WO1996004441A1

WO1996004441A1 - Floor panel

Info

Publication number: WO1996004441A1
Application number: PCT/US1995/009630
Authority: WO
Inventors: Warren Skistad
Original assignee: Sico Incorporated
Priority date: 1994-07-29
Filing date: 1995-07-28
Publication date: 1996-02-15
Also published as: AU3153895A; JPH08100510A

Abstract

A dance floor section (20) includes a core assembly (44) which has a molded edging (24) placed thereon. The core assembly (44) has a central honeycomb material (40) of impregnated cardboard and a frame member (40) extending around the edge of the honeycomb material (46). Facing and backing pans (48) and (50) are added as well as a floor surface (22) to form the core assembly (44). The edging (24) forms complementary tongues (32) and grooves (30) for connecting to other sections (20). Lock members (62) and (64) mount in the edging (24) and interact with similar lock members of other floor sections (20) for connecting and retaining the edges of the sections (20) so that no spaces are formed.

Description

FLOOR PANEL

BACKGROUND OF THE INVENTION

1 • Field of the Invention The present invention relates to inter- connectable sections which can be secured together in edge to edge relationship to form an extended floor which can be easily assembled and taken apart .

2. Description of the Prior Art

Portable floors generally have a number of interlocking sections, and are used for providing a temporary hard surface floor which may be set up over carpeting or other surfaces on a temporary basis by joining floor sections together in an edge to edge relationship. Locks or other connections are provided along the edges to secure the adjacent sections together to form an extended floor surface.

Portable floors are used for a variety of purposes and are particularly useful in the hospitality and entertainment industries. It is often desired to provide a temporary smooth, hard surface for dancing or other activities which can be removed for using the space for other activities. The floors are usually connected together in an edge to edge fashion with releasable locks along their edges . A portable dance floor of this general type is disclosed in U.S. Patent 4,988,131 to Wilson et al. , assigned to the assignee of the present invention. Another portable floor of this general type is disclosed in U.S. Patent 3,310,919, also assigned to the assignee of the present invention. In that patent, floor panels are provided, each having a metallic tongue section along certain edges and a metallic groove section along certain other edges, such that the adjoining sections can be fitted together in an edge to edge relationship by tongue and groove arrangement, and held in place by locking screws threaded through to engage notches in the tongue members. Although the portable floor disclosed in that patent has been successful in providing a convenient and efficient portable floor, the present invention provides an improved floor section in construction which are believed to be advantageous. A common problem with portable dance floors is that they typically have a wood core which can be quite heavy. As a number of sections are required to form an extended surface, lifting of the panels is a labor intensive job. Typical panels have been only as large as 3 feet by 3 feet, and have a weight of approximately 36 to 37 pounds. Although it would be desirous to have 4 foot sections, which would decrease the number of panels needed and therefore the amount of time and labor involved in setting up and taking down the portable floor, it can be appreciated that with a 4 foot panel, the area is 16 square feet rather than 9 square feet. Therefore the corresponding weight of such panel with a density similar to typical panels would be upwards of 65-70 pounds. Although 4 foot by 4 foot sections are expected to weigh more than a 3 foot by 3 foot panel, weights approaching 70 pounds are too great for easy handling.

Another problem associated with dance floors is warping. As the panels become larger, the degree and probability of warping becomes greater. The wood cores are more likely to warp when a surface layer and/or backing is applied to the panels, thereby trapping moisture. When panels are warped, the flat surface is ruined and the sections are unusable. It can be seen then that an improved floor section is needed which can be of a larger size and has a rugged construction. In addition, such a floor panel should be lightweight and be easy to connect to other sections. The panel should also be easy to construct and inexpensive. The present invention addresses these as well as other problems associated with portable floor sections. SUMMARY OF THE INVENTION

The present invention is directed to a floor section which may be connected to other similar floor sections to form a temporary extended floor surface. Sections are often joined to form a temporary dance floor such as may be used in hotels, halls, auditoriums and the like. Each floor section generally includes a panel with edging formed therearound. The edging typically has male and female connectors for connecting to complimentary edges of other sections. In the embodiment shown, two edges have groove type connectors and two edges have tongue type connectors for forming tongue and groove connections. In addition, each edge has one of two complimentary locking members for locking the floor sections together.

The floor section is formed of a central honeycomb core. Around the periphery of the core is a frame member which adds strength and acts as a barrier for the injected material for molding the edging. In addition, a backing pan and a facing pan are added to the honeycomb material and frame. An additional layer for forming a particular style of dance floor surface may also be added. This forms a core assembly which is ready for adding edging. The core assembly typically has a molded edge formed therearound. The molded edge makes a mechanical connection to the facing and backing sheet which have flanges extending beyond the frame member. In this manner, a lightweight, strong and easily assembled dance floor section is obtained. The floor sections are also resistant to warping as may occur with prior sections having wood cores.

These and various other advantages and features of novelty which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and the objects obtained by its use, reference should be made to the drawings which form a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawings, wherein like reference letters and numerals indicate corresponding elements throughout the several views : Figure 1 shows a top plan view of a floor section according to the principles of the present invention;

Figure 2 shows a top plan view of a first embodiment of a core assembly frame for the floor section shown in Figure 1;

Figure 3 shows a top plan view of a honeycomb core for the floor section shown in Figure 1;

Figure 4 shows a side sectional view of a first embodiment of a core assembly for the floor section shown in Figure 1;

Figure 5 shows a side sectional view of the floor section shown in Figure 1 taken along an edge having grooves;

Figure 6 shows a side sectional view of the floor section shown in Figure 1 taken along an edge having tongues;

Figure 7 shows a top plan view of the cam side of a latch mechanism for the floor section shown in Figure 1; Figure 8 shows a top plan view of the receptacle side of a latch mechanism for the floor section shown in Figure 1;

Figure 9 shows a side sectional view of a second embodiment of a floor section; and, Figure 10 shows a top plan view of a portion of the core assembly with the facing pan removed for the floor section embodiment shown in Figure 9. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Referring now to the drawings, and in particular to Fig. 1, there is shown a floor section, generally designated 20. The floor section 20 is configured for connecting to other similar floor sections for forming a temporary extended floor surface. It will be appreciated that although an oak parquet type floor surface is shown in the drawings, other floor surface designs may also be used. The floor sections 20 connect to other sections with a tongue-and-groove arrangement formed in edging 24 extending around the periphery of the floor section 20. In the preferred embodiment, two edges 26 form grooves 30, as shown more clearly in Fig. 5. The other two edges form corresponding tongues 32, as shown more clearly in Fig. 6.

In the first embodiment of the floor section, a honeycomb central core 46 is used. The honeycomb core 46 is formed of cardboard honeycomb type material impregnated with a phenolic resin. In the preferred embodiment, the cardboard used is 18% phenolic impregnated, and then baked to add strength. Four foot by four foot section 20 using the construction of the present invention typically weigh only 47-48 pounds. It can be appreciated that this provides for a core 46 for the floor sections 20, which is strong yet very lightweight. The periphery of the core 46 has a frame formed therearound as shown in Fig. 2, which is a C-type channel cross-section member 40, as shown in Figs. 5 and 6. As shown in Fig. 2, the frame 40 includes recesses

42 for receiving lock members, as explained hereinafter.

As shown in Fig. 4, the honeycomb core 46 abuts the C channel cross-section frame member 40. A backing pan 50 and a facing pan 48 cover the bottom and top, respectively, of the honeycomb core 46 and frame 40. In addition, flanges 52 and 54 extend vertically beyond and over the C channel. The pans are thin sheets of steel which add support, but little weight to the section 20 and prevent warping. A laminate floor surface 22 is attached to form a core assembly 44. As shown in Figs. 5 and 6, the edging 24 is preferably made of an injectable plastic-type material such as a polyurea plastic. When injected, the plastic forms a mechanical lock with the flanges 52 and 54 to ensure that the edging 24 is solidly connected to the panel. As shown in Fig. 5, the edging 24 forms a groove 30 which is complementary to the tongue 32, as shown in Fig. 6. The tongues and grooves 32 and 30 are spaced along the edging to align these sections 20 when floor sections are placed proximate one another. In addition, as shown in Fig. 6, a channel 56 may be formed in the edging along the bottom surface of the tongue sides so that less material is used and lighter floor sections 20 are achieved.

Referring now to Fig. 9, a second embodiment of a floor section 100 is shown. In the second embodiment, a honeycomb core 46 is again used, as well as the backing pan 50 and the facing pan 48. The pans 48 and 50 again include flanges 52 and 54. However, the frame member is a wood-type frame member 102, which extends around the periphery of the honeycomb core 46, as also shown in Fig. 10. The wood frame 102 includes recesses formed therein for receiving the lock members. In addition, the frame 102 includes spacers 104 extending slightly outward and spaced periodically along the outer edges of the frame 102. This spaces the pans 48 and 50 outward by engaging the flanges 52 and 54, as shown in Fig. 9. The area in between the spacers 104 provide for the mechanical connection previously shown in Figs. 5 and 6, with the edging 24.

Referring now to Figs. 7 and 8, complementary lock members 62 and 64 are received in recesses 58 in the edging 24. Lock member 62 includes a cam-type member, which engages a female-type receptacle 64. The locks 62 and 64 are typically held in place by bolts or screws 78, which insert into the back portions of the lock members 62 and 64 and engage the molded edging 24 to hold the lock members 62 and 64 in place. The cam-type lock member 62 includes a pivoting cam 70, which pivots about a central portion 74. The cam 70 can be rotated by using a tool such as an Allen wrench, which extends into a hexagonal opening 76. When inserted into the edging 24, the lock member 62 can be accessed through holes 66 extending through the top surface of the edging 24, as shown in Fig. 1. Referring again to Fig. 7, the cam member 70 includes a raised circular cam edge 72 having teeth formed therein on both the top and bottom for gripping the receptacle lock member 64.

As shown in Fig. 8, the receptacle lock member 64 includes an upper and lower portion, which are spaced apart to form an opening extending in a horizontal plane for engaging the cam 70 of the cam locking member 62. A narrowed portion 66 at the edge of the lock member 64 engages the raised edge 72 of the cam member 70 to clasp the locking members 62 and 64 together and keep the edges 24 of the floor sections 20 pulled tightly against one another. The teeth of the cam edge 72 engage a pair of detents 79 with one detent extending down into the horizontal space of the receptacle and one extending from the bottom upward.

It can also be appreciated that edge trim members, which are well known in the art, can be utilized which provide a transition from the underlying surface up to the extended floor surface. The edge trim members also will utilize complementary locking members and tongue-and-groove configuration.

During the lamination process, a honeycomb core 46 is utilized. The honeycomb preferably includes cardboard which is stretched and phenolically impregnated and then baked to strengthen the honeycomb. The frame members either 102 or 40 are placed around the honeycomb core 46. The honeycomb core 46 can then be stretched out to fill the area in the interior of the frame members 40 or 102. The core and frame member are placed on the lower backing pan 54, which has an adhesive spread on an upper surface thereof. Similarly, the facing pan 48, which has adhesive spread on its lower surface, is set on top of the frame member and the honeycomb core 46. Finally, a floor surface member 22 may be adhered to the top of the facing 48. The pans 48 and 50 are generally 0.018 inch thick steel and are very lightweight yet provide reinforcement to the rest of the core assembly 44. To bind the various elements securely, several core assemblies are stacked and placed in a press, typically using a chain between the top and bottom, with an expandable bladder to pressure the various layers against one another. Typically the core assembly 44 will cure for 3 hours in the press under¬ pressure of 10 psi. Once the core assembly 44 or 100 has been cured, the edging 24 is added. It can be appreciated that with either embodiment of a core assembly 44 or 100, the frame members 40 or 102 play important roles. When the core assembly 44 or 100 is placed in the mold, the plastic will be injected into the mold around the core assembly 44 or 100. The frame member 40 or 102 not only provides reinforcement to the core assembly, but also acts as a barrier to prevent the injected material from reaching the honeycomb material. In a typical molding operation, the polyurea plastic is injected into one corner under pressure of 2,000 psi. The injected material quickly flows around the floor edges to fill the space without bubbles forming to meet at the opposite corner with excess material flowing out a vent. Excess flow triggers a proximity switch for the injector to stop adding material. Therefore, a high quality endurable edging is achieved. The edging is then allowed to cure and any parting line flash may be trimmed. The lock members 62 and 64 may then be added to form a completed floor section 20.

It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.

Claims

WHAT IS CLAIMED IS:

1. A planar floor section adapted for edge-to- edge connection with other similar floor sections to form a temporary extended floor surface, comprising: a honeycomb central core; a rectangular frame member extending around a periphery of the honeycomb core; a backing sheet and facing attached to the honeycomb core forming a panel; molded material forming edges around the panel configured for connecting to other section.

2. A planar section according to claim 1, wherein the frame member comprises a C-shaped channel member.

3. A planar section according to claim 1, wherein said edges have complementary tongue and groove connections for securing to other planar sections having similar tongue and groove connections.

4. A planar section according to claim 1, wherein the backing sheet and facing form flanges extending over and beyond the frame to form a mechanical connection to the formed edges.

5. A planar section according to claim 1, wherein the facing and backing are bonded to upper and lower surfaces of the honeycomb core and frame member.

6. A planar section according to claim 1, wherein the frame member comprises a C-shaped channel member and wherein the facing and backing are bonded to upper and lower surfaces of the honeycomb core and C-shaped channel member.

7. A planar section according to claim 3, wherein one half of said edges have male locking members and one half of said edges have female locking members.

8. A planar section according to claim 1, further comprising means selectively operable for engaging and disengaging said locking members when said edges are fitted together.

9. A planar section according to claim 3, wherein the edges have an upper surface having an aperture therethrough providing access to the selectively operable means.

10. A section according to claim 1, wherein each of the edges have recesses formed therein for receiving locking members, two of said edges having tongue portions formed therein and extending therealong, and the other two edges having complementary groove portions formed therein, and male-type locking members attached in two of said recesses, and complementary female locking members secured in the other two of said recesses.

11. A method for making a floor section adapted for edge-to-edge connection with other similar floor sections to form a temporary extended floor surface, comprising the steps of : forming a honeycomb core; placing a frame member around the honeycomb core; pressing a top and bottom sheet layer to an upper surface and lower surface, respectively, of the core and frame member to form a core assembly; and, molding an edge to the core assembly.

12. A method according to claim 10, wherein the frame member has a C-shaped cross-section.

13. A method according to claim 11, wherein the step of molding an edge to the core assembly includes placing the core assembly in a mold and injecting plastic material into the mold around the frame.

14. A method according to claim 11, wherein the top and bottom layers include a flange configured to extend beyond and over the frame.

15. A method according to claim 14, wherein the step of molding an edge to the core assembly incudes placing the core assembly in a mold and injecting plastic type material around the core assembly to interlock with the flanges.