WO2007142841A2 - Transition universelle de décollement de revêtement de sol - Google Patents

Transition universelle de décollement de revêtement de sol Download PDF

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Publication number
WO2007142841A2
WO2007142841A2 PCT/US2007/012303 US2007012303W WO2007142841A2 WO 2007142841 A2 WO2007142841 A2 WO 2007142841A2 US 2007012303 W US2007012303 W US 2007012303W WO 2007142841 A2 WO2007142841 A2 WO 2007142841A2
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WO
WIPO (PCT)
Prior art keywords
molding
blade
core
tool
kit
Prior art date
Application number
PCT/US2007/012303
Other languages
English (en)
Other versions
WO2007142841A3 (fr
Inventor
Oliver Stanchfield
Sven Kornfalt
Original Assignee
Pfleiderer Scheiz Ag
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Pfleiderer Scheiz Ag filed Critical Pfleiderer Scheiz Ag
Publication of WO2007142841A2 publication Critical patent/WO2007142841A2/fr
Publication of WO2007142841A3 publication Critical patent/WO2007142841A3/fr

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F19/00Other details of constructional parts for finishing work on buildings
    • E04F19/02Borders; Finishing strips, e.g. beadings; Light coves
    • E04F19/06Borders; Finishing strips, e.g. beadings; Light coves specially designed for securing panels or masking the edges of wall- or floor-covering elements
    • E04F19/062Borders; Finishing strips, e.g. beadings; Light coves specially designed for securing panels or masking the edges of wall- or floor-covering elements used between similar elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23DPLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D45/00Sawing machines or sawing devices with circular saw blades or with friction saw discs
    • B23D45/003Sawing machines or sawing devices with circular saw blades or with friction saw discs for particular purposes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23DPLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D45/00Sawing machines or sawing devices with circular saw blades or with friction saw discs
    • B23D45/10Sawing machines or sawing devices with circular saw blades or with friction saw discs with a plurality of circular saw blades
    • B23D45/102Sawing machines or sawing devices with circular saw blades or with friction saw discs with a plurality of circular saw blades some of which turn about perpendicular axes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B26HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26DCUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D3/00Cutting work characterised by the nature of the cut made; Apparatus therefor
    • B26D3/001Cutting tubes longitudinally
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F11/00Stairways, ramps, or like structures; Balustrades; Handrails
    • E04F11/02Stairways; Layouts thereof
    • E04F11/104Treads
    • E04F11/16Surfaces thereof; Protecting means for edges or corners thereof
    • E04F11/163Protecting means for edges or corners
    • E04F11/166Protecting means for edges or corners with means for fixing a separate edging strip
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F19/00Other details of constructional parts for finishing work on buildings
    • E04F19/02Borders; Finishing strips, e.g. beadings; Light coves
    • E04F19/06Borders; Finishing strips, e.g. beadings; Light coves specially designed for securing panels or masking the edges of wall- or floor-covering elements
    • E04F19/061Borders; Finishing strips, e.g. beadings; Light coves specially designed for securing panels or masking the edges of wall- or floor-covering elements used to finish off an edge or corner of a wall or floor covering area
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F19/00Other details of constructional parts for finishing work on buildings
    • E04F19/02Borders; Finishing strips, e.g. beadings; Light coves
    • E04F19/06Borders; Finishing strips, e.g. beadings; Light coves specially designed for securing panels or masking the edges of wall- or floor-covering elements
    • E04F19/065Finishing profiles with a T-shaped cross-section or the like
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F19/00Other details of constructional parts for finishing work on buildings
    • E04F19/02Borders; Finishing strips, e.g. beadings; Light coves
    • E04F19/06Borders; Finishing strips, e.g. beadings; Light coves specially designed for securing panels or masking the edges of wall- or floor-covering elements
    • E04F19/065Finishing profiles with a T-shaped cross-section or the like
    • E04F19/066Finishing profiles with a T-shaped cross-section or the like fixed onto a base profile by means of a separate connector
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F19/00Other details of constructional parts for finishing work on buildings
    • E04F19/02Borders; Finishing strips, e.g. beadings; Light coves
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture

Definitions

  • the invention is an integral multi-purpose structure which can be separated into various flooring transitions such as T-moldings, hard surface reducers and end moldings.
  • Hard surface floors such as wood or laminate flooring
  • this type of flooring is assembled by providing a plurality of similar panels.
  • the differing types of panels that have developed may have differing widths and thicknesses.
  • a laminate floor (often referred to as a "floating floor") abuts another hard surface, such as a resilient surface (such as vinyl), tile or another laminate surface, a ceramic surface, or other surface, e.g., natural or engineered wood flooring.
  • a laminate floor often referred to as a "floating floor”
  • a resilient surface such as vinyl
  • tile or another laminate surface such as a ceramic surface, or other surface, e.g., natural or engineered wood flooring.
  • transition moldings are often used to create a transition between the same.
  • a problem is encountered, however, when flooring materials that are dissimilar in shape or texture are used. For example, when a hard floor is placed adjacent a carpet, problems are encountered with conventional edge moldings placed therebetween. Such problems include difficulty in covering the gap that may be formed between the floorings having different height, thickness or texture.
  • the invention also provides a method by which the number of moldings can be reduced while still providing all the functions necessary of different styles of transition moldings.
  • the invention is a joint cover assembly for covering a gap between edges of adjacent floor elements, such as floor panels of laminate or wood, although it may also be used as a transition between a laminate panel and another type of flooring, e.g., carpet, vinyl, ceramic, and wood.
  • the assembly typically includes a body having a foot positioned along a longitudinal axis, and a first arm or member extending generally perpendicularly from the foot.
  • the assembly may include a second arm also extending generally perpendicular from the foot.
  • the outward-facing surface of the assembly may be formed as a single, unitary, monolithic surface that covers both the first and second arms.
  • This outward-facing surface may be decorated, for example, with a laminate or a paper, such as a monochromatic or patterned decor, impregnated with a resin, in order to increase its aesthetic value, to match, blend or contrast with the floor panels.
  • the outward facing surface has incorporated therein at least one material to increase its abrasion resistance, such as at least one type of hard particles of silica, alumina, diamond, silicon nitride, aluminum oxide, silicon carbide, cerium oxide and similar hard particles, preferably having a Moh's hardness of at least approximately 6.
  • the assembly is preferably provided with a securing means, such as a clamp or track, to prevent the assembly from moving out of position once assembled.
  • the securing means is a clamp, designed to grab the foot.
  • the clamp includes a groove into which the foot is inserted.
  • the clamp or track may be joined directly to a subsurface below the floor element, such as a subfloor, by any conventional means, such as a nail, screw or adhesive.
  • a shim may also be placed between the foot and the subfloor to provide for height adjustments to allow the assembly to be used in various situations.
  • the shim may be positioned on the underside of the clamp; however, if a clamp is not used, the shim may be positioned between the foot and the subfloor.
  • the shim may be adhered to either the foot or subfloor using an adhesive or a conventional fastener, e.g., nail or screw.
  • the assembly is typically formed from one of a variety of materials, such as a core covered with carpet, laminate, ceramic or wood tile, linoleum, turf, metal, paper, natural wood or wood veneer, vinyl, ceramic or composite finish, or any type of surface covering, while the core is generally formed from wood, engineered wood, fiberboard, such as high density fiberboard (HDF) or medium density fiberboard (MDF), flaxboard, plastics, or other structural material, such as metals (e.g., aluminum, copper, brass, alloys thereof and stainless steel) or composites, and at least over a portion of the surface thereof may be covered with a foil (metal, plastic, etc.), cork, a plastic, a paper, a decor or a laminate to match or contrast with the first and second arms, or other materials, such as those discussed by U.S. Patent Nos. 6,860,074 and 6,898,911.
  • Preferred plastics include extrudable and/or moldable thermosetting and thermoplastic resins, the latter including high density o
  • An adhesive such as a glue, a microballoon adhesive, contact adhesive, or chemically activated adhesive, including a water-activated adhesive, may be also positioned on any of the pieces of the assembly to either hold the assembly together or in place.
  • an adhesive is not necessary, but may enhance or supplement the fit and positioning of the assembly over the gap between the floor elements. Additionally, the adhesive may assist in creating a more air-tight or moisture-tight joint.
  • the assembly may be used in other non-coplanar areas, such as the edge between a wall and a floor, or even between the run and rise of stairs.
  • the assembly may include the first and second arms, and foot as described above, but instead of transitioning between two floor elements placed in the same plane, may form the joint between the horizontal and vertical surfaces of a single stair element.
  • the inventive assembly may be used for positioning between adjacent tongue-and-groove panels; in this regard, the assembly functions as a transition molding, which provides a cover for edges of similar or dissimilar surfaces. For example, when installing floors in a home, the assembly could be used to provide an edge between a hallway and a bedroom, between a Kitchen and living or bathroom, or any areas where distinct flooring is desired. Additionally, the assembly may be incorporated into differing types of flooring, such as wood, tile, linoleum, cork, carpet, or turf.
  • the invention also is drawn to an inventive method for covering a gap between adjacent panels of a generally planar surface.
  • the method includes multiple steps, including, inter alia, manipulating a generic element by removing a part of the generic element to produce one or more moldings, and thereafter, installing the moldings where needed.
  • the invention additionally includes a new and innovative securing means used to install both the inventive moldings as described herein, as well as other moldings, such as those described by U.S. Patent Nos. 6,517,935, and 6,898,911 , and WO0240809.
  • This securing means is, most often, a track or clamp which can be glued, or otherwise secured to a subfloor and/or one or more flooring elements.
  • FIG. 1 is a side-view of a structure from which the moldings of the invention can be made.
  • FIGS. 2, 3 and 4 are side-views of intermediate elements which can be used in the construction of the molding of the invention.
  • FIG. 7 is a side-view of one carpet reducer embodiment formed from the generic element of FIG. 5;
  • FIG. 8 is a side-view of a hard surface reducer formed from the generic element of FIG. 5.
  • FIG. 9 depicts two end-moldings in accordance with the invention.
  • FIG. 10 shows a different carpet reducer/hard surface reducer in accordance with the invention.
  • FIG. 11 represents a T-molding installed with the track of the invention.
  • FIG. 13 represents an installation of the reducer of FIG. 10 using the track of FIG. 11.
  • FIG. 14 shows an installed end molding in accordance with the invention.
  • FIG. 16 shows another T-molding embodiment formed from the combination of FIG. 15.
  • FIG. 17 is an end molding formed from the combination of FIG. 15.
  • FIG. 21 shows a T-molding formed from the combination of FIG. 19.
  • FIG. 22 shows end moldings formed from the combination of FIG. 19.
  • FIG. 24 is another T-molding with a break away feature.
  • FIG. 25 is a reversible CR/HSR.
  • FIG. 28 represents an assembled and installed carpet reducer.
  • FIG. 29 represents an assembled and installed hard surface reducer.
  • FIG. 32 shows another T-molding of the invention installed in its track.
  • FIGS. 33 and 34 depict a stair nose attachment of the invention.
  • FIGS. 35-37 show elements of the generic molding of the invention, indicating a construction method.
  • FIGS. 38-41 show additional embodiments of the generic molding of the invention, and products produced therefrom.
  • FIG. 42 schematically represents a generic element, having been provided with cuts by a laser.
  • FIGS. 43 and 44 schematically show shaped core materials before a surface material is applied and the core material modified to its final shape.
  • FIG. 47 is an exploded perspective view of the cutting tool of Fig. 46.
  • FIG. 1 shows a structure 1, from which the present invention can be formed.
  • Structure 1 typically has a core 1A, an upper face 1B, a first lateral face 1 C, a second lateral face 1 D and a lower face 1 E.
  • the decorative outer face can have a variety of finishes, such as varnishes, lacquers, paints, polyurethane, hard surfaces (optionally containing hard particles, to increase the durability, e.g., abrasion and scratch resistance, of the surface materials), such as laminates (such as taught by U.S. Application No. 10/902,062), or hardwood flooring finishes, veneers, foils, stainable papers, or digital printing or other flooring materials, such as vinyl, metal, composites or plastics or natural materials such as cork. It is additionally within the scope of the invention to provide the decorative outer face of quarter round 6 with ceramic or wood tiles, as taught by U.S. Patent No. 6,860,074. Typical laminates which can be used are those taught by U.S.
  • Patent No. 6,517,935 including monochromatic or patterned (including random) decor sheets which may or may not be impregnated with a thermosetting resin, and a cellulosic overlay paper, such as one made from alpha-cellulose, which also may or may not be impregnated with a resin.
  • Other laminates include ones in which the overlay is eliminated, and may be substituted by a polymer containing cellulosic particles, evenly or randomly distributed throughout a (typically otherwise clear) resin.
  • the outer surface may be a conventional laminate, such as a high pressure laminate (HPL), direct laminate (DL), compact laminate (CPL) or a post-formable laminate (as described in U.S. Appl. No.
  • the appearance of wood may be simulated by coating the decorative outer surface with a laminate having a decor that simulates wood.
  • the decor can simulate marble, ceramic, terrazzo, stone, brick, inlays, or even fantasy patterns.
  • the decorative face or surface includes a laminate formed from a thermosetting resin, having a decor sheet, optionally an overlay layer (with or without cellulosic fibers atop or therein) or sheet and hard particles therein in order to impart an abrasion resistance thereto, which is affixed or joined to the remainder of the quarter round 6 in a high-pressure laminate process step.
  • a laminate formed from a thermosetting resin, having a decor sheet, optionally an overlay layer (with or without cellulosic fibers atop or therein) or sheet and hard particles therein in order to impart an abrasion resistance thereto, which is affixed or joined to the remainder of the quarter round 6 in a high-pressure laminate process step.
  • Such laminate may be affixed as described by U.S. Patent No. 6,805,951.
  • the outer face can be other finishing materials such as thermoplastic containing laminates, wood veneers, thermosetting polymers, such as melamine or phenolic resins, thermoplastic polymers such as olefins, foils (such as thermosetting, thermoplastic, paper or metal foils), optionally impregnated with or without hard particles, polyesters, vinyls, metals (such as sheets or strips), or combinations thereof.
  • the outer face can include multiple elements, as described herein. It is additionally considered within the scope of the invention to affix a material to the outer face during a direct lamination step, as is known in the art.
  • the outer face is provided with a patterned paper sheet therein, wherein the pattern resembles a natural or synthetic object, such as wood, ceramic, stone (including marble and granite), or fantasy patterns (i.e., those not found in nature), including a monochromatic or random field.
  • the specific decor can be selected to enhance the appearance of the surfaces which will be adjacent to quarter round 6 when installed.
  • Such enhancement can be accomplished by matching exactly the visual pattern to that of the adjacent surface, or by contrasting the patterns, for example, such that when installed, a visual pattern extends from a flooring element (wall base or wall), onto and possibly completely across, the molding, as described by U.S. Patent Application Publication No. 2002/0038924, filed September 28, 2001.
  • the moldings of the invention typically have a durability rating.
  • such products can have an abrasion resistance rating of anywhere from AC1 to AC5.
  • Typical abrasion resistances are > 300 cycles, > 400 cycles, > 500 cycles, at least 900 cycles (AC1), at least 1800 cycles (AC2), at least 2500 cycles (AC3), at least 4000 cycles (AC4) and at least 6500 cycles (AC5), as measured by European Standard EN 13329 (Annex E).
  • Typical products according to the invention can also have impact resistance ratings of IC1 , IC2 or IC3, as measured by European Standard EN 13329.
  • Such texturing can be created to be "in register" with, offset from, or to contrast with the image of, e.g., the paper sheet.
  • Such texturing may be created by physical pressing, e.g., embossing (as taught by U.S. Appl. No. 10/440,317, U.S. Patent No. 7,003,364, and WO9731775 and WO9731776) or chemically created (as taught by U.S. Patent No. 6,991.830).
  • the texture can be selected to enhance (e.g., match or contrast with) any texture of adjacent surfaces.
  • the texture may also be provided such that features of the texture extend from a flooring element (or wall base or wall) onto, and possibly completely across, the molding, which texture may, or may not coincide with the underlying decor.
  • core 1 A is shown as being a single unitary structure without any joints or connections therein, it is considered within the scope of the invention to form core 1A by joining two or more separate elements. Such separate structures need not be of the same material(s), and may be joined by, for example, by friction joints, tongue-and-groove joints, compression joints, glue, adhesive strip, double-sided tape, or any combination thereof.
  • core 1 A shows core 1 A as being solid, it is additionally considered within the scope of the invention to utilize a hollow structure, optionally with one or more supports or reinforcements provided in the interior thereof, or a composite core, incorporating an interiayer of a softer and/or resilient material, e.g., balsa or other relatively soft wood, plastic, rubber, paper, or foamed materials, in combination with a wood-fiber layer.
  • an interiayer is optionally positioned in locations to facilitate removal, such as by peeling, to form the desired shapes of the invention.
  • structure 1 is provided with one or more cuts 2.
  • cuts 2 can be created by milling or cutting with, for example, a blade or even a laser, on or into core 1 A of structure 1.
  • structure 1 is provided with cuts 2 already therein, by, for example, an extrusion or other molding process.
  • the particular location and number of cuts 2 are selected based upon the final shapes to be created, as will be described below.
  • structure 1 is provided with a first cut 2A in face 1C, a second cut 2B in upper face 1 B, and a third cut 2C in face 1 D, with no cuts in lower face 1 E, as is shown in FIG. 2.
  • Lower face 1E may be provided with a groove, which groove can be sized and shaped to accommodate for heads of screws used to affix the securing elements to the subfloor.
  • Known lasers include gas lasers (e.g., CO 2 , CO, HeNe, argon), having a power output of between 5 and 100 W 1 up to 100 kW, preferably 20-60 W, and more preferably approximately 30 W, having a wavelength in the range of 5 ⁇ m - 550 nm, typically 7-15 ⁇ m or 450-550 nm.
  • Other known lasers include metal ion lasers (e.g., HeAg and NeCu), having wavelengths between 220 and 250 nm, chemical lasers (e.g., HF and Deuterium flouride), having wavelengths between 2700 and 4000 nm, excimer, solid state, semiconductor (e.g., Nd: Y AG) and dye lasers.
  • any laser used to produce a cut should be selected depending upon, in part, on issues such as the material to be cut, the depth and/or length of the cut.
  • the cutting laser can be part of a flying optic machine - where the cutting laser moves over the structure to be cut, although it is considered within the scope of the invention to process the workpiece by moving the workpiece with respect to the cutting laser.
  • laser scoring can penetrate at any desired depth depending upon the material that is being used and depending upon the speed and strength of the laser used when scoring the material.
  • Laser strength can van/ from 5W to 10OkW, preferably within a range of 4kW to 8kW when scoring HDF or MDF material and other strengths used depending upon the materials and speed of scoring.
  • the laser cut or scoring does not need to be filled with shims or other materials for support (although shims are not prohibited).
  • the preferred opening of each laser score or cut 1110 is approximately 0.05-1 mm, most preferably approximately 0.3mm, however it can be less or greater than this measurement.
  • the opening typically corresponds to the type and thickness of the blade used to cut the surface material above the cut, by example a 0.3mm opening using a blade slightly less than 0.3mm or even less than 0.3mm to 0.2mm or slightly less can produce a cleaner cut edge with as little unsupported surface material 1 111 , surface material at the edge of the cut that does not have core material supporting it, as possible.
  • the ideal opening and type blade and blade thickness will leave a smooth cut of the surface material with as much supporting core material as possible.
  • a larger opening is used with a smaller blade thickness, by example, 0.6mm opening with a 0.3mm blade, a larger portion around the cut edge of the surface material is left unsupported by core material. This configuration is less preferred because unsupported surface material can partially crack, tear and/or separate. In such a configuration, the cut edge can be sanded or otherwise smoothed to cure the cracks, tears, etc.
  • the horizontal laser cuts 1110 can be parallel to the top surface of the molding. Specifically, one or both of an upper cut definition 1010A and a lower cut definition 1010B can be parallel to the surface of the molding. However, either or both of the upper cut definition 1010A and lower cut definition 1010B can be at an angle, i.e., not parallel, to the surface of the molding (the upper surface and/or the bottom surface, which are preferably, but need not be, parallel).
  • a vertical laser cut 1112 can be used as well.
  • Fig. 43 shows an example the generic element 1100, having been provided with the parallel cuts 1110, but prior to affixing of the surface material 1111
  • Fig. 44 shows the generic element 1100 with angled cuts 1110.
  • HSR and CR parts of the molding are attached to the underside of the "T, increasing the strength of these parts as desired as well as the amount of core material that remains between the end of the cut or laser score and where the underside milling begins on each piece.
  • the preferred use is for cutting laminate, foil, wood veneer, covered flooring transitions or wall trim.
  • cuts 2 penetrate the respective face 1 B-D, but do not make a separate piece from parts of structure 1.
  • the depth of cuts 2 can vary greatly. If, however, covering 4A (as described below) is strong enough, it is possible for one or more cuts 2 to separate a part of structure 1 , because the covering 4A can maintain the structural integrity. It is also within the scope of the invention to form cuts 2 such that a frangible connection is made between various sections of structure 1.
  • filler material such as shims 3A-C are inserted into cuts 2A-C, respectively.
  • Shims 3 preferably have a width slightly smaller than the width of the respective cut 3A- C.
  • shims 3 typically fit snugly in the cut 3.
  • no particular length for shims 3 is required, it is preferable that shims 3 are substantially shorter than the length of the respective cut 2, which cut can have differing dimensions across its length and/or width. Such may be accomplished by using tools, e.g., blades and lasers, of different dimensions.
  • cuts 2 and shims 3 are shown as all being of the same shape/dimensions, it is within the scope of the present invention to vary the size, shape and dimensions of the respective cut/shim combination.
  • shims 3 are manually or mechanically inserted into the respective cut 2, and pushed inside cut 2, it is possible to provide shims 3 having a length greater than the depth of the respective cut 2, and after insertion, remove any portion outside cut 2, and optionally a small section to provide an opening for a cutting blade, as described below. It is additionally possible to use shims 3 which have a smaller width, in combination with an adhesive or sealant to maintain shim 3 in position. If, however, cut 2 is sufficiently small, it is possible to eliminate the need for shim 3.
  • the material for shims 3 is preferably an olefin, polyester, or other moldable and/or extrudable thermoplastic or thermosetting material such as vinyl; solid or engineered wood or other cellulosic material, or metal. It is additionally within the scope of the invention to provide the material for shims 3 in a flowable form, which sets, hardens or dries into a solid form.
  • the material may also be expandable, such as by foaming or by heating or chemical reaction, such that after expansion, the material substantially fills the respective cut 2.
  • the material for shims 3 is substantially incompressible, once set/hardened/dried.
  • the interlayer (as previously described) is positioned in alignment with the cuts 2, such that removal of the various sections is easily accomplished once the covering 4A is cut, sliced, scored, etc.
  • the interlayer allows for the sections to be peeled away.
  • the interlayer is provided with a notch therein, to facilitate easy separation from the remainder of the generic element 5; however, it is considered within the scope of the invention to provide an interlayer without any notch, which notch can be formed during the slicing, cutting, scoring, etc. of the covering 4A.
  • FIG. 4 shows structure 1 having a covering 4A thereon.
  • covering 4A is a laminate formed from a thermosetting resin, having a decor sheet, optionally an overlay layer (with or without loose cellulosic fibers atop or therein) or sheet and hard particles in proximity thereto (e.g., in, on, above, or below, with or without a separate structure therebetween) in order to impart an abrasion resistance thereto, which is affixed to structure 1 in a high-pressure laminate process step.
  • Such laminate may be affixed to structure 1 as described by U.S. Patent No. 6,805,951.
  • Covering 4A can also be other finishing materials such as thermoplastic containing laminates, wood veneers, thermosetting polymers, such as vinyl or polyesters, thermoplastic polymers such as olefins, foils (such as thermosetting, thermoplastic, paper or metal foils), impregnated with or without hard particles, polyester, metals (such as sheets or single or strips), or combinations thereof.
  • covering 4A can include multiple elements, as described herein. It is additionally considered within the scope of the invention to affix covering 4A during a direct lamination step, as is known in the art.
  • structure 1 can be shaped to form the generic molding 5 as to be sold.
  • generic molding 5 may have one more notches 5A disposed in under face 1 E.
  • Such notches may additionally include elements or structures as described by U.S. Appl. No. 11/343,199.
  • Such shaping may be performed by manual or automated cutting, such as by severing, broaching, machining, routing, sawing, chipping, planning, sanding, or by any other method for removing material from the structure of structure 1.
  • the method used to shape structure 1 is usually selected depending upon the material used for structure 1 and the desired shape for generic element 5. For example, if structure 1 were extruded or molded, it is possible to form structure 1 with the notches 5A therein, such that a separate shaping step is not necessary.
  • generic element 5 can be manipulated by a further shaping step to form more than one flooring molding.
  • the configuration of generic element 5 depends upon the desired traditional flooring moldings potentially formed by manipulating generic element 5. Accordingly, FIG. 5 shows a typical generic element 5 in accordance with the invention.
  • connection 5B is typically ledges or other elements, which hold removable sections 5C and 5D to central section 5E.
  • FIG. 5 shows connections 5B as being merely extensions of the material of core 1A, it is additionally within the scope of the invention to form connections 5B as frangible joints, friction joints, tongue-and-groove joints, compression joints, glue (or other adhesive), or any combination thereof, in order to maintain such connections 5B made without any physical connections because the cut goes all the way, relying, at least in part, on covering 4A to maintain structural integrity.
  • the various separable sections of the invention are preferably break-away sections, i.e., can be separated from other sections in a single unitary piece by breaking a connection between the break-away section and at least one other section. In contrast, when a milled-away section is removed from another section, such milling does not form a unitary piece, but rather smaller particles, such as dust.
  • generic element 5 including covering 4A and connections 5B, various flooring profiles or moldings can be formed. Removing removable sections 5C and 5D from generic element 5 can produce a T-molding 6, while removing only section 5C from generic element 5 can produce a carpet reducer 7, and removal of only section 5D from generic element 5 can produce a hard surface reducer 8. If core 1 A is provided with a cut 2B in upper surface 1 B, it is further possible to divide T-molding 6 to form two end moldings 10.
  • a generic molding can be manufactured having only two removable sections, such that in its original configuration, the generic molding is a T-molding 400 (FIG. 24), and when separated along breakaway 401 , two end moldings 402 are produced (FIG. 26).
  • This T-molding 400 can be used in combination with a reversible element 402 (FIG. 25) to form a HSR or CR (depending upon the orientation of reversible element 402), as described by U.S. Appl. No. 11/066,099 and U.S. Appl. No. 1 1/343,199.
  • the T-molding 400 and reversible element 402 can be used with a different track 404 to hold the resulting assembly in place (Figs.
  • an alternate track 405 is used (FIG. 31).
  • the track 405 can be formed by cutting or breaking track 404 to match the latitudinal length of the end molding 402.
  • T-molding 501 Another generic molding which can be used without manipulation is T-molding 501 (FIG. 38).
  • This T-molding 501 has a number of removable sections 502, 503, and 504 (A and B), which can produce different shapes.
  • removal of sections 503 and 504B can produce a CR 501 A (FIG. 39).
  • Removal of section 504B only could produce a first modified T-molding 501 B (FIG. 40), which can be used for shallow tile, vinyl or low carpet (e.g., Berber).
  • Removal of sections 502, 503, 504A and 504B can produce a second modified T-molding 501 C (FIG. 41) for higher floorings, such as tile and hardwoods and deeper carpets.
  • removable section 5C or 5D can be shaped to form a traditional quarter- round molding when removed from section 5E.
  • generic element 5 may be shaped to form a traditional stair nose molding when one or both of removable sections 5C and 5D are separated.
  • shape generic molding 5 such that when separated, removable section 5C can be used as a quarter-round molding, while the remaining structure, i.e., section 5D joined to section 5E, can be used as a stair nose molding, as discussed below.
  • covering 4A must be cut or severed in order to separate the removable sections. Such a process typically requires the use of a specialized tool, which divides covering 4A, e.g., with a blade or other cutting tool, along the respective cut 2. Once covering 4A has been subdivided, it becomes possible to separate any necessary removable sections. Typically, a great deal of force is required to break connection 5B, such that if the generic molding 5 were used with the removable section in place, the generic molding 5 would maintain its structural integrity, although in other embodiments, little or no force is required.
  • the cutting tool or a second tool can be used to provide that force, for example, a standard flat-head screwdriver or other narrow width tool can be inserted into cut 2, either through the slot in severed covering 4A or from a longitudinal end of generic molding 5, and the removable section pried from the remainder of generic molding 5. Thereafter, the remaining part of generic molding 5 can be sanded to remove any burrs or other rough surfaces created during the prying. In one embodiment, the cutting, prying and sanding can all be performed by the same tool. Thus, it is possible to package one generic molding 5 along with the three-function tool.
  • a cutting blade 1000 can also be used as part of a tool to separate the elements of the generic molding 5, with different embodiments shown in Figs. 45A-E.
  • the cutting blade is substantially circular, and can be made of any conventional cutting material, e.g., ferrous or non-ferrous metals (such as stainless-steel) or ceramics. While the blade 1000 typically has a thickness of between 0.2 mm and 0.3 mm, the thickness of the blade 1000 should be selected depending upon the desired thickness of the resulting cut 2.
  • the blade 1000 rotates, as it can be circular or non-circular. Additionally, the blade 1000 can be stationary or reciprocate as it cuts.
  • the blade 1000 can have a substantially rounded shape (e.g., elliptical), such that as it rotates, the cutting surface reciprocates against the surface to be cut.
  • the cutting blade can have a smooth bevel Fig.45A, where one bevel from each side of the blade meets equidistant to the center thickness of the blade, such that the two bevels are of equal length. However, one bevel may be longer than the other.
  • the cutting blade may also have a single non-beveled cutting edge (Fig. 45B), where cutting edges are on each side, running from one side through the entire thickness of the blade to the opposite side, resembling a wedge shape around the perimeter of the circular blade.
  • a non-beveled (e.g., square-edge) blade Fig. 45C can be used, where the cutting edges are on each side of the perimeter of the circular blade created by a vertical or near vertical or perpendicular surface rather than the one edge created by a beveled surface around a circular blade.
  • An advantage of this "vertical edge” blade, depending upon the material cut, is sanding of the cut edge of the material may not be necessary, saving an additional operation that maybe required when using a beveled edge blade.
  • a rounded edge blade Fig. 45D is used, without any cutting edge.
  • This type of blade presses through the covering material into the void beneath the material creating, depending upon the material, a rolled edge that in many cases will not require sanding or smoothing.
  • the perimeter of the blade typically has a semicircular surface running smoothly from one side of the blade side surface to its opposite side.
  • a reverse double or chevron-shaped blade (Fig. 45E) can also be used. This blade has the advantage of cutting along both angled surfaces simultaneously.
  • Such cutters or blades can be stationary or moveable, e.g., by reciprocating, but are preferably rotating and can be used to cut surface materials that are placed over a shaped, extruded or molded core material that is scored, has cuts or extruded or molded grooves.
  • the core is made of wood based material, e.g., fiberboard, such as HDF, MDF, particle board or solid wood, composites, plastics or metals that can be covered by a variety of surface materials such as wood veneer, foils, laminate, paper, metal, plastic, cork, leather, linoleum, vinyl, rubber, bamboo, ceramic or glass tiles, textiles and the tool may be designed to score the surface of hard materials such as ceramic, making it possible to break the ceramic after the scoring.
  • breaking or separating connection 5B require the use of a tool, it is within the scope of the invention to have a weaker attachment.
  • connection 5B may be broken by human hand and arm pressure alone, i.e., without the use of any type of tool.
  • a specialized cutting tool 1100 is preferably used to cut the structure 1 into the separate parts.
  • the tool 1100 has a body 1101 , defining a workspace 1102, into which the structure 1 is passed.
  • the tool 1100 has a length no greater than the width of the structure 1 , to allow for simple packaging of a tool 1100 with a structure 1.
  • the tool 1 100 typically includes a horizontal cutter 1103 and a vertical cutter 1104, in which separate cutting blades 1000 are located.
  • each of the cutting blades 1000 in the tool 1100 are of the same structure, but it is within the scope of the invention to have different blades 1000.
  • Each of the blades 1000 are connected to an axis 1107, which axis is mounted in a horizontal cutter housing 1108 or a vertical cutter housing 1109, respectively.
  • the vertical cutter 1104 preferably penetrates the body 1101 through vertical cutter aperture 1110.
  • the structure 1 is relatively moveable through the workspace 1102 to come in contact with either the horizontal cutter 1104 and/or vertical cutter 1104, depending upon the desired shape of the structure 1 after cutting.
  • the structure 1 can be moved with respect to the tool 1100, the tool 1100 may be moved with respect to the structure 1 , or both the 1100 and the structure may be moved with respect to each other.
  • the structure can be inserted into the workspace with cut 2C positioned toward the horizontal cutter 1103. As the structure 1 passes the blade 1100, the edge of the blade 1100 will penetrate sever the covering 4A, thereby exposing the cut 2C.
  • section 5D can then be removed by, for example, simply allowing it to fall away, separating a glue, prying and/or snapping section 5D from the remainder of the structure 1.
  • an additional tool such as the operative end of a flat-head screwdriver can be inserted into the cut 2C and twisted to assist in the separation.
  • the structure 1, having been cut can be sanded if needed to remove any jagged or rough ends formed by the removal step.
  • the individual pieces can be separated by hand and arm pressure alone or with the use of a tool.
  • the blade 1000 inside the vertical cutter 1104 is typically moved away. This can be accomplished by simply pulling up on the vertical cutter 1104 to move the blade 1000 therein upwards to move the blade to an inoperative, yet preferably retained in the tool 1100, position, or the vertical cutter housing 1109 be physically disconnected from the tool 1104, allowing removal of the blade 1000 therein, depending upon the particular configuration of the tool 1 100.
  • section 5D If, after section 5D is removed, the user wants to form a T-molding by removing section 5C, the structure 1 can be relatively moved through the workspace 1102 a second time, whereby the blade 1000 in the horizontal cutter 1103 severs the covering 4A over cut 2A. Thereafter, section 5C is removed.
  • the structure 1 can be passed through the tool 1100, with the blade 1000 inside the vertical cutter 1104 in the operative or engaged position. Accordingly, the vertical cutter 1104 will sever the covering over cut 2B.
  • the tool 1100 can be operated with one or both of the vertical cutter 1104 and the horizontal cutter 1103 in an operative position, it is possible to use both cutters simultaneously or in any sequence to achieve the desired configuration of the structure 1 (e.g., the cut 2B can be formed before cut 2A or 2C).
  • the tool 1100 is provided with a removable and/or detachable second horizontal vertical cutter 1103' (not shown) positioned opposite the first horizontal cutter 1103 to permit all three severing steps to be performed at the same time or in any desired sequence without having to install the cutters.
  • CT parts can be separated from the "1/2 T" (End Molding Part) and/or the HSR and CT parts can be removed along the horizontal cuts and then the "T-Molding can be divided in half along the vertical cut into two end moldings. Ideally we can break these parts off with hand pressure alone.
  • the cutters can have 2, 3, 4, or 5 individual blades, each of which can be of any of the shapes and types described herein.
  • One or more blades can independently rotate or be stationary, and/or one or more blades may independently reciprocate.
  • the vertical cutter 1104 and horizontal cutter 1103 are designed such that the entire cutter can be removed from the horizontal position and placed in the vertical position, or vice versa. In such an embodiment, only one cutter need be provided to perform all of the cutting functions.
  • a second cutting tool 1200 is schematically shown in Fig. 48, and operates in a substantially similar manner to the first cutting tool 1100.
  • the cutting tool 1200 includes a body 1201 and a lower section 1202 defining a workspace 1203 therein, with the blade(s) 1000 being mounted similarly to as described in connection with the first cutting tool 1 100.
  • the lower section 1202 is fixedly joined to the body 1201 , either by being integrally formed with or affixed thereto by, e.g., screws, glue, or straps.
  • the tool 1200 has a length no greater than the width of the structure 1 , to allow for simple packaging of a tool 1200 with a structure 1.
  • the tool 1200 typically includes a cutter 1204 which can be placed in its horizontal position, or in the alternative, in its vertical position. Depending upon the particular cutting of the structure 1 to be made, the cutter 1204 can be shifted from the first position to the section position. This is typically accomplished by pulling the cutter 1204 distally outward to disengage the blade 1000 disposed therein from its location where it can engage the structure 1 , and sliding the cutter 1204 along the body 1201 until the cutter reaches the second operative position. Preferably, when in the disengaged position, the blade 1000 is retained inside the tool 1200. Thereafter, the cutter 1204 can be pushed to move the blade 1000 such that it can engage the structure 1 in the second operative position.
  • the cutter 1200 is provided with a second cutter 1204', such that a vertical cut and a horizontal cut can be made simultaneously. Accordingly, in order to prevent unwanted severing of the structure 1 , either or both of the cutters 1204, 1204' can be removed entirely or simply disengaged from the operative location.
  • shim 3 is inserted into cut 2, separation of a removable section from generic molding 5 often will cause shim 3 to fall out. However, instead of simply discarding shim 3 as trash, shim 3 may be used as a shim to be utilized when installing any resulting molding, above or below any means for attaching the resulting molding, such as a track or clamp.
  • Patent Nos. 6,517,935 and 6,898,911 , covering 4A should not have any dividing lines or other demarcations marring the decorative surface.
  • covering 4A is provided with a patterned paper sheet therein, wherein the pattern resembles a natural or synthetic object, such as wood, ceramic, stone (including marble and granite), or fantasy patterns (i.e., those not found in nature), including a monochromatic or random field.
  • the specific generic molding 5 can be selected to enhance the appearance of the surfaces which will be adjacent to the generic molding 5 (or parts thereof) when installed. Such enhancement can be accomplished by matching exactly the visual pattern of generic molding 5 to that of the adjacent surface, or by contrasting the patterns, for example, such that when installed, a visual pattern extends from a flooring element onto and possible completely across the molding.
  • covering 4A with a textured upper surface which enhances the pattern of the underlying paper sheet.
  • Such texturing can be created to be "in register" with, offset from, or to contrast with the image of the paper sheet.
  • Such texturing may be created by physical pressing, e.g., embossing (as taught by U.S. Appl. No. 10/440,317 (filed May 19, 2003), U.S. Patent No. 7,003,364, WO9731775 and WO9731776) or chemically created (as taught by U.S. Patent No. 6,991.830).
  • the texture of the covering 4A can be selected by the installer to enhance (e.g., match or contrast with) any texture of adjacent surfaces.
  • removable sections 5C and 5D with opposite decorative surfaces (as disclosed by U.S. Application No. 10/748,852, No. 11/066,099, and 11/343,199), such that after being removed from generic molding 5, removable sections 5C and/or 5D can be re-attached in a reverse configuration to section 5E by, for example, tongue-and-groove joints, friction joints, or adhesive.
  • U.S. Application No. 10/748,852, No. 11/066,099, and 11/343,199 removable sections 5C and/or 5D can be re-attached in a reverse configuration to section 5E by, for example, tongue-and-groove joints, friction joints, or adhesive.
  • FIG. 11 removable section 105 has been removed to create a T/End molding 104.
  • T/End molding 104 can be connected to a securing element 110, which securing element 110 is preferably not affixed to a sub-floor. Securing element 110 is, however, preferably affixed to one or both adjacent flooring elements 103A, 103B. This can be accomplished with a fresh adhesive, pre- glue, magnetically, or by any conventional mechanical device, such as a screw, nail, etc. Arms or extensions of T/End molding 104, as well as T molding 6, can overlap finished flooring approximately 0.25"-0.75" (approximately 6.5-20 mm), preferably approximately 0.5" (13 mm).
  • An underlayment 102 can be placed between flooring elements 103 and subfloor 101.
  • Underlayment 102 can be any conventionally known underlayment, such as those used as moisture barriers and/or sound/shock/electric charge dampening, and can be affixed to flooring elements 103, or simply laid down before flooring elements are installed. It is additionally considered within the scope of the invention to utilize an underlayment which creates moisture channels below flooring elements 103, such as PLATON STOP and/or PLATON FLOOR, by lsola as of Norway, such as described by U.S. Patent Application No. 11/522,535. [0113] As shown, T/End molding 104 overlaps the flooring elements 103A, 103B.
  • each of the flooring elements 103A could move independently of each other. It is also considered within the scope of the invention to affix securing element 110 to one of the flooring elements 103A, which would cause T/End molding 104 to move with flooring element 103A, while the other flooring element 103B would not be so constrained.
  • Track 110 is preferably made of a plastic, metal or composite material, and can be used to secure any of the parts described herein to flooring elements 103A, 103B and/or a subfloor.
  • Vertical portions 112 are shown as upstanding from base 11 1. Although shown as being perpendicular to base 111, vertical portions 112 can be at any angle therefrom. For example, while a first vertical portion 112A can be perpendicular to base 111 , a second vertical portion can be disposed at any angle. In one preferred embodiment, vertical portions 112 are upstanding from base 111 , but angle towards each other. As a result, vertical portions 112 are biased inwards, and the biasing assists in holding the molding in place.
  • First wing 113 is a portion of base 111 which is designed to be placed below a flooring element 103 (as shown in FIG. 1 1).
  • a distal portion 113A of wing 113 can be folded back 180° to form a shim, in order to raise track 110 or other parts to accommodate thicker flooring elements 103.
  • a second vertical portion 114 Disposed adjacent to, but preferably not in contact with, a vertical portion 112 is a second vertical portion 114.
  • This second vertical portion helps to support, for example, removable section 105, by preventing back and forth movement.
  • second vertical portion 114 acts to maintain removable section 105 in the correct location.
  • Track 110 can also have a second wing 115, which second wing 115 can include a pre-applied adhesive (e.g., an encapsulated glue as described by U.S. Patent No. 7,029,741 and Appl. No. 10/270,163), adhesive tape, fresh adhesive or can have a mechanical or magnetic attachment (as described by U.S. Appl. No. 10/747,261) to affix track 110 to the underside of flooring elements 103 and/or the subfloor.
  • Second wing 115 may also be provided with a groove 116, sized and shaped to receive tab 108, which helps to hold removable section 105 in place and, simultaneously, allows removable section 105 to rotate in adjustment as the height of flooring elements 103 increases. It is considered within the scope of the invention to swap the relative locations of the tab 108 and grove 116.
  • a track having a single upstanding section, positioned between lower lateral ends can be inserted into a groove positioned in an underside of generic structure 5.
  • the foot, or middle lower depending portion of generic structure 5 can be reduced in size or eliminated, as the interaction between this track and groove can be sufficient to hold the structure in its installed condition.
  • an uppermost end of the track can be provided with barbs, spikes, projections, joint elements (such as tongue/groove) or other elements which can enable the track to lock or more securely hold the structure in its installed condition.
  • T/End molding 104 is shown, in an installed condition, as a carpet/hard surface reducer (with removable section 105) and an end molding (without removable section 105), respectively.
  • foot 109 of T/End molding 104 is secured in track 110 by vertical sections 112.
  • Track 110 is secured to a subfloor 101 with an adhesive, magnetic forces or mechanical attachments.
  • T/End molding 104 is installed adjacent a wall 118.
  • a sealant or adhesive 117 may be placed in any gaps between T/End molding 104 and another structure, such as a wall 118. As shown in FIG.
  • T/End molding 104 can be used without any securing element, as the presence of adhesive 117, may be sufficient to maintain T/End molding 104 in place.
  • adhesive 117 can be a fresh glue or a pre-applied glue (e.g., a "preglue" applied at the factory).
  • adhesive 117 is a foaming adhesive, e.g., a silicone sealant or alternate foaming adhesive, such that after adhesive 117 and T/End molding 104 are installed, adhesive 117 foams or expands to fills voids between wall 118 and T/End molding 104.
  • FIGS. 15-22 depict an additional molding assembly of the invention.
  • This extrudable assembly 202 is preferably formed from an extrudable polymeric, composite or metal material, but may also include or be substituted by milled composite materials, wood, fiberboard, or any other material discussed herein suitable for core 1A.
  • assembly has a decorative outer surface 201 , which surface 201 is preferably selected from the same materials for the outer faces of structure 1.
  • assembly 200 can be constructed with a combination HSR/CR 202 and a
  • Breakaways 204 can be narrowed or scored or other sections of assembly 202, allowing for separation of the parts of assembly 200. Breakaways 204 can also be joints between two separate elements, formed by, for example, friction joints, tongue-and-groove joints, compression joints, glue, or any combination thereof.
  • Assembly 200 can be fixed to a subfloor using any material described herein, such as adhesive (e.g., pre-applied or fresh glue), tape or magnetic strip (optionally with tape or adhesive).
  • Installing assembly 200 in a first configuration produces a HSR, while inverting assembly 200 produces a CR (FIG. 18).
  • assembly 200 can be used in a variety of configurations. As can be seen in FIG. 15. applying force to push or pull the sections of assembly 200, different shapes, to accommodate different flooring heights. Desired positions for legs 208 can be selected and locked in place by utilizing a glue, sealant, epoxy, or other chemical element, or in the alternative (or in combination with), barbs or teeth 212.
  • T-molding 220 By splitting or breaking assembly 200 at breakaways 206, different moldings can be realized.
  • Another T-molding 220 is created by separating assembly 200 at each of breakaways 206B and 206C.
  • This T-molding 220 is preferably joined to one flooring element with an adhesive 222, which can take the form of any glue or adhesive described herein, but preferably is a peel-and-stick adhesive, and is positioned to join to both an upper surface and a lower surface of the flooring element.
  • an adhesive 222 can take the form of any glue or adhesive described herein, but preferably is a peel-and-stick adhesive, and is positioned to join to both an upper surface and a lower surface of the flooring element.
  • Such a construction similar to other embodiments, allows T-molding 220 to "float" with the joined flooring element, independent of other flooring elements.
  • T-molding 220 can be affixed to the subfloor with any glue, adhesive or magnetic means (discussed herein), alone
  • assembly 200 is split or separated at breakaways 206A and 206C, an end molding
  • the end molding 230 can be produced (FIG. 17).
  • the end molding 230 can be affixed to the upper surface of an adjacent flooring element, or if used in combination with a track 232, both the track 232 can be joined to either the subfloor or the underside of the adjacent flooring element, alone, or in combination with the end molding 230 being affixed to the flooring element. If the end molding 230 is used without the track 232, a lower end of end molding 230 can also be affixed to the subfloor.
  • FIG. 15 An alternate embodiment of the assembly 200 shown in FIG. 15 is an additional assembly 250 (Figs. 19 and 20), which can also function as a HSR or CR, depending upon its installed orientation.
  • This assembly 250 has a supporting strut 252 that is adjustable and can move when adjustable legs 253 are raised/lowered for different finished flooring thicknesses.
  • the adjustable strut 252 provides additional strength to the structure of the assembly 250.
  • a locking mechanism such as barbs, glues/adhesives, or other means for maintaining the strut 252 in its desired configuration.
  • the assembly 250 can be broken at breakaways 254A-C for form various products.
  • a T-molding 256, and its optional associated track 256 (FIG. 21), can be formed by separating assembly 250 at breakaways 254B and C.
  • Two end moldings 257 (FIG. 22) can be produced by separating assembly 250 at breakaways 254A, B and C.
  • FIG. 23 Another embodiment of the generic molding of the invention is shown as generic molding 300 (FIG. 23).
  • the generic molding 300 is a breakaway version with multiple horizontal sections for forming a versatile molding capable of being used for a large range of finished flooring thicknesses.
  • This version can be an extrusion or other milled or shaped material such as HDF, MDF, composites, metal, wood or plastic.
  • a core 301 of the generic molding 300 can also be manufactured from any structural material discussed herein in connection with other embodiments of the invention.
  • a finished surface material 302 covers at least a portion of the core 301 and preferably provides the generic molding 300 with a decorative outer surface, and may be any type of decorative surface discussed elsewhere herein.
  • the generic molding 300 is preferably installed with a track 303, which track can include one or more gripping flanges 303A which can interact with one or more gripping grooves 303B (not shown) to help to maintain the generic molding in place.
  • the generic molding 300 is provided with rounded shoulders 304, formed as part of the core 301 or as an additional structure, which bears against legs of the track 303 to add support to each of the sections holding the generic molding 300 in place.
  • the 300 is typically provided with breakaways 305A-D, to independently reduce the height of the core 301 of the generic molding 300 to form a T molding, end molding, CR or HSR as discussed herein, for a number of heights.
  • breakaways 305A-D to independently reduce the height of the core 301 of the generic molding 300 to form a T molding, end molding, CR or HSR as discussed herein, for a number of heights.
  • breakaways 305A-D to independently reduce the height of the core 301 of the generic molding 300 to form a T molding, end molding, CR or HSR as discussed herein, for a number of heights.
  • the invention additionally includes a stair nose assembly 600 (Figs. 33A and 34).
  • the stair nose assembly 600 can be formed by joining a T molding (such as T- molding 6, 220, 255, 400, or T/End molding 104) with a structure (such as end moldings 10 and 230).
  • T molding such as T- molding 6, 220, 255, 400, or T/End molding 10
  • structure such as end moldings 10 and 230.
  • the joint formed at the junction between the T-molding and the additional structure can be maintained by any means discussed herein, such as adhesive/glue or other chemical or mechanical element.
  • stair nose assembly 600 is a unitary structure, sold as a single unit, consisting of a first section 601 , and a second section 602, manufactured as a single structure.
  • the stair nose assembly 600 includes a core 603 and a covering 604, which are selected from the cores and covering materials discussed elsewhere herein.
  • the stair nose assembly 600 is provided with cuts 605A-C which permit the stair nose assembly 600 to be used for other purposes after being separated at cuts 605A-C. For example, dividing at cut 605A produces an end molding 10, while dividing at cut 605B produces both an end molding 10 and a T-molding 6. Dividing at cut 605A and 605C can produce an element which can be used as a quarter round or shoe molding 606 (FIG. 33B).
  • An alternate stair nose assembly 610 can be formed by forming a carpet reducer 611 , substantially similar to the carpet reducer 7, having a groove 612 in a lower surface thereof. By joining a stair nose attachment 613, by inserting a tongue 614 thereof into the groove 612, the stair nose assembly 610 can be formed. Similarly, stair nose assembly can be manufactured as a single piece by joining the carpet reducer 611 to stair nose attachment prior to adding the decorative surface thereof, or by forming the stair nose assembly 610 as a unitary structure, allowing for removal of stair nose attachment 613 at installation, at, for example, cut 615. When removed, stair nose attachment 613 can be used as a shoe molding or quarter round molding.
  • Each of the stair nose assemblies 600 and 610 can be affixed directly to the subfloor with a mechanical, chemical or other attachment means as discussed herein. Alternatively, a track may be used to secure the stair nose assemblies 600 and 610.
  • FIGS. 1-10 One preferred method for forming a generic molding element 650 is shown in FIGS.
  • two end moldings 650A and 650B, a carpet reducer part 605C and a hard surface reducer part 605D are milled or otherwise shaped from a core material (as disclosed herein) and held together (FIG. 36). This can be accomplished by, for example, using a clamp, other mechanical elements or a glue (sufficient to hold the pieces together until the covering is applied).
  • a covering 654 (as discussed herein) is applied. Through this method, the covering 654 (and optionally the glue) holds the generic molding element 650 together.
  • the molding of the invention can be produced by forming the generic structure, and providing cuts therein, before affixing the covering thereto.
  • the separable parts are completely removed from each other and can be held in place by a clamp or a mold, until the covering is affixed thereto.
  • the covering can be affixed to the generic structure prior to the separable elements being formed.
  • the cuts are formed in the underside of the structure, as the upper surface of the generic structure has the covering thereon.
  • the invention uses a paper (with or without hard particles - e.g., having a Moh's hardness of at least about 4 or 6, preferably at least about 7, therein, which can be alpha-aluminum (alumina), silicon carbide, diamond, cerium oxide, zirconium oxide, and/or glass beads), and once printed, is impregnated with a thermosetting resin. The impregnated paper is then further combined with other layers and elements to form a laminate which can be bonded to a core material.
  • a paper with or without hard particles - e.g., having a Moh's hardness of at least about 4 or 6, preferably at least about 7, therein, which can be alpha-aluminum (alumina), silicon carbide, diamond, cerium oxide, zirconium oxide, and/or glass beads
  • Suitable core materials include one or more of wood, fiberboard, such as high density fiberboard (HDF) or medium density fiberboard (MDF), polymer (thermosetting and thermoplastic), flaxboard, stone (e.g., ceramic, marble, slate), cardboard, concrete, gypsum, high density fiber reinforced plaster, veneers such as plywood, oriented strand board, cores made from particles (including discrete pieces of polymer or wood, which can be in the form of chips, curls, flakes, sawdust, shavings, slivers, stands, wavers, wood flour, wood wool and/or fibers), and other structural materials, such as metals (e.g., brass, aluminum, steel, copper, composites, composites or alloys).
  • HDF high density fiberboard
  • MDF medium density fiberboard
  • polymer thermosetting and thermoplastic
  • flaxboard e.g., ceramic, marble, slate
  • cardboard e.g., ceramic, marble, slate
  • concrete e.g., gypsum
  • the core material can be foamed (either open cell or closed cell), such as polyurethane.
  • the core is made as a composite from multiple materials (such as those listed above), either as a heterogeneous mass, multiple layers or defined sections, e.g., upper and lower veneers covering a core of particles. Any of the above materials may also be provided with antistatic or antibacterial properties, e.g., by the inclusion of silver flakes, powders or particles, carbon black, ceramics, or other metals or alloys.
  • Preferred plastics include extrudable and/or motdable thermosetting and thermoplastic resins, the latter including high density olefins and polyvinylchloride.
  • This laminate may also be covered with other types of coverings, such as foils (such as metal, paper or thermoplastic foils), paints or a variety of other decorative elements, including, but not limited to wood veneer, ceramic, metal, vinyl or other decorative materials.
  • foils such as metal, paper or thermoplastic foils
  • paints or a variety of other decorative elements, including, but not limited to wood veneer, ceramic, metal, vinyl or other decorative materials.
  • the decor is provided on the core material itself, i.e., without the paper layer, e.g., as described by, e.g.. U.S. Patent No. 6,465,046.
  • the core is optionally provided with a primer and/or a base color, on which the decorative pattern or display is printed or otherwise generated. While the term “pattern” is used herein, it is to be understood that “pattern” need not be or include any repeating units, thus “pattern” is simply a visual and/or textual display.
  • the printed decor can be covered with a wear layer, thereby giving the decor abrasion and/or scratch resistance.
  • the wear layer can be provided in the form of a sheet of alpha-cellulose which is bonded to the core, or it can be applied in a liquid form, and is typically provided with hard particles as described herein.
  • the wear layer can include melamine- formaldehyde, urea-formaldehyde, maleamid, lacquers, acrylic resins, and/or urethanes.
  • the result of the printing process of the invention resembles a natural or synthetic object, such as wood or wood tiles or boards, ceramic (e.g., tiles), stone (including marble and granite, such as tiles), or fantasy patterns (i.e., those not found in nature), including a monochromatic or random field.
  • a natural or synthetic object such as wood or wood tiles or boards, ceramic (e.g., tiles), stone (including marble and granite, such as tiles), or fantasy patterns (i.e., those not found in nature), including a monochromatic or random field.
  • the invention can have a texture which enhances the pattern of an underlying printed image.
  • texturing can be created to be "in register" with, offset from, or to contrast with the image of the paper sheet.
  • Such texturing may be created by physical pressing, e.g., embossing (as taught by U.S. Appl. No. 10/440,317 (filed May 19, 2003), U.S. Patent No. 7,003,364, and WO9731775 and WO9731776) or chemically created (as taught by U.S. Patent No. 6,991 ,830).
  • the texture can be selected by the installer to enhance (e.g., match or contrast with) any texture of adjacent or included surfaces.
  • the texture may also be provided on the decor such that features of the texture extend from a flooring element onto and possible completely across the adjacent flooring elements, which texture may, or may not coincide with the underlying decor.
  • the invention is typically used in the construction of a surface, such as a top for a counter or table, floor, ceiling, or wall.
  • a surface such as a top for a counter or table, floor, ceiling, or wall.
  • Such surfaces are often found in residential structures (e.g., single and multi-family houses, condominiums, townhomes, co-operatives, apartments, and lobbies of such buildings), commercial structures (e.g., retail stores, strip malls, shopping malls, office buildings, hotels, restaurants, supermarkets, banks, churches, airports and other transit stations), public structures (e.g., stadiums and arenas, schools, museums, theaters, post offices, hospitals, courthouses and other government buildings), as well as industrial structures (e.g., manufacturing plants, mills, and warehouses) and surfaces of vehicles (e.g., ships, trains, aircraft, public and private busses, cars and other motor vehicles).
  • residential structures e.g., single and multi-family houses, condominiums, townhomes, co-operatives,

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Forests & Forestry (AREA)
  • Floor Finish (AREA)
  • Steps, Ramps, And Handrails (AREA)

Abstract

La présente invention concerne un assemblage de couverture de joint pour recouvrir un espace à côté d'un bord d'un panneau qui recouvre une sous-surface, et un procédé pour recouvrir un tel espace. L'assemblage peut être manipulé pour former un moulage d'extrémité, un moulage en T, un réducteur pour surface dure, un réducteur pour moquette, et/ou un moulage de nez d'escalier. Un kit peut comprendre l'assemblage de couverture de joint et un outil pour former une transition de revêtement de sol à partir d'un élément générique qui possède des sections de décollement.
PCT/US2007/012303 2006-05-25 2007-05-24 Transition universelle de décollement de revêtement de sol WO2007142841A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US80812106P 2006-05-25 2006-05-25
US60/808,121 2006-05-25

Publications (2)

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WO2007142841A2 true WO2007142841A2 (fr) 2007-12-13
WO2007142841A3 WO2007142841A3 (fr) 2008-05-22

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US (2) US20070283654A1 (fr)
WO (1) WO2007142841A2 (fr)

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EP2388388A1 (fr) 2010-05-18 2011-11-23 Flooring Industries Limited, SARL Profilé de finition pour un escalier ou une marche, et ensemble pour former une telle finition
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US8505250B2 (en) 2010-05-18 2013-08-13 Flooring Industries Limited, Sarl Finishing for a staircase or step, and kit for forming such finishing
WO2016051100A1 (fr) * 2014-10-03 2016-04-07 Findes Profil monobloc sécable et outil de coupe
FR3032466A1 (fr) * 2015-02-06 2016-08-12 Bernard Proot Ensemble comportant un profil monobloc secable et un outil de coupe

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WO2011096794A3 (fr) * 2010-01-22 2011-09-29 Escada B.V. Élément de giron de marche, ornement de rénovation d'escalier, nécessaire et procédé correspondants
EP2526241B1 (fr) * 2010-01-22 2018-03-07 Sip B.V. Élément de giron de marche, ornement de rénovation d'escalier, nécessaire et procédé correspondants
EP2388388A1 (fr) 2010-05-18 2011-11-23 Flooring Industries Limited, SARL Profilé de finition pour un escalier ou une marche, et ensemble pour former une telle finition
BE1019339A3 (fr) * 2010-05-18 2012-06-05 Flooring Ind Ltd Sarl
BE1019526A3 (nl) * 2010-05-18 2012-08-07 Flooring Ind Ltd Sarl Afwerking voor een trap of trede en een kit voor het vormen van dergelijke afwerking.
US8505250B2 (en) 2010-05-18 2013-08-13 Flooring Industries Limited, Sarl Finishing for a staircase or step, and kit for forming such finishing
BE1019657A3 (fr) * 2010-11-25 2012-09-04 Findes Bvba Ensemble de finition pour surfaces disjointes, comportant un profil de jonction separable en deux modules aptes a former des profils d'arret.
WO2016051100A1 (fr) * 2014-10-03 2016-04-07 Findes Profil monobloc sécable et outil de coupe
FR3032466A1 (fr) * 2015-02-06 2016-08-12 Bernard Proot Ensemble comportant un profil monobloc secable et un outil de coupe

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WO2007142841A3 (fr) 2008-05-22
US20100115870A1 (en) 2010-05-13
US20070283654A1 (en) 2007-12-13

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