Patent ID: 12241263

DETAILED DESCRIPTION OF THE DRAWINGS

FIG.1shows a preferred embodiment of the present invention, a polyurethane floor10with a woodgrain or “wood look,” and can be best understood when considered in the context of a conventionally installed poured polyurethane floor. As best shown inFIG.1A, the polyurethane floor10comprises a base layer12of uniform thickness that is adhered to an underlying substrate14with an adhesive16. The base layer12typically comes in rolled sheets, and the installer applies a uniform layer of sealer18to the top of the base layer12. The sealer18is typically a polyurethane. A fabric mesh layer20may reside on top of the sealer18for lateral stability, if desired. Thereafter, a coating of polyurethane22, alternatively referred to as the wear or structural layer, is applied to the top of the sealer18. Typically the polyurethane structural layer22is poured on and is evenly distributed, as known in the art, to produce a layer having a uniform thickness of about two millimeters. Thereafter, the installer may add an additional layer of the same material, with the same thickness, thereby to build the total thickness up to a desired thickness, such as four millimeters, four example. Finally, the installer applies a final clear seal top coat layer24, or finish layer, to protect the polyurethane structural layer(s)22.

As shown inFIG.1, depending on the location of the floor10, the installer may install a rubber base26, such as perimeter molding, to cover a joint between the floor10and a surrounding wall28. Typically, the rubber base26is anchored to the floor10and wall28using a standard base cement, and it protects the floor10surface from erosion and wear from normal use. Furthermore, if the end of the floor10does not abut the wall28, a reducer30may be installed to create a smooth transition from the floor10to the substrate14. The reducer30also minimizes wear and damage to the exposed end of the floor10. Although the features of the invention are illustrated or described in connection with a basketball court, it is understood that the present invention may be used with any type of synthetic floor that requires a woodgrain or wood look, such as a gymnasium floor, a track, or a bowling lane, for example.

FIG.2is a flow chart that shows the steps performed to make the polyurethane floor10with a woodgrain or wood look. In this regard, the substrate14is commonly a pre-existing floor having a hard surface, such as a concrete floor or pad, for example. The substrate14may need to be prepped prior to installation of the polyurethane floor10. In some instances, the surface of the substrate14to be coated may need to be prepared by cleaning and/or stripping to remove previous coatings, priming, or other debris. For a newly formed substrate14, such as newly poured concrete, the surface may need to be inspected for proper levelness tolerance, dryness, and possible contamination. In any event, the substrate14must be in a clean and acceptable condition prior to forming the polyurethane floor10thereon.

As shown inFIG.2, according to a first step102, the installer applies the base layer12to the lower substrate14. The base layer12may be polyurethane or, in the preferred embodiment, a base mat such as a rubber granulated shock pad, for example. Where the base layer12is a base mat, step102further requires the installer to apply adhesive16to the substrate14, such as a two-component Tacly Adhesive, before application of the base mat to the substrate14. The installer may use a notched trowel to apply the adhesive16to the substrate14. Thereafter, the installer applies the base mat to the adhesive16covered substrate14. Often the base mat is rolled for storage and requires unrolling for installation to the substrate14. To ensure a seamless compression fit of the base mat to the substrate14, a flooring roller may be necessary to roll flat the base mat for adherence to the substrate14. The base layer12supplies underlying resilience for the floor10, and can vary in thickness and hardness as desired.

Once the base layer12has been applied to the substrate14, the next step104involves applying the sealer18to the base layer12to create the seal layer. In this step, the installer applies the sealer18, such as a two-component EG2000 Sealer, to the top of the base layer12and allows the sealer18to cure, which generally takes a minimum of 12 hours. The sealer18may be spread over the top of the base layer12using a trowel. Once the sealer18is applied, but not yet fully cured, a layer of fabric mesh20may be placed on the sealer18, if desired. The fabric mesh20provides lateral stability for the floor10and may be formed of a nylon or polyester weave, or other like material. After the sealer18has fully cured, the installer then applies the first coating of the polyurethane structural layer22to the sealer18, in step106. The first coating of the polyurethane structural layer22typically comprises a pigmented polyurethane resin. This step106may include two or more separate applications of polyurethane to form the structural layer22depending upon the desired characteristics for the floor10. Each application of polyurethane may be a different color, for example. To this end, each application of polyurethane resin requires sufficient cure time, which may take anywhere from 12 to 48 hours.

According to the next step108, the installer then adds the woodgrain markings to the floor10prior to completion of the curing of the top-most polyurethane structural layer22. As shown inFIG.3A, the installer preferably forms the woodgrain markings by moving a blacktop or concrete brush32or broom over the topmost semi-cured polyurethane structural layer22, generally in parallel rows across the entire floor10. If desired, some degree of waviness may be added by the installer as he/she moves the brush32over the surface, so as to create a more natural woodgrain appearance. According to the preferred embodiment, steps106and108are typically completed contemporaneously. For example, where the floor10being formed is a basketball court, after the completion of steps102and104, one or more installer(s) next mark off the perimeter and centerlines of the basketball court using chalk. The installers may also use masking tape or plastic sheeting to tape off the baselines for a clean “pull-off” area at both ends of the court after the completion of steps106and108. With respect to steps106and108, the installers may pour one half of the basketball court at a time. For each half of the court, the installers may apply the polyurethane structural layer22, including forming the woodgrain markings therein, in small sections, such as a four foot wide strip running the length of a half of the court. In this regard, one installer rolls out a four foot wide section of the polyurethane structural layer22to a uniform application. Once completely rolled out and uniform, another installer then applies the brushed striations into the partially cured polyurethane structural layer22to create the woodgrain markings. The step108of creating the woodgrain markings is preferably performed about 5-10 minutes after initial curing of the polyurethane structural layer22has begun. Typically, application of the brushed striations is completed by making two passes over the polyurethane structural layer22with the brush32. Each pass is a single, non-stop procedure performed by placing the brush32on the centerline, then stroking (i.e., pulling or pushing) the brush32over the polyurethane structural layer22the length of the half-court, in a direction that would represent the longitudinal orientation of floorboards. However, fewer or more passes may be performed as necessary to achieve the desired woodgrain markings. This process is then repeated for each four-foot section for the first half of the court, and then again for the second half of the court. To this end, the brush32causes woodgrain markings in the semi-cured polyurethane structural layer22due to the darker, base layer12residing therebelow. Once steps106and108are complete, the polyurethane structural layer22is then permitted to fully cure. Although this specification describes steps106and108being performed sequentially on smaller sections of the floor10, these steps106and108could be performed on the entire floor10at once, if desired.

Once steps106and108are complete for the entire floor10, and the polyurethane structural layer22has cured, a plurality of floorboard lines36or other markings such as boardmarkings, game lines, and logos, for example, may then be applied to the floor10, at step110. Generally, for floors requiring game lines and logos, such as a basketball court, the installer applies the game lines and logos to the floor10after the polyurethane structural layer(s)22have fully cured. In any event, once the polyurethane structural layer(s)22has cured, at step110, the installer then adds parallel longitudinal floorboard line markings36to the cured polyurethane structural layer22to mimic the look of hardwood floorboards, as best shown inFIG.3B. The longitudinal floorboard lines36are typically oriented in a generally parallel direction with the woodgrain markings. As shown, preferably, the installer uses a floorboard marking apparatus34, or tool, to create the longitudinal floorboard lines36, which will be described in additional detail below. Thereafter, the installer adds appropriately spaced transverse floorboard lines38to mimic a row of floorboards laid end to end. The transverse floorboard lines38may be applied by hand using a guide or other suitable tool. Alternatively, the transverse floorboard lines38may be applied using the floorboard marking apparatus34.

After the floorboard lines36, boardmarkings, game lines, logos, and other related markings are applied to the floor10in step110, the installer next applies the top coat or clear sealer24to seal and protect the woodgrain markings and the floorboard lines36, at step112. Sufficient cure time must pass before proceeding from step110to step112, which is typically at least 24 to 48 hours. Step112is typically completed in the same day by a multi-person crew of installers. In this regard, the installers may apply the clear sealer24to the floor10in small sections, such as an eight or ten foot wide strip running across the short dimension of the floor10(e.g., from sideline to sideline for a basketball court). For each section, the installer rolls out the clear sealer24to a uniform thickness using a roller, as is known in the industry. This process is then repeated for each section until the clear sealer24is applied to the floor10, as desired, and the clear sealer24is permitted to cure. Again, although this application refers to sequential coating of smaller sections of the floor10, step112could be performed so as to coat the entire floor10at once with the clear sealer24. Once the clear sealer24has fully cured, which typically takes anywhere from 24 hours to one week, depending on environmental conditions, the floor10is ready for use.

FIGS.4-6show a preferred embodiment of the floorboard marking apparatus34. As described above and shown inFIG.3B, the floorboard marking apparatus34is used at step110to apply parallel longitudinal floorboard lines36to the cured polyurethane structural layer22of the floor10. These floorboard lines36mimic the look of a hardwood floor (i.e., multiple parallel rows of floorboards laid end to end). As shown inFIG.4, the floorboard marking apparatus34includes a base40supported by a plurality of wheels42, a transversely oriented, elongated frame44mounted to the front of the base40, and a pair of spaced apart handles46extending upwardly from the base40. The frame44includes a pair of elongated guides48located at opposite, outermost ends50of the frame44, and a plurality of fingers52hingedly mounted to the frame44and extending in a rearward direction toward the base40. Each finger52is configured to support a marker54, such as a Sharpie®-type permanent marker, such that a marking end or tip84of the marker54is biased in a downward direction toward the floor10so as to engage the floor10for marking floorboard lines36thereon, as described in further detail below. As shown inFIGS.4,5, and6, the apparatus34uses four wide-rimmed wheels42that are preferably machine-ground to a flat condition. This assures optimum surface to surface contact between the wheels42and the floor10surface during movement, to thereby facilitate controlled rolling movement of the base40over the floor10during floorboard marking.

The handles46are used by the installer to maneuver the floorboard marking apparatus34and to apply appropriate downward force on the apparatus34during movement, particularly while marking the floorboard lines36on the floor10. With reference toFIGS.4and5, the handles46are spaced apart across a width of the base40, and each handle46extends from the rear of the base40to the front of the base40. The installer grasps the handles46to push the floorboard marking apparatus34across the floor10. Each handle46is generally U-shaped and configured to be removably attached to the base40. The base40includes a pair of attachment points56for receiving and supporting each handle46in an upright position. As shown, for each pair of attachment points56, one attachment point56is located proximate to the rear of the base40and the other attachment point56is located proximate to the front of the base40. Once engaged with the attachment points56, each end of the handle46is configured to be locked in place thereto via a locking mechanism58, such as a clevis pin, wire lock pin, cotterless hitch pin, or other similar locking device. The handles46may further include one or more braces60extending therebetween, or between each handle46and the base40to provide additional support. The brace(s)60are removably attached to the handles46using a nut and bolt combination, a bolt having a screw handle, or other suitable structure. In any event, the handles46are preferably removably attached to the base40so that they can be removed for convenience when storing or transporting the floorboard marking apparatus34.

With continued reference toFIGS.4and5, the frame44is mounted to the front of the base40in a transverse orientation to support a plurality of fingers52. The frame44may be removably mounted to the base40using bolts, for example, or be permanently fixed to the base40by welding, for example. In any event, the frame44extends along the front of the base40and has an elongated length greater than the width of the base40, such that a portion of the frame44extends beyond each side of the base40. The frame44includes a pair of opposing elongated guides48which are positioned beyond the opposite, outermost ends50of the frame44. Each guide48is held to the frame44by a corresponding support arm62that extends therefrom. More specifically, a proximal end64of each support arm62is mounted to the frame44such that the support arm62extends outwardly from the outermost end50thereof, to a distal end66to which the corresponding guide48is mounted. Thereby, each support arm62spaces a respective guide48a distance away from the corresponding outermost end50of the frame44. Each support arm62may be removably mounted to the frame44using a bolt having a screw handle, for example, or alternatively, may be fixed to the base40by welding, for example. In either case, the distal end66of each support arm62includes a tab68or extension to which the guide48is mounted, where the tab68extends perpendicular to the support arm62to facilitate mounting of the guide48in a desired position. The guides48extend beyond the front of the frame44to enable the installer to visually align the movement of the floorboard marking apparatus34in the desired direction, to create parallel floorboard lines36on the floor10surface, as shown inFIG.6. To accommodate for different floorboard widths, for example, the support arms62may be adjustable laterally, to thereby alter the spacing of the guides48from the corresponding outermost ends50of the frame44.

The frame44includes a plurality of fingers52, with each finger52adapted to removably hold a corresponding marker54in a spring-loaded, downwardly-biased condition so as to engage the floor10and to mark a line thereon as the operator moves the floorboard marking apparatus34across the floor10. In this regard, each finger52is hingedly mounted to a rearwardly extending flange70formed on the top of the frame44, and biased downwardly by a spring72. Each finger52mounts to the flange70with a hinge74having a hinge pin76that defines a horizontal hinge axis for the finger52, and each hinge74extends from the flange70rearwardly to position the respective finger52behind the frame44. The hinges74are spaced apart predetermined distances along the length of the frame44, at distances which generally correspond to the widths of a standard floorboard. In an alternative embodiment, the spacing of the hinges74and fingers52may be adjustable to accommodate different floorboard widths.

As best shown inFIG.5, each hinge74includes a first hinge leaf78mounted to the flange70and a second hinge leaf80connected to the first hinge leaf78, wherein the second hinge leaf80is part of, or transitions to the finger52as a unitary piece. To couple each finger52to the flange70, the first and second corresponding hinge leaves78,80are coupled together with the hinge pin76, nut and bolt combo, or other similar means, which defines the hinge axis for each finger52. In this configuration, each finger52extends from a corresponding hinge74in a rearward direction and terminates at an end of the mount82for rearwardly mounting of a corresponding marker54thereto. In this regard, to best position the writing end84of the marker54on the floor10, a portion of each finger52is angled in a direction from horizontal downwardly toward the floor10. That is, when the first and second hinge leaves78,80are horizontally aligned (i.e., coplanar), the corresponding finger52is bent or curved such that the end of the finger52and the corresponding mount82are angled downwardly from the horizontal plane defined by the hinge leaves78,80, so as to position the marker54in contact with the floor10. The portion of the finger52may be angled downwardly between 15 degrees to 45 degrees from horizontal, and more preferably, angled 30 degrees, downwardly from horizontal. As shown, each mount82also includes a retainer86such as one or more elastic bands, clamps, straps, or other similar structure for removably mounting the marker54to the finger52. This type of retainer86further allows for adjustability of the marker54within the mount. As shown, a barrel of each marker54is received in each corresponding mount82such that the marker54extends in a direction parallel to the angled portion of the finger52and toward the floor10for marking the floorboard lines36thereon.

With continued reference toFIG.5, the spring72of each finger52is configured to ensure engagement of the writing end or tip84of the marker54with the floor10. In this regard, the spring72generates a downward bias on the finger52to assure continued contact of the marker54with the floor10during movement of the floorboard marking apparatus34therealong. As shown, for each finger52, a rearward end of the spring72is attached to a bracket90on the underside of the finger52. The forward end of the spring72is attached to the frame44, which may have an aperture92or other attachment point56for attachment thereof, as shown inFIG.4. As a result of the hinged attachment of the finger52to the frame44, the spring72biases the finger52in a downward direction about the hinge axis and toward the floor10. More particularly, the spring72biases the marker54toward the floor10. To limit downward movement of the fingers52that are located beyond the sides of the base40, the base40may include one or more stop bars94, as best shown inFIG.6. Each stop bar94mounts to a corresponding side of the base40and extends therefrom in a direction parallel to the frame44. The stop bars94are positioned underneath the fingers52and are configured to be in a confronting relationship with the corresponding fingers52. In this regard, the fingers52are configured to abut the stop bar94at a certain rotational position about the hinge axis to thereby limit the downward biasing movement of the finger52by the spring72. As seen inFIGS.4and6, some fingers52are positioned over the base40of the floorboard marking apparatus34and extend through corresponding apertures96in the base40to engage the floor10. In an alternative embodiment, the center of the base40may include a single opening for all the fingers52positioned over the base40. In any case, for these fingers52, a portion of the base40may serve a similar function as the stop bars94to limit downward movement of the fingers52by each spring72.

Those skilled in the art will appreciate that this specification identifies and describes presently preferred embodiments of this invention. Such persons skilled in the art will also recognize that this specification focuses on currently known examples related to the present invention, but that these currently known examples should not be treated as limitations. Accordingly, the following claims set forth the subject matter which applicant regards as patentable over the known prior art, not the specific examples described above, nor any other specific details of this disclosure not included in the relevant claims.