EP1540114B1

EP1540114B1 - Method for manufacturing a resilient suspended floor

Info

Publication number: EP1540114B1
Application number: EP03738149A
Authority: EP
Inventors: Reijo Korhonen
Original assignee: Karelia-Upofloor Oy
Current assignee: Karelia-Upofloor Oy
Priority date: 2002-07-08
Filing date: 2003-07-07
Publication date: 2010-09-08
Anticipated expiration: 2023-07-07
Also published as: FI20021344A0; FI20021344A; RU2311516C2; ATE480682T1; DE60334116D1; DK1540114T3; EP1540114A1; AU2003244670A1; RU2005102931A; WO2004005649A1

Abstract

A resilient element for suspended flooring and a method for manufacturing a suspended floor. The resilient element (1) constitutes an installation element, the length of which substantially exceeds its width, and it comprises an upper structure (2) and a lower structure (3). Between the structures (2, 3) there are arranged first support means (4), which arrange the upper structure (2) and the lower structure (3) at a first height (H1) from one another. The second support means (5) are arranged on the opposite side of the lower structure (3) with respect to the first support means (4). The second support means (5) arrange the lower structure (3) at a first height (H2) from the structure beneath the structure.

Description

BACKGROUND OF THE INVENTION

The invention relates to a method for manufacturing a suspended floor, in which method a surface layer is arranged on top of resilient elements, the resilient element constituting an installation element the length of which substantially exceeds its width, the element comprising: an upper structure and a lower structure, the structures being resilient at least to some extent, mutually parallel, and substantially horizontal and superimposed in the installed resilient element; first support means that are arranged between the upper structure and the lower structure at a first distance from one another in the longitudinal direction of the resilient element, the first support means arranging the upper structure and the lower structure at a first height from one another; second support means that are arranged on the opposite side of the lower structure with respect to the first support elements and at a second distance from one another in the longitudinal direction of the resilient element, the second support means having a height to arrange the lower structure at a second height from a structure beneath the structure; the first support means being arranged in the longitudinal direction of the resilient element at substantially different locations in said resilient element than the second support means, wherein at one end of an upper and a lower structure there is a groove, and at the opposite end a tongue, the tongue and groove being designed such that the resilient element can be connected at its ends to another similar resilient element with a tongue-and-groove joint, and that in the method the resilient elements are interconnected at their ends with a tongue-and-groove joint.
In some premises the floor must not be too rigid, but it should be suitably resilient, i.e. the floor must be a suspended floor. These premises include, for instance, spaces for indoor ballgames, such as squash, basketball and volleyball fields, dance floors, ballet dancing floors, gyms and the like.
In a suspended floor, the surface layer can be made of parquet, laminate or plastic floor covering. Resilient structural elements, i.e. resilient elements, arranged between a subfloor - made of concrete, for instance - and the surface layer, are an essential part of the suspended floor. The resilient elements raise the surface layer off the subfloor and allow the surface layer and other optional floor layers above it to yield under local and often sudden loading of short duration, to which the surface layer is subjected. There are several standards that determine the resilience properties required of the suspended floors.
DE 19519193 discloses pre-assembled double swivel supports which are laid with butting assembly units, using intermediate members (Zwischenstück) for band plank layers with vertical, parallel spacing. The supports are positioned concurrent with the main floor directions, according to claim 1.
To provide a suspended floor, there is a known arrangement which employs resilient elements consisting of a plywood plate that is about 400 mm wide and 2.4 m long and its edge portions, on the lower surface of both longitudinal sides, are provided with rubber cushions with predetermined spacing. On the upper surface of both longitudinal sides there are secured plywood boards that are about 60 mm wide extending throughout the plywood plate, the plywood boards serving as joists, onto which structures provided on top of the resilient elements are secured. Prior to installing cover plates the resilient element is secured to the substrate by anchoring means arranged to go through the plywood plate. A problem with the above-described arrangement is the weight and the material consumption of the resilient elements. Moreover, the adjustment range of the resilience properties of the resilient element is limited: resilience properties can only be altered by changing the material of the rubber cushions or the distance between them. Another arrangement employing resilient elements is also known for providing a suspended floor. In this arrangement, first battens that are about 50 mm wide and made of plywood are placed lowermost with predetermined spacing on a subfloor. On the lower surface of the battens there are rubber cushions at given intervals: the battens thus rest on the rubber elements on the subfloor. Second, transversal battens made of the same plywood as the first battens are secured on top of the first battens, perpendicular thereto. Seen from above, the battens form a grid structure. Between the crossing battens it is possible to arrange rubber elements. A covering plate, for instance, a plywood plate, is attached on top of the second battens, and on top of that a surface material, such as parquet. A problem with the arrangement is complicated and slow installation, which causes installation costs.

BRIEF DESCRIPTION OF THE INVENTION

The object of the present invention is to provide an improved method for manufacturing a suspended floor.
The method of the invention as defined in claim 1 for manufacturing a suspended floor is characterized in that the resilient elements are positioned at an angle of 45 degrees to the main floor directions.
The method of the invention for manufacturing a suspended floor has an advantage that it is fast and simple to make, whereby costs of installation work remain low. A further advantage is that the resilient elements can be packed densely, and consequently the transport costs are considerably low: the required transport and storage area is only one fifth of the known truss-type structural element.
Further, the basic idea of an advantageous embodiment of a method is that its upper and lower structure and support means are at least mainly of plywood, which is a strong and flexible material resistant to fatigue. The basic idea of a second advantageous embodiment of the method is that first and/or second support elements are of elastic material, which enhances the resilience of the resilient element and of the suspended floor. Further still, the basic idea of a third advantageous embodiment of the method is that upper and lower structures are stepped with respect to one another, whereby the joints of the successively connected resilient elements form a kind of tongue and groove structure, which equalizes strains to which the element is subjected.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following, the invention will be described in greater detail with reference to the attached drawings, wherein

Figure 1 is a schematic side view of an embodiment of a resilient element for use in a method according to the invention;
Figure 2 is a schematic top view of the resilient element of Figure 1;
Figure 3 is a schematic side view of an embodiment of a support element of the resilient element for use in a method according to the invention;
Figure 4 is a schematic side view of the ends of one embodiment of the resilient element for use in a method of the invention;
Figure 5 is a schematic side view of joining a resilient element for use in a method to another similar element;
Figure 6 is a schematic side view of an embodiment of the resilient element for use in a method of the invention; and
Figure 7 is a schematic top view, partly cut open, of a suspended floor manufactured by the method of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Figure 1 is a schematic side view of an embodiment of a resilient element for use in a method of the invention and Figure 2 is a schematic top view of the resilient element of Figure 1.
The resilient element 1 comprises an upper structure 2 and a lower structure 3, which is arranged at a first distance H1 therefrom and which is parallel to the upper structure. In the installed resilient element 1 the upper structure 2 is above the lower structure 3. First support means 4, which keep the structures 2, 3 at said first distance H1 from one another, are arranged between the structures 2, 3. The resilient element 1 comprises a plurality of first support means 4 along the length of the element, the successive first support means 4 being arranged at a first distance D1 from one another.
The resilient element 1 also comprises a plurality of second support means 5 arranged on a lower surface of the lower structure 3 throughout the length of the element. The successive second elements 5 are arranged at a second distance D2 from one another. The second support means 5 keep the lower structure 3 at the second distance H1 from the structure beneath the resilient element 1. The first and the second support means 4, 5 are arranged such that they are substantially at different locations in the resilient element 1 seen in the longitudinal direction of the resilient element.
The structures 2, 3 and the support means 4, 5 are made of wood material, preferably of plywood, which is durable and elastic material. The plies of the plywood can be arranged such that they are either in a horizontal position or in a vertical position in the resilient element 1 installed on the floor. The resilient elements 4, 5 are secured to structures 2, 3 with nails, screws, glue or in a similar manner known per se.
Apart from the plywood, the structures 2, 3 and the support means 4, 5 can be made of any wood material that is partly or completely wood, plastic or metal or combinations thereof. The structures 2, 3 and the support means 4, 5 can be of the same material or of different materials.
The length of the resilient element 1 substantially exceeds its width. Its length can be e.g. 2400 mm and width 40 to 100 mm. The thickness of the upper and lower structures 2, 3 and the support means 4, 5 can be e.g. 6 to 50 mm. The measurements may naturally differ from those given, but the length should substantially exceed the width, however.
In the case of Figures 1 and 2 the structure beneath the resilient element 1 is a raising beam 8, under which there is a subfloor 9, which can be made of concrete or the like. The raising beam 8 is made of a glued laminated beam, for instance, with cross sectional measurements of 50 x 60 mm. The raising beam 8 can also be made of other wood material, metal or plastic or combinations thereof. The raising beam 8 comprises adjustment elements 10, which allow adjustment of distance between the raising beam and the subfloor 9. By means of the adjustment elements 10 the raising beam 8 can be installed in a precise horizontal position despite unevenness or inclinations of the subfloor 9. In general, the operation of the adjustment element 10 is based on a threaded bolt, which is arranged in a correspondingly threaded sleeve. The adjustment element 8 is a component known per se and therefore it is not described herein in any greater detail. When the raising beam 8 is used, the adjustment elements 10 are advantageously arranged at the first support means 4, whereby said support means reinforces the resilient element 1 when a hole is provided in the resilient element 1, for instance by drilling through the first and the second structures 2, 3 for height adjustment from above. The adjustment elements 10 can also be arranged directly in the second support means 5, whereby the resilient element 1 can be arranged immediately on the subfloor 9. Thus is achieved a particularly low floor structure. Naturally, the resilient element 1 can also be arranged directly on the subfloor 9, even without adjustment elements 10. It should also be noted that, apart from the adjustment beam 8, it is possible to arrange also other structures known per se, such as adjustment wedges, between the resilient element 1 and the subfloor 9.
In principle, the suspended floor is manufactured by means of the resilient elements 1 by arranging them side by side on the floor at a given distance from one another. Said distance can be 300 to 600 mm, for instance, but other distances are also possible, because properties required of the suspended floor in question and the surface material used determine the distance. On top of the resilient elements 1 there is first arranged a substrate layer 6, such as chipboard or a plywood plate, covering the floor area, and on top of that a surface layer, such as parquet, laminate, matting or a similar flooring surface. Certain surface materials, such as floor boards or floor planks, or load-bearing parquets, can be secured directly to the resilient element 1.
The resilient elements 1 support the surface layer 7 that is arranged to rest on them. If necessary, a plurality of resilient elements 1 can be connected in succession such that a continuous resilient element construction will extend throughout the length of the floor. If necessary, the resilient element 1 can be cut to a suitable size.
When the surface layer 7 is subjected to local loading, which is continuously the case in sports or dancing, for instance, the loading force is exerted on the upper structure 2 of the resilient element 1 underneath. On one hand, the force bends the upper structure 2 in the portion between the first support means 4 and, on the other hand, transmits part of the force via the first support means 4 to the lower structure 3. Thus the lower structure 3 bends in the portion between the second support means 5. So the resilient element 1 yields and at the same time allows the surface layer 7 and the substrate layer to yield. The floor is thus resilient in a certain way, or in other words, the floor possesses a given rigidity.
The rigidity of the resilient element 1, i.e. the resilience properties of the floor, can be adjusted in a very versatile and simple manner. For instance, by lengthening the distance between the first support means 4 and the second support means 5, i.e. by increasing the first distance D1 or the second distance D2, the rigidity of the resilient element 1 reduces. Correspondingly, by decreasing the first distance D1 or the second distance D2, the rigidity of the resilient element 1 increases. Some of the resilient elements in the floor can be adjusted to have different rigidity than other resilient elements. This can be advantageous, for instance, at entrances or under spectator constructions, where the floor must be more rigid than in other parts of the floor. In that case, the resilient element 1 is made more rigid in accordance with the above-described principle, for instance, by adding support means between the first and/or the second support means 4, 5, or by reducing in some other way the first and/or the second distance D1, D2. It is also possible to make one part of the resilient element 1 different in rigidity than other parts of the same resilient element 1. This is possible to implement by altering the distances D1, D2 between some support means 4, 5 with respect to other corresponding distances. So the first and the second distances D1, D2 need not necessarily be constant throughout the whole length of the resilient element 1. The resilient element 1 can be rendered very rigid such that the first and the second support means 4, 5 are substantially superimposed and that the first and/or the second distances D1 and D2 are further reduced. All in all, the resilience properties of the suspended floor can be customized in a very precise manner.
The properties of the resilient element 1 can also be modified by making support means 4, 5 either partly or completely of substantially elastic material, such as rubber, foam rubber or plastic, or granular rubber. In that case, in addition to the upper and the lower structures, said support means 4, 5 yield, which increases the resilience of the floor. One application of this construction could be a dance floor, for instance.
In the resilient element 1 of Figures 1 and 2, the first distance D1 is substantially equal to the second distance D2, even though this is not necessary, but said distances may differ from one another.
The lower support means 5 can be to some extent wider than the other parts of the resilient element. Thus the element stands steadily when installed prior to securing to place, which facilitates the installation work.
Figure 3 shows a schematic side view of an embodiment of an element support means. The described support means can be used as the first or the second support means 4, 5. The support means is a combination of two different materials such that the upper component 15 is of plywood, the plies of which are in a horizontal position, and the lower component 16 is of elastic material, for instance EPDM material, granular rubber, foamed plastic or the like. The upper and the lower components 15, 16 are interconnected with glue. Naturally, the parts can also be arranged vice versa, or for instance such that the elastic component is sandwiched between two substantially inelastic components. The support means can also be completely of elastic material.
By varying the rigidity or thickness of the part made of the elastic material it is possible to modify the resilience properties of the support means and thus affect the resilience properties of the suspended floor.
Figure 4 is a schematic side view of the ends of an embodiment of one resilient element. In the end portion of the resilient element 1 shown on the left in Figure 4, the upper structure 2 extends longer than the lower structure 3; correspondingly in the end portion shown on the right, the lower structure 3 extends longer than the upper structure 2. In other words, the ends of the structures 2, 3 are stepped and they end in different lines - in an imaginary outer line 17a and in an inner line 17b - at both ends of the resilient element. Said lines 17a and 17b of Figure 4 are depicted only in connection with the left end. The lines and the structures 2, 3 relate such that the structures 2, 3 are perpendicular to the outer line 17a and the inner line 17b.
The distance between the outer line 17a and the inner line 17b is equal at both ends of the resilient element 1. When two resilient elements 1 are interconnected end on end, the joint will be a kind of tongue-and-groove joint, in which the interface of the upper structures 3 is offset from the interface of the lower structures 3. This construction equalizes the stresses to which the joint is subjected. It should be noted, however, that the structures 2, 3 may just as well end in the same line.
In the resilient element 1 of Figure 4 the upper structure 2 is thicker than the lower structure 3. The structures 2, 3 may also have the same thickness or the lower structure 3 may be thicker than the upper structure 2.
The resilient elements are advantageously interconnected with nails, screws or other similar securing means and with elastic glue or paste, or with other similar adhesive or elastic material, such as glue paste or glue sealing paste. The elastic material allows the resilient elements 1 to move slightly with respect to one another. The first support means 4 arranged at the interfaces support the joint of the upper and the lower structures 2, 3. Also nails, screws, dowels or other similar securing means can be used in securing. In that case elastic material, which allows inter-element motion, can be arranged between the resilient elements 1.
Figure 5 is a schematic side view of joining the resilient element to another similar element. The first end of the upper and the lower structures 2, 3 is provided with a tongue and the opposite end with a groove, by means of which the resilient elements 1 to be attached in succession are joined with a tongue-and-groove joint 18. In the tongue-and-groove joint 18 it is possible to use elastic glue or paste, which allows the resilient elements 1 to move with respect to one another. The shape and size of the tongue-and-groove joint 18 may differ from those shown in Figure 5. The first support means 4 arranged between the structures 2, 3 support the tongue-and-groove joint 18, and the support means can belong to one of the resilient elements to be interconnected, or it can be a separate means, which is arranged to support the tongue-and-groove joint 18 after the interconnection of the resilient elements 1.
Dressed and matched structures 2, 3 can also be applied to the stepped resilient element ends shown in Figure 4. On the other hand, the plain joint of Figure 5 can be implemented without tongues and grooves, whereby straight or suitably inclined ends of the structures 2, 3 are connected to corresponding ends of a second resilient element 1 in a manner known per se, with or without elastic material. Yet another option to interconnect resilient elements 1 is to connect them by means of support means 4, 5: the support means is arranged between the ends of the first and the second structures 2, 3 of the resilient elements 1 connected end on end. Thereafter it is secured to both resilient elements with screws or nails, for instance, without connecting the structures of 2, 3 of the different resilient elements directly to one another.
Figure 6 is a schematic side view of one embodiment of an element for use in a method according to the invention. The resilient element 1 comprises an upper structure 2, a lower structure 3, first support means 4 and second support means 5, which are mutually integrated, i.e. they all constitute one piece made of the same material. In this respect the resilient element 1 of Figure 6 deviates from the above-described resilient elements, in which said components are manufactured separately and assembled thereafter with glue, nails or screws to form a resilient element. The integrated resilient element 1 of Figure 6 can be made quickly of plywood, for instance, the plies of which are in a vertical position when the resilient element is installed on the floor.
Integration can also be implemented in part such that some of the main components of the resilient elements, i.e. the structures 2, 3 or the support elements 4, 5 are integrated and some are secured to this integrated whole using known securing methods.
Figure 7 is a schematic top view, partly cut open, of a suspended floor manufactured by the method of the invention. A room 20 is provided with a parquet-covered suspended floor such that first resilient element structures 22a formed of resilient elements are installed in the in the direction of the walls on areas adjacent to the walls. There is a small gap between the wall and the first resilient element structures 22a, so that yielding motion of the resilient element would not produce sounds of friction. The majority of the resilient elements are in the second resilient element structures 22b, which are arranged at an angle of 45 degrees to the main floor directions and to the direction of the parquet boards 21 which are used as surface material. Because of the angle of the resilient elements the loading to which the floor is subjected is evenly distributed. The resilient elements 1 are connected in succession or cut into suitable size, when necessary. The edges of the surface layer are supported at all points and the resilience of the floor is even in the vicinity of the wall as well. Areas in front of the doors and other similar areas can be made rigid evenly.

Claims

A method for manufacturing a suspended floor, in which method a surface layer (7) is arranged on top of resilient elements (1), the resilient element (1) constituting an installation element the length of which substantially exceeds its width, the element comprising:
an upper structure (2) and a lower structure (3), the structures being resilient at least to some extent, mutually parallel, and substantially horizontal and superimposed in the installed resilient element (1);

first support means (4) that are arranged between the upper structure (2) and the lower structure (3) at a first distance (D1) from one another in the longitudinal direction of the resilient element (1), the first support means (4) arranging the upper structure (2) and the lower structure (3) at a first height (H1) from one another;

second support means (5) that are arranged on the opposite side of the lower structure (3) with respect to the first support elements (4) and at a second distance (D2) from one another in the longitudinal direction of the resilient element (1), the second support means (5) having a height to arrange the lower structure (3) at a second height (H2) from a structure beneath the structure;

the first support means (4) being arranged in the longitudinal direction of the resilient element (1) at substantially different locations in said resilient element (1) than the second support means (5), wherein at one end of an upper and a lower structure (2, 3) there is a groove, and at the opposite end a tongue, the tongue and groove being designed such that the resilient element (1) can be connected at its ends to another similar resilient element (1) with a tongue-and-groove joint (18),

and that in the method the resilient elements (1) are interconnected at their ends with a tongue-and-groove joint (18), characterized in that the resilient elements (1) are positioned at an angle of 45 degrees to the main floor directions.
A method as claimed in claim 1, characterized by the resilient element (1) comprising first and second support means (4, 5) alternately in the longitudinal direction of the resilient element (1).
A method as claimed in claim 1 or 2, characterized in that the upper and the lower structures (2, 3) are at least mainly of wood material.
A method as claimed in any one of the preceding claims, characterized in that the first and the second support elements (4, 5) are at least mainly of substantially inelastic wood material.
A method as claimed in any one of claims 1 to 3, characterized in that the first support elements (4) and/or the second support elements (5) are substantially of elastic material.
A method as claimed in any one of the preceding claims, characterized in that the upper structure and the lower structure (2, 3) are arranged to end in the same line (17a, 17b) and are perpendicular thereto.
A method as claimed in any one of claims 1 to 5, characterized in that the upper structure and the lower structure (2, 3) are arranged to end in different lines (17a, 17b) and are perpendicular thereto.
A method as claimed in any one of the preceding claims, characterized in that the successive resilient elements are arranged for interconnection with elastic adhesive.