Patent Publication Number: US-2015059271-A1

Title: Outdoor combination floor

Description:
BACKGROUND OF THE INVENTION 
     1. Technical Field 
     The present invention relates to floor coverings, and more particularly, to an outdoor floor covering which is convenient to lay and exhibits satisfactory structural stability. 
     2. Description of Related Art 
     A conventional outdoor floor covering is laborious and time-consuming to lay, because the laying process requires mounting a plurality of keels on the ground to provide foundations, and fixing multiple planks to the keels with a nail gun to finalize the assembly. Furthermore, the planks deform as a result of high humidity and temperature changes, and thus the nails get loosened gradually and exposed from the planks eventually, thereby jeopardizing pedestrians walking on the planks Moreover, the underlying keels rot gradually when immersed in rainwater accumulated under the planks after downpours. As time passes, the overall structural stability of the outdoor floor covering deteriorates. 
     Furthermore, recent years see a gradual increase in the demand for wood and the decreasing number of trees. This, coupled with the escalating awareness of environmental protection around the world, explains why material costs of wooden floor coverings are ever-increasing. In addition, wooden planks for use with outdoor floor coverings tend to denature for a man-made or natural reason. If the planks are not timely maintained and repaired during their denaturing process, the planks will rot and rupture when haunted by bacteria and ants, thereby shortening the service life of the planks, or even causing the outdoor floor coverings to collapse and thus compromising pedestrian safety. 
     In attempt to overcome the aforesaid drawbacks of the prior art, the industrial sector develops a composite outdoor floor covering. Unlike its conventional outdoor floor coverings whose assembly requires fixing planks to keels, the composite outdoor floor covering is assembled by coupling planks to bases and then fixing the planks to the bases with screws or any other fixing elements. It is convenient and quick to lay the outdoor floor covering. Two adjacent ones of the bases are well engaged and thus prevented from moving relative to each other horizontally, and thus the outdoor floor covering manifests enhanced structural stability. But there is not any positioning-oriented structure vertically disposed between two adjacent bases of the outdoor floor covering, and thus vertical dislocation is likely to occur between the two adjacent bases for a topographic reason. The vertical dislocation of the bases leads to protrusion of the planks from an originally defined standard plane. As a result, pedestrians may slip or get injured when their feet hit the protruding planks. 
     In conclusion, the prior art is disadvantaged by inadequate structural stability and poses a problem with pedestrian safety. 
     SUMMARY OF THE INVENTION 
     It is an objective of the present invention to provide an outdoor floor covering which is quick and convenient to lay, exhibits satisfactory structural stability, and enhances pedestrian safety. 
     In order to achieve the above and other objectives, the present invention provides an outdoor floor covering which comprises a plurality of planks, a plurality of bases, and at least a fastening element. A sliding groove is disposed at a bottom of each said plank. The bases each have a top surface, a bottom surface, two opposing first sidewall surfaces, two opposing second sidewall surfaces, and an engaging groove. The top surface has a positioning portion. The positioning portion penetrates the sliding groove. The first sidewall surfaces each have a first engaging portion and a second engaging portion. Adjacent ones of the first sidewall surfaces of the bases are engaged with each other through the first and second engaging portions. The second sidewall surfaces each have a protruding portion, a dent portion, and a snap-engaging portion. Adjacent ones of the second sidewall surfaces of the bases mesh with each other through the protruding and dent portions. The snap-engaging portions are adjacent to the protruding and dent portions, respectively, and each have a ramp. The engaging grooves are each adjacent to a corresponding one of the dent portions and formed between a terminal end of the dent portion and the snap-engaging portions. The at least a said fastening element is engaged and connected between adjacent ones of the second sidewalls of the bases. The at least a said fastening element has a bottom wall, two endwalls, and a hook-engaging wall. The endwalls extend from two ends of the bottom wall and toward the snap-engaging portions of the bases and each have a ramp. The ramps of the endwalls abut against and align with the ramps of the snap-engaging portions, respectively. The hook-engaging wall is disposed between the endwalls, extends from a side of the bottom wall toward the protruding and dent portions of the bases, and forms a hook portion at a terminal end of the hook-engaging wall. The hook portion is hook-engaged with the engaging groove. The bottom wall, the endwalls, and the hook-engaging wall define a snap-engaging slot for receiving the snap-engaging portions of the planks. 
     A through hole is disposed at each said base, and the planks are each fixed to a corresponding one of the bases through a fixing element passing through the through hole. 
     An identification area is defined on a bottom wall of at least a said fastening element and disposed between one of the endwalls and the hook-engaging wall. 
     The identification area of at least a said fastening element is a countersunk hole penetrable by a screw. 
     One of the snap-engaging portions of each said base has two said ramps, and a hook-engaging wall of at least a said fastening element has a ramp, wherein two said ramps of the snap-engaging portions abut against and align with the ramps of one of the endwalls of each said fastening element and the ramp of the hook-engaging wall. 
     The ramps of the snap-engaging portions of each said base each have a plurality of driven positioning serrate portions, and the ramps of the two endwalls of at least a fastening element each have a plurality of driving positioning serrate portions, wherein the driving and driven positioning serrate portions mesh with each other. 
     A pad extends from one of the snap-engaging portions of the bases and is positioned proximate to the bottom surface of the base. 
     A plurality of drain holes is disposed at each or one of the protruding and dent portions of the bases. 
     The sliding groove of each said plank is an T-shaped receiving space comprising a narrow passage and a wide chamber, whereas the positioning portion of each said base comprises a vertical segment and a horizontal segment, wherein the vertical segment has an end connected to the top surface of the base and has another end connected to the horizontal segment, wherein the vertical segment and the horizontal segment are received in the narrow passage and the wide chamber, respectively. 
     A reinforcing rib is disposed and defined by and between the bottom wall, the hook-engaging wall, and the hook portion of at least a said fastening element. 
     Accordingly, the present invention provides an outdoor floor covering which enables quick assembly and prevents planks from undergoing displacement relative to bases horizontally or vertically. Hence, the outdoor floor covering of the present invention is quick and convenient to lay, exhibits satisfactory structural stability, and enhances pedestrian safety. 
     To enable examiners further understand the structure, features, and objectives of the present invention, the present invention is illustrated with embodiments and drawings and described hereunder so that persons skilled in the art can implement the present invention accordingly. However, the description below is merely intended to provide the embodiments for explaining the technical contents and features of the present invention. After understanding the technical contents and features of the present invention, persons skilled in the art can carry out all kinds of modifications, replacements, and reduction of constituent components to the present invention without departing from the spirit of the present invention, and the modifications, replacements, and reduction of constituent components are deemed falling within the claims of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The technical contents and features of the present invention are described hereunder with an illustrative embodiment and the accompanying drawings, in which: 
         FIG. 1  is a partial assembled perspective view of a first preferred embodiment of the present invention, showing relative positions of components upon assembly; 
         FIG. 2  is a partial exploded view of the first preferred embodiment of the present invention, showing relative positions of the components; 
         FIG. 3  is a partial cross-sectional view of the first preferred embodiment of the present invention, highlighting technical features of sliding groove and positioning portion; 
         FIG. 4  is a perspective view of a fastening element in the first preferred embodiment of the present invention, showing technical features of driving positioning serrate portions; 
         FIG. 5  is a bottom view of the first preferred embodiment of the present invention, showing the position of the fastening element relative to the bases; 
         FIG. 6  is a partial cross-sectional view of the first preferred embodiment of the present invention, showing the position of the fastening element relative to the bases; 
         FIG. 7  is a partial cross-sectional view of the first preferred embodiment of the present invention, showing that first and second engaging portions of the bases are engaged and connected; 
         FIG. 8  is a partial cross-sectional view of the first preferred embodiment of the present invention, showing how the outdoor floor covering is fastened to keels; and 
         FIG. 9  is a perspective view of the fastening element according to a second preferred embodiment of the present invention, highlighting technical features of a reinforcing rib. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENT OF THE INVENTION 
     The structure, features, and advantages of the present invention are hereunder illustrated with preferred embodiments in conjunction with the accompanying drawings. 
     Referring to  FIG. 1  and  FIG. 2 , an outdoor floor covering  10  in a first preferred embodiment of the present invention comprises a plurality of planks  20 , a plurality of bases  30 , and at least a fastening element  40 . 
     In the first preferred embodiment, the planks  20  are made of wood and are solid or composite. A sliding groove  21  is disposed at the bottom of each plank  20 . 
     In the first preferred embodiment, the bases  30  are each formed by plastic injection molding and made of PE, PP, PS, PVC, PMMA, ABS, PA, or POM. The bases  30  each have a top surface  31 , a bottom surface  33 , two opposing first sidewall surfaces  35 , and two opposing second sidewall surfaces  37 . The first sidewall surfaces  35  are connected in a direction defined as a horizontal long axial direction  301 . The second sidewall surfaces  37  are connected in a direction defined as a horizontal short axial direction  303 . The top surface  31  has a positioning portion  311 . The positioning portion  311  is movable in the horizontal long axial direction  301  to penetrate the sliding groove  21 . A through hole  39  is disposed centrally in each base  30  to penetrate the top surface  31  and the bottom surface  33 . The planks  20  are each fixed to a corresponding one of the bases  30  by a fixing element  50  passing through the through hole  39  to allow each plank  20  to be firmly coupled to the top surface  31  of the corresponding one of the bases  30 . The first sidewall surfaces  35  each have a first engaging portion  351  and a second engaging portion  353 . Adjacent ones of the first sidewall surfaces  35  of the bases  30  are engaged with each other through the first and second engaging portions  351 ,  353 . The second sidewall surfaces  37  each have a protruding portion  371  and a dent portion  373 . A plurality of drain holes  375  is disposed at each or one of the protruding and dent portions  371 ,  373 . When adjacent ones of the second sidewall surfaces  37  of the bases  30  abut against each other through the protruding and dent portions  371 ,  373 , the drain holes  375  are exposed between the planks  20 . Hence, water is unlikely to accumulate between the planks  20  but is conveyed to beneath the bases  30  via the drain holes  375 . 
     At least a said fastening element  40  is engaged and connected between adjacent ones of the second sidewall surfaces  37  of the bases  30  to restrict the opposite displacement of the bases  30  in the horizontal long axial direction  301  or the horizontal short axial direction  303 . 
     Referring to  FIG. 3  through  FIG. 7 , the sliding groove  21  of the plank  20  is female T-shaped, whereas the positioning portion  311  of the base  30  is male T-shaped. In the first preferred embodiment, two parallel T-shaped sliding grooves  21  are disposed at the bottom of each plank  20  and extend deep into the plank  20 . The sliding grooves  21  extend from front ends  201  of the planks  20  to rear ends  203  of the planks  20 . The two T-shaped positioning portions  311  extend from the top surface  31  of the base  30  and in the direction of the corresponding one of the planks  20 . Each positioning portion  311  is a continuous structure extending in the horizontal long axial direction  301  or a segmental structure (shown in  FIG. 2 ) extending in the horizontal long axial direction  301 . Referring to  FIG. 3 , the sliding groove  21  of the plank  20  is an T-shaped receiving space which comprises a narrow passage  211  and a wide chamber  213 , whereas the positioning portion  311  of the base  30  comprises a vertical segment  313  and a horizontal segment  315 . The vertical segment  313  has one end connected to the top surface  31  of the base  30  and has the other end connected to the horizontal segment  315 . The vertical segment  313  and the horizontal segment  315  are received in the narrow passage  211  and the wide chamber  213 , respectively. Hence, according to the present invention, the sliding grooves  21  move in the horizontal long axial direction  301  and across the top surfaces  31  of the bases  30  to get engaged with the positioning portions  311 , respectively, such that the planks  20  can be easily disposed on the bases  30 , respectively, and prevented from moving in the horizontal short axial direction  303  and across the top surfaces  31  of the bases  30 , and in consequence the outdoor floor covering is convenient to lay and exhibits satisfactory structural stability. Referring to  FIG. 5  and  FIG. 6 , the second sidewall surfaces  37  of the bases  30  each have a snap-engaging portion  376 , and each snap-engaging portion  376  adjoins the protruding and dent portions  371 ,  373 . Each snap-engaging portion  376  is provided with a ramp  377  having a plurality of driven positioning serrate portions  379 . A pad  331  extends from one of the snap-engaging portions  376  and is positioned proximate to the bottom surface  33  of the base  30  so as to raise the bases  30  and define a flowing space  333  by and between the bases  30  and the ground G for the sake of drainage. An engaging groove  381  is disposed at each base  30  and positioned proximate to the dent portion  373 . The engaging groove  381  is disposed between the terminal end of the dent portion  373  and the snap-engaging portions  376 . Referring to  FIG. 4 , at least a said fastening element  40  has a bottom wall  41 , two endwalls  43 , a hook-engaging wall  45 , and a hook portion  47 . The bottom wall  41  has an identification area  411 . The identification area  411  is disposed between one of the endwalls  43  and the hook-engaging wall  45 . The endwalls  43  extend from two ends of the bottom wall  41  toward the snap-engaging portions  376  of the bases  30 . The endwalls  43  each have a ramp  431  having a plurality of driving positioning serrate portions  433 . The ramps  431  of the endwalls  43  abut against and align with the ramps  377  of the snap-engaging portions  376 . The driving and driven positioning serrate portions  433 ,  379  mesh with each other. The hook-engaging wall  45  is disposed between the endwalls  43  and extends from the bottom wall  41  toward the protruding and dent portions  371 ,  373  of the bases  30  to form the hook portion  47  at the terminal end of the hook-engaging wall  45 . The hook portion  47  is hook-engaged with the engaging groove  381 . The bottom wall  41 , the endwalls  43 , and the hook-engaging wall  45  define a snap-engaging slot  49  for receiving the snap-engaging portions  376  of the bases  30 . Hence, the bases  30  are prevented from moving horizontally across the top surfaces  31  of the bases  30  to separate from each other. 
     In conclusion, an assembly process performed by workers on the outdoor floor covering  10  of the present invention comprises the steps of: moving the sliding grooves  21  in the horizontal long axial direction  301  and across the top surfaces  31  to allow the sliding grooves  21  to engage with the positioning portions  311  such that the planks  20  can be easily disposed on the bases  30 , respectively; passing the fixing elements  50  through the through holes  39  of the bases  30  to allow the planks  20  to be fixed to the bases  30 , respectively, and thus prevent the planks  20  from undergoing horizontal or vertical displacement across the top surfaces  31  of the bases  30 ; engaging the first and second engaging portions  351 ,  353  of the bases  30  with each other in pairs; determining the direction in which at least a said fastening element  40  is mounted on one of the bases  30  according to the identification area  411  defined on the bottom wall  41  of at least a said fastening element  40 ; allowing the driving positioning serrate portions  433  disposed at one end of at least a said fastening element  40  to mesh with the driven positioning serrate portions  379  of a said base  30 , such that the hook portion  47  of at least a said fastening element  40  spontaneously gets hook-engaged with the engaging groove  381  of the base  30 ; pressing the protruding portion  371  of the other base  30  against the dent portion  373  of an adjacent one of the bases  30 ; and allowing the driven positioning serrate portions  379  of the other base  30  to mesh with the driving positioning serrate portions  433  at the other end of at least a said fastening element  40 . 
     The identification area  411  of the fastening element  40  of the present invention further has another advantage. Referring to  FIG. 8 , the identification area  411  of the fastening element  40  is a countersunk hole. Mounting the outdoor floor covering  10  of the present invention on keels L entails putting the first piece of bases  30  on the keels L, disposing at least a said fastening element  40  between the first piece of bases  30  and the keels L, passing a countersunk screw  51  through the countersunk hole, screwing the countersunk screw  51  to the keels L below the fastening element  40 , and disposing the second piece of bases  30  between the first piece of bases  30  and the at least a fastening element  40 . Hence, the outdoor floor covering  10  of the present invention can be quickly and conveniently laid and firmly mounted on the keels L. 
     Referring to  FIG. 9 , a second preferred embodiment of the present invention provides a fastening element  40 . Most technical features of the fastening element  40  in the second preferred embodiment are identical to that in the first preferred embodiment and thus are not described in detail herein for the sake of brevity. The difference between the first and second preferred embodiments is that two parallel reinforcing ribs  451  are disposed and defined by and between the bottom wall  41 , the hook-engaging wall  45 , and the hook portion  47 . The reinforcing ribs  451  augments the structural strength of the hook-engaging wall  45 . The quantity of the reinforcing ribs  451  shown in the diagram is not restrictive of the present invention. 
     In conclusion, the outdoor floor covering of the present invention has the following advantages: 
     1. The sliding groove  21  moves along the horizontal long axial direction  301  and across the top surface  31  to engage with the positioning portion  311  to thereby enable the planks  20  to be easily disposed on the bases  30 , respectively, and prevent the planks  20  from undergoing displacement in the horizontal short axial direction  303  and across the top surfaces  31  of the bases  30 . The first and second engaging portions  351 ,  353  of the bases  30  are engaged with each other in pairs to precisely restrict the displacement of the bases  30  in the horizontal long axial direction  301  and across the top surfaces  31 . The hook portion  47  of at least a said fastening element  40  is hook-engaged with the engaging groove  381  of the base  30 . The driving and driven positioning serrate portions  433 ,  379  mesh with each other, such that the bases  30  are restrained by at least a said fastening element  40  and prevented from moving across the top surfaces  31  of the bases  30  horizontally to separate from each other. Hence, the outdoor floor covering can be laid quickly and conveniently and can have a stable structure. 
     2. The fixing elements  50  penetrate the through holes  39  of the bases  30  to allow the planks  20  to be fixed to the bases  30 , respectively, and prevent the planks  20  from undergoing horizontal or vertical displacement relative to the bases  30 . A plurality of drain holes  375  is disposed in each or one of the protruding and dent portions  371 ,  373 . When two adjacent ones of the second sidewall surfaces  37  of the bases  30  abut against each other through the protruding and dent portions  371 ,  373 , the drain holes  375  are exposed between the planks  20 , such that water is conveyed to beneath the bases  30  via the drain holes  375  without being accumulated between the planks  20 . A pad  331  extends from one of the snap-engaging portions  376  and is positioned proximate to the bottom surface  33  of the base  30  so as to raise the bases  30  and define a flowing space  333  by and between the bases  30  and the ground G for the sake of drainage, so as to reduce the unevenness and wetness of the floor covering and enhance pedestrian safety. 
     The constituent components disclosed in the above embodiment of the present invention are illustrative rather than restrictive of the scope of the present invention. They can be replaced with the other equivalent components or changed and still fall within the claims of the present invention.