AU2004201692A1 - Improved Flooring System and Method of Providing Same - Google Patents

Description

I

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name of Applicant: Actual Inventor: STEVEN PETER KRSTICEVIC Steven Peter Krsticevic Address for Service: Invention Title: Details of Basic Application(s): HODGKINSON AND McINNES Patent Trade Mark Attorneys Levels 3 and 4, 20 Alfred Street MILSONS POINT NSW 2061 "Improved Flooring System and Method of Providing Same" Australian Provisional Patent Application No. 2003901901 Filed: 22 April 2003 The following statement is a full description of this invention, including the best method of performing it known to me: IMPROVED FLOORING SYSTEM AND METHOD OF PROVIDING SAME FIELD OF THE INVENTION The present invention relates to flooring systems and, in particular, to an improved flooring system and method of providing same.

The invention has been developed primarily for use with concrete floors and in two storey or multi-level buildings where wooden floors are desired and will be described hereinafter with reference to this application. However, it will be appreciated that the invention is not limited to this particular field of use.

BACKGROUND OF THE INVENTION In many buildings, wooden floors are often demanded for various reasons including durability, appearance, and ease of cleaning/maintenance. Furthermore, wooden floors are particularly desirable since the major alternative, carpet, has been recognised as a significant contributor to the onset of allergies and medical conditions such as asthma.

Unfortunately, wooden floors are known to be noisy from general use where an undesirable amount of noise is transferred to adjacent rooms or adjacent levels of a two storey or multi-storey building. The nature of wooden floors is noisier than carpet as carpet dampens the effect of noise thereon and therethrough so that wooden floors appear noisier.

It is known to affix wooden floors to concrete by fixing one or more floor battens to a concrete slab floor. In acoustic floors, a pair of "cross-layered" plywood sheets are then alternatively fixed to the battens. A plurality of wooden floor boards are then laid over the plywood layers with a sheet of loose laid acoustic rubber disposed intermediate. In some arrangements, only a single plywood layer is used. The floor boards are then affixed to either the plywood layers, flooring battens and/or concrete floor.

In single storey and multi-storey buildings not having concrete floors, a plurality of floor joists run substantially parallel to each other across a floor. The battens are then anchored to the joists and the "cross-layered" plywood layers are fixed to the battens. The floorboards are then affixed to the plywood layers, the plywood layers and the battens, or the plywood layers and the battens and then joists.

In these known systems, because at least the battens are anchored to the joists or concrete slab, a significant amount of noise is transferred from the floorboards through to adjacent rooms or to a lower level. Furthermore, when anchoring the battens to a concrete slab floor, no account is taken of the usual variation of thickness of the concrete slab which results in some form of waviness or unevenness of the laid floorboards.

Any waviness of floorboards generally indicates that the floorboards are not mated completely which allows a significant amount of noise to travel therethrough. Also, the process of sanding floorboards before staining becomes substantially more difficult when the floorboards are not completely mated.

A known flooring system which addresses some of the above problems of wooden floors is that provided by Acousta Floors Pty Ltd. In this system, traditional flooring battens are partially enclosed in a rubber sound insulation material and the batten is anchored directly to the concrete slab or joist. The floorboards are then glued or nailed to the batten thus eliminating the need for the cross-layered plywood sheets disposed intermediate the battens and the floorboards.

This system does not take into account the variation in thickness of concrete floors or level of the joists and because the battens are anchored to the slab or joist, an undesirable amount of noise is still transferred therethrough to adjacent rooms or adjacent levels of a multi-storey building.

The above system and other known systems are also incapable of using a relatively cheap membrane, for example thick plastic, to cover concrete floors so as to protect the floors from moisture. Such moisture can escape from the concrete as it cures. In the known systems, the process of anchoring the battens to the floor provides a means for moisture to seep through the membrane thus removing its efficiency for stopping the transfer of water from the slab or joists to the floorboards. Also, as the known systems require the battens to be nailed or otherwise anchored to the concrete slab or joists holes need to be drilled through the membrane.

In some cases, it is not possible to install a wooden floor on floor joists because the height of the floor therefrom reduces the floor to ceiling height to below a minimum allowable amount under local building regulations.

OBJECT OF THE INVENTION It is an object of the invention to provide flooring system and method of providing same which will overcome or substantially ameliorate at least some of these deficiencies of the prior art, or to at least provide a useful alternative.

SUMMARY OF THE INVENTION According to a first aspect of the invention there is provided a flooring system including: a plurality of flooring battens; two or more legs extending from each said batten, each said leg being movable a predetermined distance towards or away from said batten; a foot mounted to each leg; and a sole mounted to each said foot and being composed of a predetermined thickness of resilient sound insulating material; wherein said soles abut a concrete floor or timber joist and a timber floor is fixed directly onto said flooring battens.

Preferably, said legs are threadedly engaged with said battens and rotation of said legs moves said feet towards or away from said batten. More preferably, said feet are composed of metal or molded plastic and said soles are composed of sorbethane or Regupol (registered trade mark).

In preferred embodiments, said system includes insulation disposed intermediate said timber floor and said concrete slab, or intermediate said timber floor and a ceiling of a lower storey room. In other preferred embodiments, said system includes a waterproof membrane extending substantially across said floor and being disposed intermediate said soles and said concrete slab or joists.

According to a second aspect of the invention there is provided a method of providing a flooring system, said method including the steps of: providing a plurality of flooring battens each having two or more legs extending therefrom wherein each said leg is movable a predetermined distance towards or away from said batten; providing a foot on each leg; mounting a sole to each foot, each sole being mounted thereto and being composed of a predetermined thickness of resilient sound insulating material; abutting said soles to a concrete floor or timber joist; and fixing a timber floor directly onto said flooring battens.

Preferably, said method further includes the step of disposing insulation intermediate said timber floor and said concrete slab, or intermediate said timber floor and a ceiling of a lower storey room. More preferably, said method also includes the step of disposing a waterproof membrane intermediate said soles and said concrete slab or joists and substantially across said floor.

In preferred embodiments, said method includes the step of moving each said leg such that said timber floor is substantially level.

According to a third aspect of the invention there is provided a flooring system for use in two storey or multi-storey buildings, the system including one or more support frames each including a web adapted to abut a side of a joist and having a flange mounted at each end of said web, said flanges extending in opposite directions and away from said web, a top said flange being adapted for mounting to a top side of said joist and a lower said flange being recessed from said top side of said joist a predetermined distance and being configured to support a wooden floor.

In preferred embodiments, said system further includes: a plurality of flooring battens; two or more legs extending from each said batten, each said leg being movable a predetermined distance towards or away from said batten mounted to each leg; and a sole mounted to each foot and being composed of a predetermined thickness of resilient sound insulating material; wherein said soles abut said lower flange and a timber floor is fixed directly onto said flooring battens.

Preferably, said system includes a waterproof membrane extending substantially across said floor and being disposed intermediate said soles and said joists.

In preferred embodiments, said support frames include a second web adapted to abut the other side of said joist and a second lower flange extending away from said second web and substantially parallel to said lower flange, said second lower flange being adapted to support a wooden floor.

According to another aspect of the invention there is provided a method of providing a flooring system in a two storey or multi-storey building, said method including the steps of: providing one or more support frames each including a web adapted to abut a side of a joist and having a flange mounted at each end of said web, said flanges extending in opposite directions and away from said web; mounting a top said flange to a top side of said joist; recessing a lower said flange from said top side of said joist a predetermined distance; and adapting said lower flange to support a wooden floor.

Preferably, said method further includes the steps of: providing a plurality of flooring battens each having two or more legs extending therefrom wherein each said leg is movable a predetermined distance towards or away from said batten; providing a foot on each leg; mounting a sole to each foot, each sole being composed of a predetermined thickness of resilient sound insulating material; abutting said soles to said lower flange; and fixing a timber floor directly onto said flooring battens.

BRIEF DESCRIPTION OF THE DRAWINGS Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: FIG 1 is a cross-sectional view of part of a flooring system according to a first embodiment; FIG 2 is a cross-sectional view of a flooring system according to another embodiment; and FIG 3 is a perspective view of a pair of support frames shown FIG 2.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIG 1, there is shown part of a flooring system 1 in cross-section. The system 1 includes a plurality of flooring battens 2 spaced across a floor 3. The floor 3 can be in the form of a plurality of wooden joists or a concrete slab.

Each batten 2 includes two or more legs 4 for supporting the weight of the batten.

Typically, one leg will extend from each end of a batten 2, however, in long battens any number of legs 4 may be employed.

Each leg 4 includes an outside threaded portion which threadedly engages with a bore in the batten 2 having a corresponding internal threaded portion (not illustrated). Rotation of each leg 4 moves the leg toward or away from the batten 2. It is noted that in other embodiments of the invention, not illustrated, the legs 4 have no threaded portion and are engageable with the battens 2 via a clamp mounted adjacent an internal bore in the batten 2. In this way, each leg 4 can be moved toward or away from the batten 2.

A foot 5 is mounted to each leg 4. The foot 5 is composed of metal, however, in other embodiments of the invention (not illustrated) the foot 5 is composed of a moulded plastic.

A sole 6 is mounted to each foot 5 and configured for abutting the floor 3. The sole 6 is composed of a predetermined thickness of resilient sound insulating material. This resilient sound insulating material is preferably in the form of sorbethane or Regupol (registered trade mark), however, any equivalent sound insulating material may be used to compose the soles 6.

Each sole 6 is glued to the concrete floor or joist 3 with an adhesive. Preferably the adhesive provides some sound insulation properties. In other embodiments however, sole 6 simply abuts the floor.

A wooden floor 7 is laid across the room and affixed to the battens 2. The floor may be in the form of floor boards which are glued or secret nailed together, and glued or nailed to the battens 2.

Thus, there is provided a plurality of battens 2 extending across the floor of a room having soles which bear the weight of the wooden floor 7.

In order to minimise sound transmission through the wooden floor 7, particularly at joins, the legs 4 are rotated to raise or lower the height of the top 8 of battens 2 relative to the floor 3 so that a substantially level platform is provided by the tops 8 of battens 2. In this way, the floorboards 7 (or other floor) can be laid substantially level resulting in better mating of the boards and reduced sound transmission through to the floor 3. The movement of the legs 4 compensates for the waviness inherent in concrete floors and also for any misalignment of the tops of floor joists.

Although not illustrated in FIG 1, an insulation material 16 can be disposed in the space intermediate the floor 3 and floor boards 7. In the case where the floor 3 comprises a plurality of floor joists, the insulation can be disposed intermediate wooden floor 7 and a ceiling of a lower storey room (also not illustrated in FIG 1).

The flooring system 1 can further include a relatively cheap waterproof membrane extending substantially across the floor 3. The waterproof membrane (not illustrated) is disposed across the floor 3 and intermediate the soles 6 such that the membrane is not punctured.

For example, since moisture evaporates from concrete for a substantially long period of time once it is poured, the result is a moist environment for the underside of wooden floor 7 laid over concrete which has not fully cured. By not puncturing the membrane, for example by anchoring the batten 2 to the floor 3 as is commonly known, the floor boards 7 are protected from the moisture of the curing concrete and a cheap plastic material or other commonly available waterproof material may be employed. Alternatively, a waterproof film may be applied over the concrete floor by spraying means.

Although not illustrated, the feet 5 and sole 6 may be wider than the batten 2. Preferably, the soles 6 are 10 mm thick and the feet 5 are 3 mm thick. In such an embodiment, the legs 4 preferably have a range of travel of 20 mm.

Referring to FIGs 2 and 3, there is shown system 1 is shown employed on a floor 3 comprising a plurality of a wooden flooring joists. This system is particularly advantageously employed where the distance between the top of joists 3 and an existing ceiling (not illustrated in FIG 2) is of a distance that will not allow a wooden floor 7 to be installed because it would provide a floorboard 7 to ceiling height which is less than that prescribed under local relevant building regulations.

To solve this problem, one or more support frames 9 are mounted to the joist 3. The support frames 9 include a web 10 which is adapted for mounting to the side of joists 3. A plurality of bolts (not illustrated) may be used to mount web 10 of support frame 9 to the side of joist 3.

The support frames 9 also include a flange 11 and 12 mounted at each end of the web The flanges 11 and 12 extend in opposite directions to each other and away from the web A top flange 11 is adapted for mounting to a top side of the joist 3 and a lower flange 12 is recessed a the length of the web 10 from the top of the joist 3. The lower flange 12 is adapted to support the flooring system 1.

A seating material 13 in the form of fibro-cement sheeting or the like is disposed intermediate lower flange 12 and sole 6 in supporting the floor 7. As best shown in FIG 3, the fibro-cement sheeting 13 extends intermediate a pair of joists and is supported therefrom by lower flanges 12 of support brackets 9 spaced apart along adjacent joists. As with the system 1 described above, the soles 6 are glued to the fibro-cement sheeting 13 with an adhesive having sound insulating properties.

In the embodiment of FIGs 2 and 3, it can be seen that the legs 4 of the flooring system 1 can be rotated to provide a substantially level height of the tops 8 of the flooring battens 2 and hence the wooden floor 7.

Support frames 9 are preferably composed of a suitable thickness of steel, for example 6 mm and an acoustic rubber material 14 is preferably disposed intermediate the top flange 11 and web 10 of support frames 9 and the joist 3. Similarly, a predetermined thickness of resilient sound insulating material 14 is also disposed intermediate bottom flange 12 of support frames 9 and the fibro-cement sheet 13.

As is shown best in FIG 3, polyester blanket insulation 16 may be disposed intermediate the wooden floor 7 and fibro sheeting 13 and/or intermediate the fibro sheeting 13 and an existing ceiling 15 of a lower storey.

In other embodiments of the invention (not illustrated), the support frames 9 include a second web extending from upper flange 11 parallel to the web 10 and on the other side of the joist 3. A second lower flange extends from the second web, the second lower flange being in substantially the same plane as the lower flange 12 and configured to support a wooden floor 7 in which the second lower flange 12 is recessed from said upper flange 13 the same distance as the lower flange 12. In cross-section (not illustrated) this embodiment of the support frame can be said to resemble a top-hat.

The foregoing describes only a preferred embodiment of the present invention and modifications, obvious to those skilled in the art, can be made thereto without departing from the scope of the present invention.

Claims (24)

1. A flooring system including: a plurality of flooring battens; two or more legs extending from each said batten, each said leg being movable a predetermined distance towards or away from said batten; a foot mounted to each leg; and a sole mounted to each said foot and being composed of a predetermined thickness of resilient sound insulating material; wherein said soles abut a concrete floor or timber joist and a timber floor is fixed directly onto said flooring battens.

2. A system according to claim 1 wherein said legs are threadedly engaged with said battens and rotation of said legs moves said feet towards or away from said batten.

3. A system according to claim 1 or 2 wherein said feet are composed of metal or molded plastic.

4. A system according to any one of claims 1 to 3 wherein said soles are composed of sorbethane or Regupol (registered trade mark). A system according to any one of claims 1 to 4 including insulation disposed intermediate said timber floor and said concrete slab, or intermediate said timber floor and a ceiling of a lower storey room.

6. A system according to any one of claims 1 to 6 including a waterproof membrane extending substantially across said floor and being disposed intermediate said soles and said concrete slab or joists.

7. A system according to any one of claims 1 to 6 wherein said soles are glued to said concrete floor or timber joist.

8. A method of providing a flooring system, said method including the steps of: providing a plurality of flooring battens each having two or more legs extending therefrom wherein each said leg is movable a predetermined distance towards or away from said batten; providing a foot on each leg; mounting a sole to each foot, each sole being mounted thereto and being composed of a predetermined thickness of resilient sound insulating material; abutting said soles to a concrete floor or timber joist; and fixing a timber floor directly onto said flooring battens.

9. A method according to claim 8 wherein said legs are threadedly engaged with said battens and rotation of said legs moves said feet towards or away from said battens. A method according to claim 8 or 9 wherein said feet are composed of metal or molded plastic.

11. A method according to any one of claims 8 to 10 wherein said soles are composed of sorbethane or Regupol (registered trade mark).

12. A method according to any one of claims 8 to 11 including the step of disposing insulation intermediate said timber floor and said concrete slab, or intermediate said timber floor and a ceiling of a lower storey room.

13. A method according to any one of claims 8 to 12 including the step of disposing a waterproof membrane intermediate said soles and said concrete slab or joists and substantially across said floor.

14. A method according to any one of claims 8 to 13 including the step of moving each said leg such that said timber floor is substantially level. A method according to any one of claims 8 to 14 including the step of gluing said soles to said concrete floor or said timber joist.

16. A flooring system for use in two storey or multi-storey buildings, the system including one or more support frames each including a web adapted to abut a side of a joist and having a flange mounted at each end of said web, said flanges extending in opposite directions and away from said web, a top said flange being adapted for mounting to a top side of said joist and a lower said flange being recessed from said top side of said joist a predetermined distance and being configured to support a wooden floor.

17. A flooring system according to claim 16 including: a plurality of flooring battens; two or more legs extending from each said batten, each said leg being movable a predetermined distance towards or away from said batten mounted to each leg; and a sole mounted to each foot and being composed of a predetermined thickness of resilient sound insulating material; wherein said soles abut said lower flange and a timber floor is fixed directly onto said flooring battens. 12

18. A system according to claim 17 wherein said legs are threadedly engaged with said battens and rotation of said legs moves said feet towards or away from said battens.

19. A system according to claim 17 or 18 wherein said feet are composed of metal or molded plastic. A system according to any one of claims 17 to 19 wherein said soles are composed of sorbethane or Regupol (registered trade mark).

21. A system according to any one of claims 17 to 20 including insulation disposed intermediate said timber floor and a ceiling of a lower storey room.

22. A system according to any one of claims 17 to 21 including a waterproof membrane extending substantially across said floor and being disposed intermediate said soles and said joists.

23. A system according to any one of claims 17 to 22 wherein said soles are glued to said lower flange.

24. A system according to any one of claims 15 to 23 wherein said support frames include a second web adapted to abut the other side of said joist and a second lower flange extending away from said second web and substantially parallel to said lower flange, said second lower flange being adapted to support a wooden floor. A method of providing a flooring system in a two storey or multi-storey building, said method including the steps of: providing one or more support frames each including a web adapted to abut a side of a joist and having a flange mounted at each end of said web, said flanges extending in opposite directions and away from said web; mounting a top said flange to a top side of said joist; recessing a lower said flange from said top side of said joist a predetermined distance; and adapting said lower flange to support a wooden floor.

26. A method according to claim 25 including the steps of: providing a plurality of flooring battens each having two or more legs extending therefrom wherein each said leg is movable a predetermined distance towards or away from said batten; providing a foot on each leg; A .j 13 mounting a sole to each foot, each sole being composed of a predetermined thickness of resilient sound insulating material; abutting said soles to said lower flange; and fixing a timber floor directly onto said flooring battens.

27. A method according to claim 26 including the step of moving each said leg such that said timber floor is substantially level.

28. A flooring system being substantially as herein described with reference to the accompanying drawings.

29. A method of providing a flooring system, said method being substantially as herein described with reference to the accompanying drawings. A building including a flooring system being substantially as herein described with reference to the accompanying drawings. Dated this 22 nd day of April 2004 STEVItN PETER KRSTICEVIC By: HODGKINSON AND McINNES Patent Attorneys for the Applicant