US20090249732A1 - Modular floor system - Google Patents
Modular floor system Download PDFInfo
- Publication number
- US20090249732A1 US20090249732A1 US12/417,684 US41768409A US2009249732A1 US 20090249732 A1 US20090249732 A1 US 20090249732A1 US 41768409 A US41768409 A US 41768409A US 2009249732 A1 US2009249732 A1 US 2009249732A1
- Authority
- US
- United States
- Prior art keywords
- panels
- panel
- floor system
- modular floor
- lower panels
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/02194—Flooring consisting of a number of elements carried by a non-rollable common support plate or grid
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/06—Flooring or floor layers composed of a number of similar elements of metal, whether or not in combination with other material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
- E04F15/105—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of organic plastics with or without reinforcements or filling materials
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F2201/00—Joining sheets or plates or panels
- E04F2201/01—Joining sheets, plates or panels with edges in abutting relationship
- E04F2201/0138—Joining sheets, plates or panels with edges in abutting relationship by moving the sheets, plates or panels perpendicular to the main plane
- E04F2201/0146—Joining sheets, plates or panels with edges in abutting relationship by moving the sheets, plates or panels perpendicular to the main plane with snap action of the edge connectors
Abstract
A modular floor system employing shared loading between adjacent panels. The modular floor system is comprised of a plurality of lower panels with each panel having interlocking features and a plurality of upper panels with each panel having interlocking features. The lower panels are arranged in a pattern adjacent to each other. The upper panels are similarly arranged in a pattern adjacent to each other and positioned above the lower panels. The pattern of upper panels is arranged such that each upper panel interlocking features engages with the complementary interlocking features of a plurality of lower panels. The resulting unified structure forms a substantially planar surface.
Description
- This application claims the benefit of U.S. provisional patent application Ser. No. 61/072,789 for MODULAR FLOOR SYSTEM filed Apr. 3, 2008, the entire disclosure of which is fully incorporated herein by reference.
- A modular floor system is a semi-permanent surface assembled using a plurality of smaller, usually identical floor panels to provide a stable, uniform and durable surface. These floor systems are typically installed over rigid surfaces such as concrete or semi-rigid surfaces such as grass or sand to provide a temporary platform for a variety of uses. Care must be taken in that some conventional edge joined modular floor systems installed over semi-rigid surfaces will tend to “unlock” from the adjacent panels during use creating a hazard, especially for foot traffic. Other uses include covering and protecting surfaces from non-intended uses such as covering over a polished wooden basketball floor to prevent damage from hard-soled shoes or covering an ice rink so that it can be used for other functions.
- Floor panels are typically square in shape although other shapes have been used such as rectangular or polygonal. The panels are formed from a variety of materials including wood, plastic or metal and usually include complementary interlocking features around the periphery so as join with adjacent panels to form a unified structure. The key aspects of modular floor systems are that they can be quickly and easily assembled and disassembled and therefore easily transported and stored.
- The present invention relates to a modular floor system employing shared loading between adjacent panels. The modular floor system is comprised of a plurality of lower panels with each panel having interlocking features and a plurality of upper panels with each panel having interlocking features. The lower panels are arranged in a pattern adjacent to each other. The upper panels are similarly arranged in a pattern adjacent to each other and positioned above the lower panels. The pattern of upper panels is arranged such that each upper panel interlocking features engages with the complementary interlocking features of a plurality of lower panels. The resulting unified structure forms a substantially planar surface.
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FIG. 1 is a perspective view of a modular floor system according to one embodiment of the present invention with one corner area partially assembled to show construction; -
FIG. 2 is an enlarged perspective view of the partially assembled corner area ofFIG. 1 ; -
FIG. 3A is a cross-sectional view of a modular floor system panel according to one embodiment of the present invention; -
FIG. 3B is an enlarged portion ofFIG. 3A illustrating several interlocking features; -
FIG. 3C is an enlarged portion ofFIG. 3A illustrating an interlocking feature; -
FIG. 4A is a cross-sectional view of an alternate modular floor system panel according to one embodiment of the present invention; -
FIG. 4B is a cross-sectional view of an alternate modular floor system panel according to one embodiment of the present invention; -
FIG. 4C is a cross-sectional view of an alternate modular floor system panel according to one embodiment of the present invention; -
FIG. 5 is a perspective view of a modular floor system according to one embodiment of the present invention depicting assembly of the modular floor system panels; -
FIG. 6 is a cross-sectional view of an assembled modular floor system according to one embodiment of the present invention taken along section 6-6 inFIG. 2 ; -
FIG. 7 is an enlarged portion ofFIG. 6 illustrating the interlocking features. - A
modular floor system 10 as illustrated inFIGS. 1-2 includes interlockingupper panels 12,lower panels 14 andedge covers 16. According to one embodiment of the present invention,upper panels 12 andlower panels 14 are preferably the same so as to facilitate ease of manufacture and resulting cost savings. As will be described in more detail later, alternate embodiments of the present invention could include upper and lower panels that are constructed differently to tailor the floor system for a specific uses. - In describing one embodiment of the present invention, the
upper panels 12 andlower panels 14 will be assumed to be identical such that the description from hereafter, unless otherwise described, will be the same for both panels.Panel 12 is typically constructed of plastic, but other materials are possible such as aluminum.Panel 12 is made by first extruding plastic such as polypropylene, polyvinylchloride (PVC) or any other suitable plastic material into a typical cross-sectional shape as shown inFIG. 3A . The plastic extrusion process is especially well-suited for producingpanels 12 since it provides a cost efficient means of producing a consistent cross-section and allows the variability of making different lengths. Cross-sectional width W and thickness T can be designed to any practical size, but it is usually dictated by a combination of manufacturing and application considerations.Typical panel 12 widths are 8, 12 and 16 inches although other widths are easily feasible. Likewise, atypical panel 12 thickness is approximately 0.5 inch, although it can be made larger such as 1 inch, 2 inches or greater depending on the application. -
Individual panels 12 are formed by cutting the extruded plastic shape to any desired length, but preferably even lengths such as 2, 4 or 8 feet. Thepanel 12 length can be tailored to a specific application which may involve a variety of factors such as shipping and handling considerations, and ease of assembly or disassembly. For instance, a typical homeowner application may require shorter length panels than those used for commercial applications. -
FIG. 3A illustrates a typical cross-sectional shape ofextruded panel 12.Panel 12 is extruded as a unified structure and is comprised ofouter surface 20,inner surface 22,main latch 24,side latches 26,ribs 28 andlocking ribs 30 and is essentially symmetrical about a vertical centerline throughmain latch 24. Sincepanel 12 is formed by the extrusion process, these features are consistent throughout the length of the panel. Theouter surface 20 is generally planar but can include surface treatments or features to enhance aesthetics or functional characteristics such as a decorative wood grain lamination for appearance and scratch resistance, grooves or texture for traction purposes, or perforations for drainage or ventilation. Theinner surface 22 is generally planar and essentially parallel toouter surface 20.Main latch 24 is located substantially around the midpoint of the cross-sectional shape, but in an alternate embodiment can be offset in either direction depending on the panel overlap required for a particular application.Side latches 26 are located along the longitudinal sides of the extrusion and are designed to mate withmain latch 24.Ribs 28 project substantially perpendicular frominner surface 22 and are located symmetrically to either side ofmain latch 24. - Referring to
FIG. 3B ,main latch 24 is comprised of acentral portion 32 which projects substantially perpendicular frominner surface 22, twolocking flanges 34, and twoalignment flanges 36 that form recess 38.Locking flanges 34 project laterally outward fromcentral portion 32 at approximately the midpoint whilealignment flanges 36 project laterally outward and then downward to formrecess 38. - Referring to
FIG. 3C , side latches 26 are located along the longitudinal sides of the extrusion and includebody portion 40,hook 42 andside flange 44.Body portion 40 extends substantially perpendicular frominner surface 22 and is designed to flex laterally during assembly or disassembly of thefloor system 10.Hook 42 is located at the end ofbody portion 40 and projects laterally outward. The angles of the two sloping surfaces onhook 42 are designed to permit easy assembly and positive locking betweenpanels 12 but yet allow disassembly when required. -
FIGS. 4A-4B illustrate alternate cross-sectional shapes ofpanel 12 that are similar to that shown inFIG. 3A but differ in the design ofmain latch 24 and corresponding side latches 26.FIG. 4C is yet another alternate cross-sectional shape ofpanel 12 with a different design ofmain latch 24 and side latches 26 but illustrating a possible asymmetrical cross-sectional shape. - Referring to
FIGS. 1-2 , the assembly offloor system 10 will be described usingupper panels 12 andlower panels 14 for clarity of orientation, although it is still assumed that bothpanels lower panels 14 withouter surface 20 in contact with the surface to be covered.Lower panels 14 adjacent in the longitudinal direction are positioned with their ends touching and their extruded features aligned longitudinally.Lower panels 14 adjacent in the latitudinal direction are positioned such that their ends are offset from each other in a longitudinal direction so as to create a longitudinal overlap whenupper panels 12 are assembled. The longitudinal offset of adjacentlower panels 14 can be as little as two inches or as much as half the longitudinal length depending on the specific application. The longitudinal offset pattern can be a simple staggering of every other latitudinallower panel 14 or can follow a staggering pattern spread over multiple adjacent panels. For instance, the first adjacentlower panel 14 can be offset by four inches; the nextlower panel 14 is offset by an additional four inches, and so on until the pattern repeats. Once the entire field oflower panels 14 is installed over the surface to be covered, thelower panels 14 can be easily trimmed with an appropriate cutting tool to create a straight edge on each longitudinal end offloor system 10 or left as staggered edge created by the longitudinal panel offset. -
FIG. 5 illustrates a typical orientation and assembly ofupper panels 12 ontolower panels 14.Upper panels 12 andlower panel 14 with the cross-sectional shape shown inFIG. 3A are shown in a partially assembled state with oneupper panel 12 assembled with alower panel 14 and anotherupper panel 12 positioned for assembly.Upper panels 12 are positioned and installed onlower panels 14 such that they are offset latitudinally fromlower panel 14 by half the width of each panel. Like the arrangement oflower panels 14 previously described and as shown inFIGS. 1-2 ,upper panels 12 are offset longitudinally from adjacentupper panels 12 so as to overlap and directly interlock with fourlower panels 14. Additionally, eachpanel 12 will indirectly interlock with up to sixadjacent panels hooks 42 andmain latches 24. This results in each joint being supported by up to tenpanels recess 38 is specifically located as near as possible to the surface ofpanel 12 to limit joint flexure when loaded in tension so as to add further rigidity to the structure. In operation, any external load applied to the floor surface, whether above or below, is therefore shared by multiple panels resulting in a much stronger and stiffer floor. - Once
upper panel 12 is positioned overlower panels 14 with the desired longitudinal overlap and with side latches 26 aligned for engagement with the correspondingmain latches 24 of thelower panels 14, a downward force F is applied toupper panel 12 along one longitudinal edge above theside latch 26 so as to force it into engagement with the correspondingmain latch 24. The downward force can be generated in practice by merely stepping down on theupper panel 12 with a foot or through the use of a tool such as a rubber mallet or weighted roller. Asupper panel 12 travels downward, theside flange 44 pilots intorecess 38 in themain latch 24, and hook 42 of side latch 26 contacts the lockingflange 34 of themain latch 24 and is deflected laterally away from lockingflange 34. Referring toFIG. 7 , asupper panel 12 completes its engagement withlower panel 14,side flange 44 further engages and aligns itself inrecess 38, and hook 42 moves past lockingflange 34 and then is able to return back to its original shape and thereby engage lockingflange 34. Once the one longitudinal edge ofupper panel 12 is secured, the assembly procedure is repeated with themain latch 24 ofupper panel 12 as shown inFIG. 5 and then again for the remaining longitudinal edge ofupper panel 12. It is also conceivable that both longitudinal edges andmain latch 24 ofupper panel 12 can be simultaneously joined tolower panels 14 with an appropriate tool having sufficient width to span beyond the width W ofupper panel 12. For instance, a heavy roller type of tool such as a lawn roller could be employed. - Referring to
FIGS. 5-7 , asupper panel 12 is mated withlower panels 14,ribs 28 automatically align with lockingribs 30. The interlock betweenribs 28 and lockingribs 30 prohibitsribs 28 from deflecting laterally and therefore provides rigid vertical structural support toouter surface 20. - Referring to
FIGS. 1 , 2 and 6, edge covers 16 provide a functional height transition as well as a decorative edge treatment and are installed over the edge ofpanels floor system 10. Edge covers 16 are extruded plastic similar topanels -
Floor systems 10 are semi-permanent in nature and are designed to be easily disassembled. Disassembly of theexemplary floor system 10 is as simple as reversing the assembly operation. After removing edge covers 16 and then starting at one corner offloor system 10, disassembly is initiated by lifting up along one longitudinal edge of the end of oneupper panel 12 to start disengaginghook 42 frommain latch 24 inlower panel 14. Continuing with the lifting motion in a slight peeling manner will then further progressively disengagehook 42 along the longitudinal edge and simultaneously start disengagingmain latch 24 inupper panel 12 fromhooks 42 inlower panels 14. As the disassembly motion progresses, the opposite longitudinal edge ofupper panel 12 will then start to disengage fromlower panels 14 until the entireupper panel 12 is free The remainingupper panels 12 offloor system 10 are disassembled in the same manner. The disassembly process can also be described as an unsnapping or unzipping process. The disassembly process can also be made even easier by using a specially designed tool to accomplish the disengagement ofhooks 42 withmain latches 24. For instance, a wedge shaped unzipping tool can be inserted betweenhooks 42 inupper panels 12 andmain latch 24 oflower panel 14 and then pushed or pulled along the longitudinal edge to quickly and continuously unlock an entire length ofpanels 12. Then the disassembly ofmain latch 24 in eachupper panel 12 is more easily accomplished by the aforementioned lifting motion. -
Individual panels floor system 10 can be disassembled into individual pieces, it is often advantageous to disassemblefloor system 10 into large sections. For instance, iffloor system 10 is assembled frompanels - In alternate embodiments of the invention,
panels upper panel 12 can be made twice as wide aslower panel 14 so that there are fewer visible joints on the upper surface offloor system 10 thereby possibly enhancing the aesthetic appearance. This unequal panel size can also increase the structural rigidity offloor system 10. In another alternate embodiment,upper panels 12 with, for instance, two or three different widths, can be installed in an alternating pattern to provide an aesthetically pleasing appearance. - While the present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the specification to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. For example, individual components can be combined, assemblies can be divided into separate components or components can be rearranged without affecting the operation. Therefore, the invention, in its broader aspects, is not limited to the specific details, the representative apparatus, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.
Claims (14)
1. A modular floor system comprising:
a plurality of lower panels, each panel having interlocking features;
a plurality of upper panels, each panel having interlocking features;
wherein said lower panels are arranged in a pattern adjacent to each other;
wherein said upper panels are arranged in a pattern adjacent to each other and positioned above said lower panels; and
wherein said pattern of upper panels are arranged such that each said upper panel interlocking features engages with a complementary interlocking feature of a plurality of lower panels.
2. The modular floor system of claim 1 wherein said engagement of said upper panels with said lower panels forms a unified substantially planar surface.
3. The modular floor system of claim 1 wherein an external load is shared by a plurality of said upper and lower panels.
4. The modular floor system of claim 1 wherein each said lower panel is offset longitudinally from a latitudinally adjacent lower panel.
5. The modular floor system of claim 1 wherein each said upper panel is offset longitudinally from a latitudinally adjacent upper panel and interlocks with at least two said lower panels.
6. The modular floor system of claim 1 wherein said upper and lower panels are the same configuration.
7. The modular floor system of claim 1 wherein said upper panels are not the same configuration as said lower panels.
8. The modular floor system of claim 1 wherein said upper and lower panels are extruded.
9. The modular floor system of claim 8 wherein said panels are plastic.
10. The modular floor system of claim 1 wherein said each upper and lower panels further comprise a rib that automatically aligns and interlocks with a complementary feature on an opposing mating panel.
11. A method of constructing a modular floor system comprising:
arranging a plurality of lower panels adjacent to each other;
positioning a plurality of upper panels adjacent to each other and above said lower panels; and
moving said upper panels into engagement with said lower panels such that a unified substantially planar surface is formed.
12. The method of claim 11 further comprising the step of positioning each said upper panel such that it interlocks with at least two said lower panels.
13. The method of claim 11 further comprising the step of displacing longitudinally each said lower panel from a latitudinally adjacent lower panel.
14. The method of claim 11 further comprising the step of displacing longitudinally each said upper panel from a latitudinally adjacent upper panel.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US12/417,684 US20090249732A1 (en) | 2008-04-03 | 2009-04-03 | Modular floor system |
Applications Claiming Priority (2)
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US7278908P | 2008-04-03 | 2008-04-03 | |
US12/417,684 US20090249732A1 (en) | 2008-04-03 | 2009-04-03 | Modular floor system |
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US20090249732A1 true US20090249732A1 (en) | 2009-10-08 |
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ID=41131973
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US12/417,684 Abandoned US20090249732A1 (en) | 2008-04-03 | 2009-04-03 | Modular floor system |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20160290659A1 (en) * | 2013-11-12 | 2016-10-06 | Yugang ZHONG | Modular flooring |
WO2017018900A1 (en) | 2015-07-29 | 2017-02-02 | Simões Vicente Nuno Miguel | Connection system and method for fitting floor covering modules together |
Citations (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5486392A (en) * | 1994-07-05 | 1996-01-23 | Reese Enterprises, Inc. | Roll-up floor mat |
US6531203B2 (en) * | 1997-03-24 | 2003-03-11 | R&L Marketing And Sales, Inc. | Floor mat system for supporting heavy loads |
US6740380B2 (en) * | 1997-03-24 | 2004-05-25 | R&L Marketing & Sales, Inc. | Floor mat system |
US20050115181A1 (en) * | 2002-01-09 | 2005-06-02 | Sarl Grau | Modular flooring system with framed tiles |
US7108902B2 (en) * | 2004-02-03 | 2006-09-19 | Reese Enterprises, Inc. | Roll-up floor mat |
US20060260223A1 (en) * | 2005-05-17 | 2006-11-23 | Wang Dennis H | Interlocking Frame System for Floor and Wall Structures |
US7171790B2 (en) * | 2004-03-22 | 2007-02-06 | Tzu-Chiang Mei | Clamp unit for Do-It-Yourself (DIY) solid wood flooring |
US7409802B2 (en) * | 2006-01-11 | 2008-08-12 | Karl-Heinz Fiedler | Floor strip for bridging a join between two floor coverings |
US7631470B2 (en) * | 2002-12-11 | 2009-12-15 | Aero Facility Co., Ltd. | Heliport and civil engineering/building material |
US20100031596A1 (en) * | 2007-02-02 | 2010-02-11 | Proverum Ag | Profile strip system, especially for closing off edges and/or concealing joints, for a surface covering |
US7797900B2 (en) * | 2003-10-24 | 2010-09-21 | Herm. Friedr. Künne Gmbh & Co. | Floor profile arrangement for bridging a joint |
-
2009
- 2009-04-03 US US12/417,684 patent/US20090249732A1/en not_active Abandoned
Patent Citations (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5486392A (en) * | 1994-07-05 | 1996-01-23 | Reese Enterprises, Inc. | Roll-up floor mat |
US6531203B2 (en) * | 1997-03-24 | 2003-03-11 | R&L Marketing And Sales, Inc. | Floor mat system for supporting heavy loads |
US6740380B2 (en) * | 1997-03-24 | 2004-05-25 | R&L Marketing & Sales, Inc. | Floor mat system |
US20050115181A1 (en) * | 2002-01-09 | 2005-06-02 | Sarl Grau | Modular flooring system with framed tiles |
US7631470B2 (en) * | 2002-12-11 | 2009-12-15 | Aero Facility Co., Ltd. | Heliport and civil engineering/building material |
US7797900B2 (en) * | 2003-10-24 | 2010-09-21 | Herm. Friedr. Künne Gmbh & Co. | Floor profile arrangement for bridging a joint |
US7108902B2 (en) * | 2004-02-03 | 2006-09-19 | Reese Enterprises, Inc. | Roll-up floor mat |
US7171790B2 (en) * | 2004-03-22 | 2007-02-06 | Tzu-Chiang Mei | Clamp unit for Do-It-Yourself (DIY) solid wood flooring |
US20060260223A1 (en) * | 2005-05-17 | 2006-11-23 | Wang Dennis H | Interlocking Frame System for Floor and Wall Structures |
US7409802B2 (en) * | 2006-01-11 | 2008-08-12 | Karl-Heinz Fiedler | Floor strip for bridging a join between two floor coverings |
US20100031596A1 (en) * | 2007-02-02 | 2010-02-11 | Proverum Ag | Profile strip system, especially for closing off edges and/or concealing joints, for a surface covering |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20160290659A1 (en) * | 2013-11-12 | 2016-10-06 | Yugang ZHONG | Modular flooring |
US10101039B2 (en) * | 2013-11-12 | 2018-10-16 | Yugang ZHONG | Modular flooring |
WO2017018900A1 (en) | 2015-07-29 | 2017-02-02 | Simões Vicente Nuno Miguel | Connection system and method for fitting floor covering modules together |
US10287778B2 (en) | 2015-07-29 | 2019-05-14 | Nuno Miguel SIMÕES VICENTE | System for connection and fitting method between modules for floor coverings |
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Legal Events
Date | Code | Title | Description |
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |