Modulating entrance floor mats

Abstract

A rail, system and method are disclosed, the system comprising a first and second rail which are slidable between a delivery configuration and a use configuration, each of the first and second rail comprising a central section, a male section extending longitudinally along a first side of the central section, and defining a protrusion having a length, and a female section extending longitudinally along a second side of the central section, defining a groove configured to receive a protrusion of an adjacent rail, wherein when the first and second rails are in the use configuration, the protrusion is disposed within the groove to define at least one notch having a length proximate at least a first end of the rail system, and at least one endcap insertable into the at least one notch, wherein the at least one endcap is configured to lock the first rail with the second rail in the use configuration.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation of International Application No. PCT / US 2023 / 035497, filed Oct. 19, 2023, the contents of which are incorporated by reference herein in its entirety.FIELD OF THE DISCLOSED SUBJECT MATTER

[0002] The disclosed subject matter relates to an entrance floor system for use in residential or commercial establishments. Particularly, the present disclosed subject matter is directed to a modular entrance floor system comprising a plurality of floor sections and a method for interchanging select floor sections.DESCRIPTION OF RELATED ART

[0003] A variety of flooring designs and construction methods are known for entrance ways to office buildings, stores, residences and the like which are frequently provided with modular rails which are recessed into the foundation so as to be flush with the floor surface. These rails are designed to facilitate the removal of debris, such as dirt, snow, water and the like from the footwear of pedestrian traffic entering the structure.

[0004] Typical forms of such entrance gratings comprise a plurality of elongated rigid rails arranged in side-by-side, parallel relationship. These rails are generally rectangular and sized to extend large distances, and in some embodiments, over the entire entrance floor area such that a single grate can span the entire entrance floor area. The size and weight of such large gratings presents numerous problems with respect to transporting, installation, and maintenance as handling of such cumbersome gratings can prove hazardous and require assistance by numerous service personnel.

[0005] Alternative prior art floor structures are configured as a roll-up design in which rails are joined or interconnected to adjacent rails by interlocking male and female sections. Similar to the prior art designs discussed above, these roll-up mats are typically elongated rigid rails arranged parallel to each other and extend over the entire entrance floor area. Consequently, these roll-up designs are prone to the same, transporting, installation and maintenance problems referred to above. An example of such a roll-up floor mat is disclosed in U.S. Pat. Nos. 4,029,834, 4,877,672, 4,568,587, and RE32,061 and European Pat. No. 67,024, which are hereby incorporated by reference.

[0006] According to known embodiments, modular flooring systems comprising a plurality of mating rails have previously been transported from the manufacturing facility to the customer location pre-assembled such that adjacent rails are locked together. Generally, the most effective way to transport these preassembled systems is to roll the flooring systems at the joints of adjacent rails. While these prior art designs have been effective for their intended purpose, these rolled rails can be cumbersome and oversized. Therefore, there remains a need for an entrance floor system which can improve the ease of transportation, installation, and maintenance compared to existing flooring systems.SUMMARY OF THE DISCLOSED SUBJECT MATTER

[0007] The purpose and advantages of the disclosed subject matter will be set forth in and apparent from the description that follows, as well as will be learned by practice of the disclosed subject matter. Additional advantages of the disclosed subject matter will be realized and attained by the methods and systems particularly pointed out in the written description and claims hereof, as well as from the appended drawings.

[0008] To achieve these and other advantages and in accordance with the purpose of the disclosed subject matter, as embodied and broadly described, the disclosed subject matter includes rail system including a first and second rail. the first rail slideable with respect to the second rail between a delivery configuration and a use configuration. Each rail can include a central section, a male section extending longitudinally along a first side of the central section, the male section defining a protrusion having a length, and a female section extending longitudinally along a second side of the central section, the female section defining a groove having a length, the groove being configured to receive a protrusion of an adjacent rail. When in the use configuration, the protrusion of the first rail can be disposed within the groove of the second rail such that the first rail and the second rail define at least one notch having a length proximate at least a first end of the rail system. The rail system can also include at least one endcap insertable into the at least one notch, wherein the at least one endcap has a width dimension greater than a width dimension of the at least one notch and is configured to lock the first rail with the second rail in the use configuration.

[0009] According to some embodiments, the at least one end cap an be configured to lock the protrusion of the first rail within the groove of the second rail when the first rail and the second rail are in the use configuration. As embodied herein, the at least one notch can include a first notch located at a first end of the rail system and a second notch located at a second end of the rail system, the at least one endcap can include a first endcap and a second endcap, and at least one of the first end cap and the second end cap can be removable. In yet another embodiment, the first end cap can be fixed to one end of the female section of the second rail. In yet another embodiment, at least one of the first and second endcaps can be a male threaded fastener. As is also disclosed herein, the at least one endcap can be threaded into the female section when the first rail and the second rail are in the use configuration. Further, the first and second rail can include at least one drain.

[0010] According to some embodiments, each of the first rail and the second rail can include extruded aluminum. As is further disclosed herein, the central section can be a first material and each of the male section and the female section can be a second material. Additionally, at least one of the first rail and the second rail configured to receive a carpet surface. In yet another embodiment, the rail system can include a frame within which the rail system is assembled.

[0011] Also discloses herein is a rail and method of assembling a rail system. It is to be understood that both the foregoing general description and the following detailed description are exemplary and are intended to provide further explanation of the disclosed subject matter claimed.

[0012] The accompanying drawings, which are incorporated in and constitute part of this specification, are included to illustrate and provide a further understanding of the method and system of the disclosed subject matter. Together with the description, the drawings serve to explain the principles of the disclosed subject matter.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1A is a perspective view of a rail system according to the embodiments disclosed herein.

[0014] FIG. 1B is a front view of a rail system according to the embodiments disclosed herein.

[0015] FIG. 1C is a magnified view of the adjacent rails of FIG. 1B.

[0016] FIG. 2 is a perspective view of an individual rail, excluding a notch, of the rail system shown in FIGS. 1A-1B.

[0017] FIG. 3 is top perspective view of an individual rail of the rail system shown in FIGS. 1A-1B.

[0018] FIGS. 4A-C are various views of an endcap inserted within a groove of a female section of an individual.

[0019] FIG. 4D is a perspective view of an endcap.

[0020] FIGS. 4E-4F depict various embodiments for assembling the endcap within the rails.

[0021] FIG. 5 is a side view of a rail with a carpeting surface coupled thereto according to embodiments disclosed herein.DETAILED DESCRIPTION OF THE DISCLOSED SUBJECT MATTER

[0022] Reference will now be made in detail to the exemplary embodiments of the disclosed subject matter, examples of which are illustrated in the accompanying drawings. The methods and corresponding steps of the disclosed subject matter will be described in conjunction with the detailed description of the system. The methods and systems presented herein may be used for an entrance floor area. The disclosed subject matter is particularly suited for a modular entrance floor area having a variety of designs and aesthetic features.

[0023] In accordance with an aspect of the disclosed subject matter, a plurality of floor rails are positioned adjacent to each other to define an entrance floor area. Each individual floor rail can be slideable between a delivery configuration and a use configuration with respect to its adjacent rails and can include a male section, a female section, and a central section therebetween. Particularly, the female section of each induvial rail can be configured to mate with the male section of its adjacent rail. The central section can include a top surface configured to receive a top surface material which can be carpeting or any other known material to improve traction and aesthetic qualities. Each of the plurality of rails can also include at least one drain feature. The plurality of floor rails can be configured to be interchangeable with another floor rail, independent of and without removal of the other floor sections. The rails can also be configured to lock together after assembly and installation to allow for easier disassembly and transportation.

[0024] The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the disclosed subject matter.

[0025] As shown in FIGS. 1A-B, the system generally includes a modular entrance floor system 100 that has a plurality of floor rails disposed adjacent each other, such as floor rails 102, 104 as shown. As depicted in FIGS. 1A-3, each floor rail 102. 104, 202, 302 includes a central section 106, 206, 306 having opposing sides, a male section 108, 208, 308 with a protrusion 110, 210, 310 extending longitudinally along the first side and a female section 112, 212, 312 with a groove 114, 214 extending longitudinally along the second side. The central section 106, 206, 306 can also include a top surface 120, 220, 320 which can include carpeting or other flooring surfaces or attachments. Each rail 102, 104, 202, 302 can also include a plurality of drain features 122, 222, 322 as discussed in further detail below. The rail system can also include a frame to locate the rails in space, wherein assembling the rail system can include disposing the rails 102, 104, 202, 302 within the frame, as is also discussed in further detail below.

[0026] As is disclosed above, the female section 112, 212, 312 of each individual rail 102, 202, 302 can be configured to mate with the male section 108, 208, 308 of an adjacent rail 104. In this way, the protrusion 110, 210, 310 of male section 108, 208, 308 of rail 102, 202, 302 can slide longitudinally along groove 114 of female section 112 of rail 104, thus limiting the movement of rails 102, 104 relative each other in a lateral direction. In this way, rails 102, 104 can be in a delivery configuration when unmated and in a use configuration when mated. As such, the rails 102, 104, 202, 302 can be conveniently stacked upon each other for efficient shipping and transportation. Such construction further permits optimized assembly, installation, and disassembly.

[0027] FIG. 1B is a front view of a rail system 100 and FIG. 1C is a maximized view of the connection between adjacent rails of FIG. 1B. As shown, adjacent rails 102, 104 are slide together by way of the groove 114 and protrusion 110 assembly. In cross-section, the groove 114 can have any suitable shape, such as a round shape as shown. Furthermore, the protrusion 114 can have a complementary shape in cross-section with the groove 114 to appropriately lock the rails 102, 104 together. Accordingly, a diameter or width dimension of the protrusion 110 can be larger than or equal to the entrance 115 to the groove to allow for a secure coupling in certain embodiments, and can be smaller than the entrance in other embodiments as disclosed herein.

[0028] As disclosed above, each rail is configured to lock together. To this end, an endcap is provided to lock the adjacent rails together. Once adjacent rails are slid together, the rails define at least one notch having a length proximate at least a first end of the rail system. Particularly, once the protrusion 110, 210, 310 of rail 102, 202, 302 is disposed within groove 114, 214 of rail 104, the at least one endcap 418 is insertable within groove 114, 214 to lock the protrusion 110, 210, 310 within the groove 114, 214 and lock the rails together. Accordingly, when the adjacent rails 102, 104, 202, 302, are in the use configuration, the protrusion 110, 210, 310 of the rail 102, 202, 302 is disposed within the groove 114, 214, 314 of the second rail 104 such that the adjoined rails 102, 104 define at least one notch 316, 416 having a length proximate at least a first end of the rail system. In some embodiments, the length of the at least one notch 316, 416 can be greater than or equal to the length of the at least one endcap 418.

[0029] Further detail will now be provided regarding the male section 308. As best seen in FIG. 3, male section 308 can define a plurality of drains 322 and at least one notch 316. Although FIG. 3 only depicts a first end portion of male section 308 with notch 316, embodiments can also include an opposite end portion which also includes a second, corresponding notch 316. As can be seen in FIGS. 1A-1B, when protrusion 110 is mated within groove 114, drains 122 extend longitudinally along the length of the rail system. In this way, dirt, debris, and / or water which may be tracked onto the rail system can drain drained away for safety and cleanliness. Alternatively, the drains 122 can be arranged in a non-linear, intersecting, diverging or converging fashion as needed to depict various designs or indicia such as a logo, trademark, business name, or the like.

[0030] As shown in FIGS. 4A-4F, to ensure that adjacent rails lock together, the at least one endcap 416 can be mated to the groove 414 in a plurality of suitable ways. For example, the at least one endcap 418 can have a width dimension greater than a width dimension of the groove 414 prior to insertion therein. In some embodiments, the at least one removable endcap can be at least one of press-fit or threaded into the groove 414. Accordingly, the endcap 418 can be a male threaded fastener and the groove 414 can include corresponding female threads; alternatively, the threaded endcap 418 can be self-tapping and thread directly into an unthreaded groove 414. This can be possible if, for example, the female section 412 is extruded aluminum and the endcap 418 is steel. Other suitable endcap arrangements are contemplated herein. Furthermore, the rail system can include one fixed endcap and one removable endcap 418. For example, the female section 412 of rail 404 can have a fixed endcap 418 located at a first end of groove 414 such that protrusion 410 of rail 402 is disposed against fixed endcap 418, and a removable endcap 418 can be inserted on the opposing end of groove 414. Alternatively, the second endcap 418 can also be removable and can be inserted during the assembly process with endcap 418. In some embodiments, it may be possible to forego the use of a notch by connecting the groove 414 to the protrusion 410 with a fastener, as is shown in FIG. 4E. For example, each of the groove 614 and the protrusion 610 can have at least one aligning hole configured such that a male threaded fastener 626 can pass through the aligned holes and be secured on the opposing side of the rails by a nut 628 or other female threaded fastener. Alternatively, a threaded bolt 626 can pass through aligned holes in the groove 614 and protrusion 610, and thread into mating female threads on the opposing side of the groove 614; alternatively, the screw can thread into mating female threads in the protrusion 610. In an embodiment shown in FIG. 4F, threaded fasteners can screw into either end of the protrusion 610, wherein the threaded fastener includes a head or a washer 630 having a width greater than the inner diameter of the groove 614.

[0031] The flooring rails can be made from any suitable material or materials. In some embodiments, the female section of each rail 102, 104 can be monolithic, extruded aluminum, and the central and / or male sections 106, 108 can be polyvinyl chloride (“PVC”). In other embodiments, the male and the female sections 108, 112 can both be extruded aluminum and the central section can be PVC. In yet another embodiment, the entire rail can be a single material, such as extruded aluminum. As will be apparent to those having skill in the art, many other conventional manufacturing processes can be used to form the rails. Regardless of what material is used for the rails, the top surface 120, 320 can include a carpeting surface or any other surface which can increase utility such as traction and aesthetic appeal. FIG. 5 depicts a side view of a rail 502 having a carpeting surface 524 coupled thereto.

[0032] This modular configuration also allows for rapid removal and replacement of an individual rail without removing or otherwise interfering with any other rails in use. Therefore, it is possible to remove and replace only those rails of the floor sections located in the high pedestrian traffic areas, e.g., the portion of the floor which is aligned with an entrance doorway, which are prone to more frequent traffic and degradation. Consequently, and in contrast to prior embodiments, the entire entrance floor area need not be replaced due to excessive wear over only a limited portion or narrow track. Instead, the worn rails alone can be replaced, while the remainder of the entrance floor area remains intact thereby reducing maintenance time. Alternatively, the rails can be periodically moved around in orientation based on wear and can be quickly disassembled for deep cleaning. Likewise, because the rails can be locked together during assembly at a destination site, they need not be transported to the destination site in an assembled, rolled configuration. By contrast, individual rails can be stacked in a flat configuration, increasing safety and ease of transportation.

[0033] The rail system described herein is removable with respect to a frame that houses the rail system. In certain embodiments, the frame is permanently coupled to the underlying foundation. The frame can be permanently coupled to the foundation with adhesives, epoxies, cement, or any other suitable bonding agent or system that provides a sufficient union to withstand the mechanical and thermal stresses exerted on the entrance floor area. Alternatively, a non-permanently coupled frame is considered to be within the scope of the disclosed subject matter. The rails can be removably attached to the frame via any suitable fastening device including a tongue and groove interference or snap fit arrangement.

[0034] A method of assembling a modular entrance system 100 is also disclosed herein. For example, the method can include providing two individual rails 102, 104 which are disposed adjacent each other. As explained above, the protrusion 110 of male section 108 of rail 102 can slide longitudinally along groove 114 of female section 112 of rail 104 such that rails 102, 104 can be in a delivery configuration when unmated and in a use configuration when mated. Therefore, the method can further include configuring the rails 102, 104 into the use configuration by sliding the protrusion of the first rail 102 into the groove 114 of the second rail 104 such that the two rails 102, 104 are adjacent each other. Finally, the method can include locking the adjacent rails 102, 104 together by inserting at least one end cap 418 within the groove 114 of the second rail 104.

[0035] As indicated above, inserting the at least one end cap 418 within the groove 114 of the second rail 104 can include threading the at least one end cap 418 into the groove 114. Furthermore, regardless of whether the at least one end cap 418 is threaded, two end caps 418 can be used. For example, after the protrusion 110 of the first rail 102 is positioned within the groove 114, the protrusion 110 can be held in place by either threading or press-fitting an endcap 418 within a notch 316, 416 defined on either side of the protrusion 114 by the mated protrusion 114 and groove. In other words, the protrusion 114 can be disposed between either end cap 418. As is also explained above, the method of assembling the modular entrance system 100 can include assembling the rail system 100 with a frame. The method can also include disposing a carpet surface 524 on top of either or both of the rails 502, 504.

[0036] While the disclosed subject matter is described herein in terms of certain exemplary embodiments, those skilled in the art will recognize that various modifications and improvements may be made to the disclosed subject matter without departing from the scope thereof. Moreover, although individual features of one embodiment of the disclosed subject matter may be discussed herein or shown in the drawings of the one embodiment and not in other embodiments, it should be apparent that individual features of one embodiment may be combined with one or more features of another embodiment or features from a plurality of embodiments.

[0037] In addition to the specific embodiments claimed below, the disclosed subject matter is also directed to other embodiments having any other possible combination of the dependent features claimed below and those disclosed above. As such, the particular features presented in the dependent claims and disclosed above can be combined with each other in other manners within the scope of the disclosed subject matter such that the disclosed subject matter should be recognized as also specifically directed to other embodiments having any other possible combinations. Thus, the foregoing description of specific embodiments of the disclosed subject matter has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosed subject matter to those embodiments disclosed.

[0038] It will be apparent to those skilled in the art that various modifications and variations can be made in the method and system of the disclosed subject matter without departing from the spirit or scope of the disclosed subject matter. Thus, it is intended that the disclosed subject matter include modifications and variations that are within the scope of the appended claims and their equivalents.

Claims

1. A rail system, comprising:a first rail and a second rail, the first rail slideable with respect to the second rail between a delivery configuration and a use configuration, each of the first rail and second rail comprising:a central section;a male section extending longitudinally along a first side of the central section, the male section defining a protrusion having a length; anda female section extending longitudinally along a second side of the central section, the female section defining a groove having a length, the groove being configured to receive a protrusion of an adjacent rail; whereinwhen the first rail and the second rail are in the use configuration, the protrusion of the first rail is disposed within the groove of the second rail such that the first rail and the second rail define at least one notch having a length proximate at least a first end of the rail system; andat least one endcap insertable into the at least one notch, wherein the at least one endcap has a width dimension greater than a width dimension of the at least one notch and is configured to lock the first rail with the second rail in the use configuration.

2. The rail system of claim 1, wherein the at least one end cap is configured to lock the protrusion of the first rail within the groove of the second rail when the first rail and the second rail are in the use configuration.

3. The rail system of claim 1, whereinthe at least one notch comprises a first notch located at a first end of the rail system and a second notch located at a second end of the rail system;the at least one endcap comprises a first endcap and a second endcap; andat least one of the first end cap and the second end cap is removable.

4. The rail system of claim 3, wherein the first end cap is fixed to one end of the female section of the second rail.

5. The rail system of claim 3, wherein at least one of the first and second endcaps are a male threaded fastener.

6. The rail system of claim 1, wherein the at least one endcap is threaded into the female section when the first rail and the second rail are in the use configuration.

7. The rail system of claim 1, wherein each of the first rail and the second rail comprise extruded aluminum.

8. The rail system of claim 1, wherein the central section is a first material and each of the male section and the female section are a second material.

9. The rail system of claim 1, wherein at least one of the first rail and the second rail are configured to receive a carpet surface.

10. A method of assembling a rail system, comprising:providing a first rail and a second rail, the first rail slideable with respect to the second rail between a delivery configuration and a use configuration, each of the first rail and second rail including:a central section;a male section extending longitudinally along a first side of the central section, the male section defining a protrusion having a first length; anda female section extending longitudinally along a second side of the central section, the female section defining a groove having a second length, the groove being configured to receive a protrusion of an adjacent rail;sliding the protrusion of the first rail into the groove of the second rail such that the first rail is adjacent the second rail; andinserting at least one end cap within the groove of the second rail to lock the first rail with the second rail in the use configuration.

11. The method of claim 10, wherein inerting the at least one end cap within the groove of the second rail comprises threading the at least one end cap into the groove of the second rail.

12. The method of claim 10, wherein inserting the at least one end cap within the groove of the second rail comprises inserting:a first end cap at a first end of the second rail; anda second end cap at a second end of the second rail.

13. The method of claim 12, wherein the protrusion comprises a first notch proximate the first end of the second rail and a second notch proximate the second end of the second rail, and inserting the first end cap at the first end of the second rail and inserting the second end cap at the second end of the second rail comprises disposing the protrusion between each of the first and second end caps.

14. The method of claim 10, further comprising assembling the rail system within a frame.

15. The method of claim 10, further comprising disposing carpeting on a top surface of the central section of at least one of the first rail and the second rail.

16. A rail for use in a flooring system, comprising:a central section;a male section extending longitudinally along a first side of the central section, the male section defining a protrusion having a first length; anda female section extending longitudinally along a second side of the central section, the female section defining a groove having a second length, the groove being configured to receive a protrusion of an adjacent rail and define at least one notch when the groove receives the protrusion of the adjacent rail, wherein the at least one notch is configured to receive at least one endcap to lock the rail with an adjacent rail.

17. The rail of claim 16, further comprising at least one drain.

18. The rail of claim 16, wherein the central section comprises a top surface configured to receive carpeting thereon.

19. The rail of claim 16, wherein the rail comprises extruded aluminum.

20. The rail of claim 16, wherein the central section is a first material and each of the male section and the female section are a second material.

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