Patent Publication Number: US-10767374-B1

Title: Floorboard gap fixing tool

Description:
RELATED APPLICATIONS 
     The present invention was first described in and claims the benefit of U.S. Provisional Application No. 62/400,719, filed Sep. 28, 2016, the entire disclosures of which are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to a tool used to fix and close gaps between adjacent planks of floating laminate or floating plank floor systems. 
     BACKGROUND OF THE INVENTION 
     Gaps are created between adjacent floor planks on floating floor systems between the short ends of adjacent planks within a row either due to poor installation, a change in humidity, an un-level subfloor and or high traffic, and other causes. There are a few currently available methods for fixing this common occurrence. Such methods are time consuming and potentially damaging to the floor planks and or wall base board molding. 
     The current tools used to fix this common problem require the removal of the wall base board molding and quarter round commonly known as kick molding or shoe molding. The removal of the molding allows for a tool with a flange to be inserted at the beginning or the end of the row of planks where the gap between adjacent floorboards has occurred. The user inserts the tool such that the flange of the tool makes contact with the side of the floorboard that is exposed only after the removal of the wall board base molding. Force is then applied to the device by hitting with a hammer or prying with a pulling iron. The entire row of planks must be moved at one (1) time in order to close the gap. 
     There are numerous disadvantages to using the currently available devices to close the aforementioned gaps. First, wall base board molding needs to be removed in order to gain access to the end or beginning of the row in which the gap has occurred. Under most circumstances, this is not feasible because furniture or appliances are blocking access to all or a portion of the wall base board molding. Second, removal of the wall base board molding is difficult, requires special tools and skills, and it is not uncommon during the removal process for damage to occur to the molding, the wall, or the flooring planks. Third, a large amount of force must be generated in a horizontal direction in order to move the entire row of planks. The force applied can cause chipping or damage to the floor plank in which the force is initially exerted. Fourth, in order to use the currently available devices, there is a lot of setup which includes moving furniture, gather various tools to remove wall base board molding and careful removal of the wall base board molding. After the gap is closed, wall base board molding will need to be reattached to the wall and furniture will need to be move back to its previous location. The entire process will need to be repeated when another gap between adjacent flooring planks occurs. Often times the hassle of closing frequently occurring gaps using the currently available methods and tools is too great and a homeowner will not fix the gaps. 
     Another currently available method for closing gaps between floor planks is to fill in the gaps with wood filler or another filler compound. The compound is then allowed to dry. After drying the compound is then sanded and stained. There are numerous disadvantages to using compound to fill in gaps that occur between adjacent floor planks. First, the process does not allow the planks to expand and contract with changes in humidity which can lead to floor planks buckling. Second, it is difficult to match the texture and the color of the filler compound to that of the surrounding floor planks. This leaves the gap filler compound noticeably different than the surrounding floor planks. 
     There are numerous advantages that a tool can employ that lessens or eliminates the problems identified above. A first benefit that such an invention can eliminate the need to remove any wall base board molding. Such an invention attaches to the top face of the floating floor planks. No special tools, skill or care is needed to remove wall base board molding because there is no need to gain access to the side of the floating floor plank. No wall base board molding need be removed to use the invention. The amount of time needed to close gaps that occur between adjacent floor planks is minimal compared to using currently available methods and devices. A second benefit of such a tool would substantially lessen the amount of force needed to generate horizontal movement of the floor planks. Floor planks are moved one (1) at a time rather than having to move multiple floor planks at one (1) time with a force generated at the beginning or end of each row. Each floor plank is moved individually and force is exerted only on the floor plank the invention is temporarily attached. A third benefit of such a device would eliminate the need to use messy compounds, fillers or stains to close gaps. There are numerous other advantages not listed that this invention has over currently available devices. 
     Some efforts to address this issue have been made. DE 202011104029 in the name of Flimm, U.S. Pat. App. Pub. No. 2006/278046 in the name of Gargano, U.S. Pat. No. 1,161,207 in the name of Hagel, and the Pacesetter® Combination Tapping Block. However, these solutions are not satisfactory. Therefore, there is a need for such a floating floorboard gap fixing tool that is easy to manipulate, does not damage the floorboards, and is lightweight, resilient, and durable. The present invention fulfills this need. 
     SUMMARY OF THE INVENTION 
     In view of the foregoing references, the inventor recognized the aforementioned inherent problems and observed that there is a need for a way to fix gaps that are inevitably formed between individual planks of floating floorboards. 
     To achieve the above objectives, it is an object of the present invention to provide a gap fixing tool that is heavy duty, lightweight, resilient enough to resist damage due to repeated striking, and capable of transferring a strike force to a subjacently attached floorboard plank to close the gap between it and an adjacent floorboard plank. Such a tool includes a base member, having a pair of distal ends, and a bottom surface. An adhesive pad is affixed to the bottom surface and is capable of removably adhering to a floorboard plank. A pair of end caps are affixed to the distal ends of the base member is some embodiments, and removably attached in other embodiment. The end caps provide a striking target for a mallet or other similar striking tool. 
     In certain embodiments, the base member is tubular with a square cross-section. Preferably, the material is made out of aluminum. However, other embodiments allow for the base member to be a solid material and also encompass any one (1) of different cross sections, such as circular, rectangular, oval, triangular, etc., and different sizes and materials, such as wood, plastic, steel, or other metal. 
     In certain other embodiments, the end caps are preferably made of heavy wall polyethylene square tubing plugs. Preferably, the end caps are permanently force fit inside the distal ends base member and do not extend beyond the top, bottom or side faces thereof. However, the end caps can be made from plastic, metal, rubber, other material and can be attached inside, outside, around the base member or not at all. 
     In certain other embodiments, the adhesive pad is made from an acrylic foam sheet that covers substantially the entire bottom face of the base member. However the micro suction pad can be made from different materials such as adhesives, dry adhesives, or suction cups. Furthermore, the adhesive pad can have different cross-sections, such as circular, square, triangular, oval etc., and it can cover varying amounts of surface area on the bottom face of the base member. Other means of bonding to the base member can occur, such as, glue, weldments, adhesive tape, or other fastening means. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which: 
         FIG. 1  is a first side view of a preferred embodiment of a gap fixing tool  12 ; 
         FIG. 2  is an exploded first side elevation view of the tool  12 ; 
         FIG. 3  is a bottom plan view of the tool  12 ; 
         FIG. 4  is a side view showing a gap  13  between adjacent floorboards  17 ,  17 A, depicting a first step in a preferred operation of the tool  12 ; 
         FIG. 5  is a close-up view of detail A (see  FIG. 4 ); 
         FIG. 6  is a side view showing a gap  13  between adjacent floorboards  17 ,  17 A, depicting a subsequent step in a preferred operation of the tool  12 ; 
         FIG. 7  is a side view showing a gap  13  between adjacent floorboards  17 ,  17 A, depicting a second subsequent step in a preferred operation of the tool  12 ; 
         FIG. 8  is a side view showing a final disposition of a preferred operation of the tool  12 ; 
         FIG. 9  is a top view showing a gap between four (4) adjacent floorboards  19 ,  19 A,  19 B,  19 C; 
         FIG. 10  is a side elevation view of the distal end  35  of the base  40  of the tool  12 ; and, 
         FIG. 11  is a side elevation view of an individual end cap  41  of the tool  12 . 
     
    
    
     DESCRIPTIVE KEY 
     
         
         
           
               9  first quarter round molding 
               9 A second quarter round molding 
               10  first wall base board molding 
               10 A second wall base board molding 
               11  first wall 
               11 A second wall 
               12  gap fixing tool 
               13  gap 
               14  first subsequent gap 
               16  second subsequent gap 
               17  first wall-adjacent floorboard 
               17 A second wall-adjacent floorboard 
               18  floating floor floorboard 
               19  first gap-adjacent floorboard 
               19 A second gap-adjacent floorboard 
               19 B third gap-adjacent floorboard 
               19 C fourth gap-adjacent floorboard 
               30  interior 
               35  distal end 
               40  base 
               41  end cap 
               42  suction pad 
               43  end cap insert member 
           
         
       
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within  FIGS. 1-3, 10, and 11  and an intended method of use depicted in  FIGS. 4-9 . However, the invention is not limited to the described embodiment, and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention and that any such work around will also fall under the scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one (1) particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope. 
     The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one (1) of the referenced items. 
     The gap fixing tool (herein described as the “tool”)  12 , is particularly suited for reducing or eliminating gaps that occur between adjacent floorboards  19 ,  20  of a floating flooring installation. Referring to  FIG. 1 , a view from a first side of the tool  12 , illustrates the base  40 , a pair of end caps  41  each removably attached to distal ends  35  of the base  40 , and a suction pad  42  bonded to a bottom surface of the base  40  in this preferred embodiment. Other materials, such as metallic, plastic, or wood may also be used as well. Also, it is appreciated that the base  40  can be a solid structure in some embodiments. Preferably the base  40  can be made from an aluminum square tube with a cross section of two inches by two inches (2×2 in.) with one-eighth inch (⅛ in.) wall and is ten inches (10 in.) long. Such a shape is beneficial in that it is able to fully fit onto most conventional sized floating floorboards on the market. 
     The base  40 , in a preferred embodiment, is hollow which defines an interior  30 . This enables for the friction fitting of the insert portion  43  of the end caps  41  on each distal end  35  of the base  40 . Preferably, the end caps  41  are made of a heavy wall polyethylene square tubing plugs specifically made for two inch square (2 in. 2 ) tubing with a one-eight inch (′/8 in.) wall. The end caps  41  are preferably permanently force fit inside the openings on each distal end  35  of the base  40 , although other embodiments may provide end caps  41  that are removably attached to the distal ends  35  of the base  40 . In the preferred embodiment, the end caps  41  each have an insert portion  43  having an area enabling minimal or no clearance with the inner wall of the interior  30  of the distal ends  35  of the base  40 . It is preferred that the perimeter edges of the end caps  41  is coextensive with the perimeter edges of the distal ends  35  of the base  40 , such that the tool  12  has a continuous width when either or both end caps  41  are affixed or attached to the base  40 . 
     The suction pad  42  is preferably made from acrylic foam sheet measuring one-point-nine hundred seventy-five inches (1.975 in.) wide by nine-point-ninety-five inches (9.95 in.) long by eight-tenths of a millimeter (0.8 mm) thick. The suction pad  42  has a first side which is bonded to the bottom of the base  40  with an adhesive. The adhesive may be permanent or non-permanent. The preferred acrylic foam sheet material is suitable for removable adherence to materials typically associated with conventional floating floorboards, such as wood or laminate. The second side opposite the first side of the suction pad  42  is preferably backed with a releasable backing, intended to be removed prior to use. 
       FIG. 2  depicts an exploded first side view of the tool  12  showing the base  40 , the end caps  41  and the suction pad  42  in this preferred embodiment. In some embodiments, the base  40  is a square tube with a cross-section of two by two inches (2×2 in.) with one-eighth inch (⅛ in.) wall and is ten inches (10 in.) long and made of aluminum. However, the base  40  can have different cross-sections, such as circular, rectangular, oval, triangular, etc., and different sizes and materials, such as wood, plastic, steel or other metal.  FIG. 10  depicts one (1) of the distal ends  35  with the respective end cap  41  not present, so the interior  30  can be seen. 
       FIG. 3  is a perspective bottom-side view of the invention showing the end caps  41  and the suction pad  42 . The suction pad  42  is preferably attached to and extends the substantially the entire width and length of the base  40  in this preferred embodiment. 
     In some embodiments, the end caps  41  are made of heavy wall polyethylene square tubing plugs two by two inches (2×2 in.) and are friction fit into the hollow longitudinal distal ends  35  of the base  40 .  FIG. 11  illustrates the insert portion  43  of an individual end cap  41  in a preferred embodiment such that it can be inserted into the distal ends  35  of the base  40  when the base  40  embodiment is tubular. However other embodiments of the device do not require end caps  41  or have end caps  41  made from plastic, metal, rubber, other material and can be attached inside, outside, or around the base  40  such that the end caps  41  and base  40  do not have a continuous outer perimeter edge. 
     In some embodiments, the suction pad  42  is a rectangle with a cross-section of one-point-nine hundred seventy-five inches (1.975 in.) wide by nine-point-ninety-five inches (9.95 in.) long by eight-tenths of a millimeter (0.8 mm) thick and covers substantially the entire bottom face of the base  40  and is bonded thereto with an adhesive. However, the suction pad  42  can have different cross-sections, such as circular, square, triangular, oval etc., and can cover varying amounts of surface area on the bottom face of the base  40 . The suction pad  42  can be bonded thereto by adhesive, glue, heat welded, taped, or another similar bonding means. 
       FIG. 4  illustrates a first step of a preferred method of use for the tool  12 , wherein a gap  13  exists between two (2) adjacent floorboards  19 ,  20 . In this illustration, there are seven (7) floorboard planks  17 ,  17 A,  18 ,  19 ,  19 A that form a single row extending from first wall  11  to second wall  11 A. A first wall base board molding  10  and a first quarter round molding  9  are attached to the first wall  11  at the beginning of the row and cover the end of the first wall-adjacent floorboard  17  in the row (as depicted in  FIG. 5 ). A second wall base molding  10 A and a second quarter round molding  9 A are attached to the second wall  11 A at the end of the row and cover the end of the second wall-adjacent floorboard  17 A in the row. A gap  13  exists between the first gap-adjacent floorboard  19  (the fourth plank in the row) and the second gap-adjacent floorboard  19 A (the fifth plank in the row). To close the gap  13  that exists between the floorboards  19 ,  19 A in the row, the gap  13  is first cleaned of all debris using a vacuum or other means. The tool  12  is preferably placed onto and adhered to the gap-adjacent floorboard closest to either wall (in the illustrated example, this would be the second gap-adjacent floorboard  19 A which is closest to the second wall  11 A). This is achieved by offering the suction pad  42  bonded to the bottom face of the tool  12  to the top face of the second gap-adjacent floorboard  19 A. The tool  12  is firmly attached to the second gap-adjacent floorboard  19 A approximately one inch (1 in.) from the edge of the second gap-adjacent floorboard  19 A nearest to the gap  13  by imparting a firm force on the tool  12 . This can be accomplished by hand. 
     The end cap  41  of the tool  12  furthest from the gap  13  is then struck with a striking tool such as a mallet or hammer. The striking force delivered to the tool  12  is then transferred to the second gap-adjacent floorboard  19 A in a horizontal direction such that the second gap-adjacent floorboard  19 A travels relative to the base floor. Each impact of the striking tool on the tool  12  will result in horizontal movement of the second gap-adjacent floorboard  19 A in the direction of the first gap-adjacent floorboard  19 . Continued striking of the tool  12  in the above manner results in closing the gap  13  that existed between the first gap-adjacent floorboard  19  and second gap-adjacent floorboard  19 A in the row. The complementary facing ends of the first gap-adjacent floorboard  19  and second gap-adjacent floorboard  19 A are now snuggly fit together. When the operation is complete, a new gap  13  will have formed between the fifth plank of the row (now described as the first gap-adjacent floorboard  19 ) and the sixth plank of the row (now described as the second gap-adjacent floorboard  19 A) as shown in  FIG. 6 . The tool  12  is removed from the fifth plank of the row by prying up on the tool  12  by hand. 
       FIG. 6  illustrates a subsequent step from that illustrated in  FIG. 4  except that  FIG. 6  shows the gap  13  that did exist between the fourth plank and fifth plank in  FIG. 4  is now closed and a new subsequent gap  14  has formed between the fifth plank (now described as the first gap-adjacent floorboard  19 ) and the sixth plank (now described as the second gap-adjacent floorboard  19 ) due to the operation of the tool  12 . To close the subsequent gap  14  that exists between the fifth plank (now described as the first gap-adjacent floorboard  19 ) and the sixth plank (now described as the second gap-adjacent floorboard  19 ) in the row, the tool  12  is adhered to the sixth plank (now described as the second gap-adjacent floorboard  19 ) by offering the suction pad  42  bonded to the bottom face of the tool  12  to the top face of the sixth plank (now described as the second gap-adjacent floorboard  19 ). The tool  12  is firmly attached to the sixth plank (now described as the second gap-adjacent floorboard  19 ) approximately one inch (1 in.) from the edge of the sixth plank (now described as the second gap-adjacent floorboard  19 ) nearest to the gap  13  by imparting a firm force (preferably by hand). 
     The end cap  41  of the tool  12  furthest from the subsequent gap  14  is then struck, which then transfers the striking to the sixth plank (now described as the second gap-adjacent floorboard  19 ) in a horizontal direction such that the sixth plank (now described as the second gap-adjacent floorboard  19 ) travels relative to the base floor. Each impact of the striking tool will result in horizontal movement of the sixth plank (now described as the second gap-adjacent floorboard  19 ) in the direction of the fifth plank (now described as the first gap-adjacent floorboard  19 ). Continued striking of the tool  12  in the above manner results in closing the subsequent gap  14  that exists between the fifth plank (now described as the first gap-adjacent floorboard  19 ) and the sixth plank  22  in the row. The complementary facing ends of the fifth plank (now described as the first gap-adjacent floorboard  19 ) and the sixth plank (now described as the second gap-adjacent floorboard  19 ) are now snuggly fit together. When the operation is complete, a new second subsequent gap  16  will have formed between the sixth plank (now described as the first gap-adjacent floorboard  19 ) and the seventh plank (now described as the second gap-adjacent floorboard  19 ) as shown in  FIG. 7 . The tool  12  is then preferably removed by hand from the sixth plank (now described as the first gap-adjacent floorboard  19 ) by prying up. 
       FIG. 7  illustrates a second subsequent step from that illustrated in  FIG. 6  except that  FIG. 7  shows the subsequent gap  14  that did exist between the fifth plank and sixth plank in  FIG. 6  is now closed and a second subsequent gap  16  has formed between the sixth plank (now described as the first gap-adjacent floorboard  19 ) and the seventh plank (now described as the second gap-adjacent floorboard  19 ) due to the operation of the tool  12 . To close the second subsequent gap  16  that exists between the sixth plank (now described as the first gap-adjacent floorboard  19 ) and the seventh plank (now described as the second gap-adjacent floorboard  19 ) in the row, the tool  12  is adhered to the seventh plank (now described as the second gap-adjacent floorboard  19 ) by offering the suction pad  42  bonded to the bottom face of the tool  12  to the top face of the seventh plank (now described as the second gap-adjacent floorboard  19 ). The tool  12  is firmly attached to the seventh plank (now described as the second gap-adjacent floorboard  19 ) approximately one inch (1 in.) from the edge of the seventh plank (now described as the second gap-adjacent floorboard  19 ) nearest to the gap  13  by imparting a firm force (preferably by hand). 
     The end cap  41  of the tool  12  furthest from the second subsequent gap  16  is then struck, which then transfers the striking to the seventh plank (now described as the second gap-adjacent floorboard  19 ) in a horizontal direction such that the seventh plank (now described as the second gap-adjacent floorboard  19 ) travels relative to the base floor. Each impact of the striking tool will result in horizontal movement of the seventh plank (now described as the second gap-adjacent floorboard  19 ) in the direction of the sixth plank (now described as the first gap-adjacent floorboard  19 ). Continued striking of the tool  12  in the above manner results in closing the second subsequent gap  16  that exists between the sixth plank (now described as the first gap-adjacent floorboard  19 ) and the seventh plank  22  in the row. The complementary facing ends of the sixth plank (now described as the first gap-adjacent floorboard  19 ) and the seventh plank (now described as the second gap-adjacent floorboard  19 ) are now snuggly fit together. When the operation is complete, the gap has traversed underneath the second quarter round molding  9 A and second wall base board molding  10 A at the second wall  9 A. The tool  12  is then preferably removed by hand from the seventh plank (now described as the first gap-adjacent floorboard  19 ) by prying up. 
       FIG. 8  illustrates the second subsequent gap  16  that did exist between the sixth plank and seventh plank in  FIG. 7  is now closed. No gaps exist between the flooring planks in the row. Also, the quarter round molding  9  at the beginning of the row covers the end of the first wall-adjacent floorboard  17  in the row and the second quarter round molding  9 A at the end of the row covers the end of the second wall-adjacent floorboard  17 A in the row. 
       FIG. 9  is a top view showing additional rows of flooring planks. There are three (3) rows of flooring planks shown. The first row is made up of seven (7) floor planks, the second row is made up of seven (7) floor planks, and the third row is also made up of seven (7) floor planks. The first wall-adjacent floorboards  17  of each row is covered by wall base molding  10  and quarter round molding  9 , both of which are attached to the first wall  11 . The second wall-adjacent floorboards  17 A of each row is covered by the second wall base molding  10 A and second quarter round molding  9 A, both of which are attached to the second wall  11 A. A gap  13  exists between the first gap-adjacent floorboard  19 , second gap-adjacent floorboard  19 A, third gap-adjacent floorboard  19 B, and fourth gap-adjacent floorboard  19 C. Closure of this gap  13  is accomplished using the method described above. 
     The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.