Note: Descriptions are shown in the official language in which they were submitted.
2166759
ANCHOREDJRESILIENT HARDWOOD FLOOR SYSTEM
Field of the Invention
This invention relates to hardwood floor
systems. More particularly, this invention relates to an
anchored and resilient sleeper for a hardwood floor
system.
Background of the Invention
Floor systems, particularly hardwood floor
systems, are commonly supported by sleepers. Sleepers are
elongated nailing members, often of wood, laid end to end
in parallel rows to form a subfloor layer for supporting
a layer of floorboards secured thereabove. The sleepers
may be relatively narrow and spaced from each other, or
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the sleepers may be relatively broad with edges of
adjacent rows in abutting relationship. If desired, one
or more subf loor layers may be used between the wear layer
and the sleepers. The sleepers support the other floor
components above a base.
One recognized advantage of supporting a floor
system with sleepers relates to moisture susceptibility.
The components of most floor systems are made of wood.
Humidity changes from season to season cause wooden
components of floor systems, and particularly an upper
layer of floorboards, to expand with moisture intake and
contract with moisture expulsion. Because sleepers
support these other components above the base, the
sleepers limit moisture transfer between the base and
these other components. Moreover, if the sleepers are
narrow and spaced away from each other, the free space
between the supported components and the base enables air
to circulate air therebetween to minimize moisture
transfer.
Because moisture-caused expansion and
contraction of floor system components may result in
buckling, it is desirable to securely anchor the floor
system, particularly the sleepers, to the base below.
Anchoring of the sleepers provides an acceptable level of
dimensional stability for the floor system, compared to a
floor system wherein the sleepers are unanchored.
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It is also desirable for hardwood floor systems
to provide a degree of resilience. In the context of this
application, resilience generally means the ability of a
floor system to absorb shock upon impact and to deflect
downwardly upon impact. Particularly for hardwood floors
used in athletic contests, the resilience of the floor
system may play a major role in reducing the incidence of
athletic injury. In short, if a floor provides some
degree of give, the stress placed upon the musculoskeletal
structure of the athlete is reduced.
It is common practice to provide resiliency for
a floor system by locating compressible pads below the
sleepers. The compressibility of the pad enables the
sleepers and the floorboards thereabove to deflect
downwardly. The amount of downward deflection and the
shock absorption of the floor system will depend upon a
number of factors, including the shape and composition of
the pads.
Recent studies indicate that, while resiliency
is important to the reduction of susceptibility to
athletic injury, uniformity in resiliency is also
critical. Thus, it is desirable to provide a floor system
with a high degree of resiliency which is also uniform
throughout its surface area.
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Unfortunately, it has proved difficult to
achieve dimensional stability, optimum resiliency and
uniformity in resiliency for hardwood floors supported by
sleepers. The enhancing of one of these two features
commonly adversely affects the other. For instance, when
sleepers are supported above the base by a plurality of
compressible pads and the sleepers are fastened to the
base, direct fastening of the sleeper produces some
initial compression, or precompression of the pads which
is greater than the normal compression due to gravity from
the components located thereabove. The pads remain
compressed to this state throughout the life of the floor,
even when the floor is unloaded.
Because of this already compressed state, the
capability of the pads for further deflection is
inhibited, and the overall resiliency of the floor system
is greatly reduced. Another disadvantage results from
this excess precompression. Because an excessive
percentage of the compressibility is "used up", the floor
has a higher chance of "bottoming out" or deflecting to
its maximum, upon impact from above. This occurs when the
pads compress maximally to a state where the floorboards
deflect into contact with the rigid fasteners. On the
other hand, if the floor system is free-floating, i.e. the
sleepers are not anchored securely to the base, the entire
floor system may be dimensionally unstable.
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While some commercially available floor systems
have achieved some degree of success in addressing one or
more of these concerns, such floor systems tend to have a
relatively high cost due to an increase in the number or
complexity of structural components required for achieving
these features and the increased costs associated with
shipping and installing these components. As a result,
the benefits of these floor systems have been limited
unnecessarily to a relatively low number of users.
It is an objective of this invention to achieve
optimum dimensional stability and optimum resiliency and
uniformity of resiliency for a hardwood floor system.
It is another objective of this invention to
substantially improve resiliency and dimensional stability
for a relatively low cost hardwood floor system.
It is still another objective of this invention
to enhance the dimensional stability of a hardwood floor
system without producing a corresponding loss of
resiliency, or loss in uniformity of resiliency.
The objectives of this invention are achieved
by a sleeper construction which utilizes an attachment or
nailing member supported by compressible pads above a base
and a fastening arrangement which secures the attachment
members directly to the base without interacting with the
pads. This fastening arrangement enables the attachment
members to deflect downwardly upon impact to upper floor
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layers but restricts upward raising of the attachment
members beyond the initial static position of the pads.
More importantly, this fastening arrangement enables the
attachment members to be anchored to the base in a manner
which does not precompress the pads when the floor system
is unloaded. Thus, this anchored/resilient sleeper
provides optimum dimensional stability and resiliency.
Because the manner of anchoring the attachment
members does not precompress the pads or hold them in a
precompressed state, i.e. beyond the normal weight bearing
compression due to components located thereabove, an even
distribution of the compressible pads along the attachment
members will assure a uniformly resilient, yet firmly
anchored, floor system.
Additionally, because of its simplicity and
relatively few number of parts, the embodiments of this
invention provide anchoring, resiliency and uniformity in
resiliency for a sleeper-type floor system at a low cost.
Fabrication and installation of the attachment members is
also simplified. Finally, because the fastening
arrangement provides secured anchoring, the lengths of the
attachment members may be increased if narrow, spaced
attachment members are used. As a result, less waste is
produced and shipping, handling and installation costs are
reduced.
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According to one preferred embodiment of the
invention, a fastener construction is utilized which may
be of one, two or three piece construction. With this
embodiment, each attachment or nailing member has at least
one vertical bore extending from an upper surface to a
lower surface thereof. At least one compressible pad is
secured to the lower surface. The vertical bore includes
an enlarged-diameter upper portion and a reduced-diameter
lower portion.
The three piece construction includes a sleeve,
a washer and the fastener. The sleeve resides within the
lower, reduced-diameter portion, with the bottom edge of
the sleeve contacting the base and the top edge of the
sleeve residing adjacent the upper portion of the bore.
The washer resides on top of the sleeve, in alignment
therewith, and the fastener extends therethrough.
According to a second variation of this first
preferred embodiment of the invention, the sleeve includes
an upper flange, and no washer is necessary. For both
variations, a fastener extends downwardly through the
flange, through the sleeve and into the base. An enlarged
head at the top of the fastening pin engages and holds the
washer or the flange against the bottom surface of the
upper portion of the bore.
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According to a third variation of the
invention, the fastener arrangement may comprise a single
anchor pin with an enlarged top end, or head, having a
diameter greater than the bore lower portion but less than
the bore upper portion, a bottom end to be driven into the
base and a depth stop located between the top and bottom
ends. The depth stop feature may not be necessary for
some installations. The vertical distance between the
depth stop and the top end is approximately equal to the
combined vertical dimension of the attachment member and
the pad.
For all three variations, because the outer
diameter of the sleeve or fastener is less than the
diameter of the reduced-diameter lower portion of the
bore, upon impact from above the attachment member may
deflect downwardly in an unimpeded manner. The combined
vertical dimension of the: 1) sleeve and the washer
(first variation); 2) the sleeve with flange (second
variation); or 3) the non-embedded portion of the fastener
(third variation), is equal to the combined vertical
dimension of the pad and the lower portion of the bores.
Thus, for all three variations, the structure provides a
solid line of rigid material between its top end and the
base, so that downward driving forces applied
via the fastening pin do not precompress the pads.
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Preferably, the vertical dimension between the
top of the fastening pin and the upper surface of the
nailing member is greater than the maximum compression of
the pads. This ensures that, upon downward deflection of
the nailing members, the fastening pin will not project
above the upper surface of the nailing member to contact
an above-subfloor or floorboard layer.
To produce this structure, the nailing members
are cut to a desired length and to a desired width, which
may be relatively narrow or relatively broad, depending
upon the type of floor system. The bores are then cut
vertically through the nailing members from the upper
surface to the lower surface. Thereafter, the
compressible pads are secured to the lower surface of the
nailing member. The number of pads and bores will depend
upon the lengths and widths of the nailing members and the
desired orientation. With the bores cut and the pads
secured, the sleepers are ready for shipping to the job
site. Alternately, if desired, these two latter steps may
be performed at the job site.
To install this structure, multiple nailing
members are laid end to end in parallel rows, with the
spacing between the rows dependent upon the widths of the
nailing members, and also dependent on whether any open
space is necessary between adjacent rows. The pads
support the members above the base. If the nailing
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members are panel-type, there will be some spacing between
adjacent rows. If desired, every other nailing member in
each row may be offset laterally. If using the first or
second variation, the sleeves and washers, or sleeves with
flanges, are then placed within the bores. Subsequently,
fastening pins are driven through the sleeves, or through
the sleeve and washer, and then into the base below. For
the third variation, the fasteners are driven into the
base without prior placement of the sleeves and/or
washers.
Alternatively, holes may initially drilled into
the base, as by extending a drill bit through the bores,
and then the fastening pins may be driven into the drilled
holes. This eliminates the possibility of cracking of the
base, which may occur upon impact when pre-drilled holes
are not used. When fully extended, the head ends of the
fastening pins engage either the top surfaces of the
washers, the top surfaces of the flanges or the nailing
member itself, depending upon which construction is used.
In this manner, the heads of the fastening pins hold the
bottoms of the counterbores in the nailing members.
Because the sleeve and washer, the sleeve with
the flange, or the fastener alone, does not compress
vertically during installation, the fastener structure
bears all the vertical force during installation. As a
result, driving of the fasteners into the base does not
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vertically compress the pads. Moreover, after
installation, when the floor system is unloaded, the pads
are not held in a compressed state, i.e. beyond the
compression due to normal weight bearing of components
thereabove. Accordingly, after installation, the
compressible pads retain their maximum compressive
capability, thereby providing optimum resiliency potential
throughout the floor system.
With the single piece anchor pin construction,
after drilling the holes in the base, the anchor pins are
extended through the bores and driven directly into the
holes in the base to achieve secured engagement therein.
The depth stops limit downward movement of the anchor pins
to position the top ends thereof at a predetermined
vertical distance above the base, this predetermined
distance being equal to the combined vertical dimension of
the pads and the lower portions of the bores of the
attachment members.
The upper flooring layers are then secured to
the tops of the nailing members. According to one
preferred construction, at least one subfloor of panels is
secured to the relatively narrow nailing members, and then
tongue-and-groove maple floorboards are secured to the
uppermost layer of panels. Because of the combination of
anchored and resilient nailing members, along with the one
or more layers of panels, this particular floor
2166759
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construction provides resiliency with a high degree of
uniformity throughout its entire surface area. As
indicated previously, recent studies suggest that, in
addition to resiliency, uniformity of resiliency also
plays a critical role in reducing athletic injury on
athletic floor systems and enhancing performance.
Alternatively, the floorboards may be secured
directly to the nailing members. This embodiment may be
desirable if only one subfloor layer of wide, panel-type
nailing members is utilized, or even if one layer of
relatively narrow, spaced rows of attachment members is
used. As still another alternative, if desired, the upper
flooring layer may comprise one or more wood or non-wooden
layers, depending upon the primary commercial use of the
floor system.
Because of the relatively few number of parts
and simple construction, this inventive structure
provides conventional stability, resiliency and uniformity
in resiliency for a hardwood floor system at a relatively
low cost, compared to prior anchored and resilient
sleeper-type floor systems.
Additionally, with the third variation of the
invention, an already installed free floating floor or an
anchored floor supported on resilient pads may be easily
retrofitted or repaired to securely anchor the attachment
2166759
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members to the base in a manner which accomodates downward
deflection but no vertical raising.
The invention contemplates several additional
features applicable to all of the embodiments, such as
"slicing" the attachment members horizontally to use a
stacked or two-component attachment member. This
eliminates the need to mill a two diameter bore, and it
also provides an additional degree of versatility in
constructing and arranging the subfloor.
These and other features of the invention will
be more readily understood in view of the following
detailed description and the drawings.
Brief Description of the Drawings
Fig. 1 is a plan view which illustrates a
hardwood floor system according to a first preferred
embodiment of the invention, wherein the attachment
members are relatively narrow.
Fig. 2A is a disassembled perspective showing
the fastener arrangement for a hardwood floor system
constructed in accordance with a first preferred
embodiment of the invention.
Fig. 2B is a cross-sectional view taken along
lines 2B-2B of Fig. 1.
Fig. 2C is an elevational view which depicts a
two-piece variation of the fastener arrangement.
2166759
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Fig. 2D is a cross-sectional view, similar to
Fig. 2B, showing another variation of the first preferred
embodiment of the invention, a one-piece fastener
arrangement.
Fig. 3A is a perspective view which depicts an
alternative embodiment of the invention which is
particularly suitable for a floor with a relatively narrow
attachment member.
Fig. 3B is a cross-sectional view taken along
lines 3B-3B of Fig. 3A.
Fig. 4A is a perspective view which depicts
another alternative embodiment of the invention which is
particularly suitable for use with relatively narrow
attachment members.
Fig. 4B is a cross-sectional view which depicts
still another alternative embodiment of the invention
which is particularly suitable for relatively narrow
attachment members.
Fig. 5 is a plan view, similar to Fig. 1, which
illustrates a hardwood floor system according to a second
preferred embodiment of the invention, wherein the
attachment members are relatively broad.
Fig. 6 is a disassembled perspective, similar
to Fig. 2A, showing the anchoring means for a hardwood
floor system constructed in accordance with a second
preferred embodiment of the invention.
2166759
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Fig. 7 is a cross-sectional view, similar to
Fig. 2B, of the hardwood floor system shown in Figs. 5 and
6.
Fig. 8 is a cross-sectional view, similar to
Figs. 2B and 7, which depicts a single piece fastening
arrangement for anchoring the attachment members to a
base, in accordance with a variation of the invention
applicable to the other embodiments.
Fig. 9 is a cross-sectional view, similar to
Fig. 8, which shows another feature of the invention which
is applicable to all of the embodiments.
Fig. 10 is a transverse cross-sectional view,
similar to Fig. 8, which shows a single piece fastener
arrangement in combination with an attachment member which
comprises two separate, layered pieces, another feature
which is applicable to all of the embodiments.
Figs. 10A is transverse cross-sectional view
which shows another subfloor structure which may be used
with the single piece fastening arrangement, separate
layered pieces of different dimension.
Fig. lOB is a bottom view of the subfloor
structure of Fig. 10A.
21667 59
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Fig. 11 is a plan view which shows yet another
version of the single piece fastening arrangement shown in
Fig. 8.
Fig. 12 is a cross-section taken along lines
12-12 of Fig. 11.
Fig. 13 shows still another embodiment of this
invention, a single piece fastener arrangement for
anchoring a resilient permanent floor system in a manner
which allows the floor system to be removed, similar to a
portable floor system.
Detailed Description of the Drawings
Fig. 1 is a plan view which depicts, in
section, a hardwood floor system 10 in accordance with a
first preferred embodiment of the invention. The floor
system 10 includes a plurality of floorboards 12 (Section
I), an upper subfloor comprising a layer 14 of panels
underlying and supporting the floorboards 12 (Section II),
a plurality of nailing or attachment members 16 laid end
to end in parallel rows to support the nailing or
attachment members 16 above a base 20 (Section III). The
construction of this floor system 10 generally includes
the pads 18, the nailing members 16 and the structural
components which anchor the nailing members 16 to the base
20.
2166759
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Typically, for athletic floors, the floorboards
12 are tongue and groove maple floorboards, as is well
known in the industry. If desired, the floorboards 12 may
have kerfs in their bottom surfaces. Kerfing the
floorboards 12 provides breaks or discontinuities in the
floor system 10 which will effect the impact response
frequency and impact deflection attenuation within a
reduced surface area. The floorboards 12 are secured by
nails (as in Fig. 3) to the subfloor layer 14. The
subfloor layer 14 is preferably formed from a plurality of
4' x 8' plywood panels having a uniform thickness of about
1/2 inch. The nailing members 16 depicted in Fig. 1 are
wood, with cross sectional height and width dimensions of
about 1-1/2" and 2-1/2", respectively, and a length of
either 4 feet or 8 feet. In the past, the spacing for the
parallel rows of this type of nailing member 16 has been
about 12", although it is to be understood that the
spacing may vary depending upon the widths of the nailing
members 16. If the nailing members 16 have a greater
width, and/or are panel-type, there may be relatively
little spacing between adjacent rows.
According to one aspect of the invention, the
lengths of the nailing members 16 of the type shown in
Fig. 1 may be increased to about 8' and the spacing
between the rows of nailing strips 16 may be increased to
about 15" to 17". The pads 18 shown in Figs. 1 and 2 are
CA 02166759 2006-03-06
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described in applicant's issued U.S. Patent No.
5,377,471 entitled "Prefabricated Sleeper For Anchored
and Resilient Hardwood Floor System". However, it is
also to be understood that the advantageous features
of this invention could be achieved with any one of a
number of pad types, as long as the pads 18 support
the nailing members 16 in spaced relation above base
20, and so long as the pads 18 are compressible.
The primary feature of the invention relates to
anchoring the nailing members 16 to the base 20 in a
manner which permits downward deflection and prevents
vertical raising but does not substantially precompress
the pads 18 during unloaded conditions. Because the
nailing members 16 are downwardly deflectable but not
vertically raisable, the floorboards 12 and the subfloor
layer 14, or any alternative upper flooring layer
supported by the nailing members 16, are also downwardly
deflectable but not vertically raisable.
To accomplish these features, each nailing
member 16 has at least one bore 22 extending vertically
therethrough from an upper surface 24 to a lower surface
25, as shown in Fig. 2A and Fig. 2B. Each bore 22 has an
enlarged-diameter upper portion 27 and a reduced-diameter
lower portion 28. Upper portion 27 has a preferable
diameter of about 1-1/8", and lower portion 28 has a
2166759
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preferable diameter of 5/8". Preferably, the vertical
dimension of the upper portion 28 is about 1/2"-3/4", and
the vertical dimension of the lower portion is about 3/4"-
1". Preferably, the bores 22 are spaced laterally away
from the pads 18, though this is not critical or
necessary.
For a thin nailing member 16 which is 4' long,
it is preferable to use two bores 22, with the nailing
member 16 supported by five pads spaced equidistantly
along the entire length of the nailing member 16. For a
nailing member which is 8' in length, it is preferable to
utilize three bores 22, with nine pads spaced
equidistantly along the length of the nailing strip 16.
However, it is also to be understood that the number of
bores 22 and/or pads 18 may be varied and reoriented,
depending upon the use of the floor system 10 and the
structural composition of the upper subfloor layer or
layers. More particularly, if the nailing members 16 are
panel-type, with a width of up to four feet, each nailing
member 16 may include up to four rows of bores 22 and pads
18.
To anchor the nailing members 16 to the base
20, according to a first variation of the first preferred
embodiment, as shown in Fig. 2B, a sleeve 30 is located
within the reduced-diameter lower portion 28 of each of
the bores 22. The sleeve 30 has a bottom edge 32 which
2166759
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contacts the base 20 and a top edge 33 located adjacent
the enlarged-diameter upper portion 27. The outer
diameter of the sleeve 30 is preferably about 9/16", so
that the nailing member 16 may deflect downwardly without
frictionally engaging the sleeve 30. A washer 35 rests
upon the top edge 33 of the sleeve 30. The washer 35 is
coaxial with the sleeve 30, and a peripheral portion of
the washer 35 rests upon a horizontal surface 36 of the
nailing member 16 which defines the bottom of upper
portion 27. The washer 35 has an inner diameter which is
less than the diameter of the sleeve 30 and greater than
the diameter of the anchor pin 40.
According to a second variation of this
embodiment, as shown in Fig. 2C, the sleeve 30 includes an
integrally-formed upper flange 37 at the top end thereof.
The combined vertical dimension of the sleeve 30 with the
flange 37, or the sleeve 30 and the washer 35, is
substantially equal to the combined vertical dimension of
the pad 18 and the lower portion 28.
For either embodiment, a fastening pin 40
extends downwardly through sleeve 30 and into the base 20,
as shown in Fig. 2B. Pin 40 has an enlarged head 41 at a
top end thereof which tightly engages and holds the washer
35, or the sleeve 30 and the flange 37, against surface
36, thereby tightly securing the bottom edge 32 of the
sleeve against the base 20. In this position, the head 41
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of the pin 40 prevents upward movement of the sleeve 30
and the washer 35, or the flange 37. The pin 40 also
cooperates with the washer 35 or the sleeve 30 and the
flange 37 to hold the nailing member 16 in a secured,
anchored position with respect to the base 20, so that the
nailing member 16 cannot raise upwardly therefrom.
Additionally, due to the relative diameter of the sleeve
30 with respect to lower portion 28, and due to the
compressibility of the pads 18, the nailing members 16 are
downwardly deflectable upon impact to the floorboards 12.
Anchoring of the nailing members 16 with the
pin 40 and sleeve 30 combination provides dimensional
stability for the nailing members 16 and the entire floor
system 10. The downward deflectability of the nailing
members 16 also provides resiliency for the entire floor
system 10. In addition, this invention optimizes the
resiliency of the compressible pads that are utilized.
The interrelationship of the bore 22, the washer 35, the
sleeve 30 and the surface 36 anchors the nailing members
16 in a manner which does not hold the pads 18 in a
precompressed state when the floor system 10 is unloaded.
Finally, because of the uniform distribution of the pads
18 and the pins 40, the floor system 10 is highly uniform
in resilient response characteristics.
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To further enhance the ability of the floor
system 10 to withstand horizontal movement due to moisture
intake or egress, the diameters of the bores 22 may be
oversized with respect to the sleeve 30.
During installation, the sleeve 30 and the
washer 35, or the sleeve 30 and the flange 37, bear the
downward compressive force applied when the pin 40 is
driven vertically downward. The pads 18 are sufficiently
isolated from the downward force so that they are not
precompressed. As a result, the floor system 10 provides
optimum resiliency characteristics for whatever type of
compressible pad is used.
Fig. 2D shows another variation, a more basic
approach which contemplates a one-piece fastener
structure, as opposed to a two-piece or three-piece
construction. With this approach, the fastener 40a alone
extends through the attachment member 16. Preferably, the
fastener 40c does not bear against the attachment member
16 within the lower portion of the bore 28.
To manufacture an anchored/resilient sleeper
according to the invention, the nailing members 16 are cut
to the desired height, width and length dimensions. As
indicated previously, if narrow sleepers are desired, the
nailing members 16 may be cut in 4', 8' or even 12'
lengths. Several benefits are achieved with these longer
lengths. The amount of wasted material is reduced, and
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shipping, handling and installation costs are decreased.
The bores 22 are then cut vertically through the nailing
members 16, from upper surface 24 to lower surface 25, and
the pads 18 are secured to the lower surface 25. The pads
18 may be adhered by gluing or mechanically fastened by
stapling.
At the job site, the nailing members 16 are
laid end-to-end in parallel rows, preferably with
staggered ends and with the pads 18 contacting the base
20. Due to the anchored, dimensional stability provided
by the pins 40 and the sleeves 30, the spacing between the
rows of attachment members 16 may be increased from the
prior commonly used dimension of 12" up to about 15", or
even 18" or 24", or possibly higher, if a subfloor layer
of panels 14 is also used. As a result of this increased
spacing, the cost of the nailing members 16 per unit
surface area of the floor is reduced.
With the nailing members 16 in place, the
sleeves 30 are placed within the bores 22. The washers 35
may then be placed on the top edges 33 of the sleeves 30.
If sleeves 30 with flanges 37 are used, no washers 35 are
necessary. The pins 40 are then extended through the
sleeves 30 and driven into the base 20. This latter step
may be performed with a nail gun or manually. As
mentioned previously, holes in the base 20 may be
predrilled, prior to driving the pins 40. When driven in,
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the heads 41 of the pins 40 engage the washers 35, or the
flanges 37, thereby causing the washers 35 or flanges 37
to tightly engage the horizontal surfaces 36 and causing
the bottom edges 32 of the sleeves 36 to engage the base
20 firmly and anchor the na i 1 ing member 16 to the base 20.
In this position, the washers 35 or flanges 37
prevent vertical raising of the nailing members 16, and
the relative diameters of the sleeves 30 and the lower
portions 28, along with the compressibility of the pads
18, enable the nailing members 16 to deflect downwardly
upon impact from above. Moreover, the pads 18 are neither
precompressed during installation nor held in a
precompressed state as a result of installation. Rather,
the pads 18 are held between the nailing members 16 and
the base 20 in a substantially uncompressed state. Thus,
the floor system 10 allows optimum resilient performance
for the pads 18, regardless of the type of compressible
pad that is used.
After installation of the nailing members 16,
the upper layer 14 of panels may be secured thereto. A
layer of floorboards 12 is then secured to the subfloor
layer 14 of panels. Because the vertical distance between
the top of pin 40 and the top of the nailing member 16 is
greater than the maximum vertical compression of the pads
18, the pin 40 cannot contact the bottom of the subfloor
layer 14 when force is applied from above, even under very
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heavy loads. This prevents "bottoming out" of the floor
system 10 upon impact, thereby avoiding interference by
the anchor pins 40 with the action of the floor system 10.
This invention also contemplates alternative
structures and methods for providing a resilient and
anchored attachment strip suppor=ted by compressible pads
held in a substantially noncompressed state when unloaded.
One such alternative is shown in Fig. 4A and involves the
use of predetermined lengths of a semi-rigid, but
flexible, member 50, such as mesh, graphite tissue, film
glass or wire mesh wrapped around the relatively narrow
nailing strips 16 and pads 18.
According to this embodiment, a central portion
52 of each of the lengths 50 of mesh spring steel is
adhered or mechanically fastened to the base 20 in an
orientation which is perpendicular to the direction of the
nailing strips 16. The nailing strip 16 is then laid upon
the base 20 with each of the compressible pads 18
supported on a centrally-adhered portion 52 of one of the
lengths 50 of mesh spring steel. Opposite ends of the
members 50 are then wrapped snugly around the nailing
strip 16 and secured in place by one or more nails or
staples 58 and/or adhesive driven into the upper surface
24 of the nailing strip 16.
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When wrapping the member 50 around the pad 18
and the nailing strip 16, care must be taken to assure
that the pads 18 will not be held therebetween in a
compressed state. Although the pads 18 may become
compressed somewhat during driving of the staples or nails
to secure the wrapped ends of the member 50, the pads 18
will be able to rebound immediately thereafter, before the
upper floor system components are secured to the nailing
strips 16. In short, the pads 18 will allow downward
deflectability, and the snugness of the secured members 50
will prevent upward raising, but the pads 18 will not be
held in a precompressed state when the floor system 10 is
unloaded.
Although this alternative embodiment of the
invention has been described with respect to a member 50
of mesh spring steel, it is also to be understood that
other flexible, high strength material would also prove
suitable. Also, the mesh may be located away from the
pads 18.
According to another embodiment of the
invention, as shown in Figs. 3A and 3B, the attachment
strips 16 are held to the base 20 by a plurality of spaced
clips 60. Each of the clips 60 has a first section 61
spaced from a second section 62, with a rigid section 63
located therebetween. Preferably, first and second
sections 61 and 62 are parallel with each other. First
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section 61 is fastened to the base 20 by a pin 66, or by
adhesive. The second section 62 contacts a top surface of
the attachment strip 16, but is positioned within a recess
or notch 68 in the upper surface 24 of the attachment
strip 16. One clip 60 is used for each notch 68. The
vertical dimension of the rigid third section 62 is equal
to the vertical dimension of the pad 18 plus the vertical
dimension of the attachment strip 16 at the notch 68.
Preferably, the depth of the notch 68 is greater than the
vertical compressibility of the pads 18 so that the floor
system 10 will not bottom out under heavy loads.
Preferably, as shown in Fig. 3A, every other clip 60 is
located on an opposite side of the attachment strip 16.
According to still another alternative
embodiment of the invention, as shown in Fig. 4B, the
attachment strips 16 are held to the base 20 by a
plurality of overlying, transversely oriented bands 70.
Preferably, the bands 20 are metal, though other materials
would also work. On opposite sides of the attachment
strip 16, the bands 70 are fastened to the base 20 by pins
72. The bands 70 are fastened in such a manner that the
attachment strips 16 may deflect downwardly upon impact,
but are not permitted to raise upwardly beyond the initial
static position of the floor system 10.
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If desired, the bands may extend all the way
across the surface area to be covered by the floor system
10. According to this variation, the bands 70 would
extend across the tops of all of the attachment strips 16
of the floor system 10.
For all of the above-described embodiments, the
attachment strips 16 are held to the base 20 in a manner
which permits downward deflection, but prevents upward
movement beyond the initial static position of the pads 18
when the floor system 10 is unloaded. Additionally, for
all of the embodiments, the attachment strips 16 are held
to the base 20 at spaced, predetermined locations along
the lengths thereof, and in a manner which does not result
in a holding of the pads 18 in a precompressed condition.
Fig. 5, 6, and 7 show a floor system
constructed in accordance with a second preferred
embodiment of the invention. More specifically, Fig. 5
shows floorboards 112 overlying and secured directly to
sleepers, or attachment strips 116, which are supported
above the base 120 by pads 18. Figs. 6 and 7 show
additional details of this floor system. In this
embodiment, the attachment members 116 are laid end to end
in parallel rows with edges of adjacent rows closely
spaced so that the attachment members 116 act as a
subfloor layer of panels. This embodiment provides a
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stable anchored and resilient floor system at a relatively
low cost and with a relatively low profile.
Fig. 8 shows a variation of the invention
applicable to the other embodiments. In this variation,
the fastener arrangement, or anchoring means, comprises a
single-piece anchor pin 140 with a head 141 at a top end
thereof, a bottom end 142 adapted to be driven into the
base 120 and a depth stop 143 located therebetween. The
depth stop 143 is oversized with respect to a predrilled
hole 144 in the base 20, thereby to limit downward
movement of the anchor pin 140 and to secure the head 141
a predetermined vertical distance 160 above the base 120.
In effect, with this variation the depth stop 143 serves
the same purpose as the sleeve in the two-piece and three-
piece arrangements, by limiting downward movement during
installation. As with the other embodiments, for this
embodiment the predetermined distance 160 is approximately
equal to the combined vertical dimension of the lower
portion 128 of the bore 122 and the pads 118 when in an
uncompressed state. Preferably, the anchor pin 140 has an
expansion curve 148 located adjacent the bottom end 142 to
enhance securement to the base 120.
For all of the fastener arrangements of this
invention, frictional engagement between the lower
subfloor and the fasteners or anchoring pin 140 may be
reduced by using a cylindrical lubricating sleeve 180,
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therebetween, as shown in Fig. 9. This sleeve 180 may be
of teflon or any other low-friction material. The sleeve
180 may also include an upper flange (not shown).
Applicant has used a teflon sleeve 180 with side walls
having a thickness of 0.08". Alternatively, a liquid
lubricant may be applied between the anchor pin 140 and
the inside surface of the lower portion 128 of the bore.
This reduction in friction reduces squeaks in the floor
system 110 during downward deflection.
The one-piece fastener construction simplifies
the structure and installment needed to anchor a resilient
floor system in the manner desired, i.e., with the upper
surface layer 112 and the subfloor 116 downwardly
deflectable but prevented from raising upwardly. This
variation eliminates the step of placing a flanged sleeve
or a sleeve and washer in the bores 122 prior to driving
the fastening members 140.
Another advantage that results from this one-
piece fastening arrangement relates to reduced
installation costs. If desired, regardless of the length
and width dimensions of the attachment members 116, the
upper portions 127 of the bores 122 may be predrilled at
the factory in an upper portion 116a of each attachment
member 116. This eliminates the need to perform this
labor step at the job site. The lower portions 128 of the
bores 122 could then be drilled in a lower portion 116b of
2166759
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each of the attachment members 116, simultaneously with
drilling of the base 120. In Fig. 8, the upper portion
116a and the lower portion 116b are defined by horizontal
line 211.
Additionally, if desired, the attachment
members can actually include two separate layers or pieces
which are stacked and then fastened together at the job
site. This is demonstrated in Figure 10, wherein the
portion 116a residing above line 211 is separately formed
as a top piece and the portion 116b residing below line
211 is separately formed as a bottom piece. In this
manner, each of these two separate layers 116a and 116b
may be predrilled at the factory. At the job site, the
layers 116a and 116b are stacked in alignment and then
fastened along line 211, as by adhesive staples,
mechanical fastener, etc., to form a composite attachment
member 116 with a plurality of two portion bores 122
formed therethrough. This feature of a dual component,
"stacked" attachment member is also applicable to the
embodiments shown in Figs. 3A, 3B, 4A and 4B.
Figs. 10A and 10B depict another variation of
this embodiment of the invention. According to this
variation, the subfloor 216 comprises an upper layer 216a
of panels supported by a lower layer 216b of spaced rails.
The upper portions 227 of the bores 222 are formed in the
panels, preferably at the factory, while the lower
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portions 228 of the bores 222 may be either predrilled at
the factory or formed simultaneously with forming the
holes 244 in the base 220, prior to driving of the anchor
pins 240 therein.
This structure also eliminates the labor costs
associated with drilling multiple two portion bores 222
through the subfloor 216 at the job site. Additionally,
the use of an upper layer 216a of panels and a lower layer
216b of spaced rails provides some open volume 205 between
the upper layer 216a of panels and the base 220, a feature
which promotes drying out of the floor 210 if moisture
problems happen to arise.
Figs. 11 and 12 show a further variation of the
floor system shown in Figs. 10, 10A and lOB. More
specifically, Fig. 11 shows a subfloor 216 which comprises
an upper layer 216a of panels and a lower layer 216b of
spaced rails. In each row of panels, adjacent panels have
the standard industry spacing required for panel-type
subfloors, i.e., 1/4-3/4 inch. Adjacently situated rows
of panels are spaced away from each other by a distance
designated 206, a predetermined distance which is
preferably in the range of about 4-12 inches. This
distance is slightly exaggerated in Fig. 11. Also, the
joints of the adjacently located rows of panels are
staggered, and the panels 216a are oriented at an acute
angle with respect to the rails 216b. No bores are formed
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or drilled through the panels 216a. Rather, the spacing
206 between adjacently situated rows forms or defines the
"upper portions" 227 of the bores 222, with each of the
lower portions 228 of the bores 222 formed through the
rails 216b and located in vertical alignment with an open
space 206 between two rows of panels. This structure
reduces costs associated with forming or drilling upper
bore portions 227 through the upper subfloor layer of
panels 216a.
Additionally, if it is desired to have the
floor system 210 act as a free floating floor, at least
within reduced area regions, not all of the rails of the
lower layer 216b are secured to the base 220. These
unsecured rails "float" above the base 220, in contact
therewith via pads 218 but not anchored thereto. This
structure isolates the unsecured rails located between
secured rails and causes the floor within each of these
reduced area sections to act in a free floating manner.
This one-piece fastener variation of the
invention is particularly suited for retrofitting, or
reanchoring, an installed resilient floor system which has
been in use for an extended period of time. To do this,
at each location of securement, a circular plug may be cut
into the upper layer and all subfloor layers but the
bottommost layer, as outlined in phantom by reference
numeral 170 in Fig. 8. The plug 170 is then removed
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therefrom to access the bottommost subfloor layer,
(attachment number 116, in this case) which is supported
above the base 120 by pads. In Fig. 8, the pads are
designated by reference numeral 118, though it is to be
understood that the actual construction and vertical
dimension of the supporting pads will vary from job to
job. A two portion bore is then formed in the lowermost
subfloor layer 116, preferably by drilling. The bore 122
is similar in configuration to the bore 22 shown in Figs.
2 and 6. A hole 144 is then drilled in the base 120, and
subsequently, an anchor pin 140 is extended through the
bore 122 and driven into the base 120 to a depth
determined by the depth stop 143. The plug 170 is then
replaced in the floorboards 112. This reanchors the floor
in a manner which allows downward deflection but no
vertical raising.
Alternatively, if more than one subfloor layer
is used, and a plug 170 is removed from an upper subfloor
layer 116a, only the reduced diameter portion 128 of the
bore is formed in the lowermost subfloor layer 116b.
After driving the anchor pin 140, the plug 171 for the
subfloor layer 116a directly above the lowermost subfloor
layer 116a is not replaced. This creates, in effect, a
two diameter portion bore 122.
CA 02166759 2006-03-06
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The correct vertical position of the depth stop
143 relative to the head 141 may be determined by studying
the specification for the installed floor or by actual
measurement. With this dimension known, customized anchor
pins 140 may be readily manufactured to re-anchor the
floor, simply by raising or lowering the position of the
depth stop with respect to the head and the bottom end of
the pin.
Because the vertical dimensions of the
fastening means may be varied as needed, the floor system
of this invention more readily accommodates an uneven
base, i.e., a base which requires substantial shimming.
According to still another embodiment of the
invention, as shown in Fig. 13, a single piece fastener
340 may be used to anchor a permanent floor system 310 in
a resilient manner, and in such a way that the normally
permanent floor system 37.0 may be removed, if necessary.
Thus, the single piece anchor pin 340 provides the floor
system 310 with the advantages of a permanently installed
floor and of a portable floor.
To accomplish this, the floor 310 comprises a
plurality of interconnected 4' x 8' sections 305, as is
typical in the construction and use of portable floors.
Applicant's corresponding U.S. Patent No. 5,303,526,
filed on January 21, 1993 and entitled "Resilient
Portable Floor System" and applicant'.s already
CA 02166759 2006-03-06
-36-
issued U.S. Patent No. 3,967,428 issued on July 6, 1976
and entitled "Portable Floor Construction" are directed to
portable floors which comprise a plurality of connectable
sections.
To form a portable floor, as disclosed in these
references, the sections 305 are secured row by row, and
the next row of sections 305 includes a horizontally
extending subfloor tongue 376a which is horizontally
received within a correspondingly shaped void or slot 376b
in the previously installed row sections 305. This locks
the adjacent sections 305 in a common horizontal plane.
In accordance with this embodiment of the
present invention, each of the connectable sections 305
includes one or more horizontally extending brackets 306
which extend a predetermined distance above the base 320.
Various versions of such brackets have been used in the
past to enhance interconnection of adjacently situated
sections 305. A plurality of bores 309 are drilled in the
base 320 below the locations of the brackets 306, and
thread-in anchors 380 are then inserted or embedded within
the bores 309. The thread-in anchors 380 preferably have
a curved midsection or expansion curve 309a to enhance
holding force within the base 320, as shown in Fig. 13.
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The single piece fastener 340 has a threaded
bottom end 381 which threadably connects within the
embedded anchor 380. The fastener 340 also has a jam/lock
nut 382 fixed thereon a predetermined distance from a head
end 341 at the top thereof. This predetermined distance
corresponds to the vertical dimension between the top of
the bracket 306 and the base 320. The fastener 340 is
threaded into the anchor 380 recessed in the base 320
until the jam/lock nut 382 contacts the base 320 and
prevents further fastening. This amount of downward
threading also places the head end 341 of the fastener
340, or a washer 383 located adjacent thereto, in direct
contact with the top of the bracket 306. As shown in Fig.
13, the washer 383 also bears against the top surface of
the bracket 306 of both adjacently located sections 305.
Thus, the jam/lock nut 382 provides a depth
stop feature for pin 340. If desired, the jam/lock nut
382 may be a washer, which is secured at the predetermined
vertical position on the anchor pin 340, as by welding.
The exact location of the depth stop will depend upon the
vertical distance between the top of the bracket 306 and
the base 320. Alternatively, the jam/lock nut 382 may be
a bolt fixed in vertical position relative to the fastener
340.
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Fig. 13 also illustrates a resilient pad 318
which rests on a shim 302 which contacts the base 320, as
is sometimes required in the industry during installation
of a permanent floor.
In this manner, as the sections 305 are
interconnected to form the floor system 310, each
successively connected row of sections 305 is secured to
the base 320. Once installed, the interconnected sections
305 are restrained from upward vertical movement but
allowed to deflect downwardly, by the thread-in fasteners
340.
If for some reason the floor 310 needs to be
removed, i.e., due to construction, water damage, or even
moving to a new location if the facility is rented or
leased by the user, etc., the fasteners 340 can be readily
unthreaded from the base 320 and the floor sections 305
are removed therefrom, row by row. When needed
thereafter, the "permanent" floor 310 can be reinstalled
just as easily as a portable floor.
From the above disclosure of the general
principles of the present invention and the preceding
detailed description of the preferred embodiments, those
skilled in the art will readily comprehend the various
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modifications to which the present invention is
susceptible. Therefore, we desire to be limited only by
the scope of the following claims and equivalents thereof.
1 claim:
