Surface covering connection joints

Abstract

The present technology relates to connection joints for surface coverings which includes but is not limited to floor coverings and building panels. Embodiments of the present technology include connection joints that are strong and allow for the use of less material than is needed for tongue and groove connection joints. The connection joints includes cleats, clefts, and/or gap shims which allow for swelling and shrinking of the floor covering while maintaining a strong connection and preventing damage to the floor covering.

1 . A method of forming a floor covering comprising:
 affixing a first floor plank to a sub-floor, the first floor plank including a first edge including a first contact side, and a wedge shaped portion including a cleat;   mating the first edge of the affixed first floor plank to a complementary shaped second edge of a second floor plank, the second edged including a second contact side and a wedge shaped slot including a cleft;   affixing the second floor plank to the sub-floor with the first edge of the first floor plank mated with the second edge of the second floor plank;   wherein the cleat and cleft are configured to maintain an overlap to limit vertical movement of the second floor plank when the second floor plank shrinks in a direction away from the first floor plank, due to a change in temperature or humidity, and increases a distance between the first edge and the second edge.   
     
     
         2 . The method of  claim 1 , wherein the first floor plank is affixed to the sub-floor with the first contact side of the first floor plank contacting the second contact side of the second floor plank. 
     
     
         3 . The method of  claim 1 , wherein the first floor plank is affixed to the sub-floor with the first contact side of the first floor plank and the second contact side of the second floor plank separated by a gap. 
     
     
         4 . The method of  claim 3 , wherein the gap is between 0.3 mm and 0.5 mm and is configured to reduce cupping or buckling of the floor covering due to swelling of the plank. 
     
     
         5 . The method of  claim 3 , wherein the wedge shaped portion of the first floor plank includes a gap shim extending from a side of the wedge shaped portion, wherein the second floor plank is affixed to the sub-floor with the gap shim contacting a side of the wedge shaped slot of the second floor plank, and wherein the gap shim prevents the first contact side of the first floor plank and the second contact side of the second floor plank from contacting during the mating of the first edge of the first floor plank to the second edge of the second floor plank. 
     
     
         6 . The method of  claim 3 , wherein the wedge shaped slot of the second floor plank includes a gap shim extending from a side of the wedge shaped slot, wherein the second floor plank is affixed to the sub-floor with the gap shim contacting a side of the wedge shaped portion of the first floor plank, and wherein the gap shim prevents the first contact side of the first floor plank and the second contact side of the second floor plank from contacting during the mating of the first edge of the first floor plank to the second edge of the second floor plank. 
     
     
         7 . A floor plank for horizontal flooring assemblies comprising:
 a top side;   a bottom side substantially parallel to the top side, wherein the floor plank is affixed to a horizontal surface with the bottom side contacting the horizontal surface;   a first edge extending from the top side to the bottom side comprising;
 a first contact side extending from the top side to a first terminal position between the top side and the bottom side; and 
 a wedge shaped portion comprising;
 a first upwardly facing side extending from the first terminal position; 
 a first angled side extending between the bottom side and the first upwardly facing side and forming an obtuse angle with the bottom side; and 
 a cleat protruding from the first angled side; 
 
   wherein the first edge is configured to mate with a second edge, of a second floor plank affixed to the horizontal surface adjacent the floor plank, the second edge having a complementary shape to the first edge; and   wherein the second floor plank is configured to shrink in a direction away from the floor plank when affixed to the horizontal surface adjacent the floor plank, creating a gap between the first edge and the second edge and the cleat of the first edge and a cleft of the third edge are configured to maintain an overlap to limit vertical movement of the second floor plank when shrunk.   
     
     
         8 . The floor plank of  claim 7 , wherein the cleat includes a horizontal cleat side extending from and forming an obtuse angle with the first angled side. 
     
     
         9 . The floor plank of  claim 8 , wherein the first upwardly facing side extends downwardly from the first terminal position to the cleat. 
     
     
         10 . The floor plank of  claim 9 , wherein the cleat includes a vertical cleat side extending from an end of the first upwardly facing side to the horizontal cleat side. 
     
     
         11 . The floor plank of  claim 8 , wherein the end of the first upwardly facing side includes a rounded portion. 
     
     
         12 . A floor plank for horizontal flooring assemblies comprising:
 a top side;   a bottom side substantially parallel to the top side, wherein the floor plank is configured to be affixed to a horizontal surface with the bottom side contacting the horizontal surface;   a first edge extending from the top side to the bottom side comprising;
 a first contact side extending from the top side to a first terminal position between the top side and the bottom side; and 
 a wedge shaped portion comprising;
 a first upwardly facing side extending from the first terminal position; and 
 a first angled side extending between the bottom side and the first upwardly facing side and forming an obtuse angle with the bottom side; and 
 
   a second edge extending from the top side to the bottom side and opposite the first edge, wherein the second edge comprises a second edge geometry having a complementary shape to the first edge;   wherein the first edge is configured to mate with a third edge, of a second floor plank affixed to the horizontal surface adjacent the floor plank, the third edge comprising the second edge geometry, and   wherein the first edge is configured to form a gap between the first contact side of the floor plank and a second contact side of the second floor plank.   
     
     
         13 . The method of  claim 12 , wherein the gap is between 0.3 mm and 0.5 mm and is configured to reduce cupping or buckling of the floor covering due to swelling of the plank. 
     
     
         14 . The floor plank of  claim 12 , wherein the wedge shaped protrusion further comprises a cleat protruding from the first angled side, and
 wherein the cleat is configured to contact a side of the third edge of the second floor plank in order to create the gap between the first contact side of the floor plank and the second contact side of the second floor plank.   
     
     
         15 . The floor plank of  claim 12 , wherein the second edge geometry includes a gap shim extending from a side of a wedge shaped slot complementary in shape to the wedge shaped portion, and
 wherein a side of the wedge shaped portion is configured to contact the gap shim of the second floor plank in order to form the gap.   
     
     
         16 . The floor plank of  claim 15 , wherein the second edge geometry includes an inwardly angled side, forming a bottom portion of the wedge shaped slot, and the gap shim extends out from the inwardly angled side. 
     
     
         17 . The floor plank of  claim 15 , wherein the wedge shaped portion includes a vertical end side configured to contact the gap shim of the second plank. 
     
     
         18 . A floor plank for horizontal flooring assemblies comprising:
 a top side;   a bottom side substantially parallel to the top side, wherein the floor plank is configured to be affixed to a horizontal surface with the bottom side contacting the horizontal surface;   a first edge extending from the top side to the bottom side comprising;
 a first contact side extending from the top side to a first terminal position between the top side and the bottom side; and 
 a wedge shaped slot comprising;
 a first downwardly facing side extending from the first terminal position and facing toward the bottom side; 
 a first angled side extending from the bottom side toward the first downwardly facing side and forming an obtuse angle with the bottom side; and 
 a gap shim extending outwardly from a side of the wedge shaped slot; and 
 
   wherein the first edge is configured to mate with a second edge of a second floor plank affixed to the horizontal surface adjacent the floor plank, the second edge having a complementary shape to the first edge, and   wherein the gap shim is configured to contact a side of a wedge portion of the second edge to form a gap between the first contact side of the floor plank and a second contact side of the second floor plank.   
     
     
         19 . The floor plank of  claim 18 , wherein the gap shim extends from the first angled side. 
     
     
         20 . The floor plank of  claim 18 , wherein the first downwardly facing side includes a portion forming and acute angle with the top side, and
 wherein the gap shim extends downwardly from the portion.