Patent Publication Number: US-8973326-B2

Title: Modular floor system

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a system for fitted floors, and in particular for flooring consisting of wooden panels, comprising a number of interlocking modular bearing plates to which a plurality of panel elements can be fixed to cover outdoor surfaces such as terraces, patios, swimming pool borders and the like. 
     2. Description of the Related Art 
     This type of flooring is currently made using conventional methods that, in the majority of cases, involve the assembly and the subsequent processing in situ of the various flooring components. 
     An example of the flooring of the known art is shown in figures from  14   a  to  14   c . With reference to these figures, said flooring comprises a number of supporting elements  101 , generally arranged equidistantly over the whole surface area to be covered with flooring, that serve the purpose of supporting the flooring, which is constructed thereon, and of separating it from the subfloor. 
     A number of beam members  102 , made of wood or metal, arranged in parallel rows at a preset distance (generally in the range of 40 to 80 cm) are attached to the supporting elements by means of screws or similar means, as shown in  FIG. 14   a.    
     The wooden panels  103  that constitute the flooring surface are then attached to this framework; in particular, said panels are installed in a direction perpendicular to that of the beam members  102 , as shown in  FIG. 14   b.    
     Clips  104  are used to attach said panels  103  to the beam members  102 , said clips being fixed to the beam members by means of screws or the like. 
     More in detail, said clips have an omega-shaped profile with two ends  105  suitable for engaging in grooves  106  provided along the edges of the panels  103  in order to retain the panels in a fixed position and separated from one other, as shown in  FIG. 14   c.    
     The gap between one panel and the next is essential not only to allow for water to run off into the space underneath (onto the subfloor), but also and above all to enable the panels to expand and contract as a result of variations in humidity and temperature. 
     Alternatively, the flooring panels may be attached directly to the beam members by means of screws but, in this case, in order to allow for their expansion, the panels must undergo a preliminary perforation to create a special recess for containing the screws. 
     In addition, with this system the gap between one panel and the next must be achieved manually by inserting shims or the like between two adjacent panels. 
     Said known types of flooring have a number of drawbacks, however. 
     In fact, the above-mentioned steps needed to construct the flooring in situ are rather time-consuming and demand the use of special equipment; and for the floor to be properly installed, they need to be done by skilled and experienced personnel. 
     Moreover, the flooring thus configured consists of a large number of components (supporting elements, different types of screw, beam members, panels, clips, etc) that prevent any standardisation of the production process. 
     All these characteristics mean that this type of flooring has always been too expensive to be used on a large scale and it has consequently remained a product for a niche market. 
     Another disadvantage of these systems relates to the quality of the flooring, and particularly to its stability and durability. 
     In fact, the supporting elements  101  and the beam members  102  are placed, as mentioned previously, a certain distance apart, that is generally between approximately 40 cm and 80 cm. 
     The panels  103  that are installed on top of said beam members are consequently supported not over their whole length, but only in certain places (coinciding with the supporting elements  101 ) where the bending strains become concentrated. 
     As a result, the static loads that can be brought to bear, for instance, by the weight of objects resting permanently on the floor (such as plant pots, furniture, etc) and the dynamic loads deriving from usage induces a gradual deflection of the panels. Because of these deflections, the surface of the flooring is no longer perfectly aligned, giving rise to an unattractive aesthetic effect as well as to practical problems (e.g. the risk of tripping, problems with supporting furniture, etc). 
     In addition, this continuous bending in line with the places where the panels are fixed can lead to cracking that, with time they damage the panels completely. Another problem that occurs with systems of this type concerns the installation of the flooring on surfaces that are not perfectly level and horizontal. 
     In such cases, it becomes necessary to manually add shims to some of the supporting elements in order to make sure that all the supporting elements  101  actually provide support for the beam members and panels, and this takes more time. 
     Some supporting elements allow for their height off the subfloor to be adjusted but, here again, levelling the various supporting elements takes a considerable amount of time. 
     There are also other types of paneled flooring for outdoor installations available on the market, that differ slightly from those described above. 
     Some, for instance, have rapid couplings for the panels instead of the classic clips, that enable the panels to be snap-fastened in place under pressure. 
     In this case, the assembly of the panel element is facilitated somewhat, but the drawbacks relating to the preparation of the supporting framework (supporting elements, beam members, etc) remain and so do the problems relating to the fact that the panels are supported not over their full length, but only on certain places, where the bending strains become concentrated. 
     BRIEF SUMMARY OF THE INVENTION 
     In the light of, the above considerations, the object of the present invention is a modular fitted flooring system, particularly for wood paneled flooring, that overcomes the above-described drawbacks of the known art. 
     In particular, one object of the invention is a modular fitted flooring system that provides a stable and solid base for the flooring, enabling a uniform distribution of the loads on the panel elements in order to contain their deformation, and that is quick and easy to install thanks to its modular design. 
     Another object of the present invention is a modular fitted flooring system, particularly for wood panel flooring, with a panel fixing system that enables a rapid and efficient water run-off from the flooring surface and that allows for the panel elements to expand and contract as a result of variations in humidity and temperature. 
     Another object of the present invention is a modular fitted flooring system, particularly for wood panel flooring, that is suitable for manufacturing in standardised form to contain the production costs, but that also allows for the creation of different installation patterns (e.g. in strips with the joints randomly-staggered or alternating, in square basket patterns, etc). 
     The above-stated objects are substantially achieved by a modular fitted flooring system comprising a plurality of bearing plates and a plurality of panel elements designed to be hooked onto said bearing plates, said bearing plates comprising a flat plate with a lower surface having a plurality of supporting elements that provide the base for resting the plate on a subfloor, and an upper surface with panel hooking means and load-bearing elements, the lateral edges of said plates including jointing elements for connecting one bearing plate to another adjacent thereto, characterised in that said panel hooking means consist of a plurality of teeth extending from said upper surface of the bearing plate and designed to engage in grooves provided on at least two edges of the panel element, said teeth being arranged on the bearing plate so as to create a gap between one panel element and another adjacent thereto in a direction crosswise to the direction of installation of the panel elements. 
     This makes it possible to achieve a solid, stable modular fitted flooring system that is quick and easy to install, thanks to the modular system of bearing plates and to the panel hooking means, which enable the panel elements to be installed simply under pressure, without needing to use particular equipment or specialised personnel. 
     In particular, the teeth are arranged in parallel rows located respectively along the lateral edges of each panel element so as to create a gap between one panel element and the next. 
     The teeth are thus free to bend during the installation of the panel element and following any expansion of the panel element as a result of variations in humidity and temperature, in addition to enabling the run-off of water from the floor surface. In addition, said bearing plate supporting elements can be designed to have a height that is constant or that increases progressively from one side towards the opposite side so as to create a supporting surface sloping at a given angle in relation to the bearing plate. 
     This solution ensures that the installed flooring is always perfectly flat irrespective of any sloping of the subfloor. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further characteristics and advantages will emerge more clearly from the following non-limiting description of a preferred, but not exclusive embodiment of the invention, as shown in the attached figures, wherein: 
         FIG. 1  is a perspective view of the modular fitted flooring system according to the invention; 
         FIG. 2  is a lateral cross-sectional view along A-A of the modular fitted flooring system of  FIG. 1 ; 
         FIG. 3  is a perspective view from below of a bearing plate for the modular fitted flooring system of  FIG. 1 ; 
         FIG. 4  is a plan view from below of a bearing plate for the modular fitted flooring system of  FIG. 1 ; 
         FIG. 5  is a perspective view from above of a bearing plate for the modular fitted flooring system of  FIG. 1 ; 
         FIG. 6  is a plan view from above of a bearing plate for the modular fitted flooring system of  FIG. 1 ; 
         FIG. 7  is a lateral cross-sectional view of the modular fitted flooring system showing the panel hooking steps; 
         FIG. 8  is a perspective view of a panel element for the modular fitted flooring system of  FIG. 1 ; 
         FIGS. 9   a  and  9   b  are two views of a detail of the bearing plate for the modular fitted flooring system of  FIG. 1 ; 
         FIG. 10  is a lateral cross-sectional view of the modular fitted flooring system according to another embodiment; 
         FIG. 11  is a lateral cross-sectional view showing the modular fitted flooring system installed on a subfloor; 
         FIGS. 12   a  to  12   d  are four plan views showing various flooring installation patterns; 
         FIG. 13  is a lateral cross-sectional view showing the modular fitted flooring system according to another embodiment; and 
         FIGS. 14   a - 14   c  depict known examples of fitted flooring. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     With reference to the attached  FIGS. 1 and 2 , the modular fitted flooring system globally indicated by the numeral  1  comprises a plurality of bearing plates  2  joined together to form a supporting surface and a plurality of panel elements  3  fixed to said bearing plates  2  to form the flooring surface. 
     Said bearing plates are preferably made of a plastic material, e.g. nylon, polyethylene, polypropylene or the like, by injection moulding or similar procedures. 
     This characteristic enables a supporting surface to be obtained with a good mechanical strength for bearing the static and dynamic loads coming to bear on the flooring, while at the same time it guarantees sufficient flexibility to ensure that the supporting surface can adhere to and follow the surface of the subfloor perfectly. 
     The various bearing plates  2  are connected together by means of suitable joints located on the lateral edges that enable a supporting surface of the required shape and size to be created within an installation time that is reduced to a minimum. 
     Each bearing plate  2  in turn comprises a flat plate, indicated by the numeral  4 , with an upper surface  5  and a lower surface  6 . 
     On said lower surface  6 , there is a plurality of supporting elements  7  that constitute the base on which the plate rests on the subfloor. 
     In detail, said supporting elements may be of various shape and size providing they are distributed evenly over the lower surface  6  so as to provide a solid and stable supporting surface for the plate  4 . 
     With reference to  FIGS. 3 and 4 , said supporting elements  7  preferably consist of cylindrical surfaces  8  extending from the surface  6 , in which further reinforcement ribbing (not shown in the figure) may be incorporated. 
     The extent of said supporting elements  7  (i.e. of the cylindrical surfaces  8  and of any ribbing) may be chosen at will, but it generally comes preferably in the range of 15 cm to 40 cm. 
     In fact, the purpose of the supporting elements  7 , in addition to supporting the plate  4 , is also to provide a gap between said plate and the surface of the subfloor to allow for the run-off of water draining from the surface of the floor and also of any water already on the subfloor. 
     For this purpose, the supporting elements  7  are arranged over the surface  6  so as to create a series of passages  10  between one element and the next, to allow for the run-off of water towards the water collection and drainage systems. 
     The cylindrical surfaces  8  also advantageously have the edge on which they rest  11  shaped so that only a part of it is in contact with the subfloor, leaving a plurality of passages  12  for water run-off. 
     The space between the subfloor and the plate  4  can also be used for the passage of piping or electric wiring, which thus remains completely out of sight, for a pleasing aesthetic effect. 
     With reference to  FIGS. 5 and 6 , on the upper surface  5  of the plate  4  there is a plurality of means for hooking to the panel elements  3 , indicated by the numeral  13 , that enable a rapid hooking of the panels under the effect of pressure, and a plurality of load-bearing elements for said panels, indicated by the numeral  14 . 
     In detail, said hooking means consist of a plurality of teeth  13  extending from said upper surface  5 , each comprising a supporting stem  15  extending from the upper surface  5  and integral therewith, and a coupling clip  16  located at the end of said supporting stem. 
     Said hooking means  13  are arranged on the upper surface  5  of the plate  4  in parallel rows in the direction of installation of the panel elements  3 , as shown by the letter X in  FIGS. 5 and 6 . 
     In particular, each panel element  3  is retained by two rows of teeth  13  located along its lateral edges in the direction X. 
       FIG. 7  shows the system for hooking the panel elements  3  onto the bearing plate  2 . 
     As mentioned previously, each panel element  3  is retained by two rows of hooking means, identified in the figure as  13   a  and  13   b , along the lateral edges  3   a  and  3   b  of the panel element  3 . 
     The panel element is locked onto the bearing plate  2  thanks to the shaping of the coupling clip  16 , designed to engage in a groove  17  provided along the lateral edges of the panels in the direction X, as shown in  FIG. 8 . 
     Said clip  16  preferably has a profile with a substantially trapezoid shape tapering upwards so as to define a sloping wall  16   a  on which the panel element slides when it is inserted. 
     The panel element  3  is also advantageously shaped so that the corresponding lower edges  18  are slightly recessed with respect to the lateral edges  3   a  and  3   b , so as to co-operate with the walls  16   a  of the clips  16  to facilitate the insertion of the panel element ( FIG. 8 ). 
     The dimensions and the materials of the hooking means are chosen so as to enable the teeth to bend without the risk of breaking during the insertion of the panel elements ( FIG. 7 ). 
     The rows of hooking means  13   a  and  13   b  are located so as to leave a gap of several millimeters (approximately 3-5 mm) between one panel element and the next in a direction Y crosswise to that of installation X. 
     This gap is indispensable both during the installation of the flooring, so that the hooking means  13  can bend during the insertion of the panel element, and also during the use of the flooring, to allow for the run-off of rainwater, for instance, or of washing water, from the floor surface onto the upper surface  5  of the plate  4  underneath, and from there onto the subfloor below. 
     For this purpose, the invention advantageously includes a plurality of through openings  19  provided on the plate  4  that place the space between the plate  4  and the panel elements in communication with the space underneath, between the plate  4  and the subfloor, as shown in  FIGS. 5 and 6 . 
     The water thus runs off the floor surface between adjacent panel elements onto the upper surface  5  of the plate  4 , and from there through said openings  19  onto the subfloor, from where it runs into the water collection and drainage systems. 
     Said openings can be in various shapes providing they are equally distributed over the whole surface of the plate  4  to ensure the maximum water run-off efficiency. Again with reference to  FIGS. 5 and 6 , the elements that bear the load of the panel elements  3  comprise a plurality of ribs  14  extending from the upper surface  5  of the plate  4  and lying parallel to one another in the direction of installation X of the panel elements  3 . 
     Said load-bearing elements enable the panel element  3  to be separated from the upper surface  5  of the plate  4  while simultaneously providing support for said panel element substantially over its whole length. 
     As explained previously, the space between the lower surface of the panel element and the plate  4  is indispensable to enable rain water to drain into the space between the plate  4  and the panel elements, and from there into the space underneath, between the plate  4  and the subfloor. 
     The dimensions of the ribbing  14 , the teeth  13  and the profile of the panel elements  3  are calculated so that, when the panel element  3  is hooked in place, its underside remains pressed against the ribbing  14  by the teeth  13  to avoid any slack that, with time, could damage the flooring. 
     Moreover, thanks to the arrangement of the rows  13   a  and  13   b  of teeth  13 , that leave a gap between one panel element and the next, said panel elements can expand and contract as a result of variations in humidity and temperature, exploiting the elasticity of the teeth  13 . 
     As mentioned previously, there are male-female jointing elements on the lateral edges of each bearing plate  2  for joining adjacent bearing plates together to form an integral supporting surface. 
     In detail, there is a plurality of male jointing elements  20  on two adjacent lateral edges, while there is a like number of female jointing elements  21  on the other two lateral edges, as shown in  FIGS. 9   a  and  9   b.    
     According to another embodiment, the bearing plate  2  comprises further hooking means for the panel elements  3  in order to fix them more firmly in the event of particularly demanding conditions of use of the flooring. 
     In detail, said further hooking means comprise teeth  23  substantially identical to the teeth  13 , designed to engage in grooves  24  provided for said purpose on the underside  25  of the panel element  3 , as shown in  FIG. 10 . 
     Said teeth  23 , like the teeth  13 , are arranged in two rows  23   a  and  23   b  lying in the direction of installation X of the panel elements and inserted in between the rows  13   a  and  13   b.    
     The installation of flooring using the modular fitted flooring system according to the invention is extremely quick and easy, giving rise to a flooring such as the one shown in  FIG. 11 . 
     After preparing (levelling, cleaning, etc) the subfloor, the various bearing plates  2  are placed in position and joined together by means of the jointing elements  20  and  21 , until the whole surface requiring flooring has been covered. 
     Then the panel elements  3 , made of any material chosen by the customer (various types of wood, particle board, plywood, plastic materials, etc) are installed, hooking them onto the bearing plates  2  by exerting a vertical pressure such that the teeth  13  (and possibly also the teeth  23 ) bend and the clips  16  engage in the grooves  17  provided on the lateral edges of the panel elements  3  (and possibly also in the grooves  24 ). 
     The presence of the jointing elements thus configured and located allows for different installation patterns to be obtained, as shown in figures from  12   a  to  12   d . For instance, arranging all the bearing plates  2  with the rows  13   a  and  13   b  of teeth  13  aligned in the same direction enables an installation of the strips with randomly-staggered joints ( FIG. 12   a ), alternate joints ( FIG. 12   b ), aligned joints ( FIG. 12   c ), or the like. 
     Joining the various bearing plates  2 , with the rows  13   a  and  13   b  of teeth  13  alternately arranged in directions perpendicular to one another, enables different patterns to be obtained, such as the square basket pattern ( FIG. 12   d ). 
       FIG. 13  shows another embodiment of the present invention. 
     In detail, said further embodiment involves the bearing plates  2  being complete with supporting elements  7  with a different height. 
     In particular, the height of said supporting elements increases progressively from one lateral edge towards the opposite lateral edge of the plate, so as to create a supporting surface that slopes at a preset angle in relation to the plane of the plate  4 . 
     This solution enables a perfectly flat flooring surface to be obtained irrespective of the gradient of the subfloor. 
     This may be useful both when the subfloor has yet to be made, and when it has already been prepared and cannot be altered. 
     In the former case, the bedding layer for the subfloor can be made slightly sloping (e.g. 0.6-0.7%) to improve water run-off, using bearing plates with a standard gradient (e.g. 0.5%) between this supporting surface and the flooring panel so as to compensate for the slope of the subfloor and keep the floor surface substantially horizontal. 
     In the latter case, if the existing subfloor has a considerable slope and cannot be altered, the invention allows for special bearing plates to be used with a relative gradient between the supporting surface and the flooring panel that can be customised to restore the flooring to the horizontal plane. 
     This solution is very useful in the above-described cases and it entails no extra manufacturing costs because it simply involves inserting suitable plugs with the required angulation inside the mould in line with the shaping of the supporting elements  7 , without having to make a special mould for each sloping angle required. 
     The present invention consequently enables the production of a modular fitted flooring system that is quick and easy to install thanks to the modular system of bearing plates and panel hooking means that enable the panels to be fixed in place simply by exerting a pressure, without needing to use particular equipment or specialised personnel. 
     Thanks to the supporting elements  7  and to the load-bearing elements  14 , the panel elements are supported along their whole length, preventing any bending phenomena typical of the known systems. 
     Another advantage of the present invention lies in that it guarantees a quick and efficient run-off of water draining from the floor surface, and it also enables the panel elements to expand and contract as a result of variations in humidity and temperature thanks to the teeth  13  being made of a flexible material and arranged so as to leave a gap between one panel and the next. 
     Moreover, thanks to the fact that the bearing plates have a standardised shape and are made by moulding a plastic material, the production costs can be contained while different variants of the bearing plates can be produced with supporting elements characterised by different gradients. 
     This also makes it possible to limit the number of parts constituting the flooring, meaning a smaller number of items that need to be kept in stock, with a considerable saving in the costs of managing the system. 
     The above-described modular fitted flooring system may undergo numerous modifications and variants, all coming within the scope of the inventive concept; in addition, all the parts may be substituted by other, technically equivalent components.