Patent Publication Number: US-2006019762-A1

Title: Panel structure for a bowling lane

Description:
FIELD OF THE INVENTION  
      This invention is directed to a bowling lane, and more particularly, to a panel structure for a bowling lane.  
     BACKGROUND OF THE INVENTION  
      Traditional bowling lanes are constructed of strips of hardwood fastened together to form a smooth, flat surface. Recently, paneled surfaces formed of a laminate structure have been used as a lane panel when refurbishing traditional bowling lanes and when installing new bowling lanes. The lane panel is typically attached to an underlayment that may include the original wooden bowling lane surface or, alternatively, some other wooden or metallic structure. The underlayment may provide support and may add stiffness to the lane panel.  
      The lane panel should be attached to the underlayment in a manner that allows the bowling lane surface to maintain its flatness. Accordingly, during installation, the lane panel may require a number of adjustments to its position. The installation process may include attaching the lane panel to the underlayment, measuring the flatness of the lane panel, detaching the lane panel from the underlayment, shimming between the lane panel and underlayment, and repeating this process until the desired flatness is achieved.  
      One known method for installing a lane panel includes forming a recess in the lane panel and driving a screw into the recess to the underlayment. Thus, the screw head pushes downward on the bottom of recess. However, such a system applies force in the downward direction only, against the bottom of the recess. Because the thickness of the panel is reduced at the bottom of the recess, the bottom of the recess may be weak and may fracture. In the event that additional adjustment of the lane panel is required, the force from the screw may be removed and re-applied, thereby increasing the risk of fracture. Repairing damage to the lane panel caused by fractured recesses can be time consuming and expensive.  
      This invention is directed to a system for attaching the lane panel to the underlayment.  
     SUMMARY OF THE INVENTION  
      In the following description, certain aspects and embodiments of the present invention will become evident. It should be understood that the invention, in its broadest sense, could be practiced without having one or more features of these aspects and embodiments. In addition, it should be understood that any features and aspects of one embodiment may be used in the other embodiments. It should also be understood that these aspects and embodiments are merely exemplary.  
      As embodied and broadly described herein, an aspect of the invention includes a panel structure for a bowling lane. The panel structure may include a lane panel having a top surface and a bottom surface, the top surface forming a bowling surface of the bowling lane. An underlayment may be disposed below the lane panel. A tapered hole may extend from the top surface to the bottom surface of the lane panel. The area of the hole may be larger at the top surface than at the bottom surface. The panel structure may also include a fastener having a head and a securing portion. The head may be disposed in the tapered hole and may have a wall tapered at substantially the same angle as the tapered hole. The securing portion may extend from the head into the underlayment.  
      In one aspect, the lane panel may be formed of a laminate structure, and the tapered hole may be a conical frustum.  
      In another aspect, the head includes a recess formed therein. The recess may be configured to receive a tool, such as a hex socket wrench or a spanner wrench. In another aspect, a plug may be disposed within the tapered hole above the fastener. The plug may include an upper surface substantially flush with the top surface of the lane panel. The plug may also include a wall tapered at substantially the same angle as the tapered wall of the hole. In one aspect, the plug may include a projection configured to project into the recess in the head. In another aspect, the plug is formed of a generally fluid material, such as a liquid urethane. In another embodiment, the plug and the head are attached to each other by a ball joint. In another aspect, the head of the fastener has a thickness less than thickness of the lane panel.  
      In yet another aspect, an insert may be disposed in the underlayment. The insert may be configured to receive the securing portion of the fastener and may include threads.  
      In one aspect, the head and the securing portion are integral. In another aspect, the head is configured to connect onto the securing portion. The securing portion may include a first section and a second section, with the first section being configured to attach to the head and the second section extending into the underlayment.  
      Another aspect of the present invention is directed to a method for installing a bowling lane. The method may include forming a tapered hole in a lane panel. The lane panel may be a laminate structure having a top and a bottom surface. The tapered hole may extend from the top surface of the lane panel to the bottom surface of the lane panel. The area of the hole may be larger at the top surface than at the bottom surface. The lane panel may be placed on an underlayment. A securing portion of a fastener may be driven into the underlayment. A head of the fastener may be driven into the tapered hole in the lane panel. The head may have a wall tapered at substantially the same angle as the tapered hole.  
      In addition to the structural and procedural arrangements set forth above, the invention could include a number of other arrangements such as those explained hereinafter. It is to be understood that both the foregoing general description and the following detailed description are exemplary only. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The accompanying drawings illustrate embodiments of the invention and together with the description, serve to explain some principles of the invention.  
       FIG. 1  is a diagrammatic representation of an exemplary bowling lane.  
       FIG. 2  is a diagrammatic representation of an isometric view of an exemplary paneling structure.  
       FIG. 3  is a diagrammatic representation of a cross-sectional view of the assembled paneling structure of  FIG. 2 .  
       FIG. 4  is a diagrammatic representation of an isometric view of another exemplary embodiment of a paneling structure.  
       FIG. 5   a  is a diagrammatic representation of a cross-sectional view of the assembled paneling structure of  FIG. 4 .  
       FIG. 5   b  is another diagrammatic representation of a cross-sectional view of an assembled paneling structure.  
       FIG. 6  is a diagrammatic representation of an isometric view of another exemplary embodiment of a paneling structure.  
       FIG. 7  is a diagrammatic representation of a cross-sectional view of the assembled paneling structure of  FIG. 6 .  
       FIGS. 8A, 8B , and  8 C are diagrammatic representations of another exemplary embodiment of a paneling structure. 
    
    
     DESCRIPTION OF THE EMBODIMENTS  
      Reference will now be made in detail to exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.  
      As described in more detail below, embodiments of the present invention include a hole with tapered walls extending through a lane panel. The lane panel is secured to an underlayment by a fastener having a tapered head extending into the hole in the lane panel. The tapered head contacts the tapered walls of the hole, urging the lane panel toward the underlayment. The contact applies a force against the lane panel having a component in both the vertical and horizontal directions. Because the hole is a through hole, lacking a recess, and because applied forces are not only in the downward direction, the lane panel may be less likely to fracture during installation. Accordingly, installation of the lane panel may be more efficient and cost effective.  
       FIG. 1  illustrates a bowling lane  100  consistent with an aspect of the present invention. The bowling lane  100  includes a pin deck  102 , lane panels  104 , an approach area  106 , and gutters  108 . The upper surface of any of the pin deck  102 , lane panels  104 , and the approach area  106  may form the visible surface of the bowling lane  100 , and may constitute a bowling surface  109 . The pin deck  102 , the lane panels  104 , and/or the approach area  106  may be formed of a paneling structure  110  shown in greater detail in  FIGS. 2-8 .  
       FIGS. 2 and 3  are perspective and cross-sectional views, respectively, of a portion of a paneling structure  110  consistent with a further aspect of the present invention. The paneling structure  110  may include a lane panel  112 , an underlayment  114 , and a fastener  116 . The lane panel  112  may be formed of any of a number of suitable materials, including, for example, a solid phenolic panel, a laminate structure of sheets bonded to a particle board, and a wooden panel. Other materials may also be used. In one exemplary embodiment, the lane panel  112  is formed of a phenolic laminate panel. The laminate panel may include sheets of phenolic soaked craft paper and a decorative layer (not shown), bonded together with a high pressure bonding process known in the art. The decorative surface of the lane panel  112  may form the bowling surface  109  (shown in  FIG. 1 ) of the bowling lane  100 , and may be an image, such as an image of wooden strips. In another exemplary embodiment, the lane panel  112  may include a melamine layer forming the top surface of the bowling lane  100 . In one exemplary embodiment, the thickness of the lane panel  112  is within the range of about 0.3 to 1.5 inches. However, the lane panel could have a different thickness as would be apparent to one skilled in the art.  
      The lane panel  112  includes a top or first surface  118  and a bottom or second surface  120 . A hole  122  extends through the lane panel  112  from the top surface  118  to the bottom surface  120 . In the embodiment shown in  FIGS. 2 and 3 , the hole  122  is a conical frustum including a tapered wall  123  ( FIG. 3 ). Accordingly, the hole  122  may have a first diameter at the top surface  118  and a second, relatively smaller, diameter at the bottom surface  120  of the lane panel  112 . A taper angle θ, measured at the walls of the hole  122 , may be, in one exemplary embodiment, within a range of 20 to 120 degrees. In another exemplary embodiment, the taper angel θ is within a range of 30 to 40 degrees.  
      The underlayment  114  includes a top surface  124  and is located below the lane panel  112 . The underlayment  114  may be formed of a medium or high density fiberboard, oriented strand board, plywood, structural wood, metallic supports, a previously provided bowling lane surface, a structural foundation, and/or other suitable materials. The underlayment  114  may provide support and stability to the lane panel  112 .  
      The fastener  116  includes a head  126  and a securing portion  128 . The head  126  includes a tapered wall  130 , a top surface  132 , and a bottom surface  133 . As seen in  FIG. 3 , the tapered wall  130  of the head  126  is formed at an angle that substantially aligns with the taper angle θ of the hole  122  formed in the lane panel  112 . In addition, the bottom surface  133  of the head  126  may have a diameter that is substantially equal to or greater than the diameter of the bottom of the hole  122 , at the bottom surface  120 . This helps ensure that the bottom of the fastener  116  does not pass through the bottom of the hole  122 .  
      In the exemplary embodiment shown in  FIG. 3 , the height of the head  126  substantially corresponds to the height of the lane panel  112 . Therefore, when fully installed, the top surface  132  of the head  126  is substantially flush with the top surface  118  of the lane panel  112 , and the bottom surface  133  of the head  126  is substantially flush with the bottom surface  120  of the lane panel  112 .  
      The top surface  132  of the head  126  may include a recess  134  formed to receive a tool for rotating the head  126  to drive or screw the securing portion into the underlayment  114 . The tool may be, for example, a hex-headed socket wrench. The recess  134  may be formed to fit other tools as may be apparent to one skilled in the art. In one exemplary embodiment, the surface  132  includes multiple recesses that may be configured to receive a tool, such as a spanner wrench.  
      In the embodiment shown in  FIGS. 2 and 3 , the securing portion  128  is integrally attached to and extends from the head  126 . The securing portion  128  may include threads for grabbing, such as, for example, those found on a wood screw. In one exemplary embodiment, a hole (not shown) may be preformed in the underlayment  114 , and the securing portion  128  may be a dowel that may be secured into the preformed hole with, for example, an adhesive. The securing portion  128  may be any length sufficient to attach to the underlayment  114  and, in one embodiment, has a length of about 1.75 inches. However, other lengths may be used. In one exemplary embodiment, the diameter of the securing portion  128  is less than the diameter of the bottom surface  133  of the head  126 , and likewise, may be less than the diameter of the hole  122  at the bottom surface  120  of the lane panel  112 . In another exemplary embodiment, the diameter of the bottom surface  133  of the head  126  is about equal to the diameter of the hole  122  at the bottom surface  120 .  
      As shown in  FIG. 3 , the securing portion  128  protrudes into the underlayment  114 . Accordingly, when the fastener  116  is driven through the hole  122  of the lane panel  112 , the head  126  contacts and urges the lane panel  112  against the underlayment  114 . In some exemplary embodiments, shims or other materials may be applied between the underlayment  114  and the lane panel  112 .  
       FIGS. 4, 5   a , and  5   b  show a portion of another paneling structure  110  consistent with a further aspect of the present invention. In this embodiment, the head  126  has a height less than the lane panel  112 . Accordingly, as best seen in  FIGS. 5   a  and  5   b , when the fastener  116  is driven through the hole  122  into the underlayment  114 , the top surface  132  of the head  126  is recessed below the top surface  118  of the lane panel  112 .  
      In this exemplary aspect, a plug  140  is included as a part of the paneling structure  110 . The plug  140  may be formed of any material including a material that is the same as, or a material that is different, from the lane panel  112 . In one exemplary embodiment, the plug  140  is formed of the same material used to form the head  126 .  
      The plug  140  includes a tapered surface  142 , a top surface  144 , and a bottom surface  146 . The tapered surface  142  may be formed at an angle that substantially aligns with the taper angle θ of the hole  122  formed in the lane panel  112 . The height and diameter of the plug  140  may be established so that the top surface  144  of the plug  140  is substantially flush with the top surface  118  of the lane panel  112  when the plug  140  is installed in the hole  122 . In one exemplary embodiment, the plug  140  may be configured so that, when installed in the hole  122 , a gap is formed between the top surface  132  of the head  126  and the bottom surface  146  of the plug  140 . In another exemplary embodiment, the plug  140  is configured so that the bottom surface  146  of the plug  140  is flush against the top surface  132  of the head  126 .  
      In the exemplary embodiment shown in  FIGS. 4 and 5   a , the plug  140  includes a projection  148  extending from its bottom surface  146  that is configured to fit within the recess  134  of the fastener  116 . The projection  148  may have any shape, including, for example, a hex socket shape, that may match or fit within the shape of the recess  134 . Securing the projection  148  to the fastener  116  in the hole  122  aids in reducing the chance of dislocation of the plug  140  from the hole  122 . The projection  148  may be secured in the recess by any method, including, for example, a friction fit or an adhesive. In addition, the plug  140  may be secured within the hole  122  with an adhesive. In one exemplary embodiment, the plug  140  does not include the projection  148 , but is secured to the fastener  116  and/or the tapered wall  123  of the hole  122  using an adhesive.  
      In yet another embodiment, the plug  140  is formed in the hole  122 . In this embodiment, a generally fluid material, such, for example, a liquid, epoxy, polymer, or putty-type material, may be placed in the hole after insertion of the fastener  126 . The fluid material may be any material capable of forming to the shape of the hole  122 , and may set, dry, or harden in the hole  122  to form the plug  140 . In one exemplary embodiment, the plug  140  may be formed of pourable urethane. The urethane may be poured into the hole  122  in a substantially liquid form, and may harden, forming the plug  140  with the top surface  132  of the plug  140  being substantially flush with the top surface  118  of the lane panel  112 .  
       FIG. 5   b  shows another exemplary embodiment of the paneling structure  110 . In this embodiment, the paneling structure  110  includes a ball joint  170  connecting the head  126  of the fastener  116  to the plug  140 . As shown, the ball joint  170  includes a ball  172  formed on the head  126  and a recess  174  formed in the plug  140 . The recess  174  receives the ball  172  to connect the plug  140  to the head  126 . In the embodiment shown the recess  174  is formed in the shape of a ball to have a narrow opening and a wider cavity, thereby enabling the recess  174  to snap onto the ball  172 . Because of the ball joint  170 , the orientation of the plug  140  is not dependent on the straightness of the head  126 , and the plug  140  can connect to the head  126  when the head  126  is not straight within the hole  122 . Therefore, the top surface  144  of the plug  140  may lie flush with the top surface  118  of the lane panel  112 , even if the fastener  116  is installed at an angle. In addition, the ball joint  170  helps hold the plug within the hole  122 . It should be noted that the ball could be on the plug  140  and the recess could be in the head  126 . It should also be noted that an adhesive could be used in combination with the ball joint.  
       FIGS. 6 and 7  are perspective and cross-sectional views, respectively, of a portion of yet another paneling structure  110  consistent with a further aspect of the present invention. This embodiment includes an insert  150  that may be inserted into a pre-drilled hole  152  in the underlayment  114 . The insert  150  may be a cylindrical insert formed of any material, including, for example, a metal, plastic, or wooden material, and may be configured to receive threads of the securing portion  128  of the fastener  116 . In one exemplary embodiment, the insert  150  may be removably disposed within the underlayment  114 . Therefore, if the insert  150  were to become damaged or stripped, it may be removed and replaced with a new insert. However, it should be apparent that the insert  150  may also be permanently installed within the underlayment  114 .  
      In one exemplary embodiment, the insert  150  contains internal threads that correspond in size and type with threads on the securing portion  128  of the fastener  116 . Accordingly, in this embodiment, the securing portion  128  may be a machine screw threadable into the insert  150 . In one exemplary embodiment, the plug  140 , described with reference to  FIGS. 4, 5   a  and  5   b , may be used with the fastener  116  described with reference to  FIGS. 6 and 7 .  
      In another exemplary embodiment, the insert  150  is an expansion type insert having one or more slits extending from a bottom surface, substantially parallel to a longitudinal axis of the fastener, toward a top surface. The slits may extend less than the complete length of the fastener. The sides of the insert may be tapered with an outer diameter at the top surface being less than the outer diameter at the bottom surface. The insert may be configured so that as the securing portion  128  moves through the insert from the top surface, the bottom surface expands, widening the slits, and forcing the bottom surface of the insert against the wall of the hole  152 . It is anticipated that other types of inserts could be used and are meant to be within the scope of this disclosure.  
      The insert may guide the fastener  116  into the hole, aiding in keeping the fastener  116  substantially perpendicular to the upper surface  118  of the lane panel  112 . This may be beneficial to ensure that the top surface  132  of the head  126  sits substantially flush with, or substantially parallel to, the top surface  118  of the lane panel  112 .  
       FIGS. 8A, 8B , and  8 C are cross-sectional views of a portion of another exemplary paneling structure  110  at different stages during assembly. In a first stage shown in  FIG. 8A , the lane panel  112  includes the hole  122  having the tapered wall  123  extending from the top surface  118  to the bottom surface  120 . In a second stage,  FIG. 8B  shows the fastener  116  including the head  126  and the securing portion  128 . In this exemplary embodiment, the head  126  is separate from the securing portion  128 . The head  126  includes a bore  160  formed in the bottom surface  133 . The bore  160  may be configured to receive a part of the securing portion  128  and may include threads that may correspond to threads on the securing portion. Alternatively, the bore  160  may be smooth or have other suitable surface features. In addition, in the embodiment shown, the head includes two recesses  134  formed in the top surface  132  that are configured to be used when driving the head  126 . The recesses  134  could be formed to fit a spanner wrench, or other tool. It should be noted that the head could include any number of recesses, including one or more than two. In addition, in one embodiment, the head does not include any recesses.  
      The securing portion  128  includes a first section  162  and a second section  164 . In one exemplary embodiment, the first section  162  includes threads, such as those used on a machine screw, and the second section  164  includes threads, such as those used on a wood screw. In the exemplary embodiment shown, the first section  162  is disposed substantially within the hole  122  in the lane panel  112  and the second section  164  is disposed substantially within the underlayment  114 .  
      It should be noted that in one exemplary embodiment, the securing portion  128  is threaded entirely with a machine screw thread or entirely threaded with a wood screw thread. In another exemplary embodiment, one or more of the sections of the securing portion  128  is a dowel that may be secured to the underlayment  114  and/or the head  126  using, for example, an adhesive.  
      In a third stage,  FIG. 8C  shows that the head  126  may be threaded onto, or otherwise attached to, the first section  162 . The tapered wall  130  of the head  126  contacts the tapered wall  123  of the hole  122 , forcing the lane panel  112  downward against the underlayment  114 .  
      A method for constructing a bowling lane will now be described. The method includes a step of forming a hole  122  in a lane panel  1 . 12 . The hole  122  may extend from the top surface  118  of the lane panel  112  to the bottom surface  120  of the lane panel  112 . The hole  122  may be a through hole including a tapered wall  123 , such that the hole is a frustum or a conical shape. Therefore, the diameter of the hole  122  is larger at the top surface  118  than at the bottom surface  120 .  
      In one exemplary embodiment, the method may also include a step of forming a hole within the underlayment  114 , such as the hole  152 . The insert  150  may be inserted within the hole  152  and may be secured within the hole  152 , such as by an adhesive, or other method known in the art.  
      The lane panel  112  may be placed on the underlayment  114 . The fastener  116  having a head  126  and a securing portion  128  may be driven through the hole  122  in the lane panel  112  into the underlayment  114 , or in some embodiments, such the embodiment shown in  FIGS. 6 and 7 , into the insert  150  in the underlayment  114 .  
      In some methods, referring to  FIGS. 8   a - 8   c , the securing portion  128  may be driven into the underlayment  114  prior to placing the lane panel  112 . Then, the hole  122  in the lane panel  112  may be aligned with the securing portion  128 , and the lane panel  112  may be placed on the underlayment so that the securing portion  128  protrudes into the hole  122 .  
      As described above, the head  126  may include a tapered wall  130  substantially corresponding to the taper angle θ of the tapered wall  123  of the hole  122 . In addition, the head  126  may be sized so that the bottom surface  133  of the head  126  has a diameter that is equal to or greater than the diameter of the hole  122  at the bottom surface  120  of the lane panel  112 . Accordingly, the head  126  may be configured so that it is maintained within the hole  122 .  
      The head  126  may be threaded or driven downward into the hole  122 , such that the tapered wall  130  of the head  126  contacts the tapered wall  123  of the hole  122 . Driving the head  126  further may force or urge the lane panel  112  downward against the underlayment  114  or against a material between the lane panel  112  and the underlayment  114 .  
      The flatness of the lane panel  112  may then be measured using methods known in the art. If the flatness is outside desired tolerances, the fastener  126  may be loosened until the lane panel  112  may be raised. A shim may be placed between the lane panel  112  and underlayment  114 . The head  126  may again be threaded or driven downward until the lane panel  112  is secure, and the flatness may be re-measured.  
      In the embodiment using the insert  150 , such as the embodiment shown in  FIGS. 6 and 7 , if the insert becomes stripped or unusable, the insert may be removed and replaced with a new insert. Alternatively, a fastener  116  having a larger diameter securing portion  128  may be used.  
      Some methods may also include a step of installing the plug  140  into the hole  122  after the fastener  116  is driven into the hole  122 . In one exemplary embodiment, such as the embodiment shown in  FIGS. 4, 5   a , and  5   b , the top surface of the plug  140  may be configured to align substantially flush with the top surface  118  of the underlayment. The method may include an additional step of installing a projection  148  on the bottom surface  146  of the plug  140  into the recess  134  formed in the head  126  of the fastener  116 . In another exemplary embodiment, the step of installing the plug  140  may include installing a generally fluid material into the hole  122 . The generally fluid material could be for example, a liquid, epoxy, polymer, or putty-type material, or any material capable of forming to the shape of the hole  122 . The generally fluid material may set, dry, or harden in the hole  122  to form the plug  140 . One exemplary method includes pouring urethane into the hole  122 . The urethane may harden, forming the plug  140  with the top surface  132  of the plug  140  being substantially flush with the top surface  118  of the lane panel. In yet another embodiment, such as the embodiment shown in  FIG. 5   b , the plug  140  may be snapped onto the head  126 . This may be accomplished using a ball joint connecting a ball on the head  126  to a recess in the plug  140 , or vice versa.  
      The paneling structure of the present invention may provide increased efficiency of bowling lane installation by applying a force with a fastener against the lane panel having a component in both the vertical and horizontal directions. Because the hole is a through hole, lacking a recess, and because applied forces are not only in the downward direction, the lane panel may be less likely to fracture during installation.  
      It will be apparent to those skilled in the art that various modifications and variations can be made to the structure and methodology described herein. In addition, it will be apparent that the description of any one disclosed embodiment may be used to describe relevant portions of any other disclosed embodiment. Further, it should be understood that the invention is not limited to the examples discussed in the specification. Rather, the present invention is intended to cover modifications and variations.