and against the first side face of the body and flows into the plurality of spaced apart channels; and

allowing the self-leveling flooring material to harden into a solid floor while the self-leveling flooring material is disposed against the first side face and is disposed within each of the plurality of channels.

20. The method as recited in claim 19, wherein each of the plurality of channels also pass through at least a portion of the first side face of the body, the self-leveling flooring flowing into the plurality of channels from the area in which the self-leveling floor is to be formed.