Note: Descriptions are shown in the official language in which they were submitted.
EDGING FORMS FOR PRODUCING SELF-LEVELING FLOORS
AND METHODS OF USE
BACKGROUND OF THE INVENTION
1. The Field of the Invention
[0001] The present invention relates to edging forms for producing self-
leveling floors
and related methods. More specifically, the present invention relates to
edging forms that
can be placed, used to contain a self-leveling flooring material, trimmed to a
desired height,
and then receive a floor covering thereon.
2. The Relevant Technology
[0002] Self-leveling cement products are often used in commercial and
residential
flooring industries to create a flat and smooth substrate or underlayment onto
which a final
flooring product can be applied. The self-leveling cement products can repair
uneven,
bumpy and out of level floors and can also fill in nooks and voids. Self-
leveling cement
products, when mixed to manufacturer's standards, have a fluid or slurry like
consistency
when initially mixed with water. The self-leveling cement product is then
poured onto a
subfloor. When mixed and installed correctly, the self-leveling cement product
will flow to
level and then set up and cure. The cured material becomes a hard, flat, and
level surface on
which a flooring product, like tile, can be installed.
[0003] Before curing, the poured self-leveling cement product can also flow
into
unwanted spaces if not stopped, plugged and/or contained. Unwanted spaces can
include the
area underneath walls, cabinets, and bathtubs and can also include opening,
cutouts, and
cracks, such as pipe openings, vent openings, toilet flange openings, and
waste pipe
penetrations, that are formed on or extend through concrete and/or wood sub-
flooring. This
unwanted flow of the self-leveling cement product can lead to an un-level cure
of self-
leveling product, extra labor and cleanup time, wasted material/money on self-
leveling
cement product, and poor/unsatisfactory finished product.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Various embodiments of the present invention will now be discussed
with
reference to the appended drawings. It is appreciated that these drawings
depict only typical
embodiments of the invention and are therefore not to be considered limiting
of its scope.
[0005] Figure 1 is a perspective view of a first edging form incorporating
features of the
present invention;
[0006] Figure 2 is an exploded view of the edging form shown in Figure 1;
[0007] Figure 3 is a top plan view of the edging form shown in Figure 1;
[0008] Figure 4A is a cross-sectional side view of the edging form shown in
Figure 3
taken along line A-A;
[0009] Figure 4B is a cross-sectional side view of an alternative
embodiment of the
edging form shown in Figure 4A;
[0010] Figure 5 is a perspective view of a second embodiment of an edging
form;
[0011] Figure 6 is an exploded view of the edging form shown in Figure 5;
[0012] Figure 7 is a top plan view of the edging form shown in Figure 5;
[0013] Figure 8 is a cross-sectional side view of the edging form shown in
Figure 7 taken
along line A-A;
[0014] Figure 9 is a top perspective view of a third embodiment of an
edging form;
[0015] Figure 10 is a bottom perspective view of the edging form shown in
Figure 9;
[0016] Figure 11 is a top plan view of the edging form shown in Figure 9
showing
alternative embodiments of access channels;
[0017] Figure 12 is a top plan view of the edging form shown in Figure 9
showing
alternative embodiments of channels for locking;
[0018] Figure 13 is a top plan view of the edging form shown in Figure 9
showing other
alternative embodiments of channels;
[0019] Figure 14 is a top perspective view of the edging form shown in
Figure 9 having
alternative access channels that extend only partially through the first side
face;
[0020] Figure 15 is a bottom perspective view of the edging form shown in
Figure 14;
[0021] Figure 16 is a cross sectional side view of an alternative edging
form having the
configuration of a quarter circle;
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[0022] Figure 17 is a cross sectional side view of an alternative edging
form having a
second side face shorter that the first side face;
[0023] Figure 18 is a cross sectional side view of an alternative edging
form having the
configuration of a triangle;
[0024] Figure 19 is a cross sectional side view of an alternative edging
form having a
bottom face shorter that the top face;
[0025] Figure 20 is a cross sectional side view of an alternative edging
form having a top
face shorter that the bottom face;
[0026] Figure 21 is a perspective view of a further alternative embodiment
of an edging
form having a configuration of a circular ring;
[0027] Figure 22 is a perspective view of a further alternative embodiment
of an edging
form having a configuration of a rectangle;
[0028] Figure 23 is a perspective view of edging forms secured to a
subfloor to bound an
area;
[0029] Figure 24 is a perspective view of the assembly shown in Figure 23
where a self-
leveling flooring material is disposed within the area and a portion of the
edging forms are
cut down;
[0030] Figure 25 is a perspective view of the assembly shown in Figure 24
where the
edging forms are fully cut down and a floor covering is being applied;
[0031] Figure 26 is a perspective view of a further alternative embodiment
of an edging
form wherein a flexible backing strip is secured to the second side face;
[0032] Figure 27 is a perspective view of the edging form shown in Figure
26 applied
around a column;
[0033] Figure 28 is a top plan view of a further alternative embodiment of
an edging
form having channels communicating with the first side face and the second
side face;
[0034] Figure 29 is a perspective view of the assembly shown in Figure 24
using the
edging forms shown in Figure 28;
[0035] Figure 30 is a top perspective view of an alternative embodiment of
the edging
form shown in Figure 9 having an L-shaped transverse cross section;
[0036] Figure 31 is an elevated end view of the edging form shown in
Figure 30;
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[0037] Figure 32 is an elevated end view of an alternative design of the
edging form
shown in Figure 31; and
[0038] Figure 33 is an elevated end view of a further alternative
embodiment of the
edging form shown in Figure 31.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] Before describing the present disclosure in detail, it is to be
understood that this
disclosure is not limited to particularly exemplified structures, systems,
methods, or process
parameters that may, of course, vary. It is also to be understood that the
terminology used
herein is only for the purpose of describing particular embodiments of the
present invention
and is not intended to limit the scope of the invention in any manner.
[0040] All publications, patents, and patent applications cited herein,
whether supra or
infra, are hereby incorporated by reference in their entirety to the same
extent as if each
individual publication, patent, or patent application was specifically and
individually
indicated to be incorporated by reference.
[0041] The term "comprising" which is synonymous with "including,"
"containing," or
"characterized by," is inclusive or open-ended and does not exclude
additional, unrecited
elements or method steps.
[0042] It will be noted that, as used in this specification and the
appended claims, the
singular forms "a," "an" and "the" include plural referents unless the content
clearly dictates
otherwise. Thus, for example, reference to a "channel" includes one, two, or
more channels.
[0043] As used in the specification and appended claims, directional
terms, such as
"top," "bottom," "left," "right," "up," "down," "upper," "lower," "proximal,"
"distal" and
the like are used herein solely to indicate relative directions and are not
otherwise intended
to limit the scope of the invention or claims.
[0044] Where possible, like numbering of elements have been used in
various figures.
Furthermore, multiple instances of an element and or sub-elements of a parent
element may
each include separate letters appended to the element number. For example, two
instances
of a particular element "10" may be labeled as "10A" and "10B". In that case,
the element
label may be used without an appended letter (e.g., "10") to generally refer
to all instances
of the element or any one of the elements. Element labels including an
appended letter (e.g.,
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CA 3030193 2019-01-16
"10A") can be used to refer to a specific instance of the element or to
distinguish or draw
attention to multiple uses of the element. Furthermore, an element label with
an appended
letter can be used to designate an alternative design, structure, function,
implementation,
and/or embodiment of an element or feature without an appended letter.
Likewise, an
element label with an appended letter can be used to indicate a sub-element of
a parent
element. For instance, an element "12" can comprise sub-elements "12A" and
"12B."
[0045] Various aspects of the present forms and systems may be illustrated
by describing
components that are coupled, attached, and/or joined together. As used herein,
the terms
"coupled", "attached", and/or "joined" are used to indicate either a direct
connection
between two components or, where appropriate, an indirect connection to one
another
through intervening or intermediate components. In contrast, when a component
is referred
to as being "directly coupled", "directly attached", and/or "directly joined"
to another
component, there are no intervening elements present. Furthermore, as used
herein, the
terms "connection," "connected," and the like do not necessarily imply direct
contact
between the two or more elements.
[0046] Various aspects of the present forms, systems, and methods may be
illustrated
with reference to one or more exemplary embodiments. As used herein, the term
"embodiment" means "serving as an example, instance, or illustration," and
should not
necessarily be construed as preferred or advantageous over other embodiments
disclosed
herein.
[0047] Unless defined otherwise, all technical and scientific terms used
herein have the
same meaning as commonly understood by one of ordinary skill in the art to
which the
present disclosure pertains. Although a number of methods and materials
similar or
equivalent to those described herein can be used in the practice of the
present disclosure, the
preferred materials and methods are described herein.
[0048] In general, the present disclosure relates to edging forms for use
in the formation
of a self-leveling floor or underlayment on top of a subfloor. As described
below in greater
detail, the inventive edging forms can come in a variety of different
configurations and sizes
and when used can provide a complete sealing system for a self-leveling
flooring material
that is used to form the underlayment. Specifically, the edging forms can
bound all or part
of a perimeter of an area in which the self-leveling flooring material is
dispensed for
CA 3030193 2019-01-16
forming an underlayment and can also seal edges, fittings, drains, cutouts and
other
openings and/or structures within the area for the underlayment to prevent
intrusion by the
self-leveling flooring material.
[0049] Depicted in Figure 1 is a first embodiment of an edging form 10A
incorporating
features of the present invention and which can be used to seal or bound a
self-leveling
flooring material. As used in the specification and appended claims, a self-
leveling flooring
material is a liquid or flowable material that will flow toward level under
the force of gravity
when poured and will cure or set to have sufficient strength properties to
function as a
commercial or residential floor. Commonly, the self-leveling flooring material
will
independently flow to level solely under the force of gravity. However, in
some
embodiments or uses, a trowel or other tool can be used to assist in the
spreading and/or
leveling of the self-leveling flooring material. The self-leveling flooring
material will
typically independently flow to level in a period of time less than 30 minutes
and more
commonly less then less than 15 minutes or 5 minutes. The self-leveling
flooring material
will also typically cure or set to a non-flowing state within a period of less
than 72 hours and
more commonly less than 48 hours or 24 hours. In one embodiment, the self-
leveling
flooring material is a cement based material that is purchased dry and then
mixed with water
to form the liquid material. However, in other embodiments, the self-leveling
flooring
material can comprise a polymer-based material, gypsum based material, or
synthetic
material. Other materials can also be used. One specific example of a self-
leveling flooring
material is Ardex K 15 produced by Ardex Americas.
[0050] As depicted in Figure 2, edging form 10A comprises an elongated
body 12A and
an adhesive strip 14A that is secured to body 12A. Body 12A is shown having a
rectangular
or square transverse cross section and includes a top face 16 and an opposing
bottom face 18
that extend between a first side face 20 and an opposing second side face 22.
In the depicted
embodiment, top face 16 and bottom face 18 are disposed in parallel alignment
and
opposing side faces 20 and 22 are also disposed in parallel alignment. In
alternative
embodiments, as discussed below in greater detail, body 12A can have a variety
of other
transverse cross sectional configurations and the opposing faces thereof need
not be
disposed in parallel alignment. Faces 16, 18, 20, and 22 extend between a
first end 24 and
an opposing second end 26. First end 24 terminates at an end face 28 while
second end 26
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terminates at an end face 30. Either of side faces 20 and 22 can be the face
that comes into
contact with the self-leveling flooring material during use.
[0051] Body 12A has a height H extending between top face 16 and bottom
face 18, a
width W extending between side faces 20 and 22, and a length L extending
between end
faces 28 and 30. Height H and width W are both typically at least or less than
lcm, 2 cm, 3
cm, 4 cm, 5 cm, 7 cm, 9 cm or 10 cm or are in a range between any two of the
foregoing
values. For example, height H and width W are commonly in a range between 1 cm
and 10
cm with between 2 cm and 8 cm or between 2 cm and 6 cm being more common.
Height H
and width W can be the same dimension or can be different dimensions. For
example,
depending on the application, height H could be larger or smaller than width
W.
[0052] Length L is typically at least or less than 0.3 meters, 0.5 meters,
0.75 meters, 1
meter, 1.5 meters, 2 meters, 2.5 meters or 3 meters or in a range between any
two of the
forgoing values. For example, length L can be in a range between 0.3 meters
and 3 meters
with between 0.5 meters and 2.5 meters or between 1 meter and 2.5 meters being
more
common. The dimensions of the height H, width W and length L can vary
depending upon
the application and use preference. For example, the height H can increase as
the depth of
the desired underlayment increases. The width W can increase where it is
needed to more
securely retain body 12A to the underlying subfloor as the underlayment is
curing. Thus,
width W may also increase as the depth of the desired underlayment increases
and/or the
volume of underlayment increases. The length L can increase as the length of
the
underlayment increases. In one embodiment of the present invention, body 12A
has a length
L that is 5 feet long, a height H that is 1.5 inches tall, and a width W that
is 1 inch wide.
[00531 Body 12A is typically made of a foam-based material that is liquid
impermeable.
The material can also be flexible. In one embodiment, the foam-based material
is a
polymeric foam such as polystyrene foam, ethylene-vinyl acetate foam, low-
density
polyethylene foam, polyurethane foam, polyethylene foam, or polyvinyl chloride
foam. The
polymeric foam will typically have a density of at least 30 kg/m3, 35 kg/m3,
40 kg/m3, 45
kg/m3, 50 kg/m3 or 60 kg/m3 or be in a range between any two of the foregoing
values.
Higher densities have increased strength but lower densities are typically
less expensive and
easier to cut. Polystyrene foam has some advantages in that it is inexpensive,
lightweight,
easy to form and cut and can be produced having desired compressive
strength/density
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properties. In other embodiments, body 12A need not be made from a polymeric
foam but
could be made from a non-foam material such as a polymer, fiberglass, wood,
rubber, or
composite. Using these lateral materials would be more expensive but may have
properties
that are desirable for a specific application. For example, the later
discussed materials may
have improved strength properties that are more desirable for industrial
applications.
[0054] As depicted in Figures 3 and 4A, extending through body 12A between
top face
16 and bottom face 18 are a plurality of longitudinally spaced apart channels
32. It is noted
that channels 32 are completely encircled by body 12A and are thus spaced
apart from side
faces 20 and 22. One of the purposes of channels 32 is to allow the user to
pour a fill
material, such as a self-leveling flooring material, into the plurality of
channels 32 to
enhance the structural properties of body 12A. Channels 32 can be formed
concurrently with
the formation of body 12A or can be bored, cut out or otherwise formed after
body 12A is
formed. During use, an upper opening of channels 32 can be manipulated to be
the same
level as the cured self-leveling flooring material before the fill material is
poured into
channels 32. For example, as discussed below in greater detail, body 12A and
thus channels
32 extending therethrough can be cut down to the level of the self-leveling
flooring material
before filling channels 32 with the fill material. One of the benefits of
channels 32 is that
the fill material poured into channels 32 and allowed to cure, anchors body
12A to the
underlying subfloor. That is, the fill material further secures body 12A the
existing
subflooring to prevent unwanted shearing. The fill material poured into the
plurality of
channels 32 also functions as a reinforcement for body 12A. Specifically, the
fill material
increases the normal stress threshold and compressive strength of body 12A for
better
handling the floor covering and loads that are placed thereon.
[0055] In the depicted embodiment, channels 32 have a cylindrical
configuration
typically having a diameter in a range between 0.3 cm and 3 cm with between .5
cm and 2
cm and between 0.5 cm and 1.5 cm being more common. Channels 32 are commonly
spaced apart by a distance of at least or less than 1 cm, 1.5 cm, 2 cm, 3 cm,
5 cm, 8 cm, 10
cm, 15 cm, or 20 cm or in a range between any two of the foregoing values. For
example,
the spacing between channels 32 can be in a range between 1 cm and 20 cm with
between 1
cm and 8 cm or between 1 cm and 5 cm being more common. In one embodiment, a
single
body 12A can have at least 10, 20, 30, 40, 50 or more channels 32 extending
therethrough.
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As discussed below in greater detail, channels 32 need not be cylindrical but
could have
other configurations. For example, channels 32 could have a transverse cross
section that is
circular, as shown, or could be oval, square, triangular, or have other
polygonal or irregular
configurations.
[0056] Returning to Figure 2, adhesive strip 14A enables body 12A to tack
or otherwise
secure to an existing subfloor to prevent body 12A from shearing/moving
relative to the
subfloor when body 12A/form 10A is blocking the self-leveling flooring
material from
flowing. In one embodiment, adhesive strip 14A is disposed on bottom face 18
of body 12A
and comprises any type of high-strength sealant or other sealant that
permanently or securely
sticks to the existing subfloor on which a user applies it. Furthermore,
adhesive strip 14A
forms a liquid/slurry impermeable seal between body 12A and the existing
subfloor. A
removably cover sheet 40 is a protective sheet that can be used to cover
adhesive strip 14A
when form 10A is not being used. Cover sheet 40 can be any disposable, peel-
able sheet.
[0057] Adhesive strip 14A can comprise as a tape-like structure having a
top surface 36
and an opposing bottom surface 38. During assembly, top surface 36 of adhesive
strip 14A
is secured to bottom face 18 of body 12 such as by adhesive, welding,
fasteners, over
molding, or the like so that adhesive strip 14A is securely fixed to body 12A.
Disposed on
bottom surface 38 of adhesive strip 14A is an adhesive, such as a tacky
adhesive used on
tape, that can accomplish the above objectives. Removable cover sheet 40, such
as a
polymeric sheet or film, can be placed over the adhesive so that form 10A can
be easily
transported and handled without exposure of the adhesive. However, when it is
desired to
secure form 10A to a floor surface, cover sheet 40 is pulled off so as to
expose the adhesive.
Form 10A can then be pressed against the subfloor so that the adhesive both
secures form
10A to the subfloor and provides a liquid tight seal between form 10A and the
subfloor.
[0058] As shown in Figure 4A, in one embodiment, adhesive strip 14A can be
secured to
bottom face 18 of body 12A so as to cover and seal closed the lower end of
channels 32. In
an alternative embodiment, as shown in Figure 4B, openings 42 can be formed
extending
through adhesive strip 14A that are aligned with and communicate with channels
32. As
such, channels 32 are openly exposed at both opposing ends so that the fill
material can flow
therethrough and directly contact and bind with the subfloor.
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[0059] During one method of use, one or more edging forms 10A are laid out
and
secured to a subfloor by use of adhesive strip 14A so as to partially or
completely bound an
area on which a self-leveling flooring material is to be dispensed for forming
a solid floor or
underlayment. Next, the self-leveling flooring material is dispensed into the
area, such as by
pouring or pumping, so that the self-leveling flooring material fills the area
to a desired
level. Edging forms 10A act as dams to assist in retaining the self-leveling
flooring material
within the area. The self-leveling flooring material flows to level under
gravity and fills in
all defects formed on the subfloor.
[0060] Once the self-leveling flooring material has sufficiently cured to
be stable, forms
10A are cut down, such as by using a saw, knife, or other machine, so as to
leave a
remaining portion of forms 10A having a top surface that is now flush with the
top surface
of the underlayment formed by the cured self-leveling flooring material. A
fill material is
then dispensed into all or at least some of channels 32 to the top surface of
the remaining
portions of forms 10A. The fill material is also typically a self-leveling
liquid that hardens
when cured. The fill material can comprise a self-leveling flooring material
or can comprise
some other material, such as an adhesive or binder, that flows level and cures
hard. Is still
another embodiment, the fill material need not be a self-leveling material.
For example, it
could be an adhesive or caulk that is dispensed into select channels 32 so as
to fill channels
32 or to slightly overfill channel 32 and is then manually smoothed flat by
removing excess
fill material.
[0061] Once the fill material has sufficiently hardened, a floor covering,
such as tile,
vinyl, linoleum, carpet, wood flooring, or the like can be secured over both
the formed
underlayment and the remaining portion of forms 10A. Again, filling channels
32 with the
fill material can help secure edging forms 10A to the subfloor to prevent
unwanted
movement thereon and also adds structural and compressive strength to each
body 12A so
that they can withstand the compressive forces applied thereto.
[0062] Depicted in Figure 5 is an alternative embodiment of an edging form
10B
incorporating features of the present invention. As depicted in Figure 6, form
10B includes
a body 12B and an adhesive strip 14B that is applied to body 12B. Like
elements between
form 10A and form 10B are identified by like reference characters. For
example, body 12B
includes top face 16, bottom face 18, and opposing side faces 20 and 22.
However, side
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faces 20 and 22 can also be referred to herein as exterior side face 20 and
interior side face
22. Thus, when viewed in cross section between opposing faces 20 and 22, body
12B has a
square or rectangular transverse cross section. The configurations,
alternatives, and
dimensions associate with faces 16, 18, 20, and 22 for edging form 10A are
also applicable
to form 10B. Furthermore, body 12B can be made of the same materials as
discussed with
body 12A. Likewise, adhesive strip 14B can be made of the same materials and
attached or
applied to bottom face 18 the same as discussed above with regard to adhesive
strip 14A and
edging form 10A. A plurality of channels 32 extend through body 12B from top
face 16 to
bottom face 18 and can have the same dimensions, configurations, spacing and
numbers as
previously discussed with regard to edging form 10A. As also discussed with
regard to
edging form 10A, openings 42 can be formed on adhesive strip 14B that extend
through
adhesive strip 14B and align with channels 32 (see Figures 7 and 8).
[0063]
However, in contrast to form 10A which is linear, form 10B is in the form of a
circular ring that forms a continuous, integral loop. Specifically, exterior
side face 20 is
curved along its length and forms an outer perimeter having a circular
configuration. In
addition, interior side face 22 is curved along its length and forms an inner
perimeter having
a circular configuration that encircles an opening 44 extending through body
12B/form 10B.
Opening 44 is circular and has an inside diameter D. As discussed below in
greater detail,
form 10B is configured to encircle a structure or opening so as to block or
seal the self-
leveling flooring material from flowing to the structure or opening. The
structure or opening
that form 10B encircles can be a drain fitting or opening such as a toilet
opening, toilet
flange, pipe, hole, cutout, electrical outlet, vent opening, water line, or
any other structure or
opening formed on or extending through the subfloor. Edging form 10B can be
formed in a
variety of different sizes depending on its application. For example, where
form 10B is
encircling a 1 cm diameter pipe, form 10B can be much smaller than when form
10B is
encircling an opening for a toilet. In some embodiments, body 12B/edging form
10B can be
formed with a diameter D that is at least or less than 5 centimeters, 10
centimeters, 15
centimeters, 20 centimeters, 25 centimeters, 30 centimeters, or 40
centimeters, or is in a
range between any two foregoing values. For example, diameter D can be in
range between
centimeters and 30 centimeters or more commonly in a range between 10
centimeters and
25 centimeters.
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[0064] During one method of use, one or more edging forms 10B
are laid out and secured
to a subfloor by use of adhesive strip 14B so as to encircle an opening or
structure on the
subfloor. Forms 10B can be used in combination with or separate from edging
forms 10A.
For example, edging forms 10A can be used to at least partially bound an area
into which
self-leveling flooring material is to be dispensed for forming an underlayment
while one or
more forms 10B can be positioned within the area to seal structures or opening
from the
self-leveling flooring material. Once forms 10B are positioned, the self-
leveling flooring
material is dispensed into the area, such as by pouring or pumping, so that
the self-leveling
flooring material fills the area to a desired level. Edging forms 10B act as
dams to prevent
the self-leveling flooring material from accessing the structures or opening
encircled by
edging form 10B. That is, the self-leveling flooring material contacts and
rises against
exterior side face 20 but does not pass into opening 44. Again, the self-
leveling flooring
material typically flows to level under the force of gravity and fills in all
defects formed on
the subfloor.
[0065] The remaining process is the same as discussed above
with regard to edging
forms 10A. Specifically, once the self-leveling flooring material has
sufficiently cured to be
stable, edging forms 10B are cut down, such as by using a saw, knife, or other
machine, so
that the top surface of the remaining portion of edging forms 10B are flush
with the top
surface of the underlayment formed by the cured self-leveling flooring
material. A fill
material, as discussed above, is then dispensed into all or at least some of
channels 32 to the
top surface of the remaining portion of edging forms 10B.
[0066] Once the fill material has sufficiently hardened, a
floor covering, such as
discussed above, can be secured over both the underlayment and edging forms
10B. Again,
filling channels 32 with the fill material can help secure edging forms 10B to
the subfloor to
prevent unwanted movement thereon and also adds structural and compressive
strength to
each body 12B so that they can withstand the compressive forces applied
thereto.
[0067] Depicted in Figure 9 is another alternative embodiment
of an edging form 10C
incorporating features of the present invention. Edging form 10C is linear
like form 10A
and like elements between edging forms 10A and 10C are identified by like
reference
characters. Edging form 10C includes an elongated body 12C having top face 16,
bottom
face 18, opposing side faces 20 and 22, and end faces 28 and 30. The
configurations,
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I CA 3030193 2019-01-16
dimensions, and alternatives associated with faces 16, 18, 20, 22, 28, and 30
as discussed
with regard to body 12A are also applicable to body 12C. Likewise, the
alternative
materials used for forming edging form 12A are also applicable for edging form
12C.
[0068] Extending through body 12C from top face 16 to bottom face 18 are a
plurality of
spaced apart channels 50. However, in contrast channels 32 of body 12A where
channels 32
are completely encircled by body 12A, a portion of each channel 50 extends
through first
side face 20 so that fluid contacting first side face 20 can flow into
channels 50. More
specifically, in the embodiment depicted in Figure 9, each channel 50
comprises a primary
channel 52 that extends entirely through body 12C from the top face 16 to
bottom face 18
and is spaced apart from first side face 20 and second side face 22. Each
primary channel
52 can have a cylindrical configuration with a circular transverse cross
section or can have
other configurations with other transverse cross sections including the
configurations and
shapes discussed above with regard to channel 32 of body 12A. Furthermore,
primary
channels 52 can have the same dimensions and configurations as previously
discussed with
regard to channels 32. Likewise, channels 50 and primary channels 52 can have
the same
spacing and numbers as previously discussed with regard to channels 32.
[0069] Each channel 50 also includes an access channel 54 that extends
from primary
channel 52 through first side face 20. In the depicted embodiment, each access
channel 54
comprises a constricted slot that is narrower than primary channel 52. More
specifically,
access channel 52 can have a minimum width or diameter that is less than a
minimum and/or
maximum width or diameter of primary channel 54. For example, the minimum
width of
access channel 52 can be less than 0.9, 0.8, 0.6, or 0.4 times the maximum
diameter of
primary channel 52.
[0070] Access channel 54 can comprise a linear slot that projects
perpendicular to first
side face 20 and is bounded by opposing interior faces 56A and 56B. In one
embodiment, at
least a portion of interior faces 56A and 56B can be disposed in parallel
alignment. In an
alternative embodiment, as shown in Figure 11, an access channel 54B can
project from first
side face 20 to primary channel 52 at an oblique angle relative to first side
face 20. In
another depicted embodiment, an access channel 54C is shown that curves from
first side
face 20 to primary channel 52. Furthermore, interior faces 56A and 56B need
not be
disposed in parallel alignment. By way of example and not by limitation,
interior faces 56A
13
CA 3030193 2019-01-16
and 56B could be disposed in planes that are converging as they extend from
first side face
20 to primary channel 52, as shown by access channel 54D, or diverging as they
extend
from first side face 20 to primary channel 52, as shown by access channel 54E.
[0071] One of the benefits of channels 50, in contrast to channels 32, is
that channels 50
are automatically self-filling with the self-leveling flooring material to
proper height as the
self-leveling flooring material is dispensed into the bounded area for the
underlayment.
That is, as discussed below in greater detail, as the self-leveling flooring
material is
dispensed into the area bounded for the underlayment, the self-leveling
flooring material
freely flows into channels 50 through access channels 54 and properly fills
channels 50 to
the top surface of the formed underlayment. As such, there is no need for
separate filling or
leveling of channels 50 with a filling material.
[0072] Another benefit of forming channels 50 so that they comprise
primary channel 52
and constricted access channel 54 that extends through first side face 20 is
that this
configuration assists in interlocking edging form 10C with the resulting
underlayment.
Specifically, as discussed above, once edging form 10C is secured in position
and the self-
leveling flooring material is poured, the self-leveling flooring material
flows through access
channels 54 and into primary channels 52 where the self-leveling flooring
material cures and
hardens. Because of the constriction of access channels 54 relative primary
channels 52, the
cured flooring material within primary channels 52 cannot pass out through
access channels
54. Thus, the cured flooring material interlocks edging form 10C to the
underlayment to
prevent unwanted separation or movement between edging form 10C and the
underlayment.
[0073] It is appreciated that channels 50 can be formed in a variety of
other
configurations that facilitate interlocking between edging form 10C and the
underlayment.
By way of example and not by limitation, channels 50 can be formed with a
corner, angle,
arch or curve to help achieve interlocking. More specifically, as depicted in
Figure 12, a
channel 50F is provided having a Y-shaped configuration. Channel 50F includes
a V-
shaped primary channel 52F and a linear access channel 54F that extends from
first side face
20 to primary channel 52F. Angles or corners 58F are formed at the
intersection between
primary channel 52F and access channel 54F to facilitate the interlocking.
[0074] A channel 50G is also shown that is curved or arched along it
length. The curve
of channel 50G helps produce the interlocking between edging form 10C and the
formed
14
CA 3030193 2019-01-16
underlayment because the cured flooring material within channel 50G cannot
pull out of
channel 50G. In another alternative, an L-shaped channel 50H is depicted.
Channel 50H
includes a primary channel 52H and an access channel 54H that are both linear
but that
orthogonally intersect at an angle or corner 58H to help achieve interlocking.
[0075] Also
depicted in Figure 12 is P-shaped channel 501. Channel 501 includes a
primary channel 521 having a semi-circular configuration and an access channel
541 that is
linear and extends from first side face 20 to primary channel 521. Channels
521 and 541
intersect at an angle or corner 581 to help achieve the interlocking. In
addition, primary
channel 521 has a larger maximum width than access channel 541 so that the
cured flooring
material within primary channel 521 cannot pass through access channel 541.
Further
depicted in Figure 12 is chevron or V-shaped channel 50J. Channel 50J includes
a linear
primary channel 52J and a linear access channel 54J that extends from first
side face 20 to
primary channel 52J. Channels 52J and 54J intersect at a corner 58J having an
obtuse angle
to help achieve interlocking. Finally, depicted in Figure 12 is a T-shaped
channel 50K.
Channel 50K includes a linear primary channel 52K and a linear access channel
54K that
extends from first side face 20 to centrally intersect with primary channel
52K. Channels
52K and 54K intersect at corners 58K having a right angle to help achieve
interlocking. In
view of the foregoing, it is appreciated channels 50 could also be formed in a
variety of
other configurations that would help achieve interlocking between edging form
10C and the
formed underlayment.
[0076] In
other embodiments, the interlocking feature can also be achieved, or at least
improved, by having channels 50 extend at an oblique angle relative to first
side face 20.
For example, depicted in Figure 13 is a channel 50L that is in the form of a
linear slot that
intersects with first side face 20 at an acute angle O. If desired, a channel
50M in the form of
a linear slot can also be formed that intersects with first side face 20 at an
acute angle 0.
Channels 50L and 50M are depicted as being disposed in planes that converge
toward first
side face 20. In an alternative embodiment, channels 50L and 50M can be
configured so
that they are disposed in planes that diverge toward first side face 20.
[0077] In
other embodiments, however, it is not necessary for channels 50 to have an
interlocking configuration as discussed above. Rather, channels 50 can be
formed by simply
being recessed into first side face 20. For example, as depicted in Figure 13,
channels 50N,
CA 3030193 2019-01-16
500 and 50P are formed recessed into first side face 20 having a semi-
circular, triangular
and rectangular transverse cross section, respectively. Other polygonal and
irregular shapes
can also be used. The channels 50N, 500 and 50P help facilitate engagement
between
edging form 10C and the formed underlayment.
[0078] As depicted in Figures 9 and 10, which are top and bottom
perspective views of
edging form 10C, channels 50, including primary channels 52 and access
channels 54,
extend entirely through body 12C from top face 16 to bottom face 18. More
specifically,
access channels 54 extend through first side face 20 to primary channels 52
along the full
height of first side face 20 from top face 16 to bottom face 18. In
alternative embodiments,
however, access channels 54 need not extend along the full height of first
side face 20. For
example, depicted in Figures 14 and 15 is a top perspective view and a bottom
perspective
view, respectively, of body 12C having modified channels 50 formed thereon.
Specifically,
body 12C is formed having channels 50Q, 50R and 50S formed thereon. Channel
50Q
includes a primary channel 52Q that extends entirely through body 12C from top
face 16 to
bottom face 18 at a location spaced apart from first side face 20 and second
side face 22.
However, channel 50Q comprises an access channel 54Q that does not extend the
full height
of first side face 20. Rather, access channel 54Q extends through first side
face 20 to
primary channel 52Q only through an upper portion of first side face 20 that
is spaced apart
from bottom face 18. Access channel 540 also extends through top face 16 from
first side
face 20 to primary channel 520 but does not extend through bottom face 18 from
first side
face 20 to primary channel 52Q. Access channel 54Q allows the self-leveling
flooring
material to automatically flow into channel 50 after the flooring material has
reached a
specific level.
[0079] Channel 50R also includes a primary channel 52R that extends
entirely through
body 12C from top face 16 to bottom face 18. However, channel 50R comprises an
access
channel 54R that only extends from first side face 20 to primary channel 52R
at a location
between and spaced apart from top face 16 and bottom face 18. In the depicted
embodiment, access channel 54R comprises a cylindrical channel centrally
formed on first
side face 20. However, access channel 54R can have any desired transverse
cross section
and can be placed at other locations spaced apart from top face 16 and bottom
face 18 so
that access channel 54R does not pass through top face 16 or bottom face 18.
16
CA 3030193 2019-01-16
[0080] Finally, channel 50S includes a primary channel 52S that extends
entirely through
body 12C from top face 16 to bottom face 18. However, channel 50S comprises an
access
channel 54S that does not extend the full height of front face 20. Rather,
access channel 54S
only extends through first side face 20 to primary channel 52S through a lower
portion of
first side face 20 that is spaced apart from top face 16. Access channel 54S
extends through
bottom face 18 from first side face 20 to primary channel 52S but does not
extend through
top face 16 from first side face 20 to primary channel 52Q.
[0081] In the prior embodiments, each of bodies 12A-12C are described as
having a
square or rectangular transverse cross section that includes sides 16, 18, 20
and 22 as
previously discussed. In alternative embodiments, however, each body 12 can
have a
variety of alternative transverse cross sectional configurations. For example,
depicted in
Figures 16-20 are end views or cross sectional side views of alternative
bodies 12 that can
be used as part of any of the edging forms previously or later described
herein. Like
elements between the bodies described in Figures 16-20 and bodies 12A-12C are
identified
by like reference characters. For example, depicted in Figure 16 is a body 12D
having
bottom face 18 and first side face 20. However, top face 16 and second side
face 20 have
been replaced with a single curved top face 16A that extends from first side
face 20 to
bottom face 16. As such, body 12D has an end view or a transverse cross
section with the
configuration of a quarter circle. In this embodiment, channels 32 and 50
extend through
body 12D from top face 16A to bottom face 18 and extend through first side
face 20 as
previously discussed above.
[0082] In Figure 17, body 12E includes has a top face 16E and opposing
bottom face 18
and opposing side faces 20 and 22E. In this embodiment, however, second side
face 22E is
shorter than first side face 20 and top face 16E extends in a curve from first
side face 20 to
second side face 22E. In a modified version, top face 16E could be flat,
rather than curved,
as designated by dash line 60. Body 12F in Figure 18 is similar to the body
12D depicted in
Figure 16 except that instead of having a curved top face 16D, body 12F has a
flat top face
16F that extends from first side face 20 to bottom face 18. As such, body 12F
has an end
view or a transverse cross section with the configuration of a triangle.
[0083] In Figure 19, body 12G includes has a top face 16G and opposing
bottom face
18G and opposing side faces 20G and 22. In this embodiment, although top face
16G and
17
CA 3030193 2019-01-16
bottom face 18G are disposed in parallel alignment, bottom face 18G is short
than top face
16G. As such, first side face 20G outwardly slopes from bottom face 18G to top
face 16G.
Body 12H shown in Figure 20 is similar to the embodiment in Figure 19 except
that top face
16H is shorter than bottom face 18H so that first side face 20H slopes
inwardly as it extends
from bottom face 18H to top face 16H.
[0084] All of the above bodies 12D-12H are configured so that channels 32
and 50
extend therethrough from top face 16 to bottom face 18. Where channels 50 are
formed,
access channels 54 extend from first side face 20 to primary channels 52. All
of previously
discussed channels 50, primary channels 52 and access channel 54 and the
alternatives
thereof as discussed herein can be used with each of bodies 12D-12H.
[0085] Depicted in Figure 21 is an edging form 10B1 having a body 12B1.
Body 12B1
is in the form of a circular ring and has substantially the same configuration
as body 12B
depicted in Figures 5-8. Like elements between body 12B and body 12B1 are
identified by
like reference characters and thus body 12B1 includes faces 16, 18, 20 and 22
and bounds
opening 44 extending therethrough. Body 12B1 can be made of the same materials
and
have the same configurations, dimensions, and alternatives as previously
discussed herein
with regard to body 12B. However, one of the distinctions between body 12B and
body
12B1 is that in contrast to having channels 32 extending therethrough which
are completely
encircled by body 12B, body 12B1 has channels 50 extending therethrough which
include
primary channel 52 extending from top face 16 to bottom face 18 and access
channel 54 that
extends from first side face 20 to primary channel 52. Body 12B1 can be formed
with any
of the channels 50 or alternatives discussed herein, such as shown in Figures
11-15, and can
be formed with any of the transverse cross sectional configurations discussed
herein, such as
in Figures 16-20. The spacing and number of channels 50 on body 12B1 can be
the same as
the previously discussed spacing and number of channels 32 on body 12A.
[0086] Although body 12B1 can be formed as a single, continuous, integral
loop, in the
depicted embodiment of Figure 21, a slot 64 extends through body 12B1 from
exterior side
face 20 to interior side face 22 so that body 12B1 does not form a single,
continuous,
integral loop. That is, although body 12B1 has a circular ring shaped
configuration with
inside diameter D, body 12B1 has opposing end faces 28 and 30 that bound slot
64
therebetween. Slot 64 can be made as part of the manufacturing process. That
is, in one
18
CA 3030193 2019-01-16
embodiment, the interior opening 44 can be cut out with a blade or wire. For
example, body
12B1 can be formed from a block of prefabricated polymeric foam or other
desired material.
Exterior side face 20 can be formed by using a blade or wire to cut the block
into a circular
configuration. When using a saw, such as a scroll saw or band saw, the blade
or wire then
cuts laterally into the bock, forming slot 64, and is then used to cut out
interior opening 44.
The blade or wire can then pass back out of interior opening 44 through slot
64. If desired,
opposing end faces 28 and 30 can be secured together such as by welding,
adhesive,
fastener, tape or the like so as to form a continuous loop. In other
embodiments where body
12B1 is not formed by using a scroll saw or band saw, body 12B1 could be
formed without
the formation of slot 64. Similarly, previously discussed body 12B could be
formed with slot
64 extending therethrough.
[0087] Depicted in Figure 22 is a further alternative embodiment of an
edging form 10B2
having a body 12B2 and incorporating features of the present invention. Body
12B2 is
similar to body 12B1 except that body 12B2 has a rectangular looped
configuration rather
than a circular ring configuration. Like elements between body 12B2 and 12B1
are
identified by like reference characters. Specifically, body 12B2 is in the
form of a square or
rectangular loop having top face 16 and opposing bottom face 18 that extend
between
exterior side face 20 and opposing interior side face 22. Spaced apart
channels 50 extend
through body 12B2 from top face 16 to bottom face 18 and also extend through
at least a
portion of exterior side face 20.
[0088] Exterior side face 20 forms an outer perimeter having a square or
rectangular
configuration while interior side face 22 forms an inner perimeter that bounds
an opening
44A extending through body 10B2. Opening 44A can be square or rectangular and
will
commonly have a maximum width of at least or less than 10 cm, 15 cm, 20 cm, 25
cm, 30
cm, 40 cm, 50 cm or in a range between any two of the foregoing values.
Opening 44A
can also have a minimum width of at least or less than 5 cm, 10 cm, 15 cm, 20
cm, 25 cm,
30 cm or in a range between any two of the foregoing values. Body 12B2 is
configured for
encircling a rectangular air vent but can be used for encircling any type of
structure or
opening. Body 12B2 can be made of the same materials as previously discussed
herein with
regard to body 12B. Furthermore, body 12B2 can be formed with any of channels
50 or
alternatives discussed herein, such as shown in Figures 11-15, and can be
formed with any
19
CA 3030193 2019-01-16
of the transverse cross sectional configurations discussed herein, such as in
Figures 16-20.
The spacing and number of channels 50 can be the same as the previously
discussed spacing
and number of channels 32 on body 12A.
[0089] A slot 64A extends through body 12B2 from exterior side face 20 to
interior side
face 22 and is bounded by opposing ends faces 28A and 30A. As previously
discussed with
regard to body 12B1, slot 64A can be produced by a blade or wire while
removing material
that forms opening 44A. However, in contrast to slot 64 which is linear, slot
64A has a
substantially Z-shaped configuration which results in end face 28A forming a
protrusion 66
projecting into end face 30A adjacent to interior side face 22 and end face
30A forming a
protrusion 68 projecting into end face 28A adjacent to exterior side face 20.
Protrusions 66
and 68 overlap so that if a lateral outside force is applied to exterior side
face 20, such as
when a self-leveling flooring material is pushing against exterior side face
20, protrusion 68
pushes against or is supported by protrusion 66 so as to help prevent the
inward flexing or
moving of body 12B2 adjacent to slot 64A. Such flexing or movement of body
12B2 could
enable leaking of self-leveling flooring material into opening 44A through
slot 64A which
defeats the purpose of body 12B2. Slot 64 on body 12B1 can also be formed
having the
configuration of slot 64A to help prevent the flexing or bending of form 12B1.
In other
embodiments, body 12B2 can be formed without slot 64A so that body 12B2 forms
a single,
continuous integral loop. In still other embodiments, opposing ends faces 28A
and 30A can
be secured together such as by welding, adhesive, tape, fasteners or the like.
[0090] In contrast to having a circular or rectangular opening 44/44A, it
is appreciated
that other edging forms can also be produced in the form of a loop that
encircles an opening
having other configurations. For example, the opening could be triangular,
oval, polygonal,
irregular, or the like.
[0091] Turning to Figures 23-25, a method of using the various edging
forms described
herein and having channels 50 will now be discussed. Initially, as depicted in
Figure 23, a
plurality of separate forms 10C are secured to an existing subfloor 70 so that
edging forms
10C encircle an area 72 on which an underlayment, or other self-leveling
floor, is to be
formed. Edging forms 10C are positioned so that first side face 20 and access
channels 54
of each body 12C face area 72. Previously discussed edging forms 10C, 10B1 and
10B2
were described as not including adhesive strip 14 on bottom face 20. When
produced in this
CA 3030193 2019-01-16
configuration, an adhesive is manually applied to bottom face 20 at the time
of placing
forms 10C. The adhesive can comprise a sealant, caulking, construction
adhesive, glue,
adhesive tape, or other conventional sealants or adhesives. The adhesive
commonly comes
in a caulking tube and can be easily applied using a caulking gun. For
example, one or more
beads of caulk can be placed along the length of bottom face 20. In other
embodiments, the
adhesive can be applied by squeezing a tube, spraying, painting, spreading, or
using some
other applicator or method. Once the adhesive is applied to body 12C, body 12C
is pressed
against subfloor 70 so that the adhesive secures body 12C to subfloor 70 and
forms a liquid
tight seal therebetween. Although typically less convenient, it is also
possible to apply the
adhesive directly to subfloor 70 and then press body 12C onto the adhesive so
as to secure
body 12C to subfloor 70.
[0092] In alternative embodiments, edging forms 10C, 10B1 and 10B2 can
initially be
produced with and thus further comprise adhesive strip 14 formed on bottom
face 20. The
alternatives types, configurations, methods of attachment and use of adhesive
strip 14, i.e.,
adhesive strip 14A and 14B, previously discussed herein are all applicable to
use with forms
10C, 10B1 and 10B2 and the alternatives thereof. Where edging forms 10C
include
adhesive strip 14, edging forms 10C can be attached by simply removing cover
strip 40 and
then pressing adhesive strip 14 against subfloor 70 so that forms 10C are
secured to subfloor
70 and a liquid tight seal is formed between each body 12C and subfloor 70.
[0093] As needed, edging forms 10C are cut to length and the intersecting
ends are
abutted at the corners to prevent leaking of the self-leveling flooring
material thereat. To
further help prevent unwanted leaking at the corners, an adhesive, such as
discussed above,
can be applied between the abutting faces to secure them together in a liquid
tight
engagement. Where one side of area 72 is longer than an edging form 10C, two
or more
edging forms 10C can be abutted end to end to form a continuous side. Again,
an adhesive
can be used between the abutted end faces to secure them together in a liquid
tight
engagement.
[0094] As depicted in Figure 23, forms 10C are placed so that area 72 is
completely
encircled or bounded by forms 10C. However, this may not always be necessary.
For
example, in some cases an existing wall, footing, board, or other structure
may form part of
the perimeter boarder for area 72. In that case, edging forms 10C can be
butted against the
21
CA 3030193 2019-01-16
existing structure so that edging forms 10C only partially bound area 72 but
all of area 72 is
bounded by some structure. For example, in one method of use one or more
edging forms
10C are placed across a doorway to a room while the remainder of the subfloor
of the room
is bounded by the walls of the room. Thus, the self-leveling flooring material
can be applied
over the subfloor of the room with edging form(s) 10C only extending across
the doorway.
[0095] In still other applications, based on the slope of existing
subfloor 70 or the
intended application of the self-leveling flooring material, all of area 72
may not need to be
bounded. For example, an uphill end of area 72 may not need to be bounded by
an edging
form 10C or other structure where the self-leveling flooring material will
naturally not flow
past the uphill end because of the slope of area 72.
[0096] In addition to bounding the perimeter of area 72, as necessary,
locations within
area 72 that need to be protected from the self-leveling flooring material or
where it is
desired to prevent the unwanted flowing of self-leveling flooring material are
bounded or
sealed off by an edging form. As previously discussed, examples of such
structures or
openings to be sealed off from the flooring material can include toilet
flanges, air vents,
wiring, outlets or other openings. As shown in Figure 23, one or more forms
10B1 can be
secured to subfloor 70 within area 72 so that the structure or opening to be
sealed off from
the self-leveling flooring material is disposed within opening 44 thereof.
Form(s) 10B1 can
be secured to subfloor 70 using the same methods as previously discussed above
with regard
to form 10C. During attachments to subfloor 70, opposing end faces 28 and 30
(Figure 21)
of edging form 10B1 are abutted together and can be sealed together to prevent
leaking of
self-leveling flooring material therethrough. In contrast to or in combination
with the use of
edging forms 10B1, one or more edging forms 10B2 could also be secured to
subfloor 70
within area 72. In yet other applications, in contrast to or in combination
with the use forms
10B1 and/or forms 10B2, areas, openings or structures within area 72 can be
sealed from the
self-leveling flooring material by cutting smaller sections of form 10C and
securing them
around the area, opening or structure. This can be done in the same way, as
discussed
above, that forms 10C are used to bound/seal area 72 except that first side
face 20 and
access channels 54 now face outward toward area 72.
[0097] Turning to Figure 24, with the edging forms properly positioned, a
self-leveling
flooring material 76 is dispensed onto area 72 until self-leveling flooring
material 76 reaches
22
CA 3030193 2019-01-16
a desired level within area 72 for the underlayment. The dispensing of
flooring material 76
can be accomplished by pouring, pumping, draining, dumping or any other
dispensing
method. As flooring material 76 is dispensed into area 76, flooring material
76 will
naturally flow under the force of gravity into a level surface. As flooring
material 76
reaches first side face 20, the edging forms prevent flooring material 76 from
flowing
through or under the edging forms. Accordingly, as additional quantities of
flooring
material 76 are dispensed into area 72, the depth of flooring material 76
increases and thus
the level of flooring material rises along each first side face 20. As
flooring material 76
reaches each first side face 20, flooring material 76 flows through access
channels 54 and
into primary channels 52. Thus, once the dispensing of flooring material 76
has stopped, the
level of flooring material 76 within access channels 54 and primary channels
52 is equal to
the level of flooring material 76 within area 72.
[0098] Once flooring material 76 has covered area 72 to a desired level,
flooring material
76 is left to cure into a hardened state, thereby forming an underlayment 78.
The edging
forms are typically sized so that at least some of each edging form projects
up above the top
surface of underlayment 78. That is, one of the benefits of the present
invention is that it is
not necessary to initially design or cut the edging forms prior to dispensing
of flooring
material 76 so that the edging forms will match the height of the dispensed
flooring material
76. Rather, once flooring material 76 has cured, the excess height of the
edging forms
extending above the top surface of flooring material 76 is removed. This can
be
accomplished by using a knife, saw blade or other trimming or cutting machines
to remove
the excess material. Figure 24 shows flooring material 76 cured to form
underlayment 78
and a portion of the edging forms being cut away so that a top surface 96 of
remaining
portion 98 of the edging forms is flush with the top surface of underlayment
78. Flooring
material 76 being received and cured within channels 50 is also shown.
[0099] Producing edging forms with channels 50 that communicate with area
72 through
first side face 20 achieves a number of benefits. For example, as discussed
above, because
channels 50 communicate with area 72 through first side face 20, channels 50
automatically
fill with the same level of flooring material 76 as area 72. As such, there is
no need to
separately fill channels 50 with a fill material. Furthermore, having channels
50 filled to a
desired height with cured flooring material 76 makes it easy to remove the
excess amount of
23
CA 3030193 2019-01-16
the edging forms. This is because the top surface of the cured flooring
material 76 within
channels 50 acts as a flat, horizontal guide along which a saw blade or knife
can easily and
smoothly move for cutting away the excess edging forms. In addition, as
previously
discussed, having flooring material 76 cured within channels 50 facilitates a
secure
interlocking between the cured underlayment 78 and the edging forms. As such,
there is no
unwanted movement of the edging forms relative to the cured underlayment 78
during
cutting away of the excess edging forms, during application of the floor
covering on top of
underlayment 78, or after the floor covering has been applied.
[0100] Finally, channels 50 filled with cured flooring material 76 act as
vertical support
columns within the edging forms so that the combined edging forms and columns
have
sufficient compressive strength to enable the flooring material to be applied
directly over the
edging forms. That is, there is no need to remove the edging forms after
flooring material
76 has cured. Other benefits also exist.
[0101] As depicted in Figure 25, once all of the excess of edging forms
has been
removed so that the remaining portions 98 of the edging forms are now flush
with
underlayment 78, a floor covering can now be positioned over underlayment 78.
For
example, tiles 80 can now be laid and secured on top of both the edging forms
and
underlayment 78. Again, although the edging forms many have initially been too
fragile to
withstand the compressive applied through the floor covering, because of the
increased
compressive strength resulting from the combined edging forms and flooring
material 76
cured within channels 50 thereof, tiles 80 and other floor covering can now be
safely laid
directly on top of the edging forms.
[0102] In addition to tile 80, carpet 82 can also be laid on top of
underlayment 78 and the
edging forms. Specifically, a carpet tack strip 84 can be nailed on top of
edging forms 10C.
Again, although edging forms 10C may not have independently been sufficiently
strong to
engage and support track strip 84, because of the synergistic benefits of
having channels 50
filled with cured flooring material 76, the combined edging forms 10C and
flooring material
76 provide sufficiently structural strength to enable tack strip 84 to be
directly nailed on top
of edging forms 10C. Capet 82 can then be laid over the top of underlayment 78
and
secured to tack strips 84 using conventional techniques. Other flooring such
as vinyl,
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CA 3030193 2019-01-16
linoleum, or wood flooring can also be secured over the top of underlayment 78
and the
edging forms.
[0103] Turning to Figure 26, a further alternative edging form 10C1 is
provided. Like
elements between edging form 10C and edging form 10C1 are identified by like
reference
characters. Edging form 10C1 includes body 12C having channels 50 as previous
discussed
with regard to form 10C. Body 12C can be made of the same materials and have
all of the
same alternatives as previously discussed. However, form 10C1 also includes a
backing
strip 88 secured to and extending along second side face 22. Backing strip 88
is thinner than
and more flexible than body 12C. For example, backing strip 88 can be bent
over an angle
of at least 900, 180 , 270 , or 360 without failure and can also be rolled
into a tube having a
diameter less than 15 cm, 10 cm, or 5 cm without failure. Backing strip 88 is
commonly
made from a polymeric material and can comprise a polymeric film, sheet or
tape. Backing
strip 88 is typically attached by an adhesive but can also be attached by over
molding,
welding, fasteners or the like.
[0104] The function of backing strip 88 is to retain body 12C connected
together when
form 10C1 is bent around a radius or curvature that would typically result in
the cracking
and breaking/failure body 12C. For example, when body 12C is formed of a
polystyrene
foam, although body 12C would have some flexibility, it may fail by cracking
if bent around
an outside corner or around a small column. By having backing strip 88 secured
to second
side face 22, if edging form 10C1 is bent around a corner or small radius, as
shown in Figure
27, a crack 90 may be formed extending from each channel 50 to second side
face 22 and
backing strip 88. However, backing strip 88 will maintain body 12C secured
together and
will also act as a dam to stop flooring material 76 that may passes through
cracks 90. If
desired, an adhesive can be applied to a back side 92 of backing strip 88 for
securing edging
form 10C1, and particularly second side face 22, to an adjacent wall, column
or other
structure against which edging form 10C1 is being placed.
[0105] Depicted in Figure 28 is another alternative embodiment of an
edging form 10C2.
Edging form 10C2 includes a body 12C2 where like elements between bodies 12C
and 12C2
are identified by like reference characters. Body 12C2 is substantially the
same as body 12C
except that a plurality of spaced apart second channels 50 are also formed
extending through
body 12C2 and communicating with second side face 22. Second channels 50
CA 3030193 2019-01-16
communicating with second side face 22 can have the same configuration and
alternatives as
previously discussed with channels 50 communicating with first side face 20.
Edging form
10C2 can be used as an expansion joint where large self-leveling floors are
being poured.
For example, as shown in Figure 29, one or more edging forms 10C2 can be
positioned
within area 72 to divide area 72 into two sub-areas 72A and 72B. In this
configuration, both
of the opposing side faces of edging forms 10C2 are freely and openly exposed.
Flooring
material 76 can then be dispensed into each of sub-areas 72A and 72B so that
flooring
material 76 flows into channels 50 on both sides of edging form 10C2. Once
flooring
material 76 is cured, the excess portion of edging forms 10C and 10C2 above
the level of
flooring material 76 is removed and floor covering is applied in the same
manner as
previously discussed.
[0106] By using edging forms 10C2 as expansion joints, large self-leveling
floors can be
formed with minimal cracking due to expansion and contraction. As needed,
edging forms
10C2 can be used to divide area 72 into as many sub-areas as needed.
[0107] Depicted in Figures 30 and 31 is still another alternative
embodiment of an edging
form 10C3. Edging form 10C3 includes a body 12C3 where like elements between
bodies
12C and 12C3 are identified by like reference characters. Body 12C3 is similar
to body 12C
except that body 12C3 has a substantially L-shaped transverse cross section.
Specifically,
body 12C3 includes a top face 16J and opposing bottom face 18 that extend
between a first
side face 20J and second side face 22. In this embodiment, a notch 111 is
formed on the top
face along the length of body 12C3 so as to form the substantially L-shaped
configuration.
More specifically, top face 16J includes a first lateral portion 110 extending
from second
side face 22, a second lateral portion 112 extending from first side face 20J
and a riser
portion 114 extending between first lateral portion 110 and second lateral
portion 112. In
the depicted embodiment, first lateral portion 110 is disposed at an elevation
above second
lateral portion 112 when bottom face 18 is horizontally disposed. First
lateral portion 110
and second lateral portion 112 are depicted as being disposed in parallel
planes that both
orthogonally intersect riser portion 114. That is, riser portion 114 can
extend vertically up
from second lateral portion 112 to first lateral portion 110 when bottom face
18 is
horizontally disposed and can also extend orthogonal from bottom face 18.
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CA 3030193 2019-01-16
[0108] In alternative embodiments, first lateral portion 110 and second
lateral portion
112 need not be disposed in parallel planes. For example, one or both of
portions 110 and
112 can be sloped relative to the other and/or relative to bottom face 18. For
example, as
shown in Figure 31, in one embodiment, second lateral portion 112 can upwardly
slope
toward riser portion 114 as identified by broken line 116. Likewise, riser
portion 114 can be
sloped relative to first lateral portion 110 and/or second lateral portion
112.
[0109] In an alternative embodiment depicted in Figure 32, body 12C3 again
has a
substantially L-shaped transverse cross section and includes top face 16J,
bottom face 18
and side faces 20J and 22. In this embodiment, however, top face 16J includes
first lateral
portion 110, second lateral portion 112 and a riser portion 114A. In contrast
to riser portion
114 which is disposed in a single plane, riser portion 114A comprises an
angled shoulder
portion 118 that upwardly slopes from second lateral portion 112 and an
extension portion
120 that extends between shoulder portion 118 and first lateral portion 110.
The formation
of shoulder portion 118 reinforces body 12C3 at the intersection of second
lateral portion
112 and riser portion 114A to help minimize undesired failure thereat.
Shoulder portion 118
typically intersects second lateral portion 112 at an outside angle in a range
between 120
and 150 but other angles can also be used. In the embodiment depicted,
portions 118 and
120 are linear. However, in other embodiments, one or both of portions 118 and
120 could
be curved. Furthermore, in contrast to riser portion 114A being formed in two
connecting
portions, riser portion 114A could also be formed with three, four, or more
interconnected
portions.
[0110] In still another alternative embodiment depicted in Figure 33, body
12C3 again
has a substantially L-shaped transverse cross section and includes top face
16J, bottom face
18 and opposing side faces 20J and 22. In this embodiment, however, top face
16J includes
first lateral portion 110 and a riser portion 114B. Riser portion 114B has a
concave
curvature that extends from first side face 20J to first lateral portion 110.
This configuration
again reinforces body 12C3 so as to prevent failure along riser portion 114B.
[0111] Returning to Figure 30, a plurality of spaced apart channels 50
extend through
body 12C3 from top face 16J to bottom face 18 so as to communicate with first
side face
20J. More specifically, channels 50 extend through body 12C3 from second
lateral portion
112 to bottom face 18 and communicate with or extend through first side face
20J. As
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CA 3030193 2019-01-16
previously discussed, each channel 50 includes primary channel 52 which is
extending
through body 12C3 from second lateral portion 112 to bottom face 18 and access
channel 54
that extends from first side face 20J to primary channel 52. All of the
configurations and
alternatives as previously discussed with regard to channels 50, primary
channels 52 and
access channel 54 are applicable to and can be incorporated into the
embodiments and
alternatives discussed with regard to Figures 30-33. For example, in the
depicted
embodiment, primary channel 52 is shown as having a triangular transverse
cross section. In
other embodiments, primary channel 52 and access channel 54 can also have the
configurations as shown or discussed with regard to the embodiments in Figures
9-15.
When applied to the embodiment depicted in Figure 33, channels 50 and primary
channels
52 extend through riser portion 114B to bottom face 18 while access channels
54 extend
from first side face 20J to primary channels 42. Other properties previously
discussed
herein with regard to the bodies of other edge forms are also applicable to
body 12C3. Such
properties include but are not limited to lengths; dimensions; number, spacing
and
configuration of channels 50; material composition; material properties; and
structural
properties.
[0112] Edging forms 10C3 are used in substantially the same
way as the edging forms
previously discussed and the prior use disclosure is applicable to edging
forms 10C3. For
example, once edging forms 10C3 are secured to a subfloor and the self-
leveling flooring
material is dispensed, the self-leveling flooring material flows to and rises
against first side
face 20J. In so doing, the self-leveling flooring material also automatically
flows into
channels 50 as previously discussed. Once the self-leveling flooring material
hardens into a
solid floor or underlayment, the portion of body 12C3/edging form 10C3
projecting above
the underlayment is cut flush with the top surface of the underlayment using a
saw or other
tool, as previously discussed. The remaining process of applying a covering,
as previously
discussed, can then be completed.
[0113] One of the benefits of using edging form 10C3 having
the substantially L-shaped
configuration, is that in some situations the self-leveling flooring material
will rise above
first side face 20J so as to overflow second lateral portion 112 and flow
against riser portion
114. As a result, once the self-leveling flooring material has hardened to
form the
underlayment, the portion of edging forms 10C3 that projects above the
underlayment and
28
I] CA 3030193 2019-01-16
that needs to be removed has a decreased thickness. That is, the portion
projecting above
the underlayment has a thickness that extends from riser portion 114, 114A or
114B to
second side face 22 as opposed to between first side face 20J and second side
face 22. As
such, by using edging forms 10C3 in these situations, it is significantly
easier and less time
consuming to remove the portion of edging forms 10C3 that projects above the
underlayment. Furthermore, there is less waste and less clean up during use
and a lower
material cost in production.
[0114] In other alternatives, it is also appreciated that the circular,
square, rectangular,
and other polygonal edging forms discussed herein, such as edging forms 10B1,
10B2, 10C1
and the like previously discussed with regard to Figures 21-27, and
alternatives discussed
therewith, can also be formed having the substantially L-shaped configurations
as discussed
above with regard to Figures 30-33.
[0115] Select embodiments of edging forms and related methods described
herein can
achieve a number of unique benefits. For example, in some embodiments, the
edging forms
provide an easy and efficient way for bounding an area where a self-leveling
floor is to be
formed and/or sealing off areas, openings and structures where it is desired
to prevent the
flow of self-leveling flooring material. As a result, in some embodiments and
methods a
consistently level and uniform floor can be produced with decreased labor,
minimal waste of
material and/or minimal clean up. Furthermore, some of the edging forms are
inexpensive
and easy to produce, handle, cut and/or place, especially when made of a
polymeric form.
In addition, in some applications the inventive edging forms can be left in
place with the
floor covering being placed on top of them, thereby avoiding the time and mess
associated
with needed removal. Other benefits and advantages also exist.
[0116] The present invention may be embodied in other specific forms
without departing
from its spirit or essential characteristics. The described embodiments are to
be considered
in all respects only as illustrative and not restrictive. The scope of the
invention is,
therefore, indicated by the appended claims rather than by the foregoing
description. All
changes which come within the meaning and range of equivalency of the claims
are to be
embraced within their scope.
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