U.S. patent application number 11/410506 was filed with the patent office on 2006-12-21 for synthetic support base for modular flooring.
Invention is credited to Andrew Gettig, Charlie M. Graves, Thayne B. Haney, Troy D. Mohr, David F. Smith, Joseph M. Ure, Ronald A. Yokubison.
Application Number | 20060285920 11/410506 |
Document ID | / |
Family ID | 37215437 |
Filed Date | 2006-12-21 |
United States Patent
Application |
20060285920 |
Kind Code |
A1 |
Gettig; Andrew ; et
al. |
December 21, 2006 |
Synthetic support base for modular flooring
Abstract
A flooring system configured to accommodate sports play and
other activities, wherein the flooring system comprises a support
base having a synthetic component, such as a synthetic support
structure, wherein the support base is configured to provide a
support surface for receiving and supporting a flooring
configuration. The support base may further comprise a filler
material operable with the synthetic support component, wherein the
synthetic support component is integrated into the filler
material.
Inventors: |
Gettig; Andrew; (Salt Lake
City, UT) ; Yokubison; Ronald A.; (Park City, UT)
; Smith; David F.; (Highland, UT) ; Graves;
Charlie M.; (Park City, UT) ; Mohr; Troy D.;
(Draper, UT) ; Haney; Thayne B.; (Syracuse,
UT) ; Ure; Joseph M.; (Murray, UT) |
Correspondence
Address: |
THORPE NORTH & WESTERN, LLP.
8180 SOUTH 700 EAST, SUITE 200
SANDY
UT
84070
US
|
Family ID: |
37215437 |
Appl. No.: |
11/410506 |
Filed: |
April 24, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60674123 |
Apr 22, 2005 |
|
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|
Current U.S.
Class: |
404/31 ;
404/73 |
Current CPC
Class: |
E01C 13/045
20130101 |
Class at
Publication: |
404/031 ;
404/073 |
International
Class: |
E01C 3/00 20060101
E01C003/00 |
Claims
1. A method for constructing a flooring system configured to
accommodate sports play and other activities, said method
comprising: preparing a portion of ground to comprise a
substantially flat subgrade; situating a synthetic support
structure about said ground to form a support base having a support
surface of a generally planar configuration; preparing said support
base and said support surface; and overlaying said flooring
configuration on said support surface.
2. The method of claim 1, further comprising anchoring said support
structure to said ground in at least one location.
3. The method of claim 1, further comprising relating at least a
portion of said flooring configuration to at least a portion of
said support base.
4. The method of claim 1, further comprising situating an
intermediate layer situated between said support surface and said
flooring configuration, said intermediate layer being configured to
facilitate a proper functioning relationship between said support
base and said flooring configuration.
5. The method of claim 1, further comprising: depositing a filler
material about said synthetic support structure prior to overlaying
said flooring configuration, thus integrating said support
structure with said filler material; compacting said filler
material and said synthetic support structure to form said support
base; and preparing said filler material and said synthetic support
structure to form said support surface, and to receive said
flooring configuration.
6. The method of claim 5, further comprising adding a binding agent
to at least a portion of said filler material.
7. The method of claim 5, further comprising adding a soil
solidifier to at least a portion of said filler material.
8. The method of claim 1, further comprising: removing said
flooring configuration from said support surface; removing said
synthetic support structure from said ground; relocating said
synthetic support structure to a new location; and repeating said
steps of preparing, situating, leveling, and overlaying to
construct said flooring system at said new location.
9. The method of claim 1, wherein said step of preparing comprises
leveling at least a portion of said support surface once
formed.
10. The method of claim 1, wherein said step of situating comprises
interconnecting a plurality of synthetic support structure modules
together to form said synthetic support structure.
11. The method of claim 1, wherein said step of situating
comprises: obtaining a plurality of synthetic panels, each having
at least one through slot formed therein; aligning at least two
slots from at least two different synthetic panels; interconnecting
said at least two synthetic different panels together by mating
said at least two slots from said at least two different synthetic
panels, said interconnecting forming a three-dimensional layout;
repeating said steps of aligning and mating as often as necessary
to construct said synthetic support structure.
12. The method of claim 11, wherein said obtaining comprises:
obtaining said synthetic panels in a bundled package configured to
be unpackaged on site; and unpackaging said synthetic panels on
site to perform said steps of aligning, interconnecting, and
repeating.
13. The method of claim 1, further comprising coupling said support
base to an adjacent structure selected from the group consisting of
an adjacent synthetic support base, a building structure, a
retaining wall, and any combination of these.
14. The method of claim 1, further comprising operably associating
one or more reinforcing means with said support base to increase
the overall strength of said support base.
15. The method of claim 1, wherein said step of overlaying
comprises interconnecting a plurality of modular synthetic floor
tiles together to form said flooring configuration.
16. The method of claim 1, further comprising configuring said
support base to receive and absorb all or a portion of a load as
distributed from and acting on said flooring configuration, said
flooring configuration thus transferring said load, said support
base operating with said flooring configuration to provide said
flooring system with an increased impact absorbing capacity.
17. The method of claim 1, further comprising selecting a specific
type of synthetic support structure to operate with a specific
flooring configuration to provide a desired ratio of distributed
shock absorption between said flooring configuration and said
support base.
18. The method of claim 1, further comprising extending said
flooring system a distance by tying said synthetic support
structure into a second support structure, and repeating said step
of preparing to form an extended support base, and said step of
overlaying to extend said flooring configuration, said second
support structure being selected from the group consisting of an
existing concrete slab, an existing asphalt slab, an existing
synthetic support base, and any combination of these.
19. A method for constructing a flooring system configured to
accommodate sports play and other activities, said method
comprising: locating a portion of ground; preparing said portion of
ground to comprise a soil composition having suitable friability;
applying a synthetic soil solidifier to said soil composition;
preparing said soil composition containing said soil solidifier to
form a support base having a support surface of a generally planar
configuration; curing said support base to cause said soil
solidifier to bond with said soil; and overlaying said flooring
configuration on said support surface.
20. A flooring system configured to accommodate sports play and
other activities, said flooring system comprising: a support base
configured to receive and support a flooring configuration, said
support base comprising a synthetic support structure situated
about a prepared portion of ground, said support base being
configured to provide a support surface having a generally planar
configuration; and a flooring configuration disposed about said
support surface of said support base.
21. The flooring system of claim 20, wherein said synthetic support
structure comprises a plurality of synthetic panels interconnected
together to form a three-dimensional layout, said synthetic panels
each having at least one through slot formed therein configured to
be aligned and mated with a through slot of a different synthetic
panel to form said synthetic support structure.
22. The flooring system of claim 21, wherein said through slot
extends laterally from an edge of said synthetic panel, partially
through said synthetic panel.
23. The flooring system of claim 20, further comprising a filler
material operable with said synthetic support structure to form
said support surface, said filler material being selected from the
group consisting of rocks, gravel, loose soil or dirt, sand,
rubber, CHAT, baseball mix, and any combination of these.
24. The flooring system of claim 20, further comprising means for
securing said synthetic support structure to said ground.
25. The flooring system of claim 20, further comprising an
intermediate layer situated between said support surface and said
flooring configuration, said intermediate layer being configured to
facilitate a proper functioning relationship between said support
base and said flooring configuration.
26. The flooring system of claim 25, wherein said intermediate
layer is selected from the group consisting of a solid, a synthetic
panel, and a geotextile fabric pervious to water drainage.
27. The flooring system of claim 20, wherein said portion of ground
is prepared to comprises a suitable subgrade.
28. The flooring system of claim 20, wherein said synthetic support
structure comprises: an upper surface being configured to
facilitate formation of said support surface; a lower surface
opposite said upper surface and being configured to be positioned
adjacent said portion of ground; and means for supporting said
first and second surfaces in a spaced apart orientation with
respect to one another.
29. The flooring system of claim 28, wherein said upper and lower
surfaces comprise a series of apertures formed therein to
facilitate water drainage.
30. The flooring system of claim 28, wherein said synthetic support
structure comprises a plurality of individual, support structure
modules fittable together to form an assembled support
structure.
31. The flooring system of claim 20, wherein said upper surface is
configured to function as said support surface.
32. The flooring system of claim 20, wherein said means for
supporting comprises a plurality of extension members extending
between said upper and lower surfaces, and defining a plurality of
apertures therethrough.
33. The flooring system of claim 20, further comprising a flexible
membrane disposed about said lower surface and configured to
stabilize said support structure and to facilitate water
drainage.
34. A sports flooring system comprising: a support base configured
to receive and support a flooring configuration, said support base
comprising a synthetic support structure situated about a portion
of ground and configured to receive and absorb a force acting
thereon, said support base being configured to provide a support
surface having a generally planar configuration; a flooring
configuration disposed about said support surface of said support
base, said flooring configuration being configured to receive and
absorb a force acting thereon; and a force transfer element for
transferring at least a portion of said force acting on said
flooring configuration to said support base, said flooring
configuration operable with said support base to absorb shock by
distributing loads acting within said flooring system.
35. The sports flooring system of claim 34, wherein said force
transfer element comprises a mechanical interface existing between
said flooring configuration and said support base.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Application No.
60/674,123, filed Apr. 22, 2005, and entitled, "Synthetic Support
System for Modular Flooring," which is incorporated by reference in
its entirety herein.
FIELD OF THE INVENTION
[0002] The present invention relates generally to synthetic sport
and other flooring configurations, such as a modular sport flooring
configuration comprising a plurality of interlocking modular tiles,
designed for use in athletic play or for a variety of other
purposes. More particularly, the present invention relates to a
support base having a primarily synthetic component, wherein the
support base is designed and configured to support a sports or
other similar flooring configuration, and wherein the support base
is configured to replace traditional support bases, such as
concrete and asphalt.
BACKGROUND OF THE INVENTION AND RELATED ART
[0003] In recent years, the use of flooring configurations made of
synthetic or artificial materials to form a flooring surface
intended for sports play and other activities has grown in
popularity. These synthetic flooring configurations are
advantageous for several reasons. First, they are easily
manufactured and typically formed of materials which are generally
inexpensive and lightweight. Thus, if a portion of the flooring
configuration is damaged it may easily be removed and replaced.
Second, these synthetic flooring configurations are easily
removable as they are temporarily placed over a support base. Thus,
if the entire flooring configuration needs to be relocated, each
individual modular floor tile making up the flooring configuration
can easily be detached from one another, relocated, and then
reattached to form the flooring configuration in a new location.
Third, the durable plastics from which these flooring
configurations are formed are long lasting. Fourth, unlike the
alternative traditional floors of asphalt and concrete, which are
made up of primarily natural materials, a synthetic material
comprises better performance characteristics, such as improved
shock or impact absorption, while also reducing the likelihood of
injury in the event of a fall. The connections for the modular
flooring configuration can even be specially engineered to absorb
lateral forces to further reduce the chance of injury. Fifth,
synthetic flooring configurations generally require little
maintenance as compared to non-synthetic flooring materials, such
as wood.
[0004] To construct a usable synthetic flooring configuration, a
suitable support base is required. The support base provides many
functions, namely to provide and maintain a level surface on which
the flooring configuration may rest, and to provide a suitable
support that resists buckling of the flooring configuration
overlaid thereon. Support bases are typically constructed of
concrete or asphalt, particularly if the synthetic flooring
configuration to be overlaid on the support base is intended for
use outdoors or in large indoor areas, such as recreational
centers, gymnasiums, etc.
[0005] Although traditional support bases of concrete and asphalt
are commonly used, there are several inherent difficulties
associated with these. First, and foremost, these are permanent
structures that require significant effort and expense to install.
In addition, once installed, it is highly impractical, from a cost
and labor standpoint, to try and remove and relocate these support
bases in the event one desires to relocate the synthetic flooring
configuration. Rather, upon removing and relocating the synthetic
flooring configuration to a new location, a new support base is
typically constructed at the new location.
[0006] Moreover, it is not uncommon for the support base to
comprise up to one half or more of the total cost of installing a
synthetic flooring configuration, particularly if the support base
requires retaining or reinforcement of any kind. This is one reason
installations of such flooring configurations is so high.
Contributing to this are various fluctuations in material
availability. In the aftermath of natural disasters or other
unforeseeable events, such materials can be in short supply, thus
driving costs even higher.
[0007] Considering international aspects, there are many countries
in which concrete or asphalt is unavailable altogether. In these
locations, concrete must be imported, which is much too cost
prohibitive and impractical in most instances for a game court. In
other countries, the technology needed to construct large slabs of
concrete or asphalt is practiced or known by only a few, and
equipment needed is either scarce or nonexistent.
[0008] Another significant problem centers around water drainage.
In most instances, current support bases are impervious to water
drainage, and therefore must comprise some degree of slope or grade
to allow water to flow from its surface. Recently, the number of
government covenants and/or regulations placing restrictions on the
use of concrete and asphalt has been on the rise as such slabs
cause water to run off instead of being absorbed by the ground.
This has caused many city aquifers to be depleted.
[0009] Despite water drainage problems, many cities and counties
have restricted the construction of additional concrete or asphalt
slabs for various other reasons. This has significantly limited the
number of play areas within certain locations, particularly in
large cities where much of the landscape comprises concrete or
asphalt. Because of these restrictions or prohibitions, there are
several people in these areas that do not have proximate access to
a play area or sports facility.
[0010] Traditional support bases are also very rigid and hard. They
do not provide any degree of inherent flexibility or give, nor do
they exhibit any impact absorption characteristics. Thus, any
impact or other forces are required to be borne or absorbed solely
by the flooring configuration. As such, this has been a critical
factor in the design of many synthetic flooring configurations.
[0011] Concrete and asphalt are also very susceptible to cracking.
As these slabs can often experience extreme weather conditions,
such conditions can have a detrimental effect on the concrete or
asphalt surface. After time, the concrete or asphalt surface can
become irregular, inconsistent, and unusable.
[0012] Finally, although not necessarily problematic, concrete and
asphalt support bases are not particularly aesthetically
pleasing.
[0013] Based on the foregoing, it would be advantageous to provide
a support base that is less permanent, that is able to better
facilitate water drainage from the flooring configuration, that is
relatively easy and inexpensive to install, that can be easily
relocated and installed at another location, that comprises
characteristics or properties that contribute to overall
performance, that helps to reduce the likelihood of injury, and
that provides other needed advantages.
SUMMARY OF THE INVENTION
[0014] In light of the problems and deficiencies inherent in the
prior art, the present invention seeks to overcome these by
providing a support base comprised, at least in part, of a
synthetic component, and that is designed and configured to replace
conventional or traditional support bases, namely concrete,
asphalt, and other similar surfaces that are comprised of primarily
of natural aggregate or sub-aggregate materials, such as rock,
gravel, sand, and similar materials.
[0015] In accordance with the invention as embodied and broadly
described herein, the present invention features a method for
constructing a flooring system configured to accommodate sports
play and other activities, the method comprising: (a) preparing a
portion of ground to comprise a substantially flat subgrade; (b)
situating a synthetic support structure about the ground to form a
support base having a support surface of a generally planar
configuration; (c) preparing the support base and the support
surface; and (d) overlaying the flooring configuration on the
support surface.
[0016] The present invention also features a method for
constructing a flooring system configured to accommodate sports
play and other activities, the method comprising: (a) locating a
portion of ground; (b) preparing the portion of ground to comprise
a soil composition having suitable friability; (c) applying a
synthetic soil solidifier to the soil composition; (d) preparing
the soil composition containing the soil solidifier to form a
support base having a support surface of a generally planar
configuration; (e) curing the support base to cause the soil
solidifier to bond with the soil; and (f) overlaying the flooring
configuration on the support surface.
[0017] The present invention further features a flooring system
configured to accommodate sports play and other activities, the
flooring system comprising: (a) a support base configured to
receive and support a flooring configuration, the support base
comprising a synthetic support structure situated about a portion
of ground, the support base being configured to provide a support
surface having a generally planar configuration; and (b) a flooring
configuration disposed about the support surface of the support
base.
[0018] The present invention still further features a sports
flooring system comprising: (a) a support base configured to
receive and support a flooring configuration, the support base
comprising a synthetic support structure situated about a portion
of ground and configured to receive and absorb a force acting
thereon, the support base being configured to provide a support
surface having a generally planar configuration; (b) a flooring
configuration disposed about the support surface of the support
base, the flooring configuration being configured to receive and
absorb a force acting thereon; and (c) a force transfer element for
transferring at least a portion of the force acting on the flooring
configuration to the support base, the flooring configuration
operable with the support base to absorb shock by distributing
loads acting within the flooring system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The present invention will become more fully apparent from
the following description and appended claims, taken in conjunction
with the accompanying drawings. Understanding that these drawings
merely depict exemplary embodiments of the present invention they
are, therefore, not to be considered limiting of its scope. It will
be readily appreciated that the components of the present
invention, as generally described and illustrated in the figures
herein, could be arranged and designed in a wide variety of
different configurations. Nonetheless, the invention will be
described and explained with additional specificity and detail
through the use of the accompanying drawings in which:
[0020] FIG. 1 illustrates a general layout of a generic flooring
system according to one exemplary embodiment of the present
invention, wherein the flooring system comprises a flooring
configuration that is supported by a synthetic support base
comprised of a sub-surface support structure secured to the ground,
a filler material, and an optional intermediate layer;
[0021] FIG. 2 illustrates a perspective view of a modular,
sub-surface support structure to be used in a support base,
according to one exemplary embodiment of the present invention;
[0022] FIG. 3 illustrates a perspective view of a modular,
sub-surface support structure to be used in a support base,
according to another exemplary embodiment of the present
invention;
[0023] FIG. 4 illustrates a partial perspective view of an
exemplary flooring system utilizing the modular, sub-surface
support structure of FIG. 3;
[0024] FIG. 5 illustrates one alternative to providing a flooring
system comprised of a plurality of modular support structures,
wherein the support structure comprises a rollable
configuration;
[0025] FIG. 6 illustrates a partial perspective view of an above
ground, modular support structure to be used in a support base,
according to still another exemplary embodiment of the present
invention;
[0026] FIG. 7 illustrates an exploded perspective view of a
flooring system in accordance with still another exemplary
embodiment of the present invention;
[0027] FIG. 8 illustrates a flow diagram depicting a method for
constructing a flooring system according to one exemplary
embodiment of the present invention; and
[0028] FIG. 9 illustrates a flow diagram depicting a method for
constructing a flooring system in accordance with another exemplary
embodiment.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0029] The following detailed description of exemplary embodiments
of the invention makes reference to the accompanying drawings,
which form a part hereof and in which are shown, by way of
illustration, exemplary embodiments in which the invention may be
practiced. While these exemplary embodiments are described in
sufficient detail to enable those skilled in the art practice the
invention, it should be understood that other embodiments may be
realized and that various changes to the invention may be made
without departing from the spirit and scope of the present
invention. Thus, the following more detailed description of the
embodiments of the present invention is not intended to limit the
scope of the invention, as claimed, but is presented for purposes
of illustration only and not limitation to describe the features
and characteristics of the present invention, to set forth the best
mode of operation of the invention, and to sufficiently enable one
skilled in the art to practice the invention. Accordingly, the
scope of the present invention is to be defined solely by the
appended claims.
[0030] The following detailed description and exemplary embodiments
of the invention will be best understood by reference to the
accompanying drawings, wherein the elements and features of the
invention are designated by numerals throughout.
[0031] The present invention describes and features a method and
system for supporting a flooring configuration, such as the type
manufactured and sold by Connor Sport Court International of Salt
Lake City, Utah, which flooring configurations are commonly sold
under the SPORT COURT.RTM. brand name and other associated
trademarks. More specifically, the present invention describes and
features a flooring system comprising, at least in part, a
synthetic support base configured to replace traditional support
bases and to provide the necessary support to a flooring
configuration, modular or otherwise, overlaid upon, situated about,
coupled thereto, or otherwise interacting with the support base, in
response to the several forces (e.g., normal, lateral,
longitudinal, shear, and other forces) induced and acting upon the
flooring configuration. The present invention flooring system,
namely both the flooring configuration and the support base
supporting it, is designed to be easily removable and much less
permanent than existing flooring systems utilizing traditional
support bases, such as cement. Although flooring configurations, as
known in the art, are easily removable from the traditional support
bases supporting them, the support bases themselves are not easily
removable. Indeed, the construction of a flooring system, such as
the ones described and referred to herein, utilizing a traditional
support base requires a great commitment in that the support base
is typically a more permanent structure, even though the flooring
configuration overlaid thereon is not as permanent. Moreover,
traditional flooring systems lack efficient and sophisticated
support characteristics that are provided by the present invention
flooring system, such as improved water drainage, increased shock
and force absorption capabilities, and ease of leveling and
re-leveling of the support base, if needed, just to name a few.
[0032] Unlike conventional or traditional support bases used to
provide the necessary support for a modular and other similar
synthetic flooring systems, such as concrete, asphalt, etc., the
present invention provides a synthetic support base designed to
introduce new and different advantages into flooring systems of the
type described and otherwise referred to herein. In effect, the
present synthetic support base is intended to replace the need for
traditional support bases.
[0033] Some of the advantages realized by the present synthetic
support base are recited herein. For example, the present synthetic
support base is designed to mimic many of the positive
characteristics of traditional support bases formed of concrete or
asphalt, such as good stability, good ball bounce, ease of
maintenance, their ability to be leveled, their ability to function
as a weed growth inhibitor.
[0034] In addition, the present invention synthetic support base
may be configured to be pervious to water, thus facilitating
improved water drainage from the flooring system. Each component in
a constructed flooring system, including the flooring configuration
overlaid upon the support base, may facilitate water drainage.
Indeed, the support base, having a synthetic component that may be
manufactured to comprise any size and/or configuration, may
therefore be configured to operate directly with the flooring
configuration to channel water from the uppermost contact or
playing surface of the flooring system, through the flooring
configuration, through the support base, and finally into the
ground.
[0035] The present invention synthetic support base is easy to
install and easy to prepare, meaning that it is easy to manipulate
(e.g., level, extend, etc.) to form or define a generally planar
support surface on which the flooring configuration may be placed.
This defined support surface may be easily initially leveled. In
addition, the support surface may be easily modified or manipulated
after the support base is constructed and the flooring
configuration installed. For instance, the support surface of the
support base may be re-leveled without difficult maintenance or
replacement of the support base, and without having to remove the
entire flooring configuration.
[0036] The present invention synthetic support base provides
improved impact absorbing properties, while maintaining desirable
ball bounce and jumping characteristics. As stated herein, the
support base may be configured to absorb some of the forces acting
on the contact surface and within the flooring configuration.
Unlike traditional surfaces that did not absorb any of the impact,
or a negligible amount, and that required the flooring
configuration to function as the only means for absorbing a force
or shock, a support base having a synthetic component may be
configured, as desired, to comprise an impact absorbing
characteristic that operates with the flooring configuration to
provide a shock absorbing system. This may ultimately improve the
design potentials of synthetic modular floor tiles and the flooring
configurations assembled with these floor tiles as designers and
manufacturers may be less concerned with building shock absorbing
characteristics directly into these floor tiles.
[0037] The present invention synthetic support base is designed to
be less permanent than traditional support bases. Indeed, the
present invention support base is easily removable, thus allowing
easy replacement, or relocation of the support base to another
location to form a similar flooring system. In the case of a
modular synthetic support structure, all that is required to move
or repair this structure is to disassemble all or a portion of it
and to perform the same or a similar installation, either on-site
for the new portion, or at the new location if being relocated.
[0038] The present synthetic support base facilitates one or more
advantageous types of interaction or interface with the flooring
configuration overlaid thereon. Indeed, because of its ability to
comprise any shape or feature, the support base may be configured
to couple or otherwise relate to or interact with the flooring
configuration for one or more purposes. For example, in a flooring
system comprising a modular flooring configuration made up of a
plurality of interlocked floor tiles, the support base may be
configured to couple to the flooring configuration to minimize the
shifting of the individual tiles. Still further, as discussed
herein, the flooring configuration may be configured to transfer
various loads or forces acting thereon to the support base and the
synthetic support structure component therein. Stated differently,
the flooring system may comprise a force transfer element that
functions to transfer at least a portion of the forces acting on
the flooring configuration to the synthetic support base. By doing
this, impact and other forces are distributed between the flooring
configuration and the support base. The ratio of distribution may
be different for each flooring system installed, and may be
determined based on a number of factors. In any event, the present
invention provides this benefit, and such may be determined by
those skilled in the art.
[0039] The present invention synthetic support base will enable a
greater number of sports and activity facilities to be constructed,
particularly in areas having restrictions on the use of traditional
surfaces. A synthetic support base may be configured to eliminate
many of the problems associated with traditional surfaces that
caused their restriction. For example, an exemplary synthetic
support base may be configured to provide good water drainage that
allows the water to drain and be absorbed by the ground rather than
entering city or county water systems. By meeting city or county
guidelines, a greater population of individuals may be provided
with sports and activity areas. Other possible uses are
contemplated, such as by the military for activity areas, MASH
units, etc. For example, a stationed unit may easily integrate a
synthetic support structure into an exiting ground location to form
a support base on which a flooring configuration may be placed.
Moreover, because of their low cost and ability to be manufactured
and installed without expensive equipment, a present invention
sports or activity flooring system may be a reality for many in
locations where such would not otherwise be possible if a
traditional support base was required, such as in third world and
other countries where technology and resources are scarce.
Temporary housing locations, remote scientific research stations,
summer camps, and a myriad of others are also contemplated.
[0040] Each of the above-recited advantages will be apparent in
light of the detailed description set forth below, with reference
to the accompanying drawings. These advantages are not meant to be
limiting in any way. Indeed, one skilled in the art will appreciate
that other advantages may be realized, other than those
specifically recited herein, upon practicing the present
invention.
[0041] With reference to FIG. 1, illustrated is general layout of a
generic flooring system according to one exemplary embodiment of
the present invention, wherein the flooring system comprises a
flooring configuration that is supported by a support base
comprised, at least in part, of a synthetic support structure
positioned about and optionally secured or anchored to the ground.
In general, the synthetic support structure may be located in an
above ground, sub-surface, or partial sub-surface position.
Although not necessary, depending upon the particular type, the
support base may further comprise a filler material configured to
receive and to retain the synthetic support structure, thus
integrating the synthetic support structure within the filler
material. The filler material may be disposed about all or a
portion of the support structure in order to facilitate the setting
of the support structure in its proper place and to help retain its
set position during use of the flooring system. In addition, the
flooring system may include an optional intermediate layer situated
between the support base and the flooring configuration.
[0042] In the embodiment shown in FIG. 1, the flooring system 10
more specifically comprises a support base 14 and a flooring
configuration 18 configured to be overlaid upon a support surface
16 defined by the support base 14 upon construction or formation of
the support base 14. The support base 14 comprises several
different components, namely a modular, sub-surface synthetic
support structure 30, a filler material 8, and an intermediate
layer 88.
[0043] The synthetic support structure 30 is configured to comprise
the primary support component of the support base 14, and in some
embodiments, may be configured to provide a suitable support
surface on which a flooring configuration may be directly placed.
As shown, the support structure 30 may be positioned about a
prepared portion 4 of ground 2, which will typically comprise a
grated or flattened ground portion having a suitable subgrade. In
light of its intended use, the support structure 14 may be designed
to comprise suitable load bearing, force distributing, weather
resistant, corrosion resistant, and other properties. In essence,
the support structure 30 may be designed and installed in a manner
so as to resist movement within the support base 14. In this
manner, the support base 14 provides at least one function similar
to that of traditional support bases, namely to provide a stable
durable support surface for the flooring configuration 30.
[0044] It is contemplated that the synthetic support structure 30
may comprise any type of structure capable of performing as
intended herein, namely to form or construct the present invention
support base for the present invention flooring system.
Specifically, the support structure 30 may comprise any suitable
type, arrangement, configuration, and design. Some exemplary
designs are set forth in the drawings and discussed in greater
detail below. However, one skilled in the art will recognize that
these are not all inclusive, and that other designs and types of
synthetic supports structures may be used to practice the present
invention. Indeed, depending upon the factors and parameters
surrounding the construction of a particular flooring system, the
support structure 30 may take on any one of a variety of designs.
As such, those specifically shown in the drawings and discussed
below are not to be construed as limiting in any way.
[0045] The support structure 30 is preferably comprised of a
synthetic or artificial material, such as plastic, thus allowing it
to be designed and engineered as needed, such as to include
different force or load absorbing and distributing characteristics,
or to include solid or perforated tops, etc. The support structure
30 may be comprised of a plurality of support structure modules,
each one being configured to couple to or interconnect with at
least one other support structure module, or it may comprise a
single, unitary structure.
[0046] Once in place, the support structure 30 may be anchored or
otherwise secured to the ground 2 using any type of anchoring or
securing means. The support structure 30 may further be anchored or
secured to an existing structure, such as an adjacent building
structure, a retaining wall, an adjacent support base, or any
combination of these. Anchoring the support structure 30 to the
ground 2 or to another structure or support base functions to
prevent unwanted movement or shifting of the support structure 30
and the support base 14, especially during use of the flooring
system 10. The support structure 30 may be anchored or secured to
the ground 2 using any one of a variety of known devices and
techniques. In one aspect, the support structure 30 may be anchored
using spikes or stakes. Other types of anchoring or securing means
are intended. When anchoring to an adjacent support base, the
support structure may be anchored to an adjacent support base using
rebar, pencil bar mesh, or another similarly configured support
structure.
[0047] As indicated above, one of the benefits of the present
invention support base is its ability to accept and distribute a
load acting on the flooring configuration. As such, the flooring
system is configured to comprise a force transfer element that
transfers all or a portion of a load or force acting on the
flooring configuration to the support base. In one exemplary
embodiment, the force transfer element may comprise a mechanical
interface existing between flooring configuration and the support
base. For example, the force transfer element may comprise the
various posts located on the underside of the flooring
configuration that are used to support the contact surface in an
elevated position above the support base. As a force is applied to
the contact surface of the flooring configuration, it is
transferred to the posts, which further function to transfer the
force to the support base, namely the synthetic support structure
component of the support base. Because of the synthetic makeup of
the support structure, and its intended capability to receive and
absorb a force, thus providing a distributed load pattern across
the entire flooring system, such a force transfer is made possible.
Other force transfer elements are contemplated herein.
[0048] The present invention also contemplates being able to select
a specific type of synthetic support structure to operate with a
specific flooring configuration to provide a desired ratio of
distributed shock absorption between the flooring configuration and
the support base. Various factors may go into determining this
ratio, such as the location of the flooring system, the intended
sports or activities or events the flooring system will be used
for, and others.
[0049] The support structure may further be used to tie into
another or second support structure to extend the support base and
ultimately the flooring configuration. Specifically, the flooring
system may be extended a desired distance by tying a first,
existing synthetic support structure into a second synthetic
support structure, or even a building structure. This may be
accomplished using any known coupling means, or the coupling
configuration currently existing on the installed support
structure. Other necessary steps, such as preparing the extended
support base to define a support surface may be required. Once the
support base has been extended, the flooring configuration may also
be extended to complete the flooring system.
[0050] In still another embodiment, the present invention synthetic
support base may be used to extend an existing support base made of
traditional materials, such as concrete. In this case, the one or
more reinforcement members (e.g., rebar, wire mesh, etc.) may be
used to couple the concrete to the synthetic support structure of
the synthetic support base. With this, it is contemplated that any
existing support base may be extended to provide a flooring system
of increased size.
[0051] The support base 14 may further comprise and the synthetic
support structure 30 may be integrated into a filler material 8. A
filler material 8 is most likely to be used in those situations
where the synthetic support structure 30 is configured to be
present in a sub-surface or partial sub-surface arrangement.
However, an above-ground arrangement may still warrant use of some
filler material. The filler material 8 may be configured to support
or retain the support structure 30. The filler material 8 is
intended to be of sufficient size and quantity so as to encase,
surround, penetrate, and/or cover the support structure 30 for the
purpose of facilitating the setting and retaining of the support
structure 30 in a fixed or semi-fixed position and to resist
movement of the support structure 30 to provide a stable support
base 14. In other words, the filler material 8 may function to
stabilize the support structure 30 about the ground 2. The support
structure 30 may be configured to receive at least a portion of the
filler material 8 within its interior through various apertures,
grooves, channels, or other openings formed in the support
structure 30. As such, the filler material 8 functions to help set
the support structure 30 in its proper position, as well as to
facilitate leveling and re-leveling of the support structure 30 and
the defined support surface of the support base. Additional anchors
or securing means may or may not be necessary.
[0052] The filler material 8 may further be configured to provide
or define the support surface of the support base 14. The filler
material 8 may be caused to cover or enclose the synthetic support
structure 30, wherein the filler material 8 functions as the
uppermost surface of the support base 14 (unless an intermediate
layer is used). In this situation, the filler material 8 will most
likely benefit from additional preparation, such as compacting, in
order to obtain a suitable surface having a generally planar
configuration.
[0053] The support base may indeed be configured to be temporary.
However, if desired, the support base may be configured to be more
permanent. In such situations, a binding agent may be added to the
filler material to further "set" the filler material. One example
of a binding agent includes Portland cement in any pre-determined
concentration,
[0054] The filler material 8 may comprise an aggregate,
sub-aggregate or other arrangement. Examples of filler materials
include, but are not limited to, rocks, gravel, loose soil or dirt,
sand, rubber, CHAT, baseball mix, and any combination of these, as
well as others known in the art. The filler material 8 preferably
comprises a sub-aggregate or other similar arrangement capable of
being disposed about and/or within the synthetic support structure
30. In some cases, the filler material 8 may be caused to enter the
various apertures formed within the synthetic support structure 30,
as well as to encompass the exterior of the synthetic support
structure 30, thus retaining the synthetic support structure 30.
The filler material 8 may then be compacted or otherwise prepared
to form or define the support surface on which the flooring
configuration 18 may be placed.
[0055] Though not necessary, the flooring system 10 may further
comprise an intermediate layer 88, which may be disposed or
situated between the support base 14 and the flooring configuration
18. The intermediate layer 88 may be configured to interface with
the support base 14 and the flooring configuration 18 to operably
relate the two in one or more ways, such as to facilitate the
proper support of the flooring configuration 18 about the support
base 14, or to improve the performance of the support base 14 in
supporting the flooring configuration 18. Although the flooring
configuration 18 may be overlaid directly upon the support
structure 30, there may be a need to incorporate the intermediate
layer 88.
[0056] In one aspect, the intermediate layer 88 is intended to
perform various enhancing functions. For example, the intermediate
layer may be configured to facilitate a proper functioning
relationship between the support base and the flooring
configuration 18. More specifically, the intermediate layer 88 may
be configure to act as a barrier between the flooring configuration
18 and the support base to prevent buckling of the flooring
configuration 18. The intermediate layer 88 may be configured to be
porous, thus making it pervious to water to facilitate water
drainage. Furthermore, the intermediate layer 88 may function as a
barrier to prevent unwanted weed or other vegetation growth through
the flooring system. In this context, the intermediate layer 88 may
comprise any material or configuration, but will preferably
comprise a flexible, porous fabric, such as a geotextile fabric,
and will preferably be situated or disposed over any filler
material used.
[0057] In another aspect, the intermediate layer 88 may be designed
to provide a rigid surface that the flooring configuration 18 may
be overlaid upon. In this embodiment, the intermediate layer 88
would function to provide a smooth finished surface, that may or
may not be pervious to water, that is designed to accommodate the
flooring configuration 18.
[0058] The intermediate layer 88 may be further configured to
interface with the support base and any synthetic support structure
30 in one or more ways. In one aspect, the intermediate layer 88
may be anchored or somehow coupled or secured directly to the
support structure 30 once the support structure 30 has been
properly situated about the ground 2. In another aspect, such as in
a partial sub-surface configuration, the intermediate layer 88 may
be formed as part of the support structure 30 itself. In any event,
it is intended that the intermediate layer 88 comprise an
above-ground component that is configured to directly receive the
flooring configuration 18. Incorporating a properly configured
intermediate layer into the flooring system of the present
invention allows existing and other flooring configurations to be
overlaid on the support base in a functional manner just as they
would a traditional support base.
[0059] In essence, the intermediate layer 88 may comprise any type,
configuration, shape, design, etc. needed for a particular flooring
system. In addition, the intermediate layer 88 may be formed of any
suitable material, such as fabric or plastic. The surface of the
intermediate layer 88 may be a solid or smooth surface, or it may
comprise a porous, grid-like or random pattern. In addition, the
intermediate layer 88 may be configured with various attachment
means used to attach the intermediate layer 88 to the support
structure 30 and/or the flooring configuration 18.
[0060] The flooring configuration 18 may comprise any type commonly
known in the art. However, those types of flooring configurations
for which the present invention is well suited, and which will be
discussed herein merely for exemplary purposes, are those types of
flooring configurations that are synthetic and modular in nature,
and that are intended for sports play and various other activities.
In one exemplary aspect, the flooring configuration 18 may comprise
a modular flooring configuration, wherein a plurality of individual
floor tiles are interlocked together to form an assembled flooring
configuration having an upper or contact surface for playing sports
or participating in other activities. In another exemplary aspect,
the flooring configuration 18 may comprise a unitary or
non-modular-type flooring configuration. Each are well known in the
art and are thus not specifically discussed in detail herein.
[0061] With reference to FIG. 2, illustrated is a perspective view
of a single synthetic support structure module for use within a
modular synthetic support structure 30 in accordance with one
exemplary embodiment. This particular support structure comprises
the Versicell subsurface drainage module manufactured and sold by
Elmich Co. of Australia. As shown, FIG. 2 illustrates the synthetic
support structure module 32 configured to interconnect with other
similar modular components to form the modular support structure
30. As shown, each support structure module 32 comprises an upper
surface 34 and a lower surface 38 separated by a pre-determined
distance or height. The support structure module 32 is shown as
also comprising a rectangular shape with a first end 42, a second
end 46, a first side 50, and a second side 54. Located on each side
is coupling means 70 in the form of either a female receiver 74 or
a male coupler 78, thus allowing the support structure module 32 to
be interconnected with the corresponding coupling means on one or
more adjacent support structure modules.
[0062] In one exemplary aspect, the support structure module 32
comprises a plurality of extension members 58 of a pre-determined
length or height extending between the upper surface 34 and the
lower surface to define a plurality of apertures 62 spaced apart
from one another in any patterned or random arrangement about the
support structure 30 and that extend from the upper surface 34 to
the lower surface 38. In another exemplary aspect, the support
structure module 32 may comprise a generally solid makeup with the
plurality of apertures 62 being formed therethrough in any pattern
or arrangement, wherein the apertures 62 also extend between the
upper surface 34 to the lower surface 38. The extension members 58
are configured as the primary load bearing components of the
support structure, and are designed to bear the loads that will be
transferred to the support structure through the flooring
configuration. As such, they may be designed with pre-determined
load limits, configurations, etc.
[0063] The apertures 62 within the support structure also perform
several functions. First, the apertures function to accept or
receive and retain a filler material, as described above, to
facilitate the setting of and to stabilize the support structure.
The apertures allow the filler material to enter into an interior
portion of the support structure while the structural extension
members retain the filler material. Second, the apertures
facilitate water drainage by allowing water to flow from the
flooring configuration, down through the support configuration and
support base, and into the ground. Third, the apertures reduce the
weight of the support structure without sacrificing performance.
The extension members defining the apertures, if so configured,
function to provide the support structure with shock or impact
absorption characteristics. Other functions not specifically
recited herein may be apparent to those skilled in the art.
[0064] FIG. 3 illustrates a perspective view of a single synthetic
support structure module for use within a modular synthetic support
structure 130 in accordance with another exemplary embodiment. This
particular support structure comprises the Gravelpave2 paving
product manufactured and sold by Invisible Structures, Inc. of
Golden, Colo. As shown, FIG. 3 illustrates the synthetic support
structure module 132 configured to interconnect with other similar
support structure modules to form a modular support structure 130.
As shown, each support structure module comprises a first
structural layer 140 in the form of a grid-like infrastructure. The
first structural layer 140 defines the lower surface 138. Extending
upward from and situated about the intersection of the respective
members of the lower layer 140 are a plurality of extension members
158, each of which are independent from one another. The uppermost
portions of the extension members 158 function to define the upper
surface 134. The extension members 158 are cylindrical in form and
comprise a circular cross-section with a pre-determined diameter.
The extension members 158 further comprise a pre-determined height.
As such, each extension member 158 comprises an interior 162
defined by its sidewalls, wherein the interior portion 162 is
configured to allow water to drain therethrough, to receive and
retain a filler material therein, if desired, and to perform all of
the functions similar to those discussed above in relation to the
embodiment shown in FIG. 2.
[0065] In one exemplary aspect, the extension members 158 may be
independent and separated from one another as shown in FIG. 3. In
another exemplary aspect, the extension members 158 may be
integrally formed with one another. In addition, the
cross-sectional geometry of the extension members 158 may be
circular, square, rectangular, triangular, hexagonal, or any other
geometric configuration.
[0066] FIG. 3 also illustrates the support structure 130 as
comprising a flexible, breathable, permeable or semi-permeable
membrane 94 deposited or disposed about the lower surface 138 of
the lower layer 140. In the exemplary embodiment shown, the
membrane 94 comprises a non-woven, geotextile fabric. The purpose
of the membrane 94 is to facilitate the retaining of the filler
material within and about the support structure, as well as to
stabilize and limit the vertical displacement of the support
structure 130 once in place. The membrane 94 also facilitates water
drainage, functions to prevent cavities or potholes from forming
beneath the support base, and acts as a vegetation growth
inhibitor. The membrane 94 may be formed from many different types
of fabrics or materials as will be apparent to one skilled in the
art.
[0067] It is noted herein that other support structure
configurations are contemplated for use with the present invention.
Examples of these include, but are not limited to, the NeoTerra
Solid Top product manufactured and sold by Mateflex of New York;
the NeoTerra Perforated product also manufactured and sold by
Mateflex of New York; the Piastrella product manufactured and sold
by Progetto Plastica of Comano, Italy; the Guidonia, Aprilia 2000,
Aprilia Pierced Line 2000, Aprilia Line 900, Millepiedi, and
Four-Leaf Clover products manufactured and sold by Arplast of
Lograto; the Salvaprato Geoflor product manufactured and sold by
Geoplast srl of Grantorto, Italy; and the Green Parking product
manufactured and sold by Momico of Italy.
[0068] FIG. 4 illustrates a partial perspective view of an
exemplary flooring system utilizing the modular, sub-surface
support structure of FIG. 3. Specifically, FIG. 4 illustrates the
several components comprising the exemplary flooring system 10. As
shown, the support structure 130 is situated about the prepared
portion 4 of the ground 2. A filler material 8 is shown as being
configured to be disposed about the support structure 130, and
within the several cylindrical extension members 158 extending from
the lower grid-like layer 140. Sitting atop the support structure
130 is an intermediate layer 88 comprising a porous geotextile
fabric. Of course, an intermediate layer formed of a rigid material
may be incorporated as well. The intermediate layer 88 is situated
between the support structure 130 and the flooring configuration
18. The intermediate layer 88 is designed to be above-ground over
which the flooring configuration 18 may be laid. The filler
material 8, the support structure 130, and the intermediate layer
88 all interrelate to form the support base for the flooring
configuration 18. The flooring configuration 18 is shown comprising
an isogrid floor tile 102 having an upper surface 106 and a lower
surface (not shown) adjacent the support surface of the support
base. The floor tile 102 further comprises coupling means 114 in
the form of both female 114 and male 118 counterparts, thus
allowing the floor tile 102 to be interconnected with other similar
tiles, as commonly known. In this assembly, the flooring
configuration 18 is sufficiently supported about the support
surface of the support base below.
[0069] FIG. 5 illustrates one alternative to providing a flooring
system comprised of a plurality of support structure modules
interconnected together. Specifically, FIG. 5 illustrates a unitary
support structure capable of being rolled up as shown. The specific
embodiment of the unitary support structure shown in FIG. 5
comprises a plurality of extension members 258 disposed about a
lower layer 240, wherein the extension members 258 and the lower
layer 240 are each similar to the extension members and lower layer
of the support structure described above and shown in FIG. 3. FIG.
5 illustrates that the support structure used to provide a support
base for a flooring configuration may be a single, unitary
structure, rather than a plurality of modular sections.
Alternatively, FIG. 5 illustrates how an assembled modular support
structure formed of a plurality of support structure modules, such
as those described above in relation to FIG. 3, may be rolled
together and stored in their assembled state.
[0070] FIG. 6 illustrates a partial perspective view of flooring
system comprising an above ground, support structure module to be
used in a support base having a modular support structure. FIG. 6
further illustrates a flooring configuration configured to be
overlaid on the support structure. Specifically, FIG. 6 illustrates
a flooring system 310 as comprising a synthetic support structure
330 having an upper surface 334 and a lower surface 338. The
support structure 330 comprises a plurality of apertures 362 formed
therein that extend through the support structure 330 from the
upper surface 334 to the lower surface 338. The support structure
330 is configured to be disposed about a prepared portion 4 of the
ground 2, and optionally contained within a filler material, with
its upper surface 334 positioned above the ground 2. as such, the
support structure 330, and optional filler material 8, function to
define a support base 314 having a support surface 316.
[0071] The flooring system 310 further comprises an intermediate
layer 88 disposed about the upper surface 334 of the support
structure 330. The intermediate layer 88 is configured to operably
relate with the support structure 330 to provide a suitable support
surface over which the flooring configuration may be laid. As
shown, the intermediate layer 88 comprises a solid surface
configuration. The intermediate layer 88 may be coupled to the
support structure 330. In addition, the support structure 330 may
be coupled to the ground 2. The support structure 330, the prepared
ground portion 4, and the intermediate layer 88 function to provide
a suitable and advantageous support base for a flooring
configuration, which flooring configuration is shown as comprising
a modular tile 102, as commonly known in the art. The tile 102
comprises a grid-like upper surface 106, and coupling means 114 in
the form of a male coupler 122 and a female receiver 118
counterpart to facilitate the assembly of a plurality of modular
tiles into the flooring configuration.
[0072] FIG. 7 illustrates a flooring system in accordance with
still another exemplary embodiment of the present invention. As
shown, the flooring system 410 comprises a support base 414 having
a synthetic support structure 430 formed from a plurality of
individual support panels 432, shown as panels 432-a, 432-b, 432-c,
and 432-d. Support panels 432 each comprise a plurality of slots,
shown as slots 436-a, 436-b, and 436-c that extend laterally from
an edge 440 part way through the support panel 432. Although each
panel 432 is shown having three slots, this is not to be limiting
in any way. The slots are each configured to receive and engage a
corresponding slot from a different support panel, thus
interconnecting the two different support panels. As shown, support
panels 432-b, 432-c, and 432-d each are configured to interconnect
with support panel 432-a via their corresponding slots 436, once
properly aligned, to form the assembled synthetic support structure
430, being in the form of a grid-like structure. Any number of
support panels 432 may be interconnected together to construct a
support base of a particular size.
[0073] The advantage of the embodiment of FIG. 7 is that the
support structure 430, which in its assembled state provides a
three-dimensional layout, may be constructed using a plurality of
panels that may be packaged or bundled tightly together, shipped,
and unpackaged and assembled easily on-site.
[0074] FIG. 7 further illustrates the synthetic support structure
430 as being configured to receive filler material 8, the two being
operable together to form a support base having a support surface
for receiving the flooring configuration 18. The filler material 8
may be configured and utilized as described above.
[0075] FIG. 7 further illustrates a reinforcement member 452, which
may be designed for use with any of the synthetic support
structures discussed herein. The reinforcement member functions to
reinforce the support base, as needed. In the embodiment shown, the
reinforcement member comprises a wire pencil bar mesh. Other
reinforcement members are contemplated herein, such as rebar, and
even an additional synthetic support structure.
[0076] FIG. 8 illustrates a flow diagram depicting a method for
constructing a flooring system according to one exemplary
embodiment of the present invention. In this method, the first
step, step 504 comprises preparing a portion of ground to comprise
a substantially flat ground surface, or subgrade. The next step,
step 508, comprises situating or disposing a support structure
about the ground surface. The next step, step 512, which is
optional, comprises securing the sub-surface support structure to
the ground. The next step, step 516, which is also optional,
comprises covering the support structure with a filler material,
such as loose gravel or dirt. The next step, step 520, comprises
compacting the filler material into the support structure, if so
applied. The next step, step 524, comprises further preparing the
filler material and the support structure to form a suitable
support surface having a generally planar configuration. The next
step, step 528 comprises overlaying a flooring configuration on the
support surface of the support base. The method for constructing a
flooring system may further comprise, as an optional step, step 532
situating an intermediate layer between the support surface of the
support base and the flooring configuration, such that the flooring
configuration is overlaid upon the intermediate layer. The method
for constructing a flooring system may still further comprise step
536, which is relocating the flooring system to a new location.
This step involves removing the flooring configuration from the
support base, removing the support structure from the ground,
relocating and reinstalling the support base in the new location,
and again overlaying the flooring configuration about the support
base.
[0077] The present invention further features a method for
constructing a flooring system configured to accommodate sports
play and other activities in accordance with another exemplary
embodiment. With reference to FIG. 9, this particular method
comprises step 604, namely locating a portion of ground; step 608,
preparing the portion of ground to comprise a soil composition
having suitable friability; step 612, applying a synthetic soil
solidifier to the soil composition; step 616, preparing the soil
composition containing the soil solidifier to form a support base
having a support surface of a generally planar configuration; step
620, curing the support base to cause the soil solidifier to bond
with the soil; and step 624, overlaying the flooring configuration
on the support surface. In the event the support base needs to be
repaired, the above steps may be repeated, as shown in step
628.
[0078] As referred to herein, friability refers to the lack of
hardness of the soil particles making up the soil composition used.
In relative terms, some soil particles are "hard" and others are
"soft." The harder the soil particles, the less friable they are,
and the more resistant the resulting support base will be to wear
and tear. Conversely, the softer the soil particles, the more
friable they are, and the less resistant the resulting support base
will be to wear and tear. Generally speaking, "hard" soil particles
include various particles such as silica sand or crushed quarry
rock. "Soft" soil particles may include limestone screenings or
decomposed granite particles. Ordinary soil dirt can consist of
various proportions of hard and soft soil particles.
[0079] The present invention contemplates the use of any known soil
solidifier or stabilizer. One particular example of a soil
solidifier is the PolyPavement.TM. brand soil solidifier
manufactured and sold by Polypavement, Inc. of Los Angeles, Calif.
PolyPavement soil solidifier contains three basic
ingredients--synthetic polymers, water and emulsifiers, of which
the synthetic polymers are the active ingredients. Water functions
as the transport medium for the polymers, while the emulsifiers,
which are surface acting agents, function to keep the polymers
suspended in the water.
[0080] Alternative embodiments are contemplated by the present
invention in which a support base is constructed using a soil
solidifier, such as the PolyPavement soil solidifier discussed
above, in combination with a synthetic support structure and/or a
filler material. Indeed, it is contemplated that a synthetic
flooring system may utilize any of the various synthetic components
discussed herein in combination with one another to achieve a
variety of different types of synthetic support bases. Thus, it is
conceivable that a support base may comprise a combination of a
soil solidifier and a filler material, or a soil solidifier, a
filler material and a synthetic support structure, or a soil
solidifier and a synthetic support structure, etc.
[0081] The foregoing detailed description describes the invention
with reference to specific exemplary embodiments. However, it will
be appreciated that various modifications and changes can be made
without departing from the scope of the present invention as set
forth in the appended claims. The detailed description and
accompanying drawings are to be regarded as merely illustrative,
rather than as restrictive, and all such modifications or changes,
if any, are intended to fall within the scope of the present
invention as described and set forth herein.
[0082] More specifically, while illustrative exemplary embodiments
of the invention have been described herein, the present invention
is not limited to these embodiments, but includes any and all
embodiments having modifications, omissions, combinations (e.g., of
aspects across various embodiments), adaptations and/or alterations
as would be appreciated by those in the art based on the foregoing
detailed description. The limitations in the claims are to be
interpreted broadly based on the language employed in the claims
and not limited to examples described in the foregoing detailed
description or during the prosecution of the application, which
examples are to be construed as non-exclusive. For example, in the
present disclosure, the term "preferably" is non-exclusive where it
is intended to mean "preferably, but not limited to." Any steps
recited in any method or process claims may be executed in any
order and are not limited to the order presented in the claims.
Means-plus-function or step-plus-function limitations will only be
employed where for a specific claim limitation all of the following
conditions are present in that limitation: a) "means for" or "step
for" is expressly recited; and b) a corresponding function is
expressly recited. The structure, material or acts that support the
means-plus function are expressly recited in the description
herein. Accordingly, the scope of the invention should be
determined solely by the appended claims and their legal
equivalents, rather than by the descriptions and examples given
above.
* * * * *