U.S. patent application number 14/740711 was filed with the patent office on 2016-12-22 for modular flooring substrate system and element.
The applicant listed for this patent is Ben Dombowsky, Michael Dombowsky. Invention is credited to Ben Dombowsky, Michael Dombowsky.
Application Number | 20160369503 14/740711 |
Document ID | / |
Family ID | 57586974 |
Filed Date | 2016-12-22 |
United States Patent
Application |
20160369503 |
Kind Code |
A1 |
Dombowsky; Michael ; et
al. |
December 22, 2016 |
MODULAR FLOORING SUBSTRATE SYSTEM AND ELEMENT
Abstract
A modular substrate system for use in the support of a flooring
surface including a plurality of elongate substrate members which
can be rapidly assembled to provide a semi-rigid support surface
for a floor. Various flooring elements can be adhered to the
semi-rigid support surface using an adhesive to, in cooperation
with the modular substrate system, provide an enhanced composite
rigidity to the assembled floor. The substrate member itself
includes an upper surface, side surfaces, and lateral flange
portions, the lateral flange portions of the substrate members
maintain adjacent substrate members in parallel spaced apart
relationship to each other defining substrate channels
therebetween. The substrate channels strengthen the assembled
modular substrate system and provide routes of egress for water
from below the flooring surface disposed thereon.
Inventors: |
Dombowsky; Michael; (Moose
Jaw, CA) ; Dombowsky; Ben; (Moose Jaw, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Dombowsky; Michael
Dombowsky; Ben |
Moose Jaw
Moose Jaw |
|
CA
CA |
|
|
Family ID: |
57586974 |
Appl. No.: |
14/740711 |
Filed: |
June 16, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 5/02 20130101; E04B
5/10 20130101; E04F 15/18 20130101; E04F 15/00 20130101; E04F 17/00
20130101; E04B 5/12 20130101; E04B 5/40 20130101 |
International
Class: |
E04B 5/02 20060101
E04B005/02 |
Claims
1. A modular flooring system, comprising: a substrate system
comprising a plurality of adjacent and parallel elongate substrate
members each having a substantially flat upper surface, side
surfaces meeting the upper surface in upper edges, and lateral
flange portions at the distal ends of the side surfaces, each
substrate member being substantially rigid along a longitudinal
axis and torsionally flexible around the longitudinal axis, the
flat upper surfaces of the substrate members forming an
upwardly-facing substrate mounting surface; and a floor surface, a
bottom of which is adhesively attached to the substrate mounting
surface; wherein the substrate system is created by parallel
alignment of the substrate members such that each pair of adjacent
substrate members is retained in position by interaction of the
lateral flange portions of the adjacent side surfaces of the pair,
creating a substrate channel therebetween which remains open to the
bottom of the floor surface; and wherein the adhesive attachment of
the bottom of the floor surface to the substrate mounting surface
creates a space between the floor surface and the substrate system
allowing for movement of water across the substrate mounting
surface and into the substrate channels such that water between the
floor surface and the substrate mounting surface has unimpeded flow
access to the substrate channels to exit from one edge to the other
of the substrate mounting surface.
2. The modular flooring system of claim 1, wherein each substrate
member forms a U-shaped structure.
3. The modular flooring system of claim 1, wherein the lateral
flange portions of a substrate member are configured to engage
lateral flange portions of adjacent substrate members.
4. The modular flooring system of claim 1, wherein the adhesive
attachment of the floor surface to the substrate mounting surface
comprises a plurality of setting adhesive mounts which will support
the floor surface to create the space between the floor surface and
the substrate system.
5-17. (canceled)
18. A method of constructing a modular flooring system comprising:
(a) a substrate system comprised of a plurality of adjacent and
parallel elongate substrate members each having a substantially
flat upper surface, side surfaces meeting the upper surface in
upper edges, and lateral flange portions at the distal ends of the
side surfaces, each substrate member being substantially rigid
along a longitudinal axis and torsionally flexible around the
longitudinal axis, the flat upper surfaces of the substrate members
forming an upward-facing substrate mounting surface; and (b) a
floor surface having a bottom adhesively attached to the substrate
mounting surface; the method comprising i) aligning the plurality
of elongate substrate members by parallel alignment of the lateral
flange portions of adjacent pairs thereof such that each pair of
adjacent substrate members is retained in position by interaction
of the lateral flange portions of the adjacent side surfaces of the
pair, creating a substrate channel therebetween which remains open
to the lower surface of the floor surface and in aggregate defining
the substrate system; ii) attaching the aligned substrate members
to each other; and iii) adhesively attaching the bottom of the
floor surface to the substrate mounting surface such that a space
is created between the floor surface and the substrate system
allowing for movement of water across the substrate mounting
surface and into the substrate channels; wherein each substrate
channel remains open to the lower surface of the floor surface so
that water between the floor surface and the substrate mounting
surface has unimpeded flow access across the substrate mounting
surface to the substrate channels to exit from one edge to the
other of the substrate mounting surface.
Description
FIELD OF THE INVENTION
[0001] The present invention relates in general to flooring and
decking/patio systems, and more specifically, relates to a modular
substrate system for use in the support, of a floor surface.
Various flooring elements can be adhered to the semi-rigid support
surface to, in cooperation with the modular substrate system,
provide an enhanced composite rigidity to the assembled floor
incorporating the modular substrate system.
DESCRIPTION OF RELATED ART
[0002] In the construction of decking and floors a common approach
is to build a wooden or metal frame upon which upon some form of
decking material is then placed to provide a suitable surface upon
for furnishings or the like to be placed, as well as which can be
occupied by people. In some cases the decking surface can consist
of wooden or composite planks attached to the underlying frame. In
these cases, the planks are attached such that there is a small
space between each plank to allow for expansion, and for water to
be shed from the top surface of the deck.
[0003] A common problem with this type of decking system is that
the area under the deck is un-protected from moisture, and so the
support structure is typically exposed to the elements an subject
to degradation over time as a result. Where wooden joists are used,
they can when contacted with water below any waterproof treatment
or membrane decay. If a metal substrate surface is used, with
screws placed therethrough etc., often times that will rust and the
rusting of the substrate can again lead to a structural
destabilization of the overall installation as well as potentially
ruining the visible appearance of the product if the rust bleeds
through. Wooden and even composite materials must be maintained
over time in order to preserve both the structural integrity of the
deck or patio, as well as to maintain aesthetic appearance. If it
were possible to create a substrate for use underneath the deck or
other flooring installation which was manufactured of materials
that were resistant to most types of decay this would represent an
enhancement over current available products.
[0004] In addition to prior art problems with the ingress of water
below an attached flooring surface into the substrate in a floor
installation, it would also be desirable to provide a system for
the rapid deployment of a semi-rigid flooring substrate in a
minimal amount of material and steps, to speed the overall assembly
of decks or other floors. For example where a wooden joist
structure is created, significant time is often required to cut and
assemble the joist work and substrata beneath such an installation.
Different types of brackets and other systems have been created to
ease the creation to a degree the assembly of a flooring substrate,
but if it were possible to address the issue of structural
integrity and water egress from the substructure of a deck or floor
with a subassembly that was rapidly and simply assembled this would
also be considered desireable.
[0005] Prior art methods of substrates and support for flooring
surfaces have included the use of flexible surfaces such as thin or
metal, plywood or the like, which are either too flexible,
resulting in cracking or the possibility of cracking of the
overlying floor surface, or which require the addition of a
concrete layer or the like to provide additional rigidity.
Provision of a method and apparatus for the construction of a
modular substrate which would allow for rapid deployment of a
substrate of reasonable rigidity would be attractive from a
commercial perspective.
[0006] Metal is often seen as a desireable material for
construction due to its fluid resistant characteristics (dependent
upon choice of material and fastening system). One of the issues
with a metal surface of significant size however is often that it
is too flexible for a flooring or decking purpose. If the substrate
of a deck is too flexible, it is more likely that the flooring
overlay or surface will crack or otherwise be damaged when the
substrate flexes under weight load. As such, it is desired to
provide a substructure assembly that is at least semi-rigid and
would not flex so much as to make it ineffective as a supporting
substrate for a deck or floor. If it were possible to create a
substrate for adhesive attachment of flooring elements which
enhance the ability of water to exit from beneath the flooring
surface and had maximized rigidity, to provide maximum support to
the overlying flooring surface it is also believed that this would
be well received.
BRIEF SUMMARY OF THE INVENTION
[0007] The present disclosure describes components and methods of
manufacture and installation of said components to provide a
modular substrate system. The decking system provides a number of
advantages over prior methods and components in that the components
are simple to manufacture and assemble into a finished decking
system. The modular substrate system described herein provides for
the use of rigid or semi-rigid decking surface materials arranged
in such a way that the components cooperatively provide an
effective degree of flexibility to the system while avoiding the
over-flex of the substrate which would result in the cracking or
disruption of the flooring surface or membrane.
[0008] The modular substrate system of the present invention is
made for use in the support of a flooring surface. The floor
surface might comprise a single membrane, or a multi-component
diaphragm. Both such approaches are contemplated within the scope
hereof. The substructure is further designed to permit ingress of
air and egress of water such that the growth of mold or mildew, or
damage to supporting structures by water is effectively
prevented.
[0009] In some embodiments, the modular substrate system may
comprise a group of elongate substrate members configured to
cooperatively form a substrate mounting surface for the adhesive
attachment of flooring elements thereto.
[0010] The modular substrate system is manufactured of metal which
minimizes the likelihood of water-based decay and provides
sufficient strength and workability to be advantageous as a
material of manufacture. Adhesive is the likely desireable means of
attachment of the flooring surface, to maintain the integrity of
the substrate mounting surface as well as to achieve the flexible
rigidity desired in terms of the cooperative action of the flooring
surface and the modular substrate system under weight load.
[0011] The completed modular substrate system comprises a plurality
of elongate substrate members which align themselves with each
other by cooperation of aspects thereof. Once the plurality of
elongate substrate members are properly aligned to complete the
modular substrate system, they can be attached to each other, and
the top of the assembled modular substrate system comprises the
substrate mounting surface.
[0012] It is contemplated that in many embodiments the substrate
member will effectively comprise a U-shaped member which will be
inverted in installation. The substrate member may include a
substantially flat upper surface, side surfaces meeting the upper
surface in upper edges, and lateral flange portions at the distal
ends of the side surfaces. The lateral flange portions are the
portions of the substrate member which will cooperate with like
components of adjacent substrate members to maintain them in
properly spaced relationship in the assembly of the modular
substrate system.
[0013] In some embodiments, each substrate member is substantially
rigid along a longitudinal axis, but is torsionally flexible around
the longitudinal axis; each lateral flange portion of each
substrate member capable of holding the substrate member when
placed in parallel alignment with an adjacent substrate member such
that a substrate channel is defined therebetween; and/or whereby
when the modular substrate system is assembled the upper surfaces
of the substrate members.
[0014] In some embodiments, when the modular substrate system is
assembled the upper surfaces of the substrate members may comprise
the substrate mounting surface and substrate channels run from one
edge to the other of the substrate mounting surface along the upper
edges of the substrate members. In addition to providing channels
for water to exit from the substructure, the substrate channels
also effectively act as strengthening joists or corrugations within
the completed assembly of the modular substrate system, which
provide added strength and minimize the flexibility of the modular
substrate system.
[0015] In some embodiments, the lateral flange portions of a
substrate member are configured to engage lateral flange portions
of adjacent substrate members. The lateral flange portions, at the
distal ends of the side surfaces of the substrate member, might
comprise a flange extending outwards in a plane substantially
parallel to the plane of the upper surface of the substrate member,
optionally with a retaining tab at the end thereof to provide a
system which can most easily and completely be rapidly assembled,
and which will best strengthen the overall modular substrate system
while maintaining the parallel and spaced apart relationship of
adjacent substrate members during assembly or completion of the
modular substrate system.
[0016] In some embodiments; the modular substrate system is
installed on a pre-existing rigid surface. In other cases, a
supporting frame might be used beneath the plurality of substrate
members to further support, or raise the height, of the finished
modular substrate system. In some embodiments, the supporting frame
may include risers to raise the modular substrate system above the
rigid surface.
[0017] In addition to the modular substrate system of the present
invention, there is also disclosed a substrate member for use in
construction of a modular substrate system for use in support of a
floor surface. The substrate member comprises an elongate structure
that is substantially rigid along a longitudinal axis, but is
torsionally flexible around the longitudinal axis; and has a
substantially flat upper surface, opposing side surfaces meeting
the upper surface in upper edges, and lateral flange portions at
the distal ends of the side surfaces. The lateral flange portions
will engage a surface onto which installation of the floor surface
is desired; and are capable of holding said substrate member when
placed and engaged in parallel alignment with an adjacent substrate
member such that a substrate channel is defined therebetween. The
lateral flange portions can further comprise engagement tabs at the
ends thereof, to fixedly engage the lateral flange portions of
adjacent substrate members.
[0018] Many different cross-sectional profiles can be envisioned
for the substrate member, including a substantially U-shaped
crosssection. The substrate member disclosed can be used in the
assembly of a modular substrate system such as that outlined
herein.
[0019] Also disclosed is a method of constructing a modular
substrate system for use in support of a floor surface, said
modular substrate system comprising a plurality of elongate
substrate members configured to cooperatively form a substrate
mounting surface for the adhesive attachment of flooring elements
thereto, each of the substrate members comprising an elongate
U-shaped member having a substantially flat upper surface, side
surfaces meeting the upper surface in upper edges, and lateral
flange portions at the distal ends of the side surfaces, and being
substantially rigid along a longitudinal axis, but torsionally
flexible around the longitudinal axis; and the lateral flange
portions of substrate members maintaining adjacent substrate
members in parallel spaced apart relationship to each other
defining substrate channels therebetween, said method comprising
aligning the desired plurality of elongate substrate members
parallel to each other by alignment of the lateral flange portions
thereof; and attaching the aligned substrate members to each other.
When the modular substrate system is assembled the upper surfaces
of the substrate members comprise the substrate mounting surface
and the substrate channels run from one edge to the other of the
substrate mounting surface along the upper edges of the substrate
members.
[0020] In the method, the lateral flange portions of a substrate
member are configured to engage lateral flange portions of adjacent
substrate members.
[0021] In some cases the method might be used to construct a
modular substrate system on a pre-existing rigid surface, versus in
others where a supporting frame was the be used beneath the
substrate members the method might also include the installation of
said supporting frame in advance of placement of the substrate
members thereon.
[0022] In assembly of a modular substrate system in accordance with
the present invention, the substrate members can be cut and shaped
to accommodate the general shape of the installation area, as can
any supporting frame be manufactured to the proper height and size
as well as potentially allowing for accommodation of surface
irregularities at the point of installation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] To easily identify the discussion of any particular element
or act, the most significant digit or digits in a reference number
refer to the figure number in which that element is first
introduced.
[0024] FIG. 1 is a perspective view of an embodiment of a substrate
member of the present disclosure.
[0025] FIG. 2 is a perspective view of an embodiment of a partially
assembled substrate mounting surface, secured to a supporting
frame. substrate mounting surface
[0026] FIG. 3 is a view of an embodiment of adjacent substrate
members and showing the nesting of lateral flange portions of the
adjacent members, and a means of securing to a supporting
frame.
[0027] FIG. 4 is a perspective view of an embodiment of a partially
assembled system according to the present disclosure, depicting a
supporting frame, substrate members forming a substrate mounting
surface, and surface elements installed on the substrate mounting
surface.
[0028] FIG. 5 is a end on view of substrate members onto which
surface elements have been placed directly without providing for an
intervening space between the substrate members and surface
elements.
[0029] FIG. 6 is an embodiment shown in edge on view, in which the
surface elements and substrate members are separated by flexible
cushions into which the surface elements are mounted.
DETAILED DESCRIPTION
[0030] As discussed above, most decking systems have limitations
due to their design. In simple decking systems, the decking
material is typically planks or slats that are installed with
spaces between each slat/plank member. This design allows for the
shedding of water, and permits airflow under the decking such that
water does not accumulate and cause damage over time either
directly, or by stimulating the growth of mold and mildew. In order
to overcome this limitation and provide a more uniform surface, a
variety of approaches including multilayer decking systems have
been developed. However, these systems suffer from the limitation
that they are more complicated to install, have more components,
and thus are more expensive to manufacture, install and maintain.
The present modular substrate system overcomes the limitations
presented by prior art systems.
[0031] A modular substrate system in accordance with one embodiment
of the present invention is shown in FIG. 1. In some embodiments,
for example as depicted in FIG. 1, a component of the system
comprises a substrate member 10. In some embodiments, the substrate
member 10 can be formed from a piece of sheet metal such that it
forms a U-shape structure. The formed substrate member 10
preferably has an substantially flat upper surface 12, side
surfaces 14, and lateral flange portions 16. The lateral flange
portions 16 can also be formed with a hole through which a fastener
can be passed in order to secure each substrate member 10 to an
underlying supporting frame 20, and to an adjacent substrate member
10.
[0032] Preferably a substrate member 10 can be fashioned from metal
stock, such as that used in the making of the metal version of
2.times.4 members used in building construction. The U-shape of the
substrate member 10 provides several structural and functional
advantages. First, the U-shape provides for significant rigidity
along the longitudinal axis of the member, such that it will be
relatively resistant to bending--as a result of the multiple
corrugations in its structure. Thus, a substrate member 10 is
capable of supporting a significant weight load without collapsing
or failing.
[0033] Further, as a result of the open U-shape, each substrate
member 10 will be capable of some torsional rotation around the
longitudinal axis. This provides two advantages. First, the ability
to rotate one end of the substrate member 10 relative to the other
means that the underlying supporting frame 20 does not have to be
perfectly aligned in order to install a substrate member 10
spanning different parts of the supporting frame 20. In addition,
this torsional flexibility provides for the ability of the
substrate member 10 to adapt to small changes in the shape of the
finished deck or flooring system that may occur over time. Such
changes can occur as a result of movement of the underlying surface
upon which the system is mounted, such as may occur with ground
movement, or as a result of regular changes due to thermal
expansion and contraction of the materials of which the decking
system is comprised. As will be seen from the description below,
the nature of the surface elements that are used to cover the
substrate members, 10 and the way in which they are mounted and
sealed, also provides for a membrane or surface that behaves as a
rigid decking system, but which is able to flex without disrupting
the integrity of the overall system.
[0034] In constructing the modular substrate system of the present
invention, and as shown in FIG. 2, a plurality of elongate
substrate members 10 are secured to an underlying supporting frame
20. The supporting frame 20 can be fashioned from any suitable
building material including wood, composite or metal beams. The
supporting frame 20 will in some cases be mounted on risers 22,
that are in turn mounted on the ground, or some other type of
supporting surface, such as concrete or a prepared aggregate. In
some cases, it may be preferable to place the supporting frame 20
directly on the ground or other surface, without the need for
risers 22. The particular type of installation of the supporting
frame 20 will depend on the particular characteristics of the
location where the modular substrate system is to be installed.
[0035] In still other embodiments, it is possible to place the
modular substrate system comprising a plurality of elongate
substrate members 10 secured to each other directly upon a surface.
The surface on which the system is placed can be the ground, a
prepared site such as concrete or gravel fill, or on other
materials such as foam sheets or other semi-rigid material. The
modular substrate system is in this regard quite adaptable and
suitable for use in a variety of locations. Moreover, because of
the ease of assembly, the system is potentially even usable as a
temporary substrate system that can be assembled, then disassembled
for use at a different location.
[0036] As also shown in FIG. 2 a plurality of elongate substrate
members 10 can be placed adjacent to each other to span the
distance between opposing portions of a supporting frame 20, where
such a supporting frame 20 is used. Conveniently, the U-shape of
the substrate member 10 and lateral flange portions 16 cooperate to
maintain adjacent substrate members 10 in a parallel, spaced-apart
relationship, defining substrate channels 21 between adjacent
substrate members 10. These substrate channels 21 serve to let
water run out from the system, and to admit air, circulation in
order to avoid the development of condensation, and drying
underneath the finished surface that is eventually supported by the
substrate system. This provides the advantage of protecting the
substrate system from damage due to mold, mildew and corrosion from
standing water. The substrate channels also effectively act as
strengthening joists within the structure of the modular substrate
system.
[0037] FIG. 3 provides a more detailed view of the relationship
between the supporting frame 20 and adjacent substrate members 10.
As can be seen, each substrate member 10 comprises an upper surface
12, side surfaces 14, and lateral flange portions 16. The lateral
flange portions 16 are shaped such that the lateral flange portion
16 of one substrate member 10 conveniently nests into the lateral
flange portion 16 of an adjacent substrate member 10. Once nested
in this fashion, the substrate members 10 can then be secured to
the underlying supporting frame 20 with a fastener 18.
[0038] In some embodiments, the lateral flange portions 16 and
distal ends of the side surfaces 14 of the substrate members 10
will engage a surface onto which installation of a horizontal floor
surface is desired, for example, and as shown, an underlying
supporting frame 20. Fasteners can include any suitable fastener
known to those of skill in the art, and the choice of fastener is
not meant to be limiting to the scope of the invention. As can also
be appreciated from FIG. 3, the side surfaces 14 are angled away
from the perpendicular with respect to the upper surface 12 of each
substrate member 10, thus creating slightly trapezoidal shaped
substrate channels 21 between adjacent substrate members in some
embodiments.
[0039] FIG. 4 depicts a partially completed modular substrate
system, manufactured and assembled as described herein. As can be
appreciated, the supporting frame 20 is completely covered by a
plurality of elongate substrate members 10, arranged substantially
parallel to each other, and secured to the supporting frame 20 as
shown in FIG. 3 and FIG. 4. The plurality of elongate substrate
members 10 thus act cooperatively to provide a substrate mounting
surface onto which surface elements 40 can be mounted. In the
depicted embodiment, each surface element is depicted as a square
tile. Other type of elements are suitable for use in the system,
and other shapes are contemplated as well. As an example, for
aesthetic reasons, a triangular shaped surface element might be
desired. Because of the ease of assembly and adaptability of the
present system, a wide variety of shapes, and types of material can
be used in the surface elements. Tiles, or surfacing elements of
many different types of material, can be used--including wood,
plastic, ceramic, cement, vinyl, composite lumber to name a
few.
[0040] FIG. 5 depicts an edge-on view of a portion of the modular
substrate system. In this case, three adjacent substrate members 10
are depicted mounted on an underlying supporting frame 20. A series
of adjacent surface elements 40 are also shown, installed on top of
the substrate structure formed by the substrate members 10. The
shape of the edges results in the formation of a void 44, which in
the finished decking product is filled with a flexible adhesive
joint material 46. This joint material 46 serves a number of
functions. First, when complete, the combination of surface
elements and joint material operate such that the finished upper
surface of the modular system functions as a unitary diaphragm.
Moreover, this diaphragm is substantially waterproof, preventing
moisture from getting underneath the finished surface, and thus
substantially avoiding the risk of water damage to the underlying
substrate components of the system.
[0041] FIG. 6 depicts another embodiment wherein the surface
elements are separated from the substrate members 10 by flexible
adhesive cushions 60. The cushions 60 operate to support surface
elements 40 above the substrate members 10, thereby creating an air
space 61 of defined with between the surface elements 40 and the
substrate members 10. The air space 61 functions to admit airflow
between these layers in order to avoid accumulation of moisture
that might otherwise lead to water damage directly, or as a result
of the growth of mold and/or mildew. Preferably the cushions 60 are
formed from an elastomeric material such that they are flexible and
can deform under conditions of loading to permit the finished
flooring system to flex resiliently while in use. Any type of a
fastening approach for surface elements which allowed for
attachment of a flooring surface while maintaining the integrity of
the substrate mounting surface and the semi-rigid character of the
modular substrate system are contemplated within the scope
hereof.
[0042] In some embodiments, the modular substrate system can be
installed on a pre-existing rigid surface, for example, a
supporting frame 20 as depicted in FIG. 2. Such a supporting frame
20 can be formed in a manner known to those of skill in the art. In
some cases it will be preferable to use a metal supporting frame 20
for reasons of strength and durability. In other cases, it may be
desirable to produce a supporting frame 20 from wood or other
materials. In installing the present system the supporting frame 20
can be placed directly on a prepared surface such as the ground, or
an aggregate base. In other cases it will be convenient to mount
the supporting frame 20 on supporting structures to raise the deck
above ground level. The particular types and design of supporting
structure on which the supporting frame 20 is mounted will depend
on the nature of the building site, whether the deck is at or near
ground level or elevated, and the requirements of local building
codes.
[0043] Once the supporting frame 20 is in place, individual
substrate members 10 are secured to the frame as shown above.
Conveniently, each substrate member 10 can be secured to the
supporting frame 20 with typical fasteners such as metal screws. As
depicted above, each substrate member 10 is nested alongside an
adjacent substrate member 10 by virtue of the lateral flange
portions 16 present on each substrate member 10. These lateral
flange portions 16 will run substantially the entire length of the
substrate member 10, thus providing maximal integrity of the
substrate mounting surface formed. Further, because of the U-shape
of each substrate member 10, collectively the substrate mounting
surface formed by a plurality of elongate substrate members 10 will
include regularly spaced substrate channels that admit air, and
allow for the egress of any water that may accumulate under the
finished surface of the decking.
[0044] Once the substrate members 10 are in place and attached, the
construction of the modular substrate system is complete. A
flooring layer can then be attached--for example by placing
adhesive on each substrate member 10 and attaching flooring
elements thereto. As described, support pylons are preferably
formed from an elastomeric material that also has adhesive
properties. Alternatively, it is possible to manufacture the
substrate members with support pylons already installed, in order
to save the decking installer effort during the building of a
modular substrate system. Once the surface elements are positioned,
an installer then fills the void between each surface element with
a flexible adhesive joint material. This material is preferably
also an elastomeric material that is elastically deformable. Once
all the voids have been filled with the joint material, the upper
finished surface of the deck will function as an unitary,
substantially waterproof, membrane, that covers the underlying
substrate members and supporting frame. The resilient nature of the
joint material also permits a small amount of movement of each
surface element relative to its neighboring elements, thus allowing
the decking surface to respond to variations in temperature, or
position of the underlying supporting structure, while preventing
disruption of the membrane.
[0045] One advantage of the present system is that each of the
elements cooperate to provide a resilient and flexible decking
surface that avoids problems with cracking of surface elements as
can occur when hard materials such as tile or stone are mounted
directly on a rigid substrate.
[0046] It will be recognized that the specific materials used in
constructing the various components of the system described herein,
are not considered to be limiting to the scope of the invention.
Those of skill in the art will readily recognize and be able to
select materials and components that will accomplish the objectives
of the invention without requiring any inventive skill.
[0047] It should also be apparent to those skilled in the art that
many more modifications besides those already described are
possible without departing from the inventive concepts herein. The
inventive subject matter, therefore, is not to be restricted except
in the scope of the appended claims. Moreover, in interpreting both
the specification and the claims, all terms should be interpreted
in the broadest possible manner consistent with the context. In
particular, the terms "comprises" and "comprising" should be
interpreted as referring to elements, components, or steps in a
non-exclusive manner, indicating that the referenced elements,
components, or steps may be present, or utilized, or combined with
other elements, components, or steps that are not expressly
referenced.
* * * * *