Abstract:
A tool is provided for installing flooring with snap together edges. Specifically, the tool has a longitudinally-extending guide rod having a first impact member having a first impact face at a first end, and a second impact member having a second impact face at a second end. The first impact member has cleat extending below its lower surface adapted for engaging flooring edges. A sole is secured to the lower edge of the first impact member to protect the underlying flooring surface. The second impact member comprises a foot with an impact face. An impactor with first and second impact faces is slidably movable between the first impact member and second impact member for impacting the first and second impact faces respectively.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates generally to flooring installation tools and procedures, and in particular to a tongue-and-groove flooring installation tool and method. 
         [0003]    2. Description of the Related Art 
         [0004]    In construction, floorings are made from various materials and assembled using different techniques and tools. Engineered flooring is attractive for both the customer and the installer. Customers are attracted to engineered flooring because it is a high quality, durable product that has versatile applications, and can come in a variety of colors, finishes, surface textures, and materials, such as plastic, laminate, wood, or tile. Floor installers appreciate engineered flooring because of the consistency of the manufactured product and ease by which the material can be installed. 
         [0005]    Many engineered flooring products come in planks of varying dimensions that need to be fitted together to create the overall flooring application. Depending on the type of engineered flooring, the material is installed and secured in a variety of ways, such as nailing, stapling, gluing or floating. A floating floor is a fast and easy method of installing engineered flooring because the individual planks snap or slide together utilizing a tongue-and-groove engineering, and a limited number of tools are needed. 
         [0006]    When assembling a floating floor, the installer mates opposing tongue-and-groove edges of the flooring material together by applying a force in the direction of the joint the installer is trying to close. The most common way of applying force to join engineered flooring is using a tapping block or pulling iron to abut the edge of flooring opposite the joint, and manually striking the object with a separate striking device such as a hammer or mallet to drive the planks together. A tapping block or pulling iron is used to prevent damaging the tongue-and-groove edge of the plank. A tapping block is abutted to the edge of the plank opposite the joint the installer is trying to close, and the back of the block is struck with a striking device, driving the planks together. Tapping blocks can be made from a variety of materials, such as wood, nylon, thermoplastic, or any other material that would not damage the edge of the plank. When there is not enough room to use a tapping block and swing a striking device, a pulling iron is substituted for the tapping block to join the planks. A pulling iron has a lip which abuts the edge of the plank and a striking surface that permits room for swinging the striking device. 
         [0007]    A problem with using a tapping block, pulling iron, and striking device for installation of an engineered floor is that all of the tools are necessary for proper installation. Depending on the type of engineered flooring, the tongue-and-groove configuration can create the need for different sized tapping blocks with varying edges to prevent damage to the finished edge of the plank. Further, a pulling iron traverses the finished flooring requiring measures to be taken to prevent damage of the engineered flooring surface such as by placing a towel or cloth underneath the tool when it is in use. In addition, the striking device is often out of reach of the installer when he or she is preparing to join planks together, and when not in use, the striking device could damage the surface of the installed planks. The result is numerous tools are required to properly install engineered flooring without causing damage to the surfaces and edges of the planks, and time is wasted gathering the tools and using them properly. 
         [0008]    Heretofore there has not been available a floor installation tool and method with the advantages and features of the present invention. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0009]    In the practice of the present invention, a flooring installation tool is provided which includes a cylinder slidably mounted on a guide shaft for striking movement between a block mounted on one end of the guide shaft and a foot mounted on the other end. The block includes a cleat, which hooks and engages the edges of floor planks being installed. The planks can be installed in various floor conditions, which can be accommodated by the installation tool. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The drawings constitute a part of this specification and include exemplary aspects of the present invention and illustrate various objects and features thereof. 
           [0011]      FIG. 1  is an upper, front, side perspective view of a floor installation tool comprising an aspect of the present invention; 
           [0012]      FIG. 2  is a side view thereof, showing flooring being installed; 
           [0013]      FIG. 3  is a side view thereof, showing another flooring installation condition; 
           [0014]      FIG. 4  is a side view thereof, showing yet another flooring installation condition; 
           [0015]      FIG. 5  is a fragmentary, vertical cross-sectional view of a tongue-and-groove joint between first and second flooring planks; and 
           [0016]      FIG. 6  is another fragmentary, vertical cross-sectional view of the tongue-and-groove joint, shown in an engaged configuration. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     I. Introduction and Environment 
       [0017]    As required, detailed aspects of the present invention are disclosed herein; however, it is to be understood that the disclosed aspects are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art how to variously employ the present invention in virtually any appropriately detailed structure. 
         [0018]    Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, up, down, front, back, right and left refer to the invention as orientated in the view being referred to. The words, “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the aspect being described and designated parts thereof. Forwardly and rearwardly are generally in reference to the direction of travel, if appropriate. Said terminology will include the words specifically mentioned, derivatives thereof and words of similar meaning. 
       II. Preferred Aspect Flooring Installation Tool  2   
       [0019]    Referring to the drawings in more detail, the reference numeral  2  generally designates a flooring installation tool, as shown in  FIGS. 1-4 . Without limitation on the generality of useful applications of the present invention, the flooring installation tool  2  can be utilized for assembling an engineered flooring system  80  on a floor  72  by joining flooring planks, e.g.,  75 ,  76  and  78 . 
         [0020]    The engineered flooring system  80  is comprised of a plurality of first flooring planks  75 , second flooring planks  76  and third flooring planks  78  secured together by interlocking the groove profile  82  of a second flooring planks  76  with the tongue profile  82  of a third flooring planks  78 . The first flooring plank  75 , second flooring plank  76 , and third flooring plank  78  can comprise a variety of materials, such as plastic laminate, wood, etc. 
         [0021]      FIG. 1  shows the flooring installation tool  2 , embodying the invention. The flooring installation tool  2  generally comprises a first impact member, such as a block  4 , longitudinally connected to a second impact member, such as a collar  52  and a foot  60  by a guide shaft  44 . An impactor, such as a cylinder  46 , freely moves between the block  4  and collar  52  along the guide shaft  44 . The block  4  has a sole  20  fixedly attached to the bottom block surface  12  by sole set screws  33  within the sole  20  and the block  4 . 
         [0022]    The block  4  is composed of a durable metal (e.g., hardened aluminum) and generally includes a front block surface  6 , a back block surface  8 , top block surface  10 , bottom block surface  12 , side block surfaces  14  and a cleat  34 . The cleat  34  consists of a portion of the front block surface  6  that protrudes below the bottom sole surface  28 , creating a bottom cleat surface  38  and a back cleat surface  36 . The block  4  is fixedly secured to the front end of the guide shaft  44  by suitable mechanical fasteners, such as block set screws or pins  18  within the block  4 . 
         [0023]    The sole  20  is comprised of a suitable material that will not mar the surface of the engineered flooring system  80  (e.g. high molecular weight (HMW) plastic), and fits snugly against the bottom block surface  12  and the upper portion of the back cleat surface  36  along the top sole surface  26 , and the front sole surface  22  respectively, thereby creating the back cleat surface  36 . The sole  20  is fixedly secured to the bottom block surface  12  by sole set screws  33  within the sole  20  and the block  4 . The side sole surface  30  is flush with the side block surface  14 , and the back block surface  8  is flush with the back sole surface  24 . 
         [0024]    The cylinder  46  is comprised of a durable metal (e.g., steel) with a front cylinder surface  48 , back cylinder surface  50 , and center cylinder bore  51 . The cylinder  46  has a length of, for example, approximately 2.5″ between the front cylinder surface  48  and back cylinder surface  50 , and a diameter of, for example, approximately 2″. The center cylinder bore  51  is a diameter of, for example, approximately ⅜″ throughout extending the longitudinal length of the cylinder  46  from the center of the front cylinder surface  48  to the center of the back cylinder surface  50 . 
         [0025]    The guide shaft  44  consists of a first end  3  and second end  5 , and is comprised of a durable metal (e.g., steel) with a length of, for example, approximately 15″, and a diameter of, for example, approximately ⅜″, and extends longitudinally from the interior of the block  4  at the first end  3  through the back block surface  8 , through the center cylinder bore  51 , through the front collar surface  54 , terminating at the second end  5  within the collar  52 . The guide shaft has a cross-sectional diameter less than the diameter of the center cylinder bore  51  allowing the cylinder  46  to freely move along the guide shaft  44 . 
         [0026]    The collar  52  is located at the second end  5  of the flooring installation tool  2 , and is comprised of a durable metal (e.g., steel) with a length of, for example, approximately 2.5″, a cross-sectional diameter of, for example, approximately ¾″, and a center collar bore  53  greater than the diameter of the guide shaft  44 . The collar  52  extends longitudinally through the foot  60 . The collar  52  is fixedly secured to the second end  5  of the guide shaft  44  by suitable mechanical fasteners, such as collar set screws or pins  58  within the collar  52 . 
         [0027]    The foot  60  is located at the second end  5  of the flooring installation tool  2 , and is comprised of a suitable material that will not mar the surface of the engineered flooring system  80  (e.g. plastic), with a thickness of, for example, approximately ¾″ thick. The foot  60  fits snug around the back end of the collar  52 , fixedly secured to the second ends of the guide shaft  44 , and the collar  52  by a foot set screw  70  within the foot  60 , collar  52 , and guide shaft  44 . 
         [0028]      FIG. 2  shows an aspect of the flooring installation tool  2  as it is used to install a first flooring plank  75  when said plank abuts an obstacle such as a wall  74 . The flooring installation tool  2  is positioned relative to the first flooring plank  75  whereby the bottom cleat surface  38  is placed on the top portion of a tongue profile  82  with the lower portion of the front block surface  6  in snug contact with the remaining edge of the first flooring plank  75 . The bottom foot surface  68  rests upon the floor  72 . The first flooring plank  75  is driven into place by sliding the cylinder  46  longitudinally along the guide shaft  44  from the second end  5  toward the first end  3  thereby bringing the front cylinder surface  48  in contact with the back block surface  8  with sufficient force to move the first flooring plank  75  into the desired alignment. 
         [0029]      FIG. 3  shows an aspect of the flooring installation tool  2  as it is used to install a third flooring plank  78  into alignment with a second flooring plank  76  when there is no obstacle preventing positioning the foot  60  of the flooring installation tool on the installed portion of the engineered flooring system  80 . The flooring installation tool  2  is positioned relative to the third flooring plank  78  whereby the back edge of the bottom sole surface  28  is placed on the top portion of a tongue profile  82  with the back sole surface  24  in snug contact with the remaining edge of the third flooring plank  78 . The bottom foot surface  68  rests upon the installed portion of the engineered flooring system  80 . The groove profile  84  of the third flooring plank  78  is driven into the tongue profile  82  of the second flooring plank  76  by sliding the cylinder  46  longitudinally along the guide shaft  44  from the first end  3  toward the second end  5  thereby bringing the back cylinder surface  50  in contact with the front collar surface  54  with sufficient force to move the third flooring plank  78  into the desired alignment with the second flooring plank  76 . 
         [0030]      FIG. 4  shows an aspect of the flooring installation tool  2  as it is used to install a third flooring plank  78  when said plank abuts an obstacle such as a wall  74 . The flooring installation tool  2  is positioned relative to the third flooring plank  78  whereby the bottom cleat surface  38  is placed on the top portion of a tongue profile  82  with the back cleat surface  36  in snug contact with the remaining edge of the third flooring plank  78 . The bottom foot surface  68  rests upon the installed portion of the engineered flooring system  80 . The groove profile  84  of the third flooring plank  78  is driven into the tongue profile  82  of the second flooring plank  76  by sliding the cylinder  46  longitudinally along the guide shaft  44  from the first end  3  toward the second end  5  thereby bringing the back cylinder surface  50  in contact with the front collar surface  54  with sufficient force to move the third flooring plank  78  into the desired alignment with the second flooring plank  76 . 
         [0031]    It will be appreciated that the components of the flooring installation tool  2  can be used for various other applications. Moreover, the flooring installation tool  2  can be fabricated in various sizes and from a wide range of suitable materials, using various manufacturing and fabrication techniques. 
         [0032]    It is to be understood that while certain aspects of the invention have been shown and described, the invention is not limited thereto and encompasses various other embodiments and aspects.