Modular sprung floor

Abstract

A method, system and apparatus for a modular sprung floor. An example embodiment is a sprung floor module having interchangeable components. Interchangeable components make up standardized assemblies. An example embodiment has a frame module that may be installed in a series to cover a given area. The frame and edge modules comprise a frame that supports a performance surface. Standardized components include fiber-reinforced composite linear-structural members combined with elastomeric joints and support members.

Claims

1. A modular grid structure for a sprung floor comprising: at least two elongate members parallel to an X-axis; and at least two elongate members parallel to a Y-axis and perpendicular to said X-axis; and at least two elastomeric pads, each having a planar surface portion; and an aperture; and said at least two elastomeric pads fixedly engaged through said aperture, in an upright orientation, with said elongate members parallel to the X axis; and said at least two elastomeric pads fixedly engaged through said aperture, in an inverted orientation, with said elongate members parallel to the Y axis; and at least two frame-joint members having at least a first joint aperture and a second joint aperture; and said first and second joint apertures being perpendicular to each other; and said elongate members parallel to the X axis fixedly engaged through said first joint aperture; and said elongate members parallel to the Y axis fixedly engaged through said second joint aperture in said joint member; and at least one linear, structural channel having a first end and a second end, a right side and a left side and an elongate centerline extending from said first end to said second end; and a series of fastener holes through said linear structural channel, left of said elongate centerline, and right of said elongate centerline; and at least two performance-surface panels; and fasteners penetrating edges of one of said at least two performance-surface panels and fastener holes left of said elongate centerline; and fasteners penetrating edges of the other of said at least two performance-surface panels and fastener holes right of said elongate centerline; wherein said planar surface portion of said at least two elastomeric pads which are fixedly engaged, in an inverted orientation, with said elongate members parallel to the Y-axis being movably engaged with a sub-floor; and said planar portion of said at least two elastomeric pads which are fixedly engaged, in an upright orientation, with said elongate members parallel to the X-axis being movably engaged with said linear structural channel and said linear structural channel fixedly engaged with adjacent edges of said at least two performance-surface panels, said at least two performance-surface panels substantially covering said modular grid structure, providing a sprung floor.

2. The modular grid structure of claim 1 further comprising: at least two elongate members to be joined end-to-end; and a bracket for joining the ends of elongate members, the bracket comprising: an inverted U-shaped cross-section; and at least two through holes through said U-shaped cross section; wherein the bracket is engaged under the ends of a pair of elongate members, fasteners penetrate said through holes and said elongate members fixedly engaging said elongate members end-to-end.

3. The modular grid structure of claim 1 further comprising: a first modular grid structure residing upon a sub-floor comprising: at least four elongate members parallel with said X-axis are engaged with said frame joint members which are in turn engaged with at least four of said elongate members parallel to said Y-axis providing a first modular grid structure; and said at least four elongate members parallel to said Y-axis are each engaged, at one end, with a bracket, the brackets comprising: inverted U-shaped cross sections; and at least two through holes through said inverted U-shaped cross sections; and providing a second grid structure residing upon a sub-floor; wherein at least four elongate members of said second grid structure, parallel to said Y-axis are engaged, at one end, with said brackets which are engaged with said first modular grid structure elongate members parallel to said Y-axis; wherein multiple modular grid structures provide a structure residing upon a sub-floor for supporting a performance surface of a sprung floor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) To assist those of skill in the art in making and using the disclosed floor system and associated methods, reference is made to the accompanying figures, wherein:

(2) FIG. 1 is a perspective, partially exploded view of the embodiment 100.

(3) FIG. 2 is a perspective view of a pad (performance-surface support).

(4) FIG. 3 is a perspective view of a frame joint.

(5) FIG. 4 is a perspective, detailed view of the pad of FIG. 2 and the frame joint of FIG. 3 shown assembled in the embodiment 100.

(6) FIG. 5 is a perspective, detailed and partially exploded view of a pad and a bracket shown installed.

(7) FIG. 6 is a perspective, partially exploded view of the embodiment 100

(8) FIG. 7 is a perspective, partially exploded, detail view of the embodiment 100.

DESCRIPTION

(9) The present disclosure relates to a modular sprung floor assembly 100. A frame assembly 112 forms a grid, made up of X-axis frame members 126 and Y-axis frame members 128 that are joined at nodes by frame joints 130. A performance surface, made up of performance-surface panels 110 is supported above the frame assembly by linear, structural channels 118 that reside atop performance-surface supports 132, also referred to as pads. Pads are also used in an inverted orientation 132′ to support the frame assembly above a subfloor. Linear, structural channels 118 are fastened with fasteners, about the perimeter of performance-surface panels 110, joining edges of performance-surface panels 110 firmly. By resting atop performance-surface supports 132 the performance-surface panels 110 float and shift freely over the supports 132 as the floor expands and contracts with environmental conditions, allowing seams between performance-surface panels 110 to remain tight and unstressed without the need for edge fastening such as tongue-and-groove edge treatment. Performance-surface panels 110 may be removed individually, anywhere in an array, by removing fasteners and lifting a panel 110. At some joints, the short edges of square panels meet a long edge 107 of an adjacent panel.

(10) FIG. 2 is a perspective view of a performance-surface support or pad 132 with a top surface 160 and side surfaces 162. Top surface 160 is designed to slidably engage with linear, structural channels 118 (FIG. 1). An aperture 164 accepts X-axis frame members 126, (FIG. 1). Fastener-holes 166 affix fasteners to X-axis frame members 126. One skilled in the art understands that 132 inverted (132′, FIG. 1) can serve as a pad between the Y-axis members and a sub-floor.

(11) FIG. 3 shows a frame joint 130 which connects X-axis frame members 126 and Y-axis frame members 128 stacked at right angles in the frame assembly (FIG. 1). Aperture 182 is parallel to the frame joint's front surface 172 and receives X-axis frame members 126 (FIG. 1). Aperture 180 accepts Y-axis frame members 128 (FIG. 1). Fastener-holes 176, 178 are for affixing fasteners to X-axis frame members 126 and Y-axis frame members 128 respectively.

(12) FIG. 4, 100 shows the pad 132 of FIG. 2 and the frame joint 130 of FIG. 3 installed on a frame assembly 112. Elastomeric pads 132 in their upright position support linear, structural channels 118 (FIG. 1) and performance-surface panels 110 (FIG. 1). One skilled in the art understands the various types of laminate material that may be used as a performance surface. Inverted, the elastomeric pads 132′ support Y-axis frame members 128 and offset those members from a sub-floor. One skilled in the art understands that the same part may be used for both purposes; in the example of elastomeric pads 132 and elastomeric pads 132′ the same manufactured part is used in an upright orientation of the pad 132 and in an inverted orientation of the pad 132,′ performing different functions: one adheres the channels 118 (FIG. 2) and hence the frame assembly, another adheres to the performance surface while damping vibrations, and another damps vibrations against a sub-floor. The frame joint 130 accepts X-axis frame members 126 and Y-axis frame members 128 at right angles.

(13) A bracket 135 has an inverted U-shaped cross-section. It serves to join the X-axis frame members 126 end to end. At least one pin 134 may be used to fasten the bracket 135 to an X-axis frame member 126.

(14) Fastener holes 176 are configured to affix the frame joint 130 to X-axis frame members 126 with the use of common fasteners. Fastener holes 178 are configured to affix the frame joint 130 to Y-axis frame members 128.

(15) FIG. 5 illustrates how the elastomeric pads 132 install on the frame assembly. In their upright position the pads support structural channels (FIG. 6, 118) and performance-surface panels (FIG. 6, 110) of a sprung floor. One skilled in the art understands that this grid structure may support a performance surface of a sprung-floor assembly similar to that of FIG. 1.

(16) A bracket 135 has an inverted U-shaped cross-section. It serves to join the x-axis frame members 126 end to end. Fastener holes 137 through the bracket 135 match those 176 of the frame members 126. At least one pin 134 may be used to fasten the bracket 135 to a frame member 126. Fastener holes 137 in the pad 132 match those 176 of the frame members and may be used to fortify this joint. Perpendicular force transmits a tensile force to the brackets, which hold the elongate members together from the bottom.

(17) FIG. 6 illustrates the assembly of an example linear, structural channel 118 and an example performance-surface panel 110. An insert 119 having three fastener holes 113, 115 and 117 is placed on the underside of a linear, structural channel 118. The insert is affixed to the structural channel with a fastener 129 that passes through a hole 123 in structural channel 118 and fastened into fastener hole 115. Fastener 127 passes through a fastener hole in a first performance-surface panel 110, through hole 121 in a structural channel 118 and then fastened into fastener hole 113. One skilled in the art understands how a series of such fasteners arrayed along the edge of a first performance-surface panel 110 will affix the edge of the performance-surface panel 110 along the center of a structural channel 118.

(18) Fastener 131 passes through a fastener hole in a second performance-surface panel, through hole 125 in a structural channel 118 and is fastened into fastener hole 117. One skilled in the art understands how a series of such fasteners arrayed along the edge of a second performance-surface panel will affix the edge of the second performance-surface panel along the center of a structural channel 118 and abut the edge of the first performance-surface panel 110. Panels fastened in this manner are fixedly engaged at their edges with structural channels and may be removed by removing the fasteners, without the need to remove multiple panels as when tongue-and-groove joints are used. Structural channels 118 are thus allowed to move about the top of pads 132 (FIG. 1) to allow for expansion and contraction of the performance surface during environmental changes.

(19) FIG. 7 illustrates a detail of the channel layout. In some embodiments, a channel 118 having an end 109 may extend past a joint 108 and into a long edge of a surface panel 107 (FIG. 1). By extending the channel end 109 into a surface panel long edge 107, the structural connection is extended and so, loading is distributed into the performance surface away from the joint 108.