Flooring system for and methods of installing decking material directly atop an installation surface

A flooring system that may include one or more floor members, wherein the one or more floor members may be configured together to form a floor covering atop an installation surface, which may be a non-dry environment, and wherein one or more of the one or more floor members are secured directly to the installation surface, and wherein the one or more floor members is made of a non-wood decking material. The one or more floor members may include one or more holding floor members, and one or more floating floor members, wherein the one or more holding floor members engage with one or more of the one or more floating floor members to form the floor covering atop the installation surface, and wherein the holding floor members are configured and arranged to secure the floor covering in place atop the installation surface.

TECHNICAL FIELD

The presently disclosed subject matter relates generally to flooring systems and more particularly to a flooring system for and methods of installing decking material directly atop an installation surface, such as concrete.

BACKGROUND

Home porches and patios often have concrete floors. However, concrete floors can have certain drawbacks. For example, the appearance of concrete floors is often not aesthetically pleasing. Further, for some people, the feeling of walking or, for example, using a rocking chair on a hard concrete surface is not desirable. Because it is difficult to install fasteners into concrete, sleeper systems have been used for installing, for example, a wooden floor atop a concrete surface. However, many home porches and patios do not have enough vertical clearance to allow the installation of a sleeper system. Further, sleeper systems for wooden flooring are not suitable for non-dry environments.

SUMMARY

In one embodiment, the invention provides a flooring system. The flooring system may include one or more floor members, wherein the one or more floor members are configured together to form a floor covering atop an installation surface, and wherein one or more of the one or more floor members are secured directly to the installation surface; and wherein the one or more floor members includes a non-wood decking material. The installation surface may be a non-dry environment. The one or more floor members may include one or more holding floor members; and one or more floating floor members, wherein the one or more holding floor members engage with one or more of the one or more floating floor members to form the floor covering atop the installation surface, and wherein the holding floor members may be configured and arranged to secure the floor covering in place atop the installation surface. The holding floor members may be directly secured to the installation surface. The one or more of the one or more holding floor members and one or more of the one or more floating floor members may be directly secured to the installation surface. The one or more of the one or more holding floor members may engage with one or more of the one or more floating floor members in an interlocking fashion. The installation surface may be an existing flooring surface. The installation surface may be any one or more of a concrete surface, stone surface, tile surface, and/or brick surface. The the non-wood decking material may include at least one of composite decking material and poly(vinyl chloride) (PVC) decking material. The one or more of the one or more floor members may be secured to the installation surface using at least one of an adhesive and mechanical fastener. The mechanical fastener may be at least one of a screw, bolt, and nail. The one or more of the one or more holding floor members may include a notch formed on at least one underside side edge of the holding floor member, and wherein the notch may span substantially an entire length of the underside side edge. The one or more of the one or more floating floor members may include a notch formed on a upper side of at least one end of the floating floor member, and wherein the notch may span substantially an entire width of the at least one end. The one or more of the one or more holding floor members may include a notch formed on at least one underside side edge of the holding floor member, wherein the notch may span substantially an entire length of the underside side edge; and wherein one or more of the one or more floating floor members may include a notch formed on a upper side of at least one end of the floating floor member, wherein the notch may span substantially an entire width of the at least one end. The notch of the one or more floating floor members may be configured to interlock with the notch of the one or more holding floor members. The plurality of floating floor members may be secured in place atop the installation surface by a lessor number of holding floor members. The flooring system may further include a buffer layer disposed between the floor covering and the installation surface. The one or more of the one or more floor members may include one or more drainage channels along an underside thereof. The one or more of the one or more floor members may include a ramp feature or step transition feature on an upper surface thereof. The flooring system may further include a ramp strip. The flooring system may further include a holding strip, wherein the holding strip may be secured to at least one of the installation surface and an adjacent structure. The portion of the flooring system where the one or more holding floor members engage with one or more of the one or more floating floor members may be substantially hidden from view.

In another embodiment, the invention provides a method of installing the flooring system atop an installation surface. The method may include providing a flooring system that may include one or more floor members, wherein the one or more floor members are configurable to form a floor covering atop the installation surface, and wherein the one or more floor members are made of non-wood decking material; arranging the floor members on the installation surface to group the one or more floor members to form the floor covering configuration; and securing one or more of the one or more floor members directly to the installation surface, such that the floor covering is secured in place atop the installation surface. The one or more floor members may include one or more holding floor members; and one or more floating floor members, wherein the one or more holding floor members engage with one or more of the one or more floating floor members to form the floor covering atop the installation surface, and wherein the holding floor members are configured and arranged to secure the floor covering in place atop the installation surface. The flooring system may include a clearance height that is substantial equal to the thickness of the one or more floor members. The installation surface comprises a non-dry environment.

DETAILED DESCRIPTION

In some embodiments, the presently disclosed subject matter provides a flooring system for and methods of installing decking material directly atop a concrete surface.

The presently disclosed flooring system includes an arrangement of floor members formed of long lasting, non-wood decking material, such as, but not limited to, composite decking, cellular poly(vinyl chloride) (PVC) decking, and the like. Namely, the floor members can be formed of any material that does not substantially degrade by prolonged (i.e., years of) direct contact with a concrete surface and in non-dry environments, such as any exterior environments and in basements.

In the presently disclosed flooring system, the floor members are laid directly atop the concrete surface, wherein the majority of floor members are left floating (hereafter called floating floor members) and held by a small number of floor members that are fastened to the concrete surface (hereafter called holding floor members). Further, both the floating floor members and the holding floor members include features, such as notches, that allow the floating floor members to interlock with the holding floor members. Additionally, the floating floor members greatly outnumber the holding floor members and because preferably only the holding floor members require fastening, the amount of mechanical fasteners required in the presently disclosed flooring system is greatly reduced compared to conventional flooring/decking systems. Accordingly, the presently disclosed flooring system provides an easy way to install and secure decking material directly atop a concrete surface, or any type of surface, such as, but not limited to, stone surfaces, tile surfaces, brick surfaces, composite surfaces, wood surfaces, and any combinations thereof.

For example, to install the flooring portion of a conventional wooden floor system, such as on a deck, a 12-ft×12-ft area requires, for example, 24 6-inch wide floor boards. If nailed or screwed every 16 inches, the entire installation would require 480 nails or screws (20 per board). By contrast, the same configuration using the presently disclosed flooring system includes 22 floating floor members (that require no mechanical fastening) interlocked with 4 holding floor members only, wherein each of the 4 holding floor members can require as few as 2 mechanical fasteners only, for a total of 8 mechanical fasteners for the entire installation. In this example, 8 concrete fasteners is very feasible for the entire 12-ft×12-ft installation, wherein using 480 concrete fasteners would be very difficult and not feasible. Namely, in this example, there is about a 98% reduction in the number of mechanical fasteners compared to conventional floor systems.

An aspect of the presently disclosed flooring system and methods is that it provides an easily installed, long lasting, moisture-tolerant, aesthetically pleasing, and pleasant feeling floor covering for any concrete surface, such as for a concrete porch floor, concrete patio floor, concrete basement floor, and concrete floor of any building. Namely, the presently disclosed flooring system and methods can be used to easily provide the look and feel of wood to a concrete surface.

Another aspect of the presently disclosed flooring system and methods is that it is suitable for use atop concrete in any non-dry environments, such as in any exterior environments and in basements.

Yet another aspect of the presently disclosed flooring system and methods is that it requires about one inch only (i.e., the thickness of the floor members) of vertical clearance atop the concrete surface, as compared with the several inches (which is very limiting) that is needed to install a conventional sleeper system.

Still another aspect of the presently disclosed flooring system and methods is that it is not limited to use atop concrete surfaces only. The presently disclosed flooring system can be used atop any type of surface, such as, but not limited to, concrete surfaces, stone surfaces, tile surfaces, brick surfaces, composite surfaces, wood surfaces, and any combinations thereof.

In the presently disclosed flooring system, “holding floor member” means any floor member that is directly secured to the concrete surface by, for example, adhesive; any type of screw, bolt, or nail for securing to concrete; or any other type of mechanical fastener for securing to concrete. Namely, the holding floor member is secured independently with no reliance on adjacent members and/or structures.

In the presently disclosed flooring system, “floating floor member” means any floor member that is not directly secured to the concrete surface by, for example, adhesive; any type of screw, bolt, or nail for securing to concrete; or any other type of mechanical fastener for securing to concrete. Rather, a floating floor member is held by gravity atop the concrete surface and held in place by interlocking with one or more adjacent floor members and/or by abutting any other structure or member. Further, a floor member may begin as a “floating floor member” and then can become a “holding floor member” if directly secured to the concrete surface at a later time.

Referring now toFIG. 1is a perspective view of an example of a standard porch structure100that has a concrete floor. Namely, the standard porch structure100is representative of any type of standard porch structure that includes a poured concrete floor, such as a concrete floor110. The concrete floor110is an example of a floor that is not aesthetically pleasing to look. Further, for some people, the feeling of walking or using a rocking chair on the concrete floor110may not be not desirable.

Referring now toFIG. 2is a perspective view of an example embodiment of the presently disclosed flooring system200for installing decking material directly atop a concrete surface of the standard porch structure100. Installing the presently disclosed flooring system200directly atop the concrete floor110can reduce or substantially eliminate the undesirable characteristics of the concrete floor110. Namely, the presently disclosed flooring system200can render the concrete floor110of the standard porch structure100aesthetically pleasing to the eye and pleasantly feeling to walk. Concrete surfaces may be improved by painting, staining, or applying any other decorative coating, or by installing tile thereon. However, neither coatings nor tile can provide the look and feel of wood. Accordingly, the presently disclosed flooring system200can provide the look and feel of wood, or wood like material to a concrete surface.

Whereas concrete can be difficult to attach a floor covering to, the presently disclosed flooring system200requires minimal attachment points for easy installation thereof. Namely, in the presently disclosed flooring system200, the floor members are laid directly atop the concrete surface, wherein the majority of the floor members are left floating (hereafter called floating floor members202) and held by a small number of floor members that are fastened to the concrete surface (hereafter called holding floor members204). Namely, both the floating floor members202and the holding floor members204include features, such as notches, grooves, or the like, that allow the floating floor members202to interlock/engage with the holding floor members204. Additionally, the floating floor members202greatly outnumber the holding floor members204. Because, preferably, only the holding floor members204require fastening, the amount of mechanical fasteners required in the presently disclosed flooring system200is very minimal compared to conventional flooring/decking systems. Accordingly, a main advantage of flooring system200is that the floating floor members202simply lay by gravity atop the concrete floor110and are held in place by interlocking with the holding floor members204. In so doing, the presently disclosed flooring system200provides an easy way to install and secure decking material directly atop a concrete surface. More details of example configurations of the presently disclosed flooring system200are shown and described hereinbelow with reference toFIG. 3throughFIG. 33.

The floating floor members202and the holding floor members204of the flooring system200can be formed of any long lasting materials that are not substantially effected by the prolonged presence of moisture (i.e., materials that substantially do not rot or degrade with prolonged moisture). That is, the floating floor members202and the holding floor members204of the flooring system200can be formed of any materials suitable for use in non-dry environments, such as any exterior environments and in basements. For example, the floating floor members202and the holding floor members204can be formed of composite decking materials, PVC decking materials, weather treated wood, and the like. Examples include, but are not limited to, composite decking, such as Trex® composite decking available from Trex Company, Inc. (Winchester, Va.) and TimberTech® composite decking available from TimberTech Building Products (Scranton, Pa.); and cellular PVC decking, such as AZEK® decking available from AZEK® Building Products, Inc. (Scranton, Pa.). These composite decking and PVC decking materials are available in various lengths, such 8, 10, 12, 14, 16, and 20 feet. Also, these composite decking and PVC decking materials are available in various thicknesses and widths, such as 1×6 inch, ¾×6 inch, 1×8 inch, ¾×8 inch, 1×12 inch, and ¾×12 inch.

Referring now toFIG. 3is a perspective view of an example of the presently disclosed flooring system200that includes examples of the floating floor members202and the holding floor members204. For example, the flooring system200shown inFIG. 3includes an arrangement of one-end-notched floor members210and a one-side-notched holding member220installed atop concrete floor110. The one-end-notched floor members210are an example of the floating floor members202described inFIG. 2. The one-side-notched holding member220is an example of the holding floor members204described inFIG. 2. In one example, each of the one-end-notched floor members210and the one-side-notched holding member220is about 6 inches wide and about 1 inch thick. However, any width and thickness is possible.

Each of the one-end-notched floor members210has a notched end212and an un-notched end214. The notch in the notched end212(seeFIG. 4) is facing up when installed. The one-side-notched holding member220has a notched side222and an un-notched side224. The notch in the notched side222(seeFIG. 5) is facing down when installed. Multiple one-end-notched floor members210are arranged side-by-side with the same orientation atop concrete floor110. Further, the one-end-notched floor members210are arranged tightly together so that their sides are in contact with each other. That is, there is substantially no space between adjacent one-end-notched floor members210. The number of one-end-notched floor members210can vary depending on the area to be covered.

Next, the one-side-notched holding member220is arranged in relation to the one-end-notched floor members210. Namely, the notch in the notched side222of the one-side-notched holding member220is engaged with the opposing notches of the one-end-notched floor members210. In so doing, the entire arrangement of the one-end-notched floor members210is interlocked with a single one-side-notched holding member220. Then, the single one-side-notched holding member220is secured to the concrete floor110. In so doing, the single one-side-notched holding member220can hold the entire arrangement of the one-end-notched floor members210in place atop concrete floor110without need of other fastening for the one-end-notched floor members210. In this configuration, one or both sides of the arrangement of the one-end-notched floor members210as well as the un-notched ends214of the one-end-notched floor members210may abut another structure. Further, in this configuration, the one-side-notched holding member220can hold the one-end-notched floor members210arranged on one side only of the one-side-notched holding member220.

Referring now toFIG. 4is a perspective view and a cross-sectional view of an example of the one-end-notched floor member210, wherein the cross-sectional view is taken along line A-A of the perspective view. The notched end212of the one-end-notched floor member210includes a notch216. The one-end-notched floor member210can be, for example, about 6, 8, or 12 inches wide. The one-end-notched floor member210has a thickness t. The notch216has a height h and a depth d. In one example, both the height h and depth d of the notch216is about half the thickness t of the one-end-notched floor member210. For example, if the thickness t of the one-end-notched floor member210is about 1 inch, then both the height h and depth d of the notch216is about 0.5 inches. In another example, the height h of the notch216is about half the thickness t of the one-end-notched floor member210and the depth d of the notch216is about equal to the thickness t of the one-end-notched floor member210. For example, if the thickness t of the one-end-notched floor member210is about 1 inch, then the height h of the notch216is about 0.5 inches and the depth d of the notch216is about 1 inch.

The presence of the notch216forms a lip218at the notched end212of the one-end-notched floor member210. Accordingly, the height h and depth d of the notch216can vary so long as the lip218that is formed has suitable structural integrity (i.e., is not easily broken).

Referring now toFIG. 5is a top perspective view, a bottom perspective view, and a cross-sectional view of an example of the one-side-notched holding member220, wherein the cross-sectional view is taken along line A-A of the top perspective view. The notched side222of the one-side-notched holding member220includes a notch226. The one-side-notched holding member220has a width w and a thickness t. The width w can be, for example, about 6 inches or about 8 inches. The notch226has a height h and a depth d. In one example, both the height h and depth d of the notch226is about half the thickness t of the one-side-notched holding member220. For example, if the thickness t of the one-side-notched holding member220is about 1 inch, then both the height h and depth d of the notch226is about 0.5 inches. In another example, the height h of the notch226is about half the thickness t of the one-side-notched holding member220and the depth d of the notch226is about equal to the thickness t of the one-side-notched holding member220. For example, if the thickness t of the one-side-notched holding member220is about 1 inch, then the height h of the notch226is about 0.5 inches and the depth d of the notch226is about 1 inch.

The presence of the notch226forms a lip228at the notched side222of the one-side-notched holding member220. Accordingly, the height h and depth d of the notch226can vary so long as the lip228that is formed has suitable structural integrity (i.e., is not easily broken).

Referring now toFIG. 6is a perspective view of another example of the presently disclosed flooring system200that includes other examples of the floating floor members202and the holding floor members204. For example, the flooring system200shown inFIG. 6includes an arrangement of the one-end-notched floor members210and a two-side-notched holding member230. Again, the one-end-notched floor members210are an example of the floating floor members202described inFIG. 2. The two-side-notched holding member230is another example of the holding floor members204described inFIG. 2. In one example, each of the one-end-notched floor members210and the two-side-notched holding member230is about 6 inches wide and about 1 inch thick. However, any width and thickness is possible.

The two-side-notched holding member230has two notched sides222, each with a notch. The notches in the notched sides222(seeFIG. 7) are facing down when installed. A first arrangement of one-end-notched floor members210is provided with the notched ends212oriented the same way. Then, a second arrangement of one-end-notched floor members210is provided with the notched ends212oriented the same way and facing the notched ends212of the first arrangement of one-end-notched floor members210.

Next, the two-side-notched holding member230is arranged in relation to both arrangements of one-end-notched floor members210. Namely, the notched sides222of the two-side-notched holding member230are engaged with both the notched ends212of the first arrangement of one-end-notched floor members210and the notched ends212of the second arrangement of one-end-notched floor members210.

In so doing, both arrangements of the one-end-notched floor members210are interlocked with a single two-side-notched holding member230. Then, the single two-side-notched holding member230is secured to the concrete floor110. In so doing, the single two-side-notched holding member230can hold both arrangements of the one-end-notched floor members210in place atop concrete floor110without need of other fastening for the one-end-notched floor members210. In this configuration, one or both sides of the arrangements of one-end-notched floor members210as well as the un-notched ends214of the one-end-notched floor members210may abut another structure. Further, a feature of this configuration is that the two-side-notched holding member230can hold the one-end-notched floor members210arranged on both sides thereof.

Referring now toFIG. 7is a top perspective view, a bottom perspective view, and a cross-sectional view of an example of the two-side-notched holding member230, wherein the cross-sectional view is taken along line A-A of the top perspective view. The two-side-notched holding member230has the notched side222on both sides. Each of the notched sides222of the two-side-notched holding member230includes the notch226and the lip228, as described inFIG. 5.

Referring now toFIG. 8is a perspective view of another example of the presently disclosed flooring system200that includes yet other examples of the floating floor members202and the holding floor members204. For example, the flooring system200shown inFIG. 8includes an arrangement of two-end-notched floor members240and two of the one-side-notched holding member220. The two-end-notched floor members240are another example of the floating floor members202described inFIG. 2. Again, the one-side-notched holding member220is an example of the holding floor members204described inFIG. 2. In one example, each of the two-end-notched floor members240and the one-side-notched holding member220is about 6 inches wide and about 1 inch thick. However, any width and thickness is possible.

Each of the two-end-notched floor members240has two notched ends212and no un-notched end214(seeFIG. 9). Multiple two-end-notched floor members240are arranged side-by-side. Further, the two-end-notched floor members240are arranged tightly together so that their sides are in contact with each other. That is, there is substantially no space between adjacent two-end-notched floor members240. The number of two-end-notched floor members240can vary depending on the area to be covered.

Next, one of the one-side-notched holding member220is arranged in relation to the one end of the two-end-notched floor members240. The other one-side-notched holding member220is arranged in relation to the other end of the two-end-notched floor members240. In so doing, the entire arrangement of the two-end-notched floor members240is interlocked between a pair of one-side-notched holding members220. Then, the pair of one-side-notched holding members220are secured to the concrete floor110. In so doing, the pair of one-side-notched holding members220can hold the entire arrangement of the two-end-notched floor members240in place atop concrete floor110without need of other fastening for the two-end-notched floor members240. In this configuration, one or both sides of the arrangement of the two-end-notched floor members240may abut another structure.

Referring now toFIG. 9is a perspective view and a cross-sectional view of an example of the two-end-notched floor member240, wherein the cross-sectional view is taken along line A-A of the perspective view. The two-end-notched floor member240has the notched end212on both ends. Each of the notched ends212of the two-end-notched floor member240includes the notch216and the lip218, as described inFIG. 4.

Referring now toFIG. 10AandFIG. 10Bis example methods of securing the holding floor members204to a concrete surface. For example,FIG. 10Ashows a one-side-notched holding member220secured to the concrete floor110via an adhesive250. The adhesive250can be, for example, any type of construction adhesive. Examples of construction adhesive include, but are not limited to, Loctite® PL® 375 Heavy Duty Construction Adhesive available from Henkel Corporation, (Westlake Ohio) and DAP® 7000® Construction Adhesive available from DAP Products Inc. (Baltimore, Md.).

FIG. 10Bshows a one-side-notched holding member220secured to concrete floor110via one or more mechanical fasteners252. The mechanical fasteners252can be, for example, screws or nails that are designed to penetrate concrete. In one example, the mechanical fasteners252are the Tapcon Concrete Anchors available from ITW Brands (Schaumburg, Ill.). The Tapcon Concrete Anchors are screw type anchors that come with a concrete drill bit. A hole is drilled through the hoding floor member204and into the concrete floor110. Then, the one-side-notched holding member220can be screwed to the concrete floor110via the Tapcon Concrete Anchor. In one example, the 3/16 inch×2¼ inch Tapcon Concrete Anchor can be used in the flooring system200.

Referring now toFIG. 11throughFIG. 16is an example of a process of installing the presently disclosed flooring system200directly atop a concrete surface while using minimal fasteners. In this example, the rear portion of the flooring system200abuts a wall of a structure, such as that of the standard porch structure100, and wherein the side portions of the flooring system200may or may not abut a structure.

FIG. 11shows multiple one-end-notched floor members210oriented in the same direction and being arranged side-by-side directly atop the concrete floor110. Again, the one-end-notched floor members210are an example of the floating floor members202described inFIG. 2.FIG. 12shows the multiple one-end-notched floor members210in place (i.e., side-by-side and touching) directly atop the concrete floor110. At this point in the process, the one-end-notched floor members210are simply held by gravity directly atop the concrete floor110. All of the notched ends212are arranged together and ready to receive any type of holding floor member204. By contrast, the un-notched ends214of the one-end-notched floor members210abut the wall of the structure.

FIG. 13shows the one-end-notched floor members210being arranged in relation the notched ends212of the one-end-notched floor members210. Again, the one-side-notched holding member220is an example of the holding floor members204described inFIG. 2.FIG. 14shows the one-side-notched holding member220engaged with the notched ends212of the one-end-notched floor members210.FIG. 15shows the one-side-notched holding member220secured to the concrete floor110using, e.g., two mechanical fasteners252. However, the number of mechanical fasteners252may depend on the length of the one-side-notched holding member220. In one example, a mechanical fastener252may be installed every 4 feet along the one-side-notched holding member220. In so doing, the one-side-notched holding member220is used to hold the one-end-notched floor members210in place atop the concrete floor110.

FIG. 16shows an example of one way to secure the un-notched ends214of the one-end-notched floor members210. Because the un-notched ends214of the one-end-notched floor members210abut the wall of the structure, a holding strip260can be installed at the junction of the one-end-notched floor members210and the wall. In one example, mechanical fasteners252can be installed vertically through the holding strip260, the one-end-notched floor members210, and into the concrete floor110. In another example, mechanical fasteners252can be installed horizontally through the holding strip260and into the wall of the structure.

Multiple configurations of the floating floor members202, the holding floor member204, and fastening schemes (e.g., adhesive250, mechanical fasteners252) in the presently disclosed flooring system200are possible. By way of example,FIG. 17AthroughFIG. 21Cshow examples of different configurations of the presently disclosed flooring system200installed directly atop a concrete surface while using minimal fasteners. WhileFIG. 17AthroughFIG. 21Cshow the mechanical fasteners252, the adhesive250can be used instead of or in combination with the mechanical fasteners252or in combination. Further, the fastening schemes can vary depending on abutting structures, wherein abutting structures can be used to retain the positions of certain floor members of the flooring system200.

FIG. 17AandFIG. 17Bshow an arrangement300of the one-end-notched floor members210in relation to the one-side-notched holding member220, albeit with different fastening schemes.FIG. 17Ashows at least two mechanical fasteners252in the one-side-notched holding member220and at least two mechanical fasteners252in both the two outermost one-end-notched floor members210. In this example, the two outermost one-end-notched floor members210can be considered holding floor members204. Accordingly, the arrangement300ofFIG. 17Afeatures as few as three (3) holding floor members204only regardless the number of floating floor members202, which can be in the dozens for a large area floor. Further, the arrangement300ofFIG. 17Afeatures as few as six (6) mechanical fasteners252for the entire installation.

The arrangement300ofFIG. 17Bis substantially the same asFIG. 17Aexcept for one additional mechanical fastener252in each of the un-notched ends214of the one-end-notched floor members210. Accordingly, in the configuration shown in arrangement300ofFIG. 17B, all flooring members are holding floor members, albeit sill with a minimal number of mechanical fasteners252.

FIG. 18A,FIG. 18B, andFIG. 18Cshow an arrangement400of the one-end-notched floor members210in relation to the one-side-notched holding member220and the holding strip260, albeit with different fastening schemes.FIG. 18Ashows at least two mechanical fasteners252in the one-side-notched holding member220, at least two mechanical fasteners252in both the two outermost one-end-notched floor members210, and at least two mechanical fasteners252in the holding strip260. In this example, the two outermost one-end-notched floor members210and the holding strip260can be considered holding floor members204. Accordingly, the arrangement400ofFIG. 18Afeatures as few as four (4) holding floor members204only regardless the number of floating floor members202, which can be in the dozens for a large area floor. Further, the arrangement400ofFIG. 18Afeatures as few as eight (8) mechanical fasteners252for the entire installation.FIG. 26shows an example of the presently disclosed flooring system200that uses the arrangement400ofFIG. 18A.

The arrangement400ofFIG. 18Bis substantially the same asFIG. 18Aexcept for the absence of mechanical fasteners252in one of the outermost one-end-notched floor members210. For example, one side of arrangement400may abut a wall, which holds this outermost one-end-notched floor member210in position and obviates the need for fastening.FIG. 27shows an example of the presently disclosed flooring system200that uses the arrangement400ofFIG. 18B. The arrangement400ofFIG. 18Cis substantially the same asFIG. 18Aexcept for the absence of mechanical fasteners252in both of the outermost one-end-notched floor members210. For example, both sides of arrangement400may abut a wall, which holds these outermost one-end-notched floor members210in position and obviates the need for fastening.

FIG. 19A,FIG. 19B, andFIG. 19Cshow an arrangement500of the two-end-notched floor members240arranged between two one-side-notched holding members220, albeit with different fastening schemes.FIG. 19Ashows at least two mechanical fasteners252in both the one-side-notched holding members220, and at least two mechanical fasteners252in both the two outermost one-end-notched floor members210. In this example, the two outermost one-end-notched floor members210can be considered holding floor members204. Accordingly, the arrangement500ofFIG. 19Afeatures as few as four (4) holding floor members204only regardless the number of floating floor members202, which can be in the dozens for a large area floor. Further, the arrangement500ofFIG. 19Afeatures as few as eight (8) mechanical fasteners252for the entire installation.

The arrangement500ofFIG. 19Bis substantially the same asFIG. 19Aexcept for the absence of mechanical fasteners252in one of the outermost one-end-notched floor members210. For example, one side of arrangement500may abut a wall, which holds this outermost one-end-notched floor member210in position and obviates the need for fastening. The arrangement500ofFIG. 19Cis substantially the same asFIG. 19Aexcept for the absence of mechanical fasteners252in both of the outermost one-end-notched floor members210. For example, both sides of arrangement500may abut a wall, which holds these outermost one-end-notched floor members210in position and obviates the need for fastening.

FIG. 20A,FIG. 20B, andFIG. 20Cshow an arrangement600of one two-side-notched holding member230in relation to two arrangements of one-end-notched floor members210, albeit with different fastening schemes.FIG. 20Ashows at least two mechanical fasteners252in the two-side-notched holding member230, at least two mechanical fasteners252in both the two outermost one-end-notched floor members210of the first arrangement, and at least two mechanical fasteners252in both the two outermost one-end-notched floor members210of the second arrangement. In this example, the outermost one-end-notched floor members210can be considered holding floor members204. Accordingly, the arrangement600ofFIG. 20Afeatures as few as five (5) holding floor members204only regardless the number of floating floor members202, which can be in the dozens for a large area floor. Further, the arrangement600ofFIG. 20Afeatures as few as ten (10) mechanical fasteners252for the entire installation.

The arrangement600ofFIG. 20Bis substantially the same asFIG. 20Aexcept for one additional mechanical fastener252in each of the un-notched ends214of the one-end-notched floor members210. Accordingly, in the configuration shown in arrangement600ofFIG. 20B, all flooring members are holding floor members, albeit sill with a minimal number of mechanical fasteners252. The arrangement600ofFIG. 20Cis substantially the same asFIG. 20Aexcept for the addition of the holding strip260on each end and no fastening of any one-end-notched floor members210. For example, both sides of arrangement600may abut a wall, which holds the outermost one-end-notched floor members210in position and obviates the need for fastening.

FIG. 21A,FIG. 21B, andFIG. 21Cshow an arrangement700of one two-side-notched holding member230and two one-side-notched holding members220for holding two arrangements of two-end-notched floor members240, albeit with different fastening schemes.FIG. 21Ashows at least two mechanical fasteners252in the two-side-notched holding member230, at least two mechanical fasteners252in both the one-side-notched holding members220, at least two mechanical fasteners252in both the two outermost two-end-notched floor members240of the first arrangement, and at least two mechanical fasteners252in both the two outermost two-end-notched floor members240of the second arrangement. In this example, the outermost two-end-notched floor members240can be considered holding floor members204. Accordingly, the arrangement700ofFIG. 21Afeatures as few as seven (7) holding floor members204only regardless the number of floating floor members212, which can be in the dozens for a large area floor. Further, the arrangement700ofFIG. 21Afeatures as few as fourteen (14) mechanical fasteners252for the entire installation.

The arrangement700ofFIG. 21Bis substantially the same asFIG. 21Aexcept for the absence of mechanical fasteners252in two of the outermost two-end-notched floor members240. For example, one side of arrangement700may abut a wall, which holds these outermost two-end-notched floor members240in position and obviates the need for fastening. The arrangement700ofFIG. 21Cis substantially the same asFIG. 21Aexcept for the absence of mechanical fasteners252in all of the outermost two-end-notched floor members240. For example, both sides of arrangement700may abut a wall, which holds these outermost two-end-notched floor members240in position and obviates the need for fastening.

Referring again to the configurations shown inFIG. 17A through 21C, in the presently disclosed flooring system200, the floor members are laid directly atop the concrete surface, wherein the majority of floor members are the floating floor members202that can be held by a small number of the holding floor members204. Further, both the floating floor members202and the holding floor members204include features, such as notches, that allow the floating floor members202to interlock with the holding floor members204and obviate the need for other fastening of the floating floor members202. Additionally, the floating floor members202greatly outnumber the holding floor members204and because only the holding floor members204require fastening, the amount of mechanical fasteners required in the presently disclosed flooring system200is greatly reduced compared to conventional flooring/decking systems. Accordingly, the presently disclosed flooring system provides an easy way to install and secure decking material directly atop a concrete surface.

For example, to install the flooring portion of a conventional flooring/decking system, such as a 12-ft×12-ft deck, requires, for example, 24 6-inch wide floor boards. If nailed or screwed every 16 inches, the entire installation would require 480 nails or screws (20 per board). By contrast, and referring now again to the configuration400shown inFIG. 18Aand the configuration500shown inFIG. 19A, the same configuration using the presently disclosed flooring system200includes 22 floating floor members202(that require no mechanical fastening) interlocked with 4 holding floor members204only, wherein each of the 4 holding floor members204can require as few as 2 mechanical fasteners252only, for a total of 8 mechanical fasteners252for the entire installation. In this example, 8 concrete fasteners is very feasible for the entire 12-ft×12-ft installation, wherein using 480 concrete fasteners would be very difficult and not feasible. Namely, in this example, there is about a 98% reduction in the number of mechanical fasteners compared to conventional floor systems.

The floor members of the presently disclosed flooring system200may include other features. In one example,FIG. 22shows a set of drainage channels242can be provided along the underside of any floor member, such as two-end-notched floor members240. Because the floor members of the flooring system200can lay directly atop the concrete surface, the drainage channels242may allow any moisture that accumulates beneath flooring system200to drain. Further, the presence of the drainage channels242may allow the flooring system200to “breath.” The number and spacing of the drainage channels242can vary. Further, the depth and width of the drainage channels242can vary. In one example, each drainage channel242is about 0.125 inches wide and about 0.125 inches deep.

In another example,FIG. 23Ashows a ramp feature221integrated into the upper surface of any floor member that abuts a step (or stair). The ramp feature221provides a step transition feature to compensate for the additional thickness of flooring system200at the location of a step (or stair).FIG. 23Bshows a separate ramp strip223that can be installed at the leading edge of the floor member. In yet another example,FIG. 24shows an example of the one-side-notched holding member220that has a beveled edge225. The beveled edge225can be set at any angle. For example, the angle of the beveled edge225can be about 30 degrees, about 45 degrees, or about 60 degrees. Where needed or desired, any floating floor member202and any holding floor member204of the flooring system200can have a beveled edge225.FIG. 25shows an example of the flooring system200that includes a step transition feature, such as the ramp feature221shown inFIG. 23A.

Referring now toFIG. 26andFIG. 27is example configurations of the presently disclosed flooring system200atop the concrete surface of the standard porch structure100and including a minimal amount of fastening. Namely,FIG. 26shows an example of the flooring system200formed using the arrangement400shown inFIG. 18A.FIG. 27shows an example of the flooring system200formed using the arrangement400shown inFIG. 18B.

Optionally, a buffer layer can be provided between the concrete surface and the flooring system200. For example,FIG. 28shows an exploded view of the flooring system200that further includes a buffer layer270between, for example, the concrete floor110and the flooring system200. The purpose of the buffer layer270is to provide a “padding” effect between possibly a rough surface of the concrete floor110and the underside of the flooring system200. The buffer layer270can be any water resistant and durable material, such as, but not limited to, felt roofing paper and weather barrier material, (e.g., DuPont™ Tyvek® HomeWrap®, an air and water barrier).

Referring now toFIG. 29is a flow diagram of an example of a method800of installing the presently disclosed flooring system200directly atop a concrete surface according to a simplest configuration. A main advantage of the method800is that the majority of floor members can be installed without the use of tools and without mechanical fasteners installed in the concrete. The method800may include, but it not limited to, the following steps.

At a step810, the floating floor members202and the holding floor members204are provided. For example and referring now to the arrangement500shown inFIG. 19A, multiple two-end-notched floor members240(i.e., the floating floor members202) and two one-side-notched holding members220(i.e., the holding floor members204) are provided. The number and length of the two-end-notched floor members240depends on the area to be covered. Likewise, the length of the one-side-notched holding members220depends on the area to be covered.

At a step812, the floating floor members202are arranged on the surface to be covered, all the while using no tools or fasteners. Continuing the example of the arrangement500shown inFIG. 19A, the two-end-notched floor members240(i.e., the floating floor members202) are arranged on the concrete floor110, all the while using no tools or fasteners.

At a step814, the holding floor members204are arranged with respect to the floating floor members202on the surface to be covered. Continuing the example of the arrangement500shown inFIG. 19A, the first one-side-notched holding member220(i.e., the holding floor member204) is arranged on the concrete floor110with respect to one end of the two-end-notched floor members240(i.e., the floating floor members202). Then, the second one-side-notched holding member220(i.e., the holding floor member204) is arranged on the concrete floor110with respect to the other end of the two-end-notched floor members240(i.e., the floating floor members202).

At a step816, the holding floor members204are secured to the surface to be covered. Continuing the example of the arrangement500shown inFIG. 19A, the first one-side-notched holding member220(i.e., the holding floor member204) is secured to the concrete floor110using, for example, adhesive250or as few as two mechanical fasteners252. Then, the second one-side-notched holding member220(i.e., the holding floor member204) is secured to the concrete floor110using, for example, adhesive250or as few as two mechanical fasteners252.

At an optional step818, one or more floating floor members202are secured to the surface to be covered. Continuing the example of the arrangement500shown inFIG. 19A, the two outermost two-end-notched floor members240(i.e., now becoming holding floor member204) are secured to the concrete floor110using, for example, adhesive250or as few as two mechanical fasteners252each.

Referring now toFIG. 30is a perspective view of the presently disclosed flooring system200in combination with other standard construction members. For example, the standard porch structure100may a screened in porch that includes a wood frame structure150. The wood frame structure150includes horizontal framing members152(aka top plates or sole plates, i.e., 2×4 s) as well as multiple vertical framing members154(e.g., wall studs, i.e., 2×4 s) attached to the horizontal framing members152. In this example, a notch153may be provided in the lower edge of one or more horizontal framing members152for receiving, for example, the un-notched ends214of the one-end-notched floor members210. In one example, the height h of the notch153can be about equal to the thickness t of the one-end-notched floor members210and the depth d of the notch153can be about 0.5 inches or about 1 inch.

FIG. 31andFIG. 32show yet other configurations of the presently disclosed flooring system200installed directly atop a concrete surface while using minimal fasteners. Namely,FIG. 31shows an arrangement900of floor members280, which can be, for example, standard composite decking boards with no modifications (e.g., no notches) that are attached directly atop the concrete floor110using adhesive250and/or mechanical fasteners252. Accordingly, in the configuration shown in arrangement900ofFIG. 31, all flooring members are holding floor members, albeit sill with a minimal number of mechanical fasteners252.FIG. 32shows an arrangement1000of two-side-notched holding members230arranged side-by-side in alternating fashion. In the arrangement1000, every other two-side-notched holding member230is attached and every other two-side-notched holding member230is floating. The two-side-notched holding members230can be bounded on each side by, for example, a one-side-notched holding member220.

The notches in the floating floor members202(e.g., one-side-notched holding members220and the two-side-notched holding members230) and in the holding floor members204(e.g., the one-end-notched floor members210and the two-end-notched floor members240) provide a means for holding or interlocking the floor members together directly atop a concrete surface that is substantially hidden from view. However, the presently disclosed flooring system200is not limited to notches for holding or interlocking the floor members together directly atop a concrete surface in a way that is substantially hidden from view. Any other type of substantially hidden holding or interlocking means can be used in the presently disclosed flooring system200. For example and referring now toFIG. 33, the presently disclosed flooring system200includes peg and hole joints290for interlocking the ends of the floating floor members202to the sides of the holding floor members204. The peg and hole joints290include pegs292that can be fitted into holes294in the floating floor members202and into holes294in the holding floor members204. WhileFIG. 33shows the holes294in one side only of the holding floor member204, the holes294can be in both sides of the holding floor member204.

Referring again toFIG. 2throughFIG. 33, the heads of the mechanical fasteners252can be substantially hidden or blended with the surface of the presently disclosed flooring system200. In one example, the heads of the mechanical fasteners252can be substantially the same color as the flooring members of the flooring system200. In another example, the heads of the mechanical fasteners252can be set slightly below floor level and capped with a camouflaging cap that substantially matches the surface texture and/or color of the flooring members of the flooring system200.

Further, the presently disclosed flooring system200and method800provides an easily installed, long lasting, moisture-tolerant, aesthetically pleasing, and pleasant feeling floor covering for any concrete surface, such as for a concrete porch, concrete patio, and concrete floor of any building. Namely, the presently disclosed flooring system200and method800can be used to provide the look and feel of wood to a concrete surface.

Further, the presently disclosed flooring system200and method800is suitable for use atop concrete in any non-dry environments, such as any exterior environments and in basements.

Further, the presently disclosed flooring system200and method800requires about one inch only (i.e., the thickness of the floating floor members202and the holding floor members204) of vertical clearance atop the concrete surface to be covered, as compared with the several inches (which is very limiting) that is needed to install a conventional sleeper system.

Further, the presently disclosed flooring system200and method800is not limited to use with concrete surfaces only. The presently disclosed flooring system200and method800can be used with any type of surface, such as, but not limited to, concrete surfaces, stone surfaces, tile surfaces, brick surfaces, composite surfaces, wood surfaces, and any combinations thereof.

Further, the presently disclosed flooring system200can be easily removed because of the lesser number of holding floor members204compared to the greater number of floating floor members202.