US20200378137A1

US20200378137A1 - Subfloor assembly for athletic playing surface

Info

Publication number: US20200378137A1
Application number: US16/889,846
Authority: US
Inventors: Erlin A. Randjelovic
Original assignee: Individual
Current assignee: Individual
Priority date: 2019-06-03
Filing date: 2020-06-02
Publication date: 2020-12-03

Abstract

A subfloor assembly that supports a floor on a substrate. The assembly includes an upper profile panel, a lower profile panel, and a resilient member positioned therebetween. The upper profile panel has at least one upper protruding rib and an upper groove on each side of the upper protruding rib. The lower profile panel has at least one lower protruding rib and a lower groove on each side of the lower protruding rib. The resilient member is sandwiched therebetween and has a resilient elastic modulus that results in (i) the resilient member being spaced from the upper profile panel and from the lower profile panel when the subfloor assembly is in an unloaded state and (ii) the resilient member deforming and in contact with the upper profile panel and the lower profile panel when the subfloor assembly is in a loaded state.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 62/856,368, filed Jun. 3, 2019, and titled: SUBFLOOR ASSEMBLY FOR ATHLETIC PLAYING SURFACE.

TECHNICAL FIELD

This invention relates to subfloor assemblies incorporated below active surfaces to provide desired shock absorbing response when impacted with forces associated with recreation, exercise, dance and sports activities. The invention also relates to satisfying the use of heavy weight maintenance vehicles, portable equipment, bleacher loads and other non-athletic impacts and loads commonly applied to floors in recreational facilities and sports venues.

BACKGROUND

Subfloor construction below athletic type floor surfaces has evolved from very rigid floors having little or no resiliency and shock absorbing characteristics to very deflective sports floors frequently found in recreational and competitive sports facilities today, as well as for aerobics and dance applications. Floors installed in gymnasiums beginning in the early 1900's were constructed in the same manner as provided in industrial and commercial applications. These commonly included heavy joist and plank support below attached wood surface material initially designed for commercial and industrial applications that became commonly used in gymnasiums.
Although some manners to add resiliency, such as minimally deflective cork layers were introduced, the advent of meaningful resiliency did not take place until the late 1950's when resilient components such as rubber pads below wood subfloors became a frequent part of gymnasium floor assemblies. This also created a notable increase in the number of floors floating freely over supporting substrates as opposed to attaching subfloors to concrete substrates as typically done in the past. Numerous variations of resilient pad configurations and materials followed to improve shock absorbing and resilient response as compared to previous designs.
Floor systems commonly described as fixed resilient were introduced to the hardwood athletic flooring industry in the 1990's. These assemblies provide shock absorption as commonly found in deflective resilient padded designs that float freely on the substrate and provide a method of limiting upward movement as found in floor systems that are attached to the concrete substrate.
Numerous designs, floating and fixed resilient, include elastic materials made to react favorably depending on the aggressiveness of floor loads or impacts. These are commonly referred to as two-stage pads based on shapes made to react to light impacts such as young participants or isolated players when initially deflecting and then more supportive as impacts become more aggressive from larger players or multiple players in close proximity to each other. However, such resilient components must be manufactured in low density elastomers to provide required deflection which thus reduces resistance to compression and/or deterioration when impacted by heavy non-athletic loads.
A design as disclosed in U.S. Pat. No. 7,127,857 to Randjelovic incorporates an assembly including machined ridges into the underside of subfloor panels to press into resilient components as a manner to facilitate various degrees of athletic impacts. The invention described herein will be shown as a manner to substantially improve on this and prior athletic floor assemblies.

SUMMARY

As demonstrated in the following description, the novel subfloor assembly provides a method to construct subfloor assemblies that create greater and more rapid deflective shock absorbing response to athletic impacts than other known methods by incorporating opposing pressure ribs in alignment above and below resilient material. The narrow pinching effect produces shock absorbing reaction even when applied to high-density elastomers. This allows the use of a more dense elastic material, which thereby enables better response to a full range of athletic impacts as well as resisting negative influences from heavy non-athletic loads on the floor surface, unlike ever before possible.
Whereas the prior art relies on all deflection from an upper subfloor, the new subfloor assembly described here takes advantage of introducing pressure ribs above and below resilient material. This allows significant shock absorbing characteristics with rib deflection occurring simultaneously into the surface and underside of the resilient material. Additionally, the inclusion of bottom profile panels allows height adjustments without altering floor system performance.
In one embodiment, there is a subfloor assembly that supports a floor on a substrate. The subfloor assembly includes an upper profile panel, a lower profile panel, and a resilient member positioned between the upper profile panel and the lower profile panel. The upper profile panel has (i) at least one upper protruding rib on an upper inner surface and extending along an upper axis of the upper profile panel and (ii) an upper groove on each side of the upper protruding rib on the upper inner surface and extending along the upper axis of the upper profile panel. The lower profile panel has (i) at least one lower protruding rib on a lower inner surface and extending along a lower axis of the lower profile panel and (ii) a lower groove on each side of the lower protruding rib on the lower inner surface and extending along the lower axis of the lower profile panel. The resilient member is sandwiched between the upper protruding rib and the lower protruding rib and has a resilient elastic modulus that results in (i) the resilient member being spaced from the upper profile panel where the upper groove is located and spaced from the lower profile panel where the lower groove is located when the subfloor assembly is in an unloaded state, and (ii) the resilient member deforming and in contact with the upper profile panel where the upper groove is located and in contact with the lower profile panel where the lower groove is located when the subfloor assembly is in a loaded state.
In another embodiment there is a subfloor assembly that supports a floor on a substrate. The subfloor assembly includes an upper profile panel, a lower profile panel, and a resilient member positioned between the upper profile panel and the lower profile panel. The upper profile panel has (i) at least one upper protruding rib on an upper inner surface and extending along an upper axis of the upper profile panel and (ii) an upper groove on each side of the upper protruding rib on the upper inner surface and extending along the upper axis of the upper profile panel. The lower profile panel has (i) at least one lower protruding rib on a lower inner surface and extending along a lower axis of the lower profile panel and (ii) a lower groove on each side of the lower protruding rib on the lower inner surface and extending along the lower axis of the lower profile panel. The resilient member is sandwiched between the upper protruding rib and the lower protruding rib and the subfloor assembly is held together by a limit fastener that results in (i) the upper profile panel being spaced from the lower profile panel a first distance when the subfloor assembly is in an unloaded state and (ii) the upper profile panel being spaced from the lower profile a second distance when the subfloor assembly is in a loaded state with the second distance is less than the first distance, and (iii) the upper profile panel instantly returning to the first distance when the subfloor assembly is in an unloaded state.
In still another embodiment, there is a method for constructing a subfloor assembly that supports a floor on a substrate. The method includes the step forming an upper profile panel having (i) at least one upper protruding rib on an upper inner surface and extending along an upper axis of the upper profile panel and (ii) an upper groove on each side of the upper protruding rib on the upper inner surface and extending along the upper axis of the upper profile panel. Another step is forming a lower profile panel having (i) at least one lower protruding rib on a lower inner surface and extending along a lower axis of the lower profile panel and (ii) a lower groove on each side of the lower protruding rib on the lower inner surface and extending along the lower axis of the lower profile panel. A next step of the method is sandwiching a resilient member with and between the upper profile panel and the lower profile panel, the resilient member having a resilient elastic modulus and the upper profile panel being spaced from the lower profile panel a first distance in an unloaded state. And, a next step is compressing the resilient member between at least one upper protruding rib opposing at least one lower protruding rib with a pair of substantially equal but opposite forces acting upon the resilient member between opposing ribs when the subfloor assembly is in a loaded state and thereby the upper profile panel and the lower profile panel being spaced from each other by a second distance, the second distance being less than the first distance. Then, a successive step is, and in cyclical fashion with the prior step throughout use of the floor, relaxing the resilient member between opposing ribs when the subfloor assembly returns to the unloaded state and thereby the upper profile panel and the lower profile panel return to the first distance.
Various unique assemblies that create opposing pressure ribs combined with resilient components are provided in detailed description of the invention along with methods to adjust profile heights. A brief description of the drawings which present many embodiments of the invention are described below.

BRIEF DESCRIPTIONS OF THE DRAWINGS

The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings in which:

FIG. 1 is a perspective view of a subfloor section made according to the present invention;

FIG. 2 is an end view of a subfloor section as shown in FIG. 1 to further describe the profile panels and resilient component;

FIG. 3 is an end view of an alternate embodiment of the design showing optional profile sections that are within the scope of the invention;

FIG. 4 is a cross-sectional view of multiple subfloor sections positioned for attachment of a commonly included floor surface;

FIG. 4A is a side view following line AA of FIG. 4;

FIG. 5 is a top view of multiple subfloor sections including added subfloor plates and commonly included floor surfacing;

FIG. 5A is a cross-sectional view following line AA of FIG. 5;

FIG. 6 is a side view of a typical subfloor section with an added subfloor plate and optional floor surface;

FIG. 7 is a perspective view indicating an alternate manner of capturing subfloor sections together within the scope of the invention;

FIG. 8 is a cross-sectional view of a subfloor section as shown in FIG. 7 following line AA to better illustrate the manner in which subfloor sections are captured;

FIG. 8A is an enlarged view of the portion A in FIG. 8;

FIG. 9 is a cross-sectional view similar to FIG. 8 but of an alternate embodiment showing alignment of added subfloor plates to strategically function with subfloor sections of the invention;

FIG. 10 is a cross-sectional view of FIG. 9 and now showing position of added subfloor plates when attached to profile subfloor section;

FIG. 10A is an enlarged view of portion A shown in FIG. 10;

FIG. 11 is a top view of numerous profile subfloor sections, added subfloor plates, and common floor surface when assembled;

FIG. 11A-1 is a cross-sectional view along line AA of FIG. 11 and illustrating the invention when not yet reacting to floor surface impacts and so in an unloaded state;

FIG. 11A-2 is a cross-sectional view of that in FIG. 11A-1 but now illustrating the invention when reacting to floor surface impacts and in a loaded state;

FIG. 12 is a cross-sectional view similar to FIG. 8 but now of an alternate advantageous method of fabricating profile subfloor panels;

FIG. 13 is a cross-sectional view similar to FIG. 8 but now showing alignment of adjacent profile subfloor panels;

FIG. 14 is a cross-sectional view similar to FIG. 8 but now showing placement of substrate anchorage fasteners;

FIG. 15 is a top view of profile subfloor panels arranged in a preferred pattern;

FIG. 16 is a top view of added subfloor plates and common flooring surface as aligned and placed over profile subfloor panels as shown in FIG. 15; and,

FIG. 16A is a cross-sectional view of profile panels following line AA of FIG. 16.

DETAILED DESCRIPTION

A preferred embodiment of the invention will be described in detail with reference to the drawings wherein like referenced numerals represent like parts and assemblies throughout the several views. Reference to the preferred embodiment does not limit the scope of the invention.
In general, the present invention relates to a subfloor assembly located below a floor surface offering desired performance characteristics for active athletic applications. The following details explain how the inventor surprisingly discovered the need for, and then determined how to, create concentrated, aligned opposing pressure (preferably directly aligned) on resilient components thereby reducing required deflection of resilient material. This has the added, and unexpected, benefit of enabling the use of more dense and/or more fatigue resistant elastomers while still achieving desired flexibility. Never before possible this way have these two properties been able to both advance in the desired direction. Normally, these two properties move opposite each other such that, increasing one decreases the other, and vice versa. Now unlike before, with the inventive subfloor assembly configuration it achieves continued resiliency and can return to original profile thickness after years of repeated flexing and long term non-athletic loading and unloading (e.g., bleachers located on and off the floor, portable athletic equipment (basketball hoops, gymnastics, etc.) on and off the floor, and the like.
In reference to FIG. 1, the subfloor section 100 is made according to the present invention and is shown in the most desired manner in which a resilient blanket 101 is sandwiched between a lower profile panel 102 and an upper profile panel 103. In a preferred embodiment of the invention the resilient blanket 101, lower profile panel 102 and upper profile panel 103 each measure nominally 24″ wide and 96″ long, with the resilient blanket 101 measuring ¾″ thick manufactured of a hard rubber (as opposed to polyurethane foam currently in use and even open celled polyurethane foam of years prior) in a density that offers desired reaction to athletic impacts in both loaded and unloaded states. Alternatively, blanket 101 can preferably be recycled compressed hard rubber granule pad material. Resilient blanket 101 can be ⅜″ to 1″ thick, and preferably is ¾″ thick. Importantly, blanket 101 should have a measured density of about 6 PCF to 12 PCF (pounds per cubic foot, as determined by one of ordinary skill in the art using the athletic floor industry standard for measuring this parameter) and preferably about 8 PCF. Much differently, existing resilient blanket-like materials used in athletic floors are 12 PCF to 16 PCF. The lower profile panel 102 and upper profile panel 103 can be manufactured from ⅜″ plywood in a preferred embodiment of the invention. While likely understood, for clarity as used herein, 24″ means 24 inches, 96″ means 96 inches, ⅜″ means ⅜ inch, and any number or fraction X″ means that measurement X in inches (and its metric equivalent, though metric is not listed).
In reference to FIG. 2, the end view of the subfloor section 100 as shown in FIG. 1 further describes the profile panels 102 & 103 and resilient component 101 as illustrated when resting on a supporting substrate 104 which is most typically concrete. The upper profile panel 103 and lower profile panel 102 each include protruding ribs 105 in direct alignment with each other in a manner that effectively pinches the resilient blanket 101 from above and below when pressure is applied to the surface of the subfloor section 100. In a preferred embodiment of the invention, protruding ribs 105 are created by machined grooves 106 into the face of the upper and lower profile panels 103 & 102, generally along the upper axis (e.g., length dimension of the upper panel) and lower axis (e.g., length dimension of the lower panel). As previously described, the upper and lower profile panels 103 and 102 in a preferred embodiment of the invention measure nominally about ⅜″ thick×24″ wide (i.e., width dimension)×96″ long (i.e., length dimension), and include machined grooves 106 which are preferably about ⅛″ deep and 2″ wide spaced 4″ on center with outer grooves 106 located 2″ on center from outer side edges. Machined grooves 106 and consequent protruding ribs 105 can run continuously, or non-continuously in a series of island ribs (not shown but should be understood), from end to end of upper and lower profile panels 103 and 102. Components of subfloor section 100 are preferably connected with application of suitable adhesive where the resilient blanket 101 is in contact with protruding ribs 105 of the upper profile panel 103 and lower profile panel 102.
In other aspects, protruding ribs 105 can be from about 1″ wide to 4″ wide (preferably 2″ wide) and each rib is centered between opposing grooves 106 which can be, in inverse relative to the ribs, from about 4″ wide to 1″ wide (preferably 2″ wide). Upper and lower ribs 105 can be the same size and shape or different sizes and shapes from rib to rib, from groove to groove and top versus bottom (e.g., with one or more corner adjacent its outermost edge, or a curved outermost edge, or curved and straight portions). The depth or outward extension of outermost edge 105 a of rib 105 can be about 1/16″ plus or minus 50% of the outward extension from the inner most edge 106 a of grooves 106 on either side of each rib. While not a limitation, because plywood typically includes ⅛″ veneer layers, a machining depth of less than about ⅛″ is preferred to enable use of plywood panels without machining completely through outer ply's thereby better maintaining integrity of continuous ply layers.
In reference to FIG. 3, the end view of an alternate embodiment of the design shows a manner in which optional upper and lower profile panels 103 and 102 incorporate different profiling of machined grooves 106 to create protruding ribs 105 having an alternate shape as compared to the desired shape as shown in FIG. 2. There is no known limit to dimensions and shapes of protrusions 105 which remain within the scope of the disclosure when protruding ribs 105 of upper profile panels 103 and lower profile panels 102 are in vertical alignment when in contact with the resilient component 101. The subfloor section 100 in FIG. 3 also shows a resilient component 101 in a thinner profile thickness than illustrated in FIG. 2 to demonstrate that thicknesses other than the about ¾″ thickness described in the preferred embodiment can be provided while remaining within the scope of the disclosure.
In reference to FIG. 4, the view of multiple subfloor sections 100 are positioned for attachment of commonly installed wood flooring 107. Subfloor sections 100 are preferably placed as shown with ends offset by about 48″ in adjacent rows when provided in the preferred about 48″×96″ dimension.
In reference to FIG. 4A, the view following line A-A of FIG. 4 shows commonly installed wood flooring 107 which is secured to the upper profile panel 103 by typical mechanical flooring fasteners 108 such as steel cleats or staples. Wood flooring attachment is not limited to mechanical fasteners and can be provided instead with adhesive or other suitable means.
In reference to FIG. 5, the view of multiple subfloor sections 100 include added subfloor plates 109 and commonly attached wood flooring 107. In a preferred assembly of this alternate embodiment of the invention subfloor sections 100 are positioned diagonally to wood flooring 107 as shown with ends offset by about 48″ in alternate rows, and with plywood subfloor plates 109 measuring about ⅜″ thick by 48″ by 96″ set in a brick pattern with ends offset by 48″ in adjacent rows aligned diagonally to subfloor sections 100 and wood flooring 107.
In reference to FIG. 5A, the view of profile subfloor panels follows along line A-A of FIG. 5 showing the inclusion of an added subfloor plate 109, typically plywood or oriented strand board sheathing. The type of material used to provide added subfloor plates 109 is not limited to plywood and/or oriented strand board and can include other material such as composite wood, plastics, and other suitable panels which remain within the scope of the disclosure. Attachment of the added subfloor plate 109 to the upper profile panel 103 is accomplished with common staples and/or adhesive prior to wood flooring 107 attachment as provided by means of flooring fasteners 108 preferably penetrating the subfloor plate 109 and upper profile panel 103. More than one added subfloor plate layer can be provided if desired.
In reference to FIG. 6, the view of a typical subfloor section 100 shows an added subfloor plate 109 and optional floor surface 110. Added subfloor plates 109 and subfloor sections 100 are preferably arranged in the same manner as shown in FIG. 5 and attached by means of staples and adhesive. The most preferred optional floor surface 110 is a suitable rubber layer commonly associated with athletic floor applications. Other materials (i.e. cork, vinyl, urethane) that provide suitable surfaces for recreation, exercise, dance and sports activities are also acceptable.
In reference to FIG. 7, the view illustrates an alternate manner of capturing subfloor sections 100 together within the scope of the disclosure. A preferred overall dimension of the subfloor section 100 measures about 24″ wide by 96″ long with upper profile panel 103 and lower profile panel 102 composed of about ⅜″ plywood sheathing. Components are assembled together and captured in the alternate embodiment of the invention by means of three screw and post bindings 111 in each subfloor section 100. Three screw and binding posts 111 are aligned down the center parallel to the long edge of the subfloor section 100 with one located about 16″ in from each end and one at 48″ in from either end. Spacing and number of post bindings 111 are not limited and can vary while remaining within the scope of the disclosure.
In reference to FIG. 8, the view across the subfloor section 100 as shown in FIG. 7 better illustrates the manner in which components are captured when assembled. As provided in the invention, protruding ribs 105 from the underside of the upper profile panel 103 and from the top surface of the lower profile panel 102 are in direct opposing vertical alignment against the top and bottom of the resilient blanket 101. A preferred assembly when incorporating post bindings 111 includes about ¾″ thick by 11″ wide by 96″ long resilient blankets 101 to form a 2″ wide space 112 in the center of the 24″ wide subfloor section 100. The attachment assembly is further described in FIG. 8A.
In reference to FIG. 8A, the view taken from FIG. 8 above line A-A shows the position of a post binding 111 when containing the resilient blanket 101 between the lower and upper profile panels 102 and 103. Counterbored depressions 113 in the underside of the lower profile panel 102 and top side of the upper profile panel 103 provide desired clearance for end flanges of the post bindings 111 which holds all components in place when pressure is applied by tightening as required.
In reference to FIG. 9, the view shows alignment of 24″ wide subfloor plates 114 for strategic placement on to subfloor sections 100 which are positioned with about 1″ spaces between side edges. In a preferred assembly, the spaces between subfloor sections 100 creates about 25″ on center spacing of post binders 111, for desired alignment of 1″ spaces 115 between subfloor plates 114 where post binders 111 are located.
In reference to FIG. 10, the view shows position of added subfloor plates 114 when attached to profile subfloor sections 100. The attachment assembly is further shown in FIG. 10 A.
In reference to FIG. 10A, the view above line A-A of FIG. 10 shows the void 116 formed between subfloor plates 114 in strategic alignment with the post binder 111.
In reference to FIG. 11, the view of numerous profile subfloor sections 100 are shown with added subfloor plates 114 and wood flooring 107. Subfloor sections 100 and subfloor plates 114 are set in a staggered brick pattern with ends offset about 48″ in adjacent rows. Alignment of subfloor plates 114 allows for voids 116 above all post binders 111.
In reference to FIG. 11A-1, the view along line A-A of FIG. 11 shows the void 116 created between the top of the post binder 111 and underside of the wood flooring 107.
In reference to FIG. 11A-2, the view of FIG. 11A-1, it shows here allowable deflection of the wood flooring 107 when depressed above the post binder 111 as the surface is impacted and resilient blankets 101 are compressed.
In reference to FIG. 12, the view of an alternate method within the scope of the invention is shown as a manner to fabricate a subfloor section 100 for a manner of attachment to supporting substrates and desired full use of resources. Cutting of typical about 48″ wide plywood sheathing into nominal about 24½″ and 23½″ wide sections provides required dimensions with full resource use. This allows assembly of a wider about 24½″ section for the lower profile panel 102 and narrower 23½″ wide section for the upper profile panel 103, which when placed together form about ½″ shoulders 117 at each subfloor section end. Although the lower and upper profile panels 102 and 103 are not the same width, protruding ribs 105 remain in direct opposing vertical alignment in contact with resilient blankets 101 as per the scope of the invention.
In reference to FIG. 13, the view shows alignment of adjacent subfloor sections 100 with adjacent shoulders 117 spaced about ¼″ apart.
In reference to FIG. 14, placement of an anchorage fastener 118 is shown as penetrated into a typical concrete substrate 104. A steel washer 119 is included to soundly capture shoulders of adjacent subfloor sections 100.
In reference to FIG. 15, the view of subfloor sections 100 is shown in a desired arrangement with ends offset by about 48″ in adjacent rows and secured to the substrate with fasteners 118.
In reference to FIG. 16, a view of added subfloor plates 114 and wood flooring 107 are shown when added onto subfloor sections 100 as shown in FIG. 15. Subfloor plates 114 are preferably made from about ⅜″ thick by 48″ by 96″ plywood with about 1″ diameter circular voids 120 for strategic alignment over post binders 111. Subfloor plates 114 are preferably arranged with ends offset by 48″ in adjacent rows and spaced 1″ between side edges.
In reference to FIG. 16A, a view of a subfloor plate 114, and wood flooring 107 are shown along line A-A in FIG. 16. A circular void 120 is shown in alignment above the post binder 111 to allow space between the underside of the wood flooring 107 and top of the post binder 111. This allows desired downward movement of the wood flooring 107 and subfloor plate 114 when the resilient blanket 101 compresses while reacting to surface impacts.
In other aspects of the invention, having both an upper profile panel/batten and a lower profile panel/batten provides better subfloor assembly, and overall floor stability unlike ever before possible. For example, vapor barriers that are almost always included on the top of the concrete substrate typically include folds or wrinkles that create an uneven surface, as do heavier vapor barriers that include overlapped or taped joints. Additionally, supporting substrate 104 is not always smooth or exactly flat. Uneven support below the existing subfloor assemblies results in lower resiliency in some areas where resilient pads are pressed by elevations and unevenness in the substrate, or softer areas (“dead spots”) where pads are suspended because of low areas in the substrate or where raised spots act as fulcrum points below the elastomeric pad. The inclusion of both the bottom profile panel/batten and the top profile panel/batten of the invention addresses common substrate influences as described, to now assure the same pressure is applied on the resilient pads/blanket strips and subfloor assembly throughout. This also has the added benefit to achieve continued resiliency and help return the resilient material to original profile thickness after years of repeated flexing and long term athletic and non-athletic loading and unloading.
In yet other aspects, having lower and upper profile panels/battens requires a structure and method to capture the panels together in a limited yet moveable relationship. For example, in FIGS. 8, 8A, 11A-1, 11A-2, and 12, are seen such structures, and as they are described herein. Such adds to the challenge the inventor had to discover and develop for the inventive subfloor assembly configuration now possible. Further in this regard, the resilient member can be sandwiched between the upper protruding rib and the lower protruding rib and the subfloor assembly held together by a limit fastener, such as post bindings 111 and fasteners 118. In this way, the limit fastener results in (i) the upper profile panel being spaced from the lower profile panel a first distance when the subfloor assembly is in an unloaded state and (ii) the upper profile panel being spaced from the lower profile a second distance when the subfloor assembly is in a loaded state with the second distance being less than the first distance, and (iii) the upper profile panel instantly returning to the first distance when the subfloor assembly is in an unloaded state. Instantly returning means anything in the range of 0.1 to 0.5 second, all as needed to accommodate an active athletic playing surface.
Each and every document cited in this present application, including any cross referenced or related patent or application, is incorporated in this present application in its entirety by this reference, unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any embodiment disclosed in this present application or that it alone, or in any combination with any other reference or references, teaches, suggests, or discloses any such embodiment. Further, to the extent that any meaning or definition of a term in this present application conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this present application governs.
The present invention includes the description, examples, embodiments, and drawings disclosed; but it is not limited to such description, examples, embodiments, or drawings. As briefly described above, the reader should assume that features of one disclosed embodiment can also be applied to all other disclosed embodiments, unless expressly indicated to the contrary. Unless expressly indicated to the contrary, the numerical parameters set forth in the present application are approximations that can vary depending on the desired properties sought to be obtained by a person of ordinary skill in the art without undue experimentation using the teachings disclosed in the present application. Modifications and other embodiments will be apparent to a person of ordinary skill in the athletic floor arts, and all such modifications and other embodiments are intended and deemed to be within the scope of the present invention.

Claims

What is claimed is:

1. A subfloor assembly that supports a floor on a substrate, the subfloor assembly comprising:

a. an upper profile panel, a lower profile panel, and a resilient member positioned between the upper profile panel and the lower profile panel;

b. the upper profile panel having at least one upper protruding rib on an upper inner surface and extending along an upper axis of the upper profile panel, an upper groove on each side of the upper protruding rib on the upper inner surface and extending along the upper axis of the upper profile panel;

c. the lower profile panel having at least one lower protruding rib on a lower inner surface and extending along a lower axis of the lower profile panel, and a lower groove on each side of the lower protruding rib on the lower inner surface and extending along the lower axis of the lower profile panel; and,

d. the resilient member sandwiched between the upper protruding rib and the lower protruding rib and having a resilient elastic modulus that results in (i) the resilient member being spaced from the upper profile panel where the upper groove is located and spaced from the lower profile panel where the lower groove is located when the subfloor assembly is in an unloaded state and (ii) the resilient member deforming and in contact with the upper profile panel where the upper groove is located and in contact with the lower profile panel where the lower groove is located when the subfloor assembly is in a loaded state.

2. The subfloor assembly of claim 1, comprising at least two upper protruding ribs on the upper inner surface and each upper protruding rib extends toward the upper inner surface a same distance and forms a common upper inner surface defined by an endmost edge of each upper protruding rib.

3. The subfloor assembly of claim 1, wherein the endmost edge has a width and the width has at least a portion with a linear profile, a curved profile or a polygon profile.

4. The subfloor assembly of claim 1, comprising at least two lower protruding ribs on the lower inner surface and each lower protruding rib extends toward the lower inner surface a same distance and forms a common lower inner surface defined by an endmost edge of each lower protruding rib.

5. The subfloor assembly of claim 1, wherein the upper protruding rib has an upper rib width and the upper groove has an upper groove width, and the upper rib width is approximately equal to the upper groove width.

6. The subfloor assembly of claim 1, wherein the upper protruding rib has an upper rib width and the upper groove has an upper groove width, and the upper rib width is between 75% and 100% of the upper groove width.

7. The subfloor assembly of claim 1, wherein the upper protruding rib is disposed across from and a mirror image of the lower protruding rib.

8. The subfloor assembly of claim 1, wherein the upper protruding rib is disposed across from and a different shape than the lower protruding rib.

9. The subfloor assembly of claim 1, wherein the upper protruding rib has an upper rib width and the upper rib is disposed across from the lower protruding rib, the lower protruding rib having a lower rib width and the lower rib width is different than the upper rib width.

10. The subfloor assembly of claim 1, wherein the resilient member extends between at least two upper protruding ribs and at least two lower protruding ribs and is sandwiched between the respective upper protruding ribs and lower protruding ribs.

11. The subfloor assembly of claim 1, wherein the upper protruding rib extends toward the upper inner surface a distance less than an innermost edge of the inner surface.

12. The subfloor assembly of claim 1, wherein the lower protruding rib extends toward the lower inner surface a distance less than an innermost edge of the lower inner surface.

13. The subfloor assembly of claim 1, wherein the upper protruding rib extends toward the upper inner surface a distance approximately equal to an innermost edge of the inner surface.

14. A subfloor assembly that supports a floor on a substrate, the subfloor assembly comprising:

c. the lower profile panel having at least one lower protruding rib on a lower inner surface and extending along a lower axis of the lower profile panel, and a lower groove on each side of the lower protruding rib on the lower inner surface and extending along the lower axis of the lower profile panel;

d. the resilient member sandwiched between the upper protruding rib and the lower protruding rib and the subfloor assembly held together by a limit fastener that results in (i) the upper profile panel being spaced from the lower profile panel a first distance when the subfloor assembly is in an unloaded state and (ii) the upper profile panel being spaced from the lower profile a second distance when the subfloor assembly is in a loaded state with the second distance is less than the first distance, and (iii) the upper profile panel instantly returning to the first distance when the subfloor assembly is in an unloaded state.

15. The subfloor assembly of claim 14, wherein the limit fastener is movably secured to at least one of the upper profile panel and the lower profile panel and the limit fastener extends through the resilient member.

16. The subfloor assembly of claim 15, wherein the limit fastener is immovably secured to at least one of the upper profile panel and the lower profile panel.

17. The subfloor assembly of claim 14, wherein instantly is less than 0.5 second.

18. The subfloor assembly of claim 14, comprising multiple subfloor assemblies secured together and a floor on top of the subfloor assemblies.

19. A method for constructing a subfloor assembly that supports a floor on a substrate, the method comprising:

a. forming an upper profile panel having (i) at least one upper protruding rib on an upper inner surface and extending along an upper axis of the upper profile panel and (ii) an upper groove on each side of the upper protruding rib on the upper inner surface and extending along the upper axis of the upper profile panel;

b. forming a lower profile panel having (i) at least one lower protruding rib on a lower inner surface and extending along a lower axis of the lower profile panel and (ii) a lower groove on each side of the lower protruding rib on the lower inner surface and extending along the lower axis of the lower profile panel;

c. sandwiching a resilient member with and between the upper profile panel and the lower profile panel, the resilient member having a resilient elastic modulus and the upper profile panel being spaced from the lower profile panel a first distance in an unloaded state;

d. compressing the resilient member between at least one upper protruding rib opposing at least one lower protruding rib with a pair of substantially equal but opposite forces acting upon the resilient member between opposing ribs when the subfloor assembly is in a loaded state and thereby the upper profile panel and the lower profile panel being spaced from each other by a second distance, the second distance being less than the first distance; and,

e. relaxing the resilient member between opposing ribs when the subfloor assembly returns to the unloaded state and thereby the upper profile panel and the lower profile panel return to the first distance.