EP1462589B1 - Set of elements for forming a combined elastic sports floor, in particular for gymnasiums - Google Patents

Abstract

The floor has multiple modular units established as per predetermined format and dimensions in a structural configuration. The modular units include borders of same structure, and upper and lower components arranged with a base component (A). The base component has rigid plates (7, 8) on both of its sides, such that a selective floor is connected with upper modular intermediary units. An independent claim is also included for a method for fabricating a sport floor.

Description

The invention relates to the technical field of sports floors used in gymnasiums and other places permanently or temporarily set up on the occasion of sports events.

According to the prior art, many sports floor designs have been made in order to meet the needs not only of high sports competition, but also to allow the practice of physical and sports activities at lower levels, such as for the school use. The technical criteria of sports floors vary according to the required uses, but this entails financial and economic constraints, because investments are expensive and need to be subject to rapid depreciation. The practice of sports, and physical disciplines in general, requires floor surfaces of the order of 800 m ² to 1,000 m ² for sports such as basketball, handball, gymnastics, etc. that is to say that the choice and design of sports floors according to their criteria and conditions of use have significant financial consequences. Currently, and to the knowledge of the Applicant who has a wide practice in the design and manufacture of this type of soil, prices vary between 40 € m ² to 100 € m ² .

According to current techniques, different types of sports floors have been proposed, namely spot soils, surface soils, combined soils.

The punctual soils consist of synthetic materials made in one or more layers and are in the form of strips unrolled to length, and are directly placed on the concrete slab receptor. In this implementation, the load of the athlete is distributed only on a surface slightly greater than the foot surface of the latter and therefore the impact zone on a value of the order of a few centimeters (3 to 5 cm) around the foot. This type of coating remains satisfactory in view of its reduced cost and its durability properties (wear, maintenance, impact resistance). On the other hand, the sporting properties remain very limited by the compromise thickness-flexibility of the ground which prevents to increase the damping layer without knowing problems of stability of supports. The conditions of use of this type of soil are limited to school gymnasiums or for competition practice at a regional level.

The investment remains in line with the conditions of use.

The surface soils are made from wood-based materials, with the athlete's load spreading over a surface much larger than the surface of the foot (about 50 cm around the foot). In this implementation, the ground surface receives from the concrete slab a first established polyurethane foam coating of a certain thickness on which are arranged two superposed rows of wood panels arranged in a quincunx, with finishing coating.

This type of floor is particularly used and preferable in the rooms where there is a practice of basketball and in particular of competition by the sporting properties rendered by these grounds.

However, the investment of a surface sports floor of this type is very high. The time of assembly and removal is long due to the arrangement of the two rows of wood panels, difficulties to correctly fill the the entire surface of the room considered. In addition, and technically, there have been some disadvantages. Wood panels are sensitive to the phenomenon of moisture that tends to rise from the concrete slab. This can change soil characteristics with inappropriate effects. The cost of maintenance is also high with the requirement for regular varnish repairs.

Moreover, there can be a phenomenon of expansion and deformation of the wood panels by the ambient environment and temperature, so as to modify the sealing conditions between panels. If there is a change in the quality of the soil, and even a single part of it, then the whole soil must be replaced.

The surface soils by these constraints are used only in gyms and gymnasiums of high national level, international, for practices of particular sports activities such as basketball, handball, volleyball.

In view of all these constraints, so-called combined soils have been proposed which superimpose a surface soil with a punctual soil, thus associating the properties of a surface soil (distribution of the larger load) with those of the soil. punctual (flexibility and comfort of the athlete). The combined soil type makes the cost lower than that of the surface soil, but remains higher than the punctual soil cost. It has thus been represented figure 1 this type of soil with the layer of polyurethane foam (1) placed on the concrete slab (2), the two rows of wood panels (3-4) and the punctual soil (5).

This type of soil combined in its design is a good compromise, but still has disadvantages.
The assembly is carried out on the place of installation and one always finds the constraints of time of assembly and installation requiring a dexterity and a know-how of the setter. There are also disadvantages relating to the use of wood panels and environmental constraints (humidity, heat). Furthermore, in this implementation, the maintenance and responsibility for the installation quality of the combined floor is transferred to the individual installer, the designer manufacturing the combined floor thus being removed for the reasons mentioned above.

Thus under the prior art different solutions have been proposed in the following documents EP 411 653 , EP 1260655 , US 4330494 , DE 3904223 , FR 2812898

The Applicant's approach, which has been producing sports flooring for many years, in particular under the brand name "TARAFLEX", which is widely known in the sports field, has been to reconsider the conditions of design of sports floors combined to propose a concept and produced at a competitive price compared to specific soils, by exempting itself from the constraints related to the ambient environment (humidity, heat) and facilitating the installation of the coating with a substantial reduction in the time of assembly and installation of the sports ground object of the invention.

In addition, the Applicant in its approach wanted to overcome the dependence of intervention of the installers, and allow a choice of a less specialized staff and therefore easier to find on the labor market.

Another request from the Applicant was to design a new sports floor combined reducing the costs and constraints of maintenance and maintenance.

These goals are achieved by means of a set of elements as defined in either of the appended claims 1 and 2.

According to a first variant of the invention, the set of elements intended to be assembled to form a combined sports floor comprising a base component designed from polyurethane foam resting on a reception slab, two rows of intermediate elements and a punctual floor, said set comprising a plurality of complete modular elements set to a specific size and size, in a structural configuration for joining them by entanglement, and a plurality of modular curb elements having the same structure, is remarkable in that each complete modular element comprises a first subassembly constituted by the combination of a polyurethane foam base component and a first intermediate element, and a second subassembly consisting of a second intermediate element, a upper component constituting the punctual soil, the two subsets being integral with each other by s means for connection with an angular orientation offset so as to define bearing spans, and allow assembly by entanglement, in that the intermediate elements are arranged with a honeycomb middle structure sandwiched between two stiffening plates of the same size and dimension, said plates being of non-woven material and having reinforcing and stiffening means, and in that the plates have reinforcement means arranged in a pattern of warp and weft threads .

• La figure 1 est une vue en coupe d'un sol sportif combiné formé avec des éléments selon l'art antérieur.
• La figure 2 est une vue en coupe d'un sol sportif combiné selon l'invention.
• La figure 3 est une vue en perspective avant assemblage d'un module d'une plaque réalisée dans une structure en nid d'abeille avant assemblage.
• La figure 4 est une vue en perspective avant assemblage d'un sol sportif combiné selon la figure 2.
• La figure 5 est une vue partielle en coupe selon la figure 3.
• La figure 6 est une vue d'un sous-ensemble du sol sportif réalisé à partir de deux modules et assemblés en vue de leur pose.
• La figure 7 est une vue à caractère schématique illustrant le processus de fabrication des sous-ensembles.
• La figure 8 est une vue exposant la phase préalable de calepinage de la salle à agencer avec le sol sportif.
• Les figures 9 et 10 sont des vues des sous-ensembles d'entourage destinés à être découpés et disposés sur le pourtour périphérique de la salle.
• Les figures 11, 12, 13, 14 illustrent le procédé de pose des sous-ensembles.
• La figure 15 illustre la mise en place des sous-ensembles du périphérique.
• La figure 16 illustre le collage du sol sportif.

These and other characteristics will be apparent from the rest of the description.

• The figure 1 is a sectional view of a combined sports floor formed with elements according to the prior art.
• The figure 2 is a sectional view of a combined sports floor according to the invention.
• The figure 3 is a perspective view before assembly of a module of a plate made in a honeycomb structure before assembly.
• The figure 4 is a perspective view before assembly of a sports floor combined according to the figure 2 .
• The figure 5 is a partial sectional view according to the figure 3 .
• The figure 6 is a view of a subset of the sports floor made from two modules and assembled for their installation.
• The figure 7 is a schematic view illustrating the process of manufacturing subsets.
• The figure 8 is a view exposing the previous phase of layout of the room to be arranged with the sports floor.
• The Figures 9 and 10 are views of the surrounding subassemblies intended to be cut out and arranged around the perimeter of the room.
• The Figures 11, 12, 13, 14 illustrate the process of laying subsets.
• The figure 15 illustrates the implementation of subsets of the device.
• The figure 16 illustrates the collage of the sports floor.

In order to make the object of the invention more concrete, it is now described in a nonlimiting manner illustrated in the figures of the drawings.

The combined sports floor formed with elements according to the invention is designed to be manufactured according to modules and subassemblies which are intended to be assembled quickly according to a kit assembly allowing their manufacture, the delivery, their assembly, in optimal conditions making the proposed concept particularly attractive.

With reference to the drawings, the sports floor comprises four components (ABCD) which are assembled under the conditions set out below, namely a base component (A) intended to be placed on the concrete slab (2) of the hall to cover, two identical intermediate components (BC) in a particular structure other than wood panels and an upper component (D) constituting the punctual soil.
The base component (A) is made in the form of a polyurethane foam layer obtained for example with recycled material. This layer is of a certain thickness of the order of at least 15 millimeters while being supported on the concrete slab (2). The two intermediate components (BC) constitute by themselves modules in the form of rectangular plates or panels for example. Each module is made according to a particular design, in a material other than wood, and more specifically in a specific synthetic plastic or composite material ensuring lightness in charge. In an original way, each module has a honeycomb medial structure (6) based on plastic, and preferably polypropylene or similar material and receiving on its outer and lower face two rigid plates (7-8) identical made of a nonwoven material, each plate being secured to the honeycomb structure by any suitable means, bonding or other. Each plate (7-8) is thin and covers the entire honeycomb structure (6) to configure a module. Specifically, each plate (7-8) incorporates reinforcing means (9) arranged in a configuration of weft threads (9.1) and warp threads (9.2). These reinforcing means are for example made from glass fibers. The module thus produced allows, by means of the honeycomb structure, the air passage, and therefore a combined soil aeration, and thus effectively combat the effects of rising moisture from the concrete slab (2). Furthermore, the arrangement and orientation of the reinforcing means imparts rigidity to the plate and thus to the subset defined by the two charges and the honeycomb structure. This also makes it possible to obtain a dimensional stability.

The upper component (D) constitutes the punctiform ground portion and is conventionally made with a foam base (10) on which the outer layer (11) is exposed.

According to the invention, the implementation of these four components is carried out as follows. In a specific implementation of the invention, the four components are established in the same dimensional format to be then assembled under the optimized conditions below.

The design of the sports floor combined is such that it allows different possibilities of manufacture and in-situ delivery of components, depending on the degree of intervention desired by the manufacturer and customers.

In the case of a global supply of all sports floor, it is described below a first implementation of the method of manufacturing the components of the invention for installation.

In this case, the manufacturer proceeds to the realization of two subsets (S1-S2). The first subassembly associates the base component (A) and a first intermediate module (B) joined together by a bonding film (12) of the glue type or the like. This film ensures the specific connection of the upper face of the component (A) with the plate facing the module concerned. The second subset (S2) is made from the outer component (D) or punctual soil, and the second intermediate module (C) through the plate (7) facing stiffening. Thus, the two subsets (S1-S2) are made in the same format and dimensions to be subsequently assembled together by means of an adhesive connection means.

According to the invention and as shown figure 6 , the two subsets (S1-S2) are joined to each other in an angular position offset a few degrees of separation, so as not to be completely stackable and allow their entanglement during assembly. Thus, in the zones of angles, there are shifts defining bearing cheeks (13) during the assembly of complete modular assemblies integrating the two subsets (S1-S2).

These modular assemblies are directly joined against each other in a rapid assembly in situ.

Referring to Figures 8 to 16 As an example, the implementation of the covering of a room of a combined sports floor from the concept of the invention has been illustrated.

According to figure 8 , the layout of the room is defined, that is, the definition of its dimensional characteristics and the definition and calculation of complete modular assemblies and cut modular assemblies for the execution and filling of the periphery of the room. the room. The x and y dimensions of the room are thus defined in the perpendicular planes. According to figure 9 , after calculating the number of modular assemblies needed in width to cover the width of the room, minus the sets of borders, we define and cut the set of borders to the desired size along the line aa of the figure 9 . There is obtained a partial modular assembly having a straight edge after cutting intended to be in the length of the room. We proceed in the same way with the modular sets of borders according to the figure 10 and intended to be in the width of the room.

• Figure 11 : La salle est vide d'éléments modulaires.
• Figure 12 : On dispose en longueur le long de la bordure en longueur de la salle une pluralité d'éléments modulaires partiels obtenus selon la figure 9.
• Figure 13 : Adjacents à la pluralité d'éléments modulaires partiels, sont disposés des éléments modulaires complets à l'exception des extrémités latérales.
• Figure 14 : La salle est remplie d'éléments modulaires complets et partiels à l'exception du pourtour périphérique sur trois côtés consécutifs.
• Figure 15 : On procède à la finition du sol sportif avec l'assemblage et pose des éléments modulaires de bordures.

The following phases are illustrated below.

• Figure 11 : The room is empty of modular elements.
• Figure 12 : Along the longitudinal edge of the room, a plurality of partial modular elements obtained according to the figure 9 .
• Figure 13 Adjacent to the plurality of partial modular elements are complete modular elements with the exception of the lateral ends.
• Figure 14 : The room is filled with complete and partial modular elements with the exception of the perimeter on three consecutive sides.
• Figure 15 : Finishing the sports floor with the assembly and laying modular elements of borders.

Assuming the implementation of the two sets (S1-S2) described above, the room is almost complete, except for the execution of secondary accessory work.

It is also possible alternatively to design a delivery of the subsets differently, so that the punctual soil can be unwound in strips along the entire length of the room and not be directly associated in manufacturing with the intermediate component (C). The latter is joined to the subset (S1) in the same way as before and in the same position. The punctual soil is then reported as represented for example figure 16 .

We have shown figure 7 the manufacturing process in an automation scheme of complete modular assemblies without the punctiform soil part.

Phase P1 of the process consists of producing the component (A), namely the polyurethane foam, on one of the faces in which a sizing is arranged.

Phase P2 constitutes the bonding of the first intermediate component (B) to the component (A).

The following phase P3 consists of gluing the intermediate component (B) on the plate facing all or part of it.

Phase P4 consists of placing the second intermediate component in an offset position with respect to the first.

The following phase P5 consists of an operation of pressing the subsets (S1-S2) between them to allow a rigid connection.

The following phase P6 consists of the evacuation of the modular assembly obtained, for its storage and delivery in situ.

The new concept of combined sports floors according to the invention has many advantages.

It is emphasized firstly that it allows an industrial implementation of prefabricated kit elements significantly reducing manufacturing costs.

The lightness of the modular assemblies obtained is emphasized. The sporting properties of this type of sports floor are located at the level of surface soils at the top and very high end, but under price conditions located at the level of punctual soils.

The special honeycomb structure of the intermediate components (B-C) makes it possible to respond to the moisture problem of the slab. Intermediate components are insensitive to moisture and there is no risk of soil deformation.

The assembly and installation of modular partial and complete elements are easy, quick to perform, and do not require the intervention of qualified personnel.

It is also possible very easily and without excessive cost, and in any case not proportional, to vary the height and thickness of the honeycomb structures, and this, depending on the technical and sports criteria sought.

The constituent materials of the components (A, B, C) are chosen according to the facilities and may be based on recycled materials, for example in the context of a cost-saving research.

Another advantage of the invention lies in the fact that it is possible to work and cut the modular elements of borders according to various forms to take into account certain environmental constraints related to the room.

• réduction de force = 60 %
• déformation verticale = 3 mm
• restitution d'énergie = 0,8 m/s
• cuvette de déformation W100 = 0

Without departing from the scope of the invention, it is conceivable that the formats of the modular assemblies are geometric, rectangular, square, or other polygonal shapes.
It also highlights the excellent sports properties of the sports floor according to the invention. Compared with DIN 18032, the results of the tests carried out are as follows:

• force reduction = 60%
• vertical deformation = 3 mm
• energy return = 0.8 m / s
• deformation bowl W100 = 0

The finished material is at the weight equivalent to the surface structure of the wood panels for the polystyrene plates and lighter for the sub-assemblies constituted by the honeycomb structure made of non-woven sheets.

The invention thus has many advantages and also offers a quality of performance and a quality / price ratio without equal.

Claims (8)

1. Assembly of elements intended to be assembled to form a composite sports floor comprising a base component (A) designed from polyurethane foam bearing on a receiving slab (2), two tiers of intermediate elements (B-C) and a "pin-point load" floor (D), the said assembly comprising a plurality of complete modular elements arranged according to a specific format and size, in a structural configuration enabling them to be assembled by criss-crossing, and a plurality of modular edging elements having the same structure, characterised in that each complete modular element comprises a first sub-assembly formed by connecting a polyurethane-foam base component (A) and a first intermediate element (B), and a second sub-assembly consisting of a second intermediate element (C), an upper component (D) constituting the "pin-point load" floor, the two sub-assemblies (S1-S2) being connected to each other by connecting means with a staggered angular orientation so as to define supporting seats (13), and enable a criss-cross assembly,
   in that the intermediate elements (B-C) are formed with a honeycomb middle structure (6) sandwiched between two stiffening sheets (7-8) of the same format and size, the said sheets being of a non-woven material and having reinforcing and stiffening means,
   and in that the sheets have reinforcing means disposed in a canvas of warp threads and weft threads.
2. Assembly of elements intended to be assembled to form a composite sports floor comprising a base component (A) designed from polyurethane foam bearing on a receiving slab (2), two tiers of intermediate elements (B-C) and a "pin-point load" floor (D), the said assembly comprising a plurality of complete modular elements arranged according to a specific format and size, in a structural configuration enabling them to be assembled by criss-crossing, and a plurality of modular edging elements having the same structure, characterised in that each complete modular element comprises a first sub-assembly formed by connecting a polyurethane-foam base component (A) and a first intermediate element (B), and a second sub-assembly consisting of a second intermediate element (C), the two sub-assemblies (S1-S2) being connected to each other by connecting means with a staggered angular orientation so as to define supporting seats (13), and enable a criss-cross assembly,
   in that the intermediate elements (B-C) are formed with a honeycomb middle structure (6) sandwiched between two stiffening sheets (7-8) of the same format and size, the said sheets being of a non-woven material and having reinforcing and stiffening means,
   and in that the sheets have reinforcing means disposed in a canvas of warp threads and weft threads, the said assembly also comprising an outer component (D) in rolls which is intended to be added after installing modular elements to constitute the "pin-point load" floor.
3. Assembly according to claims 1 or 2, characterised in that the reinforcing means comprise glass fibres.
4. Assembly, according to claims 1 or 2, characterised in that the connecting means are of the adhesive film type enabling the components to be connected together.
5. Assembly according to one of claims 1 to 4, characterised in that the modular edging elements have an identical structure to the complete modular elements and are only cut in a transverse or longitudinal plane to obtain a straight edging in order to be fitted around the perimeter of the room where the floor is to be fitted.
6. Manufacturing process of a composite sports floor using an assembly of elements according to claims 1 to 5, characterised in that:

   - the component (A) is created out of polyurethane foam having adhesive on one face,

   - the first intermediate component (B) is created with a honeycomb middle structure and on either side two stiffening sheets, and the said first intermediate component is connected by gluing onto the said component (A),

   - the intermediate component is then glued onto all or part of the surface,

   - the second intermediate component (C) is created having the same structure as component (B) and then placed on the said first intermediate component (B) in a staggered position,

   - an operation is then performed whereby the two intermediate components are pressed together to achieve final connection.
7. Manufacturing process according to Claim 6, characterised in that the outer component (D) defining the "pin-point load" floor is disposed and connected according to the pre-established format of the complete and partial modular elements.
8. Manufacturing process according to claim 6, characterised in that the outer component (D) defining the "pin-point load" floor is presented in rolls on the surface of the room to be covered after putting the different modular elements in place.

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