CA2538357A1 - Subflooring assembly for athletic playing surface and method of forming the same - Google Patents
Subflooring assembly for athletic playing surface and method of forming the same Download PDFInfo
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- CA2538357A1 CA2538357A1 CA002538357A CA2538357A CA2538357A1 CA 2538357 A1 CA2538357 A1 CA 2538357A1 CA 002538357 A CA002538357 A CA 002538357A CA 2538357 A CA2538357 A CA 2538357A CA 2538357 A1 CA2538357 A1 CA 2538357A1
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Abstract
The present invention provides a subfloor system for placement over a substrate and method of forming a sports floor therewith. The subfloor consists of a base (10), a resilient pad (20), an upper member (22), and brackets (30, 32). The resilient pad is positioned on the base, preferably with an elongated slot (12) formed in the upper surface of the base. The upper member has a projection (24) and two shoulders (26, 28) and is operably connected to the top surface of the resilient pad. The brackets have upper (36, 37) and lower (34, 35) tabs and are secured to the base and to the upper member. The lower tab fits within the base and the upper tab rests on the corresponding shoulder of the upper member. Under load, the resilient pad compresses thereby causing the upper member to move towards the base. The brackets, however, limit vertical movement of the upper member relative the base.
Description
SUBFLOORING ASSEMBLY FOR ATHLETIC PLAYING SURFACE
AND METHOD OF FORMING THE SAME
Technical Field This invention generally relates to a subfloor system which is placed under a sports floor, and more specifically to a subfloor system which provides a level sports floor with increased stability and resiliency.
Background Sports floors have certain requirements above and beyond floors used for nonathlefic purposes: Athletic floors must have some degree of elasticity under load, and. yet be quite firmly supported. Further, a sports floor must be uniformly supported and level throughout the entire surface so that there are no dead spots or uneven spots which could affect the activity occurring on the sports floor.
Numerous attempts have been made to design a sports floor witi~ such ideal characteristics. Resiliency is typically obtained by implementing a shock absorbing sxstern into the subfloor. Shock absorbing systems are in wide use in sports flooring installations. Typical systems provide a subfloor of softwood sleepers or plywood sheeting supported by isolated resilient pads. These designs allbw deflection under active loads offering shock absorbency of the system to the athletic participant.
Reduction of impact forces are beneficial to the participant. E~riples of typical shock absorbing systems are disclosed in U.S. Patents 4,879,857 to Peterson et al and 4,890,434 to Niese et al. Typically referred to as floating systems, these subfloors are not anchored to the concrete substrate but rather rest on individual resilient pad supports. While these floating systems offer improved resiliency, stability is reduced.
One way to improve stability is to anchor or fasten the sports floor to the underlying concrete substrate. Anchored systems are especially resistant to buckling or upward movement associated with sports floors under changing environmental conditions. However, anchored systems lack the resiliency associated with floating systems. Also, anchored systems suffer from the disadvantage that the concrete substrate must be specially prepared or modified in order to accept and support the anchored fasteners. For example, depending on the type of subfloor used, the concrete has to be set to a specified hardness, aggregate size and type.
Flooring systems have a limited Life, and new subfloors are installed over existing substrates rather than replacing them prior to installation of the new system.
Such retrofit installations create problems. In retrofit installations; the existing concrete substrates often are severely damaged by left-over components or extended wear. As a result, it is difficult to secure the new subfloor such that the floor is sufficiently stable and level. Replacement installations often require substantial concrete preparation and modification before a new floor system is installed.
Attempts have been made to combine the resiliency of floating systems and the stability of anchored systems. For example, U.S. Pat. No. 4,856,250 to Gronau et al incorporates a suspended sleeper resting on resilient pads. The sleeper and pads are encased by flanges of a steel channel which are secured to a substrate by means of steel concrete anchors. Similarly, U.S. Patent No. 5,016,413 to Counihan incorporates isolated subfloor panels, typically two (2) plywood layers suspended on a resilient layer. U or T shaped steel channels are secured in a manner to allow outward flanges of the channel to rest upon a lower ridge in the plywood subfloor.
The channel is fastened to the substrate by means of concrete anchors. This design allows downward deflection of the subfloor upon athletic impact to provide shock absorbance while preventing upward movement of the subfloor associated with negative moisture affects on wood sports floor systems.
Summary According to one aspect of the invention there is provided a flooring system to be placed over a substrate. The system includes a plurality of subfloor members placed over the substrate and extending substantially in parallel to each other, each of the subfloor members includes a sleeper member having a top surface and a bottom surface, wherein a portion of the bottom surface is angled; a shim member positioned under the sleeper member, having a top surface and a bottom surface, the top surface adapted to substantially match the angled portion of the bottom surface of the sleeper member and the pad positioned under the shim member, having a top surface and a bottom surface. A plurality of flooring strips extend across the subfloor members and attached thereto.
According to another aspect of the invention there is provide a method of forming a flooring system over a substrate, comprising: placing a plurality of subfloor members substantially in parallel to each other over the substrate, each of said subfloor members f comprising: a sleeper member having a top surface and a bottom surface, wherein a portion of the bottom surface is angled; a shim member positioned under the sleeper member, having a top surface and a bottom surface, the top surface adapted to substantially match the angled portion of the bottom.surface of the sleeper member; and a pad positioned under the shim member, having a top surface apd a bottom surface; and placing a plurality of flooring strips across the subfloor members and attaching the flooring strips to the subfloor members.
Description of the Drawings FIGURE 1 is a sectional view of a first embodiment of a subfloor sleeper made according to the present invention.
FIGURE 2 is a sectional view of a portion of a floor system employing a subfloor made according to the present invention.
FIGURE 3 is a top view showing a flooring system constructed according to the present invention.
FIGURE 4 is a sectional view of the subfloor sleeper of FIGURE 1, shown under moderate load conditions.
FIGURE 5 is a sectional view of the subfloor sleeper of FIGURE i, shown undez maximum load conditions.
FIGURE 6 is a sectional view of an alternative embodiment of a-subfloor sleeper made according to the present invention, showing an elevated base.
FIGURE 7 is a sectional view of an alternative embodiment of a subfloor sleeper made according to the present invention, showing an angled base.
FIGURE 8 is a sectional view of an alternative embodiment of a floor system made according to the present invention, where the base is attached to the flooring.
FIGURE 9 is a sectional view of an alternative embodiment of a floor system made according to the present invention.
FIGURE 10 is a sectional view of an alternative embodiment of a floor system, made according to the present invention, showing two subfloor menibers on an uneven substrate.
Detailed Description A preferred embodiment of the invention will be described in detail with reference to the drawings, wherein like reference numeral represent like parts and assemblies throughout the several views. Ref. rence to the preferred embodiment does not limit the scope of the invention, which is limited only by the scope of the claims attached hereto.
In general, the present invention relates to a subfloor which is placed under a sports floor. The subfloor rests on a substrate which is typically concrete.
The subfloor allows for a level and evenly loaded sports floor which is resilient with a high degree of stability.
Referring now to FIGURE 1, the subfloor comprises a sleeper 5, which preferably includes a base 10, a resilient layer made up of resilient pads 20, an upper member 22, and brackets 30 and 32.
The base 10 has a rectangular shaped cross section with a top surface, a bottom surface, and two side surfaces. The top surface of the base 10 defines an elongated slot 12. The slot is parallel to the length of the base 10 and extends the substantial length of the base 10. Each side surface of the base 10 defines a groove 14 and 16. The groove is parallel to the length of the base 10 and extends the substantial length of the base 10. The base 10 is preferably made of wood, which is sufficiently rigid to support the floor, but which is machinable so that the height and profile of the base can be modified, as will be hereinafter described.
The resilient layer, made up of plurality of resilient pads 20, are disposed along the length of the slot 12. The pads 20 lies substantially within the entire slot 12. The pads are resilient and are made of generally compressible, moldable material. A preferred material is urethane, although many other elastomers are acceptable. Rather than employing a number of smaller pads, the resilient layer may also be made up of a single strip of resilient pad material which extends within the slot 12. As another alternative, the slot 12 may be omitted and the base 10 may be bored in selected locations along the top thereof to provide for placement of resilient pads 20.
The upper member 22 is operably connected to the pads 20, preferably by way of staples 21. The upper member 22 has a longitudinal axis which extends substantially parallel to the longitudinal axis of the base 10. The member 22 is shaped so as to have a protrusion 24 and shoulders 26 and 28. The protrusion 24 and shoulders 26 and 28 extend substantially the full length of the member 22. The member 22 is preferably made of rigid material designed to accept typical 5 mechanical fasteners, such as wood.
Brackets 30 and 32 are designed to operably connect the base 10 and the upper member 22. The brackets extend substantially the full length of the base 10.
Bracket 30 has an inner surface 31, a lower tab 34, and an upper tab 36. The lower tab 34 is designed td be inserted into groove 14 formed in the side surface of base 10, such that the inner surface 31 of the bracket 30 is substantially flush with the side surface of the base 10. The upper tab 36 is designed such that the inner surface of the tab 36 is proximal to the shoulder 26. Bracket 32 is similar to bracket 30, and has an inner surface 33, a lower tab 35, and an upper tab 37 which interact with the base 10 and the upper member 22 in the same manner. Brackets 30 and 32 are made of sufficiently rigid material so as to firmly secure the member 22 and the body 10;
such as steel. The brackets 30 and 32 are preferably held in position tightly to the base .10 by means of machine screws and nuts (not shown) extending through the brackets and base.
A typical floor system with which the subfloor of the present invention can be used is shown in FIGURES 2 and 3. The floor system typically includes a subfloor layer 7 attached to rows of sleepers ~. The sleepers rests upon substrate 18.
The subfloor is typically attached to the sleepers by means of staples.
Flooring 40 attached to the subfloor. Flooring 40 is generally made of hardwood floor strips which are connected together by a tongue and groove arrangement.
As shown in FIGURE 3, flooring strips 40 are placed over the subfloor layer 7, preferably in a direction substantially perpendicular to the subfloor members 5.
The flooring 40 is attached to the subfloor in a conventional manner such as staples or nails. The nails are driven into the subfloor layer 7. Alternatively, the subfloor layer may be omitted, such that the flooring 40 is attached directly to the sleepers.
As shown in Figure 2, Substrate 18 is typically a concrete layer or the like.
The base 10 of the subfloor rests upon the substrate 18. Mechanical fasteners are not generally needed nor desired, which makes installation easier and more ei~'icient.
The substrate 18 does not have to be capable of receiving fasteners which reduces the cost of preparing the substrate 18. However, if desired, a short Z-shaped sectional bracket (not shown) may be periodically placed along the side sections of brackets 30 and 32, and fastened to the substrate so as to anchor the sleepers to the substrate.
It should be noted that the various components of the subfloor are dimensioned such that the pads 20 are slightly compressed between the base 10 and the upper member 22 even when no load is applied to the floor. This helps to ensure that dead spots are not created on the floor. For installation purposes, the subfloor is preferably preassembled in standard lengths, such as 8 foot sections. Rows of the subfloor sections are placed across the area to be covered, with adjoining rows preferably being spaced approximately 12-18 inches apart.
FIGURES 4 and 5 show the effects of loading on the subfloor sleepers. In FIGURE 4, the sleeper is shown under a moderate load. A load applied to the flooring is transmitted through the upper member 22 and to the pad 20. The pad compresses and causes the upper member 22 to move towards the base 10. The shoulders 26 and 28 move away from the corresponding upper tabs 36 and 37.
FIGURE 5 shows the effects of heavy loading on the sleepers. The pad 20 is fully compressed. The bottom surface of the upper member 22 contacts the top surface of the base 10. This contact is made possible because the height of slot 12 is greater than the minimum compressed height of the pad 20. This provides the subfloor with a maximum load tolerance past which the floor will no longer flex.
This has the further advantage of protecting the pad from excessive loads.
Upon removal of the load, the pad 20 decompresses thereby pushing the upper member to the original position.
In some circumstances, it may be desirable for the pad 20 to be made of a hard, substantially non-deformable material, such that the subfloor sleeper does not flex under load. This is advantageous where firm support is necessary such as under bleachers~or a stage.
FIGURE 6 shows an alternative embodiment of a sleeper 5' which exemplifies the versatility of the invention provided by having the base made of a machinable material. The various elements of the sleeper shown in this alternative embodiment,are the same as those of Fig. 1, except for base 10', which is of an increased height. This increased height permits the subfloor to account for different height requirements such as when the substrate contains an elevated plateau of other deformities. .It is contemplated that the base 10 could take on a wide variety of heights.
FIGURE 7 shows another alternative embodiment of the present invention.
Again, the various elements of the sleeper 5" shown in this embodiment are the same as those shown .in Fig. 1, except for base 10". In this embodiment, the base 10" is provided with an angled bottom surface 42. Angled bottom surface 42 can extend along the entire length of the base, or alternatively can be in the form of slots located at discrete locations along the bottom of the base. The angled bottom surface 42 is designed to accommodate one or more shims 45, which have an upper angled surface 47 which corresponds to the angle of surface 42. This feature allows the subfloor to be adapted to a wide variety of surfaces. In particular, the shim 45 can be moved transversely relative to the base so as to raise or lower the entire subfloor assembly. This allows the subfloor to easily adapt to variations and .
imperfections in the substrate.
The base 10" is preferably angled prior to installation. However, in all of ,;
the embodiments disclosed herein, further angles, cutouts, or other modifications to the base 10 can be made in order to account for unforeseen deformities in the substrate. This increases the versatility of the system and decreases installation time.
The ability to either angle or otherwise machine the base of the sleeper is particularly advantageous when the subfloor is placed over new concrete construction. As concrete dries, the curing process creates movement in the slab and typically forms ridges at construction joints in the concrete. Normally, these high areas must be ground down prior to installation of the floor system. The present invention, however, allows customizing in the form of sanding or scarfing selected areas in the underside of the base to allow a continuous flat upper member 22.
FIGURE 8 shows an alternative embodiment of the present invention. The structure and function of this alternative embodiment is the same as the embodiment of Fig. l, with the exception that the subfloor is rotated 180 degrees along its longitudinal axis. In this embodiment, the top surface of the upper member 22 g contacts the substrate 18. The flooring 40 is attached to the base 10. This has the advantage of providing a broader nailing base, which is particularly important when no subfloor layer is provided.
FIGURE 9 shows an alternative embodiment of a flooring system of the present invention. This embodiment is similar to the embodiment of Fig. 7, but utilizes a single-piece sleeper with a pad on the bottom of the subfloor. A
sleeper member 105 is positioned below a floor system. The floor system includes a subfloor layer 107 attached to flooring 140. The flooring 140 is typically made of hardwood floor strips which are connected by a tongue and groove arrangement.
The sleeper member 105 has a bottom surface 142 that rests on a shim member 145.
The bottom surface 142 is angled. Alternatively, the bottom surface 142 has angled slots discretely located therein. The sleeper member 105 is preferably made of rigid material designed to accept typical mechanical fasteners. The sleeper member 105 is conventionally connected to the shim member 145.
The shim member 145 has an upper surface 147 configured to match the sleeper member bottom surface 142. The shim member 145 is preferably made of wood, which is sufficiently rigid to support the sleeper member 105. The shim member 145 rests upon a pad 150. The pad 150 is resilient and made of generally compressible, moldable material, so as to flex under load as previously described. A
preferred material is urethane, although many other elastomers are acceptable.
In some circumstances, it may be desirable for the pad 150 to be made of substantially non-deformable material, such that the subfloor does not flex under load. This is advantageous where firm support is necessary such as under bleachers or a stage.
The shim member 145 allows the subfloor to be adapted to a wide variety of surfaces. The shim member 145 can be moved parallel to the substrate and transversely relative to the sleeper member 105 to raise or lower the floor at that location. This accounts for the variations and imperfections in the substrate.
When the desired height is obtained, the sleeper member 105 and shim member 145 are conventionally attached to ensure the stability of the subfloor.
FIGURE 10 shows an alternative embodiment of a flooring system of the present invention. The structure and function of this alternative embodiment is similar to the embodiment of Fig. 9. Two subfloor members are shown on an uneven substrate. This embodiment contains a plate 152 below the pad 150. As shown, the sleeper member 105 rests upon a different location of the shim member 145, thereby creating a difference in height between the subfloor members. In addition, the plate 152 can be made of varying thickness to account for variations in the substrate. This is advantageous where the substrate is substantially uneven. The plate 152 is rigid enough to accept mechanical fasteners to attach to the substrate 118. Alternatively, a short z-shaped sectional bracket (not shown) may be .,.
periodically places along the side sections of the plates 152, and fastened to the substrate 118.
The present invention has many advantageous. One advantage is that the subfloor combines resiliency with stability. The subfloor provides these ideal characteristics under adverse environmental conditions such as high relative humidity or increased flooring moisture content.
Also advantageous is the fact that the subfloor does not require mechanical anchoring to the underlying substrate. As a result, the subfloor is simple and cost effective to install. The ease of installation is appreciated when retrofitting the subfloor to replace an existing sports floor. The subfloor is easily retrofitted to a concrete substrate even though the substrate is damaged or uneven. The ease of installation is advanced by providing a broader base for attaching flooring boards.
As a result, less time is needed for applying floor fasteners.
A further advantage of the present invention includes the adjustability of the subfloor to adapt to all types of surfaces. The subfloor allows for simple profile height adjustments to accommodate different height requirements. Also, the subfloor is easily modified to conform to the existing deformities in the concrete.
A further advantage of the present invention includes the adjustability of the resilient characteristics of the sports floor. The subfloor flexes up to a certain maximum Iimit which ensures that no excessive stress is placed on the subfloor components. In addition, the resiliency is modified where necessary to provide firmer support.
The foregoing constitutes a description of the preferred embodiments of the invention. Numerous modifications are possible without departing from the spirit and scope of the invention. The size and relative dimensions of the various elements can be varied where appropriate. The invention need not be used with the floor system shown in FIGURE 2, but can be used with floor systems of various types.
Hence, the scope of the invention should be determined with reference, not to the preferred embodiment, but to the appended claims.
AND METHOD OF FORMING THE SAME
Technical Field This invention generally relates to a subfloor system which is placed under a sports floor, and more specifically to a subfloor system which provides a level sports floor with increased stability and resiliency.
Background Sports floors have certain requirements above and beyond floors used for nonathlefic purposes: Athletic floors must have some degree of elasticity under load, and. yet be quite firmly supported. Further, a sports floor must be uniformly supported and level throughout the entire surface so that there are no dead spots or uneven spots which could affect the activity occurring on the sports floor.
Numerous attempts have been made to design a sports floor witi~ such ideal characteristics. Resiliency is typically obtained by implementing a shock absorbing sxstern into the subfloor. Shock absorbing systems are in wide use in sports flooring installations. Typical systems provide a subfloor of softwood sleepers or plywood sheeting supported by isolated resilient pads. These designs allbw deflection under active loads offering shock absorbency of the system to the athletic participant.
Reduction of impact forces are beneficial to the participant. E~riples of typical shock absorbing systems are disclosed in U.S. Patents 4,879,857 to Peterson et al and 4,890,434 to Niese et al. Typically referred to as floating systems, these subfloors are not anchored to the concrete substrate but rather rest on individual resilient pad supports. While these floating systems offer improved resiliency, stability is reduced.
One way to improve stability is to anchor or fasten the sports floor to the underlying concrete substrate. Anchored systems are especially resistant to buckling or upward movement associated with sports floors under changing environmental conditions. However, anchored systems lack the resiliency associated with floating systems. Also, anchored systems suffer from the disadvantage that the concrete substrate must be specially prepared or modified in order to accept and support the anchored fasteners. For example, depending on the type of subfloor used, the concrete has to be set to a specified hardness, aggregate size and type.
Flooring systems have a limited Life, and new subfloors are installed over existing substrates rather than replacing them prior to installation of the new system.
Such retrofit installations create problems. In retrofit installations; the existing concrete substrates often are severely damaged by left-over components or extended wear. As a result, it is difficult to secure the new subfloor such that the floor is sufficiently stable and level. Replacement installations often require substantial concrete preparation and modification before a new floor system is installed.
Attempts have been made to combine the resiliency of floating systems and the stability of anchored systems. For example, U.S. Pat. No. 4,856,250 to Gronau et al incorporates a suspended sleeper resting on resilient pads. The sleeper and pads are encased by flanges of a steel channel which are secured to a substrate by means of steel concrete anchors. Similarly, U.S. Patent No. 5,016,413 to Counihan incorporates isolated subfloor panels, typically two (2) plywood layers suspended on a resilient layer. U or T shaped steel channels are secured in a manner to allow outward flanges of the channel to rest upon a lower ridge in the plywood subfloor.
The channel is fastened to the substrate by means of concrete anchors. This design allows downward deflection of the subfloor upon athletic impact to provide shock absorbance while preventing upward movement of the subfloor associated with negative moisture affects on wood sports floor systems.
Summary According to one aspect of the invention there is provided a flooring system to be placed over a substrate. The system includes a plurality of subfloor members placed over the substrate and extending substantially in parallel to each other, each of the subfloor members includes a sleeper member having a top surface and a bottom surface, wherein a portion of the bottom surface is angled; a shim member positioned under the sleeper member, having a top surface and a bottom surface, the top surface adapted to substantially match the angled portion of the bottom surface of the sleeper member and the pad positioned under the shim member, having a top surface and a bottom surface. A plurality of flooring strips extend across the subfloor members and attached thereto.
According to another aspect of the invention there is provide a method of forming a flooring system over a substrate, comprising: placing a plurality of subfloor members substantially in parallel to each other over the substrate, each of said subfloor members f comprising: a sleeper member having a top surface and a bottom surface, wherein a portion of the bottom surface is angled; a shim member positioned under the sleeper member, having a top surface and a bottom surface, the top surface adapted to substantially match the angled portion of the bottom.surface of the sleeper member; and a pad positioned under the shim member, having a top surface apd a bottom surface; and placing a plurality of flooring strips across the subfloor members and attaching the flooring strips to the subfloor members.
Description of the Drawings FIGURE 1 is a sectional view of a first embodiment of a subfloor sleeper made according to the present invention.
FIGURE 2 is a sectional view of a portion of a floor system employing a subfloor made according to the present invention.
FIGURE 3 is a top view showing a flooring system constructed according to the present invention.
FIGURE 4 is a sectional view of the subfloor sleeper of FIGURE 1, shown under moderate load conditions.
FIGURE 5 is a sectional view of the subfloor sleeper of FIGURE i, shown undez maximum load conditions.
FIGURE 6 is a sectional view of an alternative embodiment of a-subfloor sleeper made according to the present invention, showing an elevated base.
FIGURE 7 is a sectional view of an alternative embodiment of a subfloor sleeper made according to the present invention, showing an angled base.
FIGURE 8 is a sectional view of an alternative embodiment of a floor system made according to the present invention, where the base is attached to the flooring.
FIGURE 9 is a sectional view of an alternative embodiment of a floor system made according to the present invention.
FIGURE 10 is a sectional view of an alternative embodiment of a floor system, made according to the present invention, showing two subfloor menibers on an uneven substrate.
Detailed Description A preferred embodiment of the invention will be described in detail with reference to the drawings, wherein like reference numeral represent like parts and assemblies throughout the several views. Ref. rence to the preferred embodiment does not limit the scope of the invention, which is limited only by the scope of the claims attached hereto.
In general, the present invention relates to a subfloor which is placed under a sports floor. The subfloor rests on a substrate which is typically concrete.
The subfloor allows for a level and evenly loaded sports floor which is resilient with a high degree of stability.
Referring now to FIGURE 1, the subfloor comprises a sleeper 5, which preferably includes a base 10, a resilient layer made up of resilient pads 20, an upper member 22, and brackets 30 and 32.
The base 10 has a rectangular shaped cross section with a top surface, a bottom surface, and two side surfaces. The top surface of the base 10 defines an elongated slot 12. The slot is parallel to the length of the base 10 and extends the substantial length of the base 10. Each side surface of the base 10 defines a groove 14 and 16. The groove is parallel to the length of the base 10 and extends the substantial length of the base 10. The base 10 is preferably made of wood, which is sufficiently rigid to support the floor, but which is machinable so that the height and profile of the base can be modified, as will be hereinafter described.
The resilient layer, made up of plurality of resilient pads 20, are disposed along the length of the slot 12. The pads 20 lies substantially within the entire slot 12. The pads are resilient and are made of generally compressible, moldable material. A preferred material is urethane, although many other elastomers are acceptable. Rather than employing a number of smaller pads, the resilient layer may also be made up of a single strip of resilient pad material which extends within the slot 12. As another alternative, the slot 12 may be omitted and the base 10 may be bored in selected locations along the top thereof to provide for placement of resilient pads 20.
The upper member 22 is operably connected to the pads 20, preferably by way of staples 21. The upper member 22 has a longitudinal axis which extends substantially parallel to the longitudinal axis of the base 10. The member 22 is shaped so as to have a protrusion 24 and shoulders 26 and 28. The protrusion 24 and shoulders 26 and 28 extend substantially the full length of the member 22. The member 22 is preferably made of rigid material designed to accept typical 5 mechanical fasteners, such as wood.
Brackets 30 and 32 are designed to operably connect the base 10 and the upper member 22. The brackets extend substantially the full length of the base 10.
Bracket 30 has an inner surface 31, a lower tab 34, and an upper tab 36. The lower tab 34 is designed td be inserted into groove 14 formed in the side surface of base 10, such that the inner surface 31 of the bracket 30 is substantially flush with the side surface of the base 10. The upper tab 36 is designed such that the inner surface of the tab 36 is proximal to the shoulder 26. Bracket 32 is similar to bracket 30, and has an inner surface 33, a lower tab 35, and an upper tab 37 which interact with the base 10 and the upper member 22 in the same manner. Brackets 30 and 32 are made of sufficiently rigid material so as to firmly secure the member 22 and the body 10;
such as steel. The brackets 30 and 32 are preferably held in position tightly to the base .10 by means of machine screws and nuts (not shown) extending through the brackets and base.
A typical floor system with which the subfloor of the present invention can be used is shown in FIGURES 2 and 3. The floor system typically includes a subfloor layer 7 attached to rows of sleepers ~. The sleepers rests upon substrate 18.
The subfloor is typically attached to the sleepers by means of staples.
Flooring 40 attached to the subfloor. Flooring 40 is generally made of hardwood floor strips which are connected together by a tongue and groove arrangement.
As shown in FIGURE 3, flooring strips 40 are placed over the subfloor layer 7, preferably in a direction substantially perpendicular to the subfloor members 5.
The flooring 40 is attached to the subfloor in a conventional manner such as staples or nails. The nails are driven into the subfloor layer 7. Alternatively, the subfloor layer may be omitted, such that the flooring 40 is attached directly to the sleepers.
As shown in Figure 2, Substrate 18 is typically a concrete layer or the like.
The base 10 of the subfloor rests upon the substrate 18. Mechanical fasteners are not generally needed nor desired, which makes installation easier and more ei~'icient.
The substrate 18 does not have to be capable of receiving fasteners which reduces the cost of preparing the substrate 18. However, if desired, a short Z-shaped sectional bracket (not shown) may be periodically placed along the side sections of brackets 30 and 32, and fastened to the substrate so as to anchor the sleepers to the substrate.
It should be noted that the various components of the subfloor are dimensioned such that the pads 20 are slightly compressed between the base 10 and the upper member 22 even when no load is applied to the floor. This helps to ensure that dead spots are not created on the floor. For installation purposes, the subfloor is preferably preassembled in standard lengths, such as 8 foot sections. Rows of the subfloor sections are placed across the area to be covered, with adjoining rows preferably being spaced approximately 12-18 inches apart.
FIGURES 4 and 5 show the effects of loading on the subfloor sleepers. In FIGURE 4, the sleeper is shown under a moderate load. A load applied to the flooring is transmitted through the upper member 22 and to the pad 20. The pad compresses and causes the upper member 22 to move towards the base 10. The shoulders 26 and 28 move away from the corresponding upper tabs 36 and 37.
FIGURE 5 shows the effects of heavy loading on the sleepers. The pad 20 is fully compressed. The bottom surface of the upper member 22 contacts the top surface of the base 10. This contact is made possible because the height of slot 12 is greater than the minimum compressed height of the pad 20. This provides the subfloor with a maximum load tolerance past which the floor will no longer flex.
This has the further advantage of protecting the pad from excessive loads.
Upon removal of the load, the pad 20 decompresses thereby pushing the upper member to the original position.
In some circumstances, it may be desirable for the pad 20 to be made of a hard, substantially non-deformable material, such that the subfloor sleeper does not flex under load. This is advantageous where firm support is necessary such as under bleachers~or a stage.
FIGURE 6 shows an alternative embodiment of a sleeper 5' which exemplifies the versatility of the invention provided by having the base made of a machinable material. The various elements of the sleeper shown in this alternative embodiment,are the same as those of Fig. 1, except for base 10', which is of an increased height. This increased height permits the subfloor to account for different height requirements such as when the substrate contains an elevated plateau of other deformities. .It is contemplated that the base 10 could take on a wide variety of heights.
FIGURE 7 shows another alternative embodiment of the present invention.
Again, the various elements of the sleeper 5" shown in this embodiment are the same as those shown .in Fig. 1, except for base 10". In this embodiment, the base 10" is provided with an angled bottom surface 42. Angled bottom surface 42 can extend along the entire length of the base, or alternatively can be in the form of slots located at discrete locations along the bottom of the base. The angled bottom surface 42 is designed to accommodate one or more shims 45, which have an upper angled surface 47 which corresponds to the angle of surface 42. This feature allows the subfloor to be adapted to a wide variety of surfaces. In particular, the shim 45 can be moved transversely relative to the base so as to raise or lower the entire subfloor assembly. This allows the subfloor to easily adapt to variations and .
imperfections in the substrate.
The base 10" is preferably angled prior to installation. However, in all of ,;
the embodiments disclosed herein, further angles, cutouts, or other modifications to the base 10 can be made in order to account for unforeseen deformities in the substrate. This increases the versatility of the system and decreases installation time.
The ability to either angle or otherwise machine the base of the sleeper is particularly advantageous when the subfloor is placed over new concrete construction. As concrete dries, the curing process creates movement in the slab and typically forms ridges at construction joints in the concrete. Normally, these high areas must be ground down prior to installation of the floor system. The present invention, however, allows customizing in the form of sanding or scarfing selected areas in the underside of the base to allow a continuous flat upper member 22.
FIGURE 8 shows an alternative embodiment of the present invention. The structure and function of this alternative embodiment is the same as the embodiment of Fig. l, with the exception that the subfloor is rotated 180 degrees along its longitudinal axis. In this embodiment, the top surface of the upper member 22 g contacts the substrate 18. The flooring 40 is attached to the base 10. This has the advantage of providing a broader nailing base, which is particularly important when no subfloor layer is provided.
FIGURE 9 shows an alternative embodiment of a flooring system of the present invention. This embodiment is similar to the embodiment of Fig. 7, but utilizes a single-piece sleeper with a pad on the bottom of the subfloor. A
sleeper member 105 is positioned below a floor system. The floor system includes a subfloor layer 107 attached to flooring 140. The flooring 140 is typically made of hardwood floor strips which are connected by a tongue and groove arrangement.
The sleeper member 105 has a bottom surface 142 that rests on a shim member 145.
The bottom surface 142 is angled. Alternatively, the bottom surface 142 has angled slots discretely located therein. The sleeper member 105 is preferably made of rigid material designed to accept typical mechanical fasteners. The sleeper member 105 is conventionally connected to the shim member 145.
The shim member 145 has an upper surface 147 configured to match the sleeper member bottom surface 142. The shim member 145 is preferably made of wood, which is sufficiently rigid to support the sleeper member 105. The shim member 145 rests upon a pad 150. The pad 150 is resilient and made of generally compressible, moldable material, so as to flex under load as previously described. A
preferred material is urethane, although many other elastomers are acceptable.
In some circumstances, it may be desirable for the pad 150 to be made of substantially non-deformable material, such that the subfloor does not flex under load. This is advantageous where firm support is necessary such as under bleachers or a stage.
The shim member 145 allows the subfloor to be adapted to a wide variety of surfaces. The shim member 145 can be moved parallel to the substrate and transversely relative to the sleeper member 105 to raise or lower the floor at that location. This accounts for the variations and imperfections in the substrate.
When the desired height is obtained, the sleeper member 105 and shim member 145 are conventionally attached to ensure the stability of the subfloor.
FIGURE 10 shows an alternative embodiment of a flooring system of the present invention. The structure and function of this alternative embodiment is similar to the embodiment of Fig. 9. Two subfloor members are shown on an uneven substrate. This embodiment contains a plate 152 below the pad 150. As shown, the sleeper member 105 rests upon a different location of the shim member 145, thereby creating a difference in height between the subfloor members. In addition, the plate 152 can be made of varying thickness to account for variations in the substrate. This is advantageous where the substrate is substantially uneven. The plate 152 is rigid enough to accept mechanical fasteners to attach to the substrate 118. Alternatively, a short z-shaped sectional bracket (not shown) may be .,.
periodically places along the side sections of the plates 152, and fastened to the substrate 118.
The present invention has many advantageous. One advantage is that the subfloor combines resiliency with stability. The subfloor provides these ideal characteristics under adverse environmental conditions such as high relative humidity or increased flooring moisture content.
Also advantageous is the fact that the subfloor does not require mechanical anchoring to the underlying substrate. As a result, the subfloor is simple and cost effective to install. The ease of installation is appreciated when retrofitting the subfloor to replace an existing sports floor. The subfloor is easily retrofitted to a concrete substrate even though the substrate is damaged or uneven. The ease of installation is advanced by providing a broader base for attaching flooring boards.
As a result, less time is needed for applying floor fasteners.
A further advantage of the present invention includes the adjustability of the subfloor to adapt to all types of surfaces. The subfloor allows for simple profile height adjustments to accommodate different height requirements. Also, the subfloor is easily modified to conform to the existing deformities in the concrete.
A further advantage of the present invention includes the adjustability of the resilient characteristics of the sports floor. The subfloor flexes up to a certain maximum Iimit which ensures that no excessive stress is placed on the subfloor components. In addition, the resiliency is modified where necessary to provide firmer support.
The foregoing constitutes a description of the preferred embodiments of the invention. Numerous modifications are possible without departing from the spirit and scope of the invention. The size and relative dimensions of the various elements can be varied where appropriate. The invention need not be used with the floor system shown in FIGURE 2, but can be used with floor systems of various types.
Hence, the scope of the invention should be determined with reference, not to the preferred embodiment, but to the appended claims.
Claims (13)
1. A flooring system to be placed over a substrate, comprising:
a plurality of subfloor members placed over the substrate and extending substantially in parallel to each other, each of said subfloor members comprising:
a sleeper member having a top surface and a bottom surface, wherein a portion of the bottom surface is angled;
a shim member positioned under the sleeper member, having a top surface and a bottom surface, the top surface adapted to substantially match the angled portion of the bottom surface of the sleeper member; and a pad positioned under the shim member, having a top surface and a bottom surface; and a plurality of flooring strips extend across the subfloor members and attached thereto.
a plurality of subfloor members placed over the substrate and extending substantially in parallel to each other, each of said subfloor members comprising:
a sleeper member having a top surface and a bottom surface, wherein a portion of the bottom surface is angled;
a shim member positioned under the sleeper member, having a top surface and a bottom surface, the top surface adapted to substantially match the angled portion of the bottom surface of the sleeper member; and a pad positioned under the shim member, having a top surface and a bottom surface; and a plurality of flooring strips extend across the subfloor members and attached thereto.
2. The flooring system of claim 1, wherein the pad of each subfloor member is formed from resilient material.
3. The flooring system of claim 1, wherein substantially all of the bottom surface of each sleeper member is angled, wherein the top surface of each shim member is angled to substantially match the bottom surface of each sleeper member.
4. The flooring system of claim 1, wherein the angled portion of the bottom surface of each sleeper member is an angled slot, wherein the top surface of each shim member is configured to fit within the angled slot of each sleeper member.
5. The flooring system of claim 1, wherein the shim members are formed from wooden material.
6. The flooring system of claim 1, wherein the sleeper members are attached to the flooring strips.
7. The flooring system of claim 1, further comprising a plate having an upper surface and a lower surface, the upper surface configured to attach to the bottom surface of the pad, the bottom surface configured to attach to the substrate.
8. A method of forming a flooring system over a substrate, comprising:
placing a plurality of subfloor members substantially in parallel to each other over the substrate, each of said subfloor members comprising:
a sleeper member having a top surface and a bottom surface, wherein a portion of the bottom surface is angled;
a shim member positioned under the sleeper member, having a top surface and a bottom surface, the top surface adapted to substantially match the angled portion of the bottom surface of the sleeper member; and a pad positioned under the shim member, having a top surface and a bottom surface; and placing a plurality of flooring strips across the subfloor members and attaching the flooring strips to the subfloor members.
placing a plurality of subfloor members substantially in parallel to each other over the substrate, each of said subfloor members comprising:
a sleeper member having a top surface and a bottom surface, wherein a portion of the bottom surface is angled;
a shim member positioned under the sleeper member, having a top surface and a bottom surface, the top surface adapted to substantially match the angled portion of the bottom surface of the sleeper member; and a pad positioned under the shim member, having a top surface and a bottom surface; and placing a plurality of flooring strips across the subfloor members and attaching the flooring strips to the subfloor members.
9. The method of claim 8, wherein the pad of each subfloor member is formed from resilient material.
10. The method of claim 8, wherein substantially all of the bottom surface of each sleeper member is angled, wherein the top surface of each shim member is angled to substantially match the bottom surface of each sleeper member.
11. The method of claim 8, wherein the angled portion of the bottom surface of each sleeper member is an angled slot, wherein the top surface of each shim member is configured to fit within the angled slot of each sleeper member.
12. The method of claim 8, further comprising moving at least one shim member parallel to the substrate so as to adjust the height of said at least one of the subfloor members.
13. The method of claim 8, further comprising placing a plate underneath the pad so as to adjust the height of at least one of the subfloor members.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US08/811,700 | 1997-03-05 | ||
| US08/811,700 US5778621A (en) | 1997-03-05 | 1997-03-05 | Subflooring assembly for athletic playing surface and method of forming the same |
| CA002283912A CA2283912A1 (en) | 1997-03-05 | 1998-03-05 | Subflooring assembly for athletic playing surface and method of forming the same |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002283912A Division CA2283912A1 (en) | 1997-03-05 | 1998-03-05 | Subflooring assembly for athletic playing surface and method of forming the same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2538357A1 true CA2538357A1 (en) | 1998-09-11 |
Family
ID=36177530
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002538357A Abandoned CA2538357A1 (en) | 1997-03-05 | 1998-03-05 | Subflooring assembly for athletic playing surface and method of forming the same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2538357A1 (en) |
-
1998
- 1998-03-05 CA CA002538357A patent/CA2538357A1/en not_active Abandoned
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| Date | Code | Title | Description |
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| EEER | Examination request | ||
| FZDE | Dead |