Patent Publication Number: US-2022228367-A1

Title: Linear surface covering system

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     The present application is a continuation of U.S. application Ser. No. 15/829,461, filed Dec. 1, 2017, which is a continuation of U.S. application Ser. No. 14/513,536, filed Oct. 14, 2014 (now U.S. Pat. No. 9,834,928), which is a continuation of U.S. application Ser. No. 12/660,583, filed Mar. 1, 2010 (now U.S. Pat. No. 8,857,121), which claims the benefit of U.S. provisional application Ser. No. 61/156,036, filed Feb. 27, 2009. The disclosures of the above applications are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The invention relates to a surface covering system, and, more specifically, to an improved linear surface covering system. 
     Conventional linear surface covering systems are sold by Armstrong World Industries, Inc. under the name WOODWORKS® Linear ceilings and Rulon Company under the name Linear Wood. These systems generally include a plurality of linear planks which are designed to install on linear carriers having factory attached clips. These conventional systems assure alignment and consistent spacing of planks. 
     The planks of these systems include a pair of grooves, or kerfs routed through the back surface of the plank. These grooves extend into the interior of the plank in a direction generally perpendicular to the back surface. The aforementioned factory-attached clips each have projections that insert into these grooves. In order for a plank to be seated fully on a linear carrier, the plank must be pushed onto the clip thereby allowing the clip projections to enter the grooves. Unfortunately, the existing groove and clip projection interface requires tool adjustment. For example, use of a clamping tool or mallet is likely necessary to ensure that the clip projections achieve a deep seat within the plank grooves and, thus, remain fixedly attached. Additionally, for proper installation, it may be required to draw tight any planks not fitting tightly on the carrier using a screw-type fastener, such as a self-tapping screw. This tightening is typically done after the planks have been seated into place by the necessary tool adjustment. 
     Additionally, since the linear planks themselves are typically made of natural building materials, they react to changes in humidity and natural stresses and, thus, have a tendency to warp, twist laterally or bow. As a result, without proper support, the seams at the plank ends, i.e. at the butt joint location, may be uneven or slightly twisted. Conventional wisdom for preventing uneven surfaces at these butt joint locations include increasing the thickness of the planks and/or adding reinforcement at the butt joint. What is needed is an improved system which facilitates quicker and simplified assembly in the field and improves stability at the plank seams. 
     SUMMARY OF THE INVENTION 
     The invention is an improved surface covering system having a plurality of planks which are installed on linear carriers having factory-applied clips attached thereto. The planks have first and second grooves routed through the back surface thereof. The factory-attached clips have projections that insert into these grooves. The improvement includes each plank having multi-directionally cut grooves. Preferably, at least a portion of these multi-directionally cut grooves are sloped in the direction toward one another. The improvement further includes clip projections which conform substantially to a notch formed by the multi-directional grooves. 
     The system also includes an improved splice plate for stabilizing two adjacent planks positioned in end-to-end relation. The splice plate has projections which are inserted into the multi-directional grooves of two abutting planks such that the splice is positioned across the butt joint. The splice plate also serves to align the planks laterally. The improvement includes the splice plate projections conforming substantially to a notch formed by the multi-directional grooves. The splice plate also includes a pair of reinforcement wings to counteract stresses which would otherwise result in misalignment at the butt joint location. 
     The aforementioned improvements also eliminate the need for tool adjustment to ensure the projections of both the clip and splice plate achieve a deep enough seat in the grooves in the back side of the plank. Mere hand pressure is enough to tightly seat the projections of both the clip and splice plate into the plank grooves. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a topside perspective view a portion of an exemplary surface covering system of the invention. 
         FIG. 2  is a side elevation view, partially exploded, of a portion of an exemplary surface covering system of the invention. 
         FIG. 3  is a perspective view of an exemplary clip. 
         FIG. 4  is a top plan view of an exemplary clip. 
         FIG. 5  is a front elevation view of an exemplary clip. 
         FIG. 6  is a side elevation view of an exemplary clip. 
         FIG. 7  is an exploded perspective view of two exemplary planks positioned end to end. 
         FIG. 8  is a detailed view of portion A shown in  FIG. 7 . 
         FIG. 9  is a perspective view of an exemplary splice plate. 
         FIG. 10  is a top plan view of an exemplary splice plate. 
         FIG. 11  is a front elevation view of an exemplary splice plate. 
         FIG. 12  is a side elevation view of an exemplary splice plate. 
     
    
    
     The same reference numbers will be used throughout the drawings to refer to the same or like parts. 
     DETAILED DESCRIPTION OF THE DRAWINGS 
       FIGS. 1 and 2  illustrate the improved surface covering system  1 . As shown, a plurality of linear carriers  10  are suspended in parallel relation to one another from ceiling hangers  12  such as the hanger wires shown therein. The linear carrier  10  may be a conventional inverted T-shaped grid element as shown. A plurality of clips  14  are attached to the carriers. As best shown in  FIGS. 3-6 , the clips have a substantially flat main body portion  15  having first and second opposed resilient carrier attachment legs  16 ,  18  which can be snapped up over the base  20  ( FIG. 2 ) of the linear carrier  10 . The attachment legs  16 ,  18  comprise a body  62  and two arms  61 , with a cutout  60  being located therebetween. The two arms  61  are located on opposite outward sides of the body  62  and include a distal end portion  63  that is bent inward toward the main body portion  15 . As the example embodiment shown illustrates, the carrier attachment legs  16 ,  18  can be snapped over the base  20 , i.e. the lower horizontal flange, of a conventional inverted T grid element. Though the clips  14  can be applied in the field, they are preferably factory attached to the linear carrier  10  for quicker and easier field installation. 
     As best seen in  FIG. 2 , the clips  14  attach a plurality of planks  22  to the linear carriers  10 , and, specifically in a direction perpendicular to the linear carriers. Each plank  22  extends along a centerline and comprises a back surface. Each plank  22  includes first and second multi-directionally grooves,  23  and  24  respectively, routed, i.e. cut, through the back surface of each plank. One improvement in and of itself over existing systems is that at least a portion of these groves are sloping, and, preferably, at least a portion of each groove is sloped inwardly in the direction toward one another. In the example embodiment shown, the grooves are formed by a first cut extending from the back surface of the plank and into the interior of the plank in an outward direction. A second cut extends inwardly, thus, forming a multi-directional groove. 
     As shown in  FIG. 2 , the first multi-directional groove  23  forms a first notch  25  in a sidewall of the first groove  23 . In the example embodiment shown, a first surface portion  26  of the first notch  25 —otherwise referred to as a first sloped surface—is sloped downwardly and outwardly. A second surface portion  27  of the first notch  25 —otherwise referred to as a first undercut surface—is sloped downwardly and inwardly. The first surface portion  26  of the first notch  25  (i.e., the first sloped surface) and the second surface portion  27  of the first notch  25  (i.e. the first undercut surface) intersect to form a first apex  29 . The second multi-directional groove  24  forms a second notch  25 ′ in a sidewall of the second groove  24 . In the example embodiment shown, a first surface portion  26 ′ of the second notch  25 ′—otherwise referred to as a second sloped surface—is sloped downwardly and outwardly. A second surface portion  27 ′ of the second notch  25 ′—otherwise referred to as a second undercut surface—is sloped downwardly and inwardly. The first surface portion  26 ′ of the second notch  25 ′ (i.e., the second sloped surface) and the second surface portion  27 ′ of the second notch  25 ′ (i.e. the second undercut surface) intersect to form a second apex  29 ′. 
     In the example embodiment shown, the first and second surface portions  26 ,  27  and  26 ′,  27 ′ form a 90 degree angle. As shown in  FIGS. 2-6 , each clip  14  has first and second projections,  28  and  30  respectively, for attaching a plank  22  to the linear carrier  10 . Each projection  28 ,  30  embodies the profile formed by the respective notch  25 ,  25 ′. More specifically, these projections  28 ,  30  are each bent in multiple directions. As with the notches  25 ,  25 ′ of the plank  22 , a first portion  31  of a protrusion extends downwardly and outwardly from the main body  15  at a first bend  35  while a second portion  32  extends integrally from the first portion  31  at a second bend  36 , the second portion  32  being bent downwardly and inwardly, i.e. in a direction toward the another clip protrusion. A third portion  34  of the protrusion extends integrally from the second portion  32  at a third bend  37 , the third portion  34  being bent downwardly and outwardly, i.e. in a direction away from the other clip protrusion. Having the third portion  34  extend downwardly and outwardly allows the protrusions  28 ,  30  to contact and readily pass by the first sloped surface of the first and second notches  25 ,  25 ′, thereby causing the protrusions  28 ,  30  to spread apart, as discussed herein. 
     In the outward direction, the third bend  37  is located between the first bend  35  and the second bend  36  and the second bend  36  is the farthest-most bend from the main body  15  in the outward direction. Along the downward direction, the second bend  36  is located between the first bend  35  and the third bend  37 , wherein the third bend is the farthest-most bend from the main body  15  in the downward direction. 
     The clips  14  are preferably made of a resilient material, such as resilient spring steel. Unlike existing linear surface covering systems, all that is required is for the projections  28 ,  30  of the clip  14  to contact a respective notch  25 ,  25 ′, thereby forcing the resilient projections to spread, thereby distorting the profile of the clip. Mere hand pressure in the direction of Arrow A ( FIG. 2 ) is all that is needed to distort the clip profile and snap the plank onto the carrier. One should here an affirmative “snap” noise to indicate that the plank is in proper position on the linear carrier. For each resilient clip  14 , the first protrusion  28  is configured to deform as the first protrusion  28  rides along the first sloped surface (i.e. the first surface portion  26  of the first notch  25 ) and passes over the first apex  29 . The first protrusion  28  is also configured to snap-fit into engagement with the first undercut surface (i.e., the second surface portion  27  of the first notch  25 ) after the third portion  34  of the first protrusion  28  passes over the first apex  29 . For each resilient clip, the second protrusion  30  is configured to deform as the second protrusion  30  rides along the second sloped surface (i.e., the second surface portion  27 ′ of the second notch  25 ′) and passes over the second apex  29 ′, and the second protrusion  30  snap-fitting into engagement with the second undercut surface (i.e., the first surface portion of the second notch  25 ′) after the third portion  34  of the second protrusion passes over the second apex  25 ′. 
     Installing the linear surface covering system  1  includes the steps of positioning a plank  22  adjacent to a resilient clip  14  that is mounted to a carrier  10  and applying pressure to the plank in the direction of Arrow A, which is substantially orthogonal to the back surface of the plank  22 . With pressure applied in the direction of Arrow A, the first protrusion  28  moves into the first multidirectional groove  23  and the second protrusion moves  30  into the second multi-directional groove  24 . During the movement of the first and second protrusions  28 ,  30  into the first and second multi-directional grooves  23 ,  24 , the first and second protrusions  28 ,  30  (1) spread outwardly from one another to allow a back portion  33  of the plank  22  to pass between the first and second protrusions  28 ,  30  during a first stage of said movement, and (2) then snap-back toward one another to engage the back portion  33  of the plank  22  upon a second stage of said movement, the second stage of said movement being subsequent to the first stage of said movement. Once snapped into place, application of pressure to the plank may be discontinued—thereby resulting in the plank being mounted to the carrier by the resilient clip. Thus, the need for tool adjustment to ensure the projections of the clip achieved a deep enough seat in the grooves is eliminated. Moreover, screws are not required to more positively secure the planks to the carriers. 
     In another embodiment, the linear surface covering system  1  is installed by positioning a plank  22  adjacent to a resilient clip  14  that is mounted to a carrier  10  and applying pressure to the plank in a direction of Arrow A, which is substantially orthogonal to the back surface of the plank. The pressure applied to the plank  22  causes the first protrusion  28  to move into the first multidirectional groove  23  and the second protrusion  30  to move into the second multi-directional groove  24 , wherein during said movement of the first and second protrusions  28 ,  30  into the first and second multi-directional grooves  23 ,  24 , the first and second protrusions  28 ,  30  (1) first spread outwardly from one another to allow a back portion  33  of the plank  22  to pass between the first and second protrusions  28 ,  30  during a first stage of said movement, and followed by snap-back toward one another to engage the back portion  33  of the plank  22  upon a second stage of said movement. The second stage of the movement is subsequent to the first stage of said movement. Finally, the application of said pressure to the plank is discontinued—thereby resulting in the plank being mounted to the carrier by the resilient clip  14 . According to the present invention, the need for tool adjustment to ensure the projections  28 ,  30  of the clip  14  achieved a deep enough seat in the grooves  23 ,  24  is eliminated. Moreover, screws are not required to more positively secure the planks  22  to the carriers  10 . 
     As shown, once the clip projections are fully seated in their respective groove, the profile will return to its undistorted, i.e. non-tensioned, profile. Specifically, the first and second protrusions  28 ,  30  are biased, causing the resilient clip  14  to return to a substantially non-deformed state after each of the plurality of planks  22  are snap-fit to the resilient clip  14 . The first portion  31 , the second portion  32 , and the third portion  34  of the first protrusion  28  of the resilient clip  14  extend into the first multi-directional groove  23  of the one of the planks  22  and the first portion  31 , the second portion  32 , and the third portion  34  of the second protrusion  30  of the clip  14  extend into the second multi-directional groove  24  of the one of the planks  22 . The notches  25 ,  25 ′ and the portion  33  of the back of the plank  22  between the two grooves  23 ,  24  will be encapsulated by the relaxed clip  14  and a portion of the protrusions will be positioned under the notches  25 ,  25 ′ which will serve to support a plank  22  suspended from the linear carrier  10 . The preferred configuration of the clip  14  supporting a plank  22  in a non-tensioned state, adds strength to the attachment of the plank to the carrier. In other words, as one of skill in the art would understand, a plank would be more easily removed from the carrier if the clips supporting the planks were in tension. 
       FIGS. 7 and 8  illustrate the use of a splice plate  40  for spanning a butt joint  42  of two planks  22  positioned end-to-end. As shown in  FIGS. 9-12 , the splice plate is formed of two halves  44 ,  46 , each half containing a body portion  48  and an attachment projection  50 . As with protrusions  28 ,  30  of clip  14 , each splice plate plank attachment projection  50  embodies the profile formed by notch  25 . Thus, the splice plate projections  50  are bent in multiple directions as described above in reference to protrusions  28  and  30 . 
     Further, as best shown in  FIG. 11 , the body portion  48  of each half includes a first portion  49  extending in a first direction and a second portion  51  extending integrally from the first portion in a direction generally perpendicular thereto. The second portions  51  of each body half include the means for attaching the body portions of each half to one another. For example, the second portions  51  of each body half may include threaded apertures for inserting one or more screw-type fasteners  53 . Once the attachment projections of each half are at least partially seated in the plank grooves, the screw-type fastener can thus be used to bring the halves closer together. 
     The splice plate of the invention provides the capability of applying more holding force around the grooves, than, for example by, snapping the splice on the abutting planks as described below. Such capability is desirable since it holds the ends of the planks tighter at the seam which, in turn, improves the visual at the seam. In addition, the added strength of the hold helps impede twisting of the plank to prevent unevenness of the planks at the butt joint, again, improving the visual. In effect, the splice plate creates a longer length of wood, i.e. create a plank unit, and most importantly, control the location of the impact of the stresses. More specifically, several planks can act and move as one, in turn, distributing the forces acting thereon to the edges of the plank unit. An additional advantage of the splice plate is that more complex edge detail of the planks (e.g. tongue and groove configuration) is not needed to impart the necessary strength at the plank seems. Thus, the edge detail can be simplified to a flat/flush edge detail. 
     While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. 
     For example, the grooves  23 ,  24  can form the notch  25  on the opposite wall, i.e. outboard wall, of a groove by inverting the direction of the cuts forming the grooves. In other words, the first surface portion  26  of the notch  25  would be sloped downwardly and inwardly and the second surface portion  27  would be sloped downwardly and outwardly. In turn, the projections  28  and  30  of the clip  14  would be bent to correspond to the contours of the notch  25 . Instead of springing the protrusions outwardly, the notches would press the protrusions inwardly. As the protrusions move deeper in their respective groove, the protrusions would spring outwardly, thus seating a portion of the protrusion below the notch. 
     Optionally, as best seen in  FIGS. 9-12 , each half of the splice plate  40  may include a reinforcement wing  50  which extends outwardly from an edge of the first portion  49  of the body distal the edge from which the second portion  51  of the body  48  extends. The wings  50  span over top of the butt joint to further counteract the stresses of the plank material. 
     Also, the splice plate could be formed of a single piece of resilient material similar to the clips described above. Thus, in the one-piece configuration, the splice plate would be snapped over the pair of notches in a similar fashion thereto.