Patent Publication Number: US-2022220745-A1

Title: Quad spacer for installation of flooring systems

Description:
BACKGROUND 
     A flooring system comprises a series of interlocking panels installed above and in contact with a subfloor. The panels may be formed of natural wood, engineered flooring, laminate flooring or vinyl, vinyl tile, wood plastic composite, stone polymer composite, etc. 
     It is desirable to provide a horizontal gap or space or “offset” between the edge of the panel and an adjacent vertical wall. The space or “offset” from the wall accommodates expansion and shrinkage of the flooring normally attributable to factors such as changes in ambient temperature and humidity. In addition, when installing flooring, the vertical walls (typically drywall) do not always extend down to the level of the subfloor. There is frequently a vertical gap of one inch (2.54 cm) or more from the subfloor level to the bottom of the vertical drywall. Most of the flooring to be installed does not have a height (thickness) above the subfloor sufficient to cover this gap. The gap or space is normally covered by moulding for aesthetic purposes. 
     In addition, when installing a flooring above a subfloor where there is an opening, such as for a doorway into a closet or an adjacent room, or even for a doorway between the interior and exterior of a house, it is desirable to provide a horizontal gap or space between the edge of the flooring panels to accommodate expansion. The gap or space is subsequently covered by a threshold rather than covered by a moulding for aesthetic purposes. 
     When installing the flooring, each successive panel (wooden or laminate planks or strips, etc.,) is forced against the previously positioned panel to make the flooring joints secure. This results in pushing the flooring under the vertical gap between the bottom of the drywall and the subfloor. This creates a problem during installation of the floor and creates a problem in not accommodating normal expansion of the flooring after the installation has been completed. 
     In the past, installers would utilize wedges or shims placed vertically between the wall and the floor. However, any movement of the flooring toward the wall, such as when successive flooring members are pushed up against already-installed flooring members frequently forced the bottom of the wedges into the vertical space or gap at which point the wedges could rotate or pivot out of position and no longer be useful. Furthermore, since there was no standard in the construction industry for the size of the vertical gap and/or for any desired horizontal gap between the vertical wall and the flooring, while installers frequently had to use multiple wedges as spacers to accommodate a horizontal gap, there was no spacer to accommodate the larger vertical gap. 
     U.S. Pat. No. 8,881,418 (Funk) illustrates a spacer to provide a fixed horizontal gap between the edge of the flooring panels and an adjacent vertical wall. PCT Application No. PCT/US2019/056860 illustrates and describes a T-shaped spacer that provides three different spacings. Publication WO 02/06609 discloses a spacer for laying flooring. U.S. Patent Publication 2016/0244975 discloses a spacer assembly. U.S. Pat. No. 5,657,598 discloses a joint-making device. 
     SUMMARY 
     The present description relates to spacers that provide four alternate non-adjustable dimensions so that the installer may select the appropriately-dimensioned spacer without the need to maintain an excessive inventory, i.e., without the need to maintain four different inventories. The spacer may be used to provide spacing between the edge of the flooring and an associated wall and may be used to provide a suitable space between the flooring being installed and an adjacent flooring for a doorway or the like to accommodate a threshold device. 
     Significantly, the quad or four-dimensioned spacer is adapted for removal after use so that the spacer may be reused in subsequent installations. 
     In one embodiment, the present description relates to a spacer for creating a properly dimensioned gap during the installation of a flooring system, the spacer including three top surfaces each a different distance from the spacer bottom, each distance corresponding to a different intended floor spacing gaps. 
     In another embodiment the spacer for creating a properly dimensioned gap during the installation of a flooring system, includes three top surfaces each a different distance from the spacer bottom, each distance corresponding to a different intended floor spacing gap, and a width having a dimension different from the three different distances between the top surfaces and the bottom, to provide four different floor spacing gaps. 
     In yet another embodiment, the present description relates to a spacer for creating a properly dimensioned gap during the installation of a flooring system, including a first element extending in a first direction and joined to a projection element, the first direction and the projection element being generally perpendicular to each other, the first element having four different widths and/or thicknesses corresponding to four potential intended expansion gaps. 
     In any of the preceding embodiments, the expansion gaps may be approximately 0.636 cm, 0.953 cm, 1.27 cm and 2.54 cm, (0.25, 0.375, 0.5 and 1.0 inch) and in any of the embodiments the spacer may be moulded of a rigid suitable thermoplastic and may be moulded as a single, unitary body. 
     In any of the preceding embodiments, the spacer may be removable and reusable. 
     Yet another embodiment of the present invention is a method for installation of a flooring system according to any one or more of the preceding embodiments further including positioning the spacer on a subfloor adjacent a vertical surface to provide the desired expansion gap and positioning the flooring system to abut the spacer. 
     Yet another embodiment of the present invention is a method for installation of a flooring system according to any one or more of the preceding embodiments further including positioning the spacer on a subfloor adjacent a vertical edge of another horizontal surface to provide the desired expansion gap and positioning the flooring system to abut the spacer. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following drawings illustrate one form of the spacer and its use. The drawings are to be interpreted in a broad, non-limiting sense and as being exemplary. In the drawings, wherein like reference numerals identify corresponding components: 
         FIG. 1  is a perspective view of a quad spacer; 
         FIG. 2  is a second perspective view of a quad spacer; 
         FIG. 3  is a third perspective view of a quad spacer; 
         FIG. 4  is a fourth perspective view of a quad spacer; 
         FIG. 5  is a sectional view of a spacer positioned between a generally horizontal surface and a generally vertical surface to illustrate the provision of an expansion gap; 
         FIG. 6  is a perspective illustration of a spacer positioned between a generally horizontal surface and a generally vertical surface; and 
         FIG. 7  is a sectional view of a spacer positioned between two generally horizontal surfaces to provide an expansion gap. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to the drawings, it should be understood that terms such as top, bottom, left, right, first end, second, end, above, below, thin and thick are used as relative terms for explanatory purposes only and are not used in a limiting sense. Similarly, references to materials and shapes are intended solely as illustrative and thus are used in a non-limiting sense. 
     A spacer  10  may be formed as a unitary product or in multiple parts subsequently attached together. The spacer may be formed of one or more materials including but not limited to metal, plastic, rubber, and/or wood, and may be moulded of a rigid suitable thermoplastic material. The spacer has a generally rectangular base  12  having a bottom  14 , opposed first and second sides  16 ,  18 , and opposed first and second ends  20 ,  22 . For ease of explanation and not in a limiting sense, the distance between the first and second ends  20 ,  22 , will be referred to as the width and the distance between the first and second sides  16 ,  18 , will be referred to as the thickness. 
     The spacer  10  has a top with three different surfaces, each a different distance from the bottom of the spacer. The top with thus be referred to as a three-part top, each part being generally flat and generally parallel to the bottom  14 . The first top part  24  extends across the entire width of the spacer, i.e., between the ends  20 ,  22  and extends approximately  20 % of the thickness of the spacer starting at the first side  16  toward the second side  18 . The first top part  24  terminates at a vertical wall  26  extending upwardly across the entire width of the spacer from end  20  to end  22 . A projection extends upwardly from the vertical wall  26  and will be explained in greater detail below. 
     The second top part  28  extends from the vertical wall  26  across the width to the remainder of the thickness of the spacer to the second side  18 . The second top part  28  is generally parallel to the bottom  14  and generally parallel to the first top part  24 . The height of the spacer is greater between the second top part  28  and the bottom  14  than the height of the spacer between the first top part  24  and the bottom  14 , i.e., the top part  28  of the spacer is above the top part  24  of the spacer relative to the spacer bottom  14 . 
     The second top part  28  extends from the end  20  approximately 40% of the width of the spacer and terminates in an upwardly extending vertical wall  30 . 
     A projection  32  extends upwardly from the top of the spacer. The projection has a width approximately 60% of the width of the spacer starting from the end  22  and extending toward the end  20 . Thus, one edge of the projection is in the same plane as the end  22 . The projection has a thickness of approximately 20% of the thickness of the spacer and includes one or more apertures  34  through the thickness. The height of the projection is preferably greater than the width or thickness of the spacer. Thus, the spacer  10  is generally L-shaped with the projection forming the longer leg of the L. The front of the projection is in the same vertical plane as the plane of the vertical wall  26 . 
     The third top part  36  extends from the rear of the projection  32  to the second end  18  (length) and from the top of the vertical wall  30  to the end  22  which is approximately 60% of the width of the spacer. The height of the spacer is greater between the third top part  36  and the bottom  14  than the height of the spacer between the second top part  28  and the bottom  14 , i.e., the top part  36  of the spacer is above the top part  28  of the spacer relative to the spacer bottom  14 . 
     The relative non-adjustable dimensions of the spacer, in a non-limiting example, will now be explained. A first width W 1  is illustrated in  FIG. 1  as the distance between the first and second ends  20 ,  22  and is preferably 2.54 cm (1.0 inch). A second width W 2  is illustrated in  FIG. 2  as the distance between the third top part  36  and the bottom  14  and is preferably 1.27 cm (0.5 inch). A third width W 3  is illustrated in  FIG. 1  as the distance between the second top part  28  and the bottom  14  and is preferably 0.953 cm (0.375 inch) and a fourth width W 4  is illustrated in  FIG. 2  as the distance between the first top part  24  and the bottom  14 . This fourth width is preferably 0.635 cm (0.25 inch). 
     Referring next to  FIGS. 5, 6 and 7 , various uses of the spacer will now be explained. In FIG. 5 , flooring planks  40  (only a single plank is illustrated) are to be installed above a subfloor  42 . The flooring plank has a leading edge  44  and it is necessary to establish a gap or space between the leading edge  44  (of each plank) and the adjacent vertical wall  46 . In  FIG. 5 , the spacer is positioned with the projection  32  on the flooring plank, with the spacer bottom  14  in contact with the vertical wall  46 , and with the third top part  36  positioned to be in abutting relationship with the leading plank edge  44  as the planks are installed. In this exemplary arrangement, the gap or space between the leading plank edge and the vertical wall will correspond to width W 2 . Thus the spacer provides a deliberate gap between a plank lying in a first plane and a wall being in a second plane perpendicular to the first plane. 
       FIG. 6  is a perspective illustration of the use of the spacer as just described with respect to  FIG. 5 . 
     Referring next to  FIG. 7 , the use of the spacer to provide a gap between two planks that are in the same plane (or parallel planes) will now be described. As explained above, a gap in this situation may be desired when a threshold is to be used between flooring in adjacent rooms or even for a doorway between the interior and exterior of a building. 
     In  FIG. 7  there are two flooring planks  40  being installed on a subfloor  42 . The spacer is arranged with the projection  32  extending upwardly, away from the subfloor, and with the opposed ends  20 ,  22 , in position to abut the leading edges  44  of two adjacent planks  40 . In this arrangement, a gap is created between the adjacent planks with the gap having a width corresponding to the width of the spacer between ends  20  and  22 , which has been previously referred to as width W 1 . 
     Although not illustrated, multiple spacers should be positioned along the length of the wall (and thus along the length of the flooring planks) and one or more additional spacer should be positioned at the end of the plank adjacent a wall (not shown) perpendicular to the wall  46 , for example as would be typical in the corner of a room in a house. In this non-limiting illustration, an expansion gap is created and maintained between the vertical wall  46  and edge  44  of the flooring planks  40 . The positioning of the spacer with the projection  32  on top of the flooring plank  40  aids in maintaining the flooring plank in position during installation and also prevents the spacer  10  from pivoting out of position. The spacer  10  is easily removable after a suitable number of flooring planks  40  have been placed in position such that the spacer  10  may be reused. 
     If it is desired to have a different expansion gap between the flooring planks and the vertical wall, the spacer  10  should be oriented so that a different width (e.g., W 3 ) is positioned between the plank edge and the vertical wall. 
     Depending on variations in the positioning of the vertical walls within a room or within a house, the spacer  10  provides the advantage that the expansion gaps need not be the same size, rather, the installer of the flooring system may use different expansion gaps. It should also be appreciated that creating a horizontal expansion gap during installation of the flooring system is not the sole benefit of the spacer  10 . As one example, it should be appreciated that there is a vertical gap between the bottom of the vertical wall  44  and the top of the subflooring  50 . This gap is normally concealed by moulding at the conclusion of the installation of the flooring system. The use of the spacer  10  prevents the flooring from being unintentionally positioned within the vertical gap. Conduits, including but not limited to electrical, plumbing and/or ventilation conduits may be placed within the vertical gap without interference from the flooring and the conduits will subsequently be concealed by moulding. Thus, the physical height of the spacer is not limited by the thickness of the flooring planks  40 . 
     Although only one spacer  10  is illustrated, it should be appreciated that during the installation of a flooring system, spacers may be positioned at regular intervals along the length of the floor. If, for example the floor is formed of a series of planks  40  of 15.24 cm width and 182.88 cm length, then spacers may be placed every 30.48 cm along the length of a flooring plank and one spacer may be placed at the end of each flooring plank where the flooring plank would otherwise contact the wall. 
     It should further be appreciated that the spacer  10  provides a reusable apparatus that provides four different size non-adjustable expansion gaps relative to the flooring system. 
     The foregoing is a complete but non-limiting description of the removable, reusable spacer and the method of its use to provide four different spacing gaps during installation of flooring.