Modular floor system

Abstract

A modular floor system comprises a plurality of modular floor elements, each of which can be individually lifted to and supported at preset heights to change the configuration of the floor. The modular floor elements can be placed, either individually or in groups, at different levels relative to each other, to form stages, stairs, seating areas, display areas, grandstands, and balconies. Each modular floor element substantially comprises a floor panel, a sliding post, a sliding post guide, and an air cylinder assembly. Each sliding post includes a low position stop pin located at the post's upper portion, a plurality of radially directed uniformly spaced positioning pin holes, a longitudinally directed keyway, and an air seal assembly located at the post's lower portion. The sliding post guide, which is rigidly set into a concrete slab, includes a key which interacts with the sliding post keyway, a pin support seat, and leveling means. The floor panel is fastened to the top of the sliding post, which, in turn, is vertically guided and laterally supported by the sliding post guide. The sliding post can be supported at any preset height by a positioning pin which is placed through a positioning hole on the sliding post. The positioning pin bears against the pin support seat located on the upper portion of the sliding post guide. The pin, in addition to the action of the combination comprising the key and keyway, also prevents rotation of the sliding post about its longitudinal axis by coacting with the pin support seat. The air cylinder assembly, which is fastened to the lower portion of the sliding post guide, is adapted to receive the sliding post and its air seal assembly. The sliding post is raised or lowered by introducing air pressure into the cylinder at a location below the lowermost position of the air seal assembly. The air supply system, which provides this air pressure, includes an orifice which, upon deactivation of the air system, allows air to controllably escape from the cylinder. This, of course, allows the sliding post to drop until the positioning pin rests upon the guide's pin support seat. Alternatively, the air cylinder and air seal assemblies can be deleted, in which case the sliding post can be raised or lowered by an overhead hoist or by a portable lift device located below the sliding post.

Description

FIELD OF THE INVENTION

This invention relates to a modular floor system and, in particular, to such a system whose elements can be individually lifted to and stably supported at predetermined heights.

BACKGROUND OF THE INVENTION

Stage and theater design techniques require economy and flexibility of floor space. One approach to this problem is the modular floor system concept. Prior Modular floor systems have relied on conventional hydraulic, pneumatic, and mechanical lifting machinery. These systems have been expensive and, consequently, their construction has not been economically feasible. Some prior systems, especially those of the pneumatic type, have exhibited slow leaks and therefore unstable height control.

Objects of the present invention are therefore to:

provide a modular floor system;

provide such a system of the pneumatic type which is not susceptible to unstable height control;

allow for a variety of seating and stage arrangements which suit the specific requirements of a particular performance; and

provide for flexibility of space by using vertically adjustable floor elements.

SUMMARY OF THE INVENTION

According to the present invention, a modular floor system comprises a plurality of modular floor elements, each of which can be individually lifted to and supported at preset heights to change the configuration of the floor. Each floor element substantially comprises a floor panel, a sliding post, a sliding post guide, and an air cylinder assembly. The floor panel is rigidly fastened to the upper portion of the sliding post and is perpendicular to the post's longitudinal axis. The floor panel incorporates anchors for mounting removable seats, hand rails, fascias, and other components. A removable cover is provided on one side of the floor panel for ready access to the quick disconnect air coupling located below on the concrete slab. In addition, the floor panel is removable and can be replaced by a variety of structures, such as a turntable. These structures, of course, can be fastened to the upper portion of the sliding post at any desired angular position. Each sliding post includes a low position stop pin located at the post's upper portion, a plurality of radially directed uniformly spaced positioning pin holes, a longitudinally directed keyway, and an air seal assembly located at the post's lower portion. The positioning pin holes are located 90.degree. from the keyway. The air seal assembly is mounted so as to permit a small amount of lateral motion. This, of course, allows the air seal to center itself inside the air cylinder in order to prevent binding. The sliding post guide, which is rigidly set into the above-mentioned concrete slab, includes; a key which interacts with the post's keyway to constrain the post's motion to the vertical direction; a pin support seat; and leveling means. The sliding post guide provides lateral support to the sliding post when the sliding post is at a predetermined position or while it is being lifted or lowered. The pin support seat is also positioned 90.degree. from the keyway. The sliding post guide provides both vertical and rotational support to the sliding post whenever the positioning pin rests on the pin support seat. The leveling means allows for accurately controlling the vertical alignment of the sliding post guide and therefore of the sliding post. The lower portion of the sliding post guide is adapted for mounting the air cylinder assembly. The longitudinal axes of the sliding post guide, the sliding post, and the air cylinder assembly are concentric. The air cylinder assembly includes a relief valve and hose connections at the bottom portion thereof. The air supply utilized for lifting or lowering the sliding post is connected to the air cylinder by means of a quick disconnect coupling and associated air hoses. The quick disconnect coupling includes an orifice which allows air to escape from the cylinder via the orifice when the compressed air supply is disconnected from the quick disconnect coupling. This, of course, allows for lowering of the sliding post until the positioning pin rests on the pin support seat.

According to another embodiment of the present invention, an overhead hoist or other mechanical means such as a portable lifting device located beneath the sliding post can be used to vertically raise the sliding post. In this embodiment, the air seal and cylinder assemblies are not required. The sliding post, floor panel, positioning pin, and sliding post guide interact substantially as before.

Features of the present invention are therefore that:

it utilizes a combination pneumatic-mechanical system for lifting and stably maintaining the floor panel at a predetermined height;

it utilizes a controlled air leak via an orifice to lower the sliding post until the positioning pin engages the pin support seat located on the sliding post guide;

it utilizes a non-precision pneumatic lift system in conjunction with a positive mechanical support means;

the air supply means is connected to the cylinder via a removable side element located on the floor panel;

a positioning pin is inserted into the sliding post to maintain the floor panel at a fixed predetermined height;

the sliding post guide maintains the vertical alignment of the sliding post, prevents rotation of the sliding post, and supports the sliding post via its pin support seat;

the sliding post and its associated guide are the only precision elements of the system; and

only the sliding post guide must be accurately positioned and leveled.

Advantages of the present invention are therefore that:

it allows for economy and flexibility of theater and stage floor space;

it is adaptable for use with simple pneumatic lift means, a portable jack assembly, or an overhead hoist;

it is safe and economical;

the floor panel can be adapted to receive seats or other desired structures;

it is not susceptible to slow air leaks; and

field installation costs thereof are minimized.

BRIEF DESCRIPTION OF THE DRAWING

Other objects, features, and advantages of the present invention will be better appreciated by a consideration of the following detailed description and the drawing in which:

FIG. 1 is a partially cross-sectional front view of a modular floor element in the raised configuration according to the present invention;

FIG. 2 is an exploded perspective view of a modular floor element in the raised configuration and associated handrails, seats, lights and anchoring devices; and

FIG. 3 is a detailed cross-sectional view of an air seal assembly according to the present invention.

DETAILED DESCRIPTION

FIGS. 1 and 2 show a modular floor element according to the present invention. Modular floor element 200 substantially comprises floor panel assembly 10, sliding post assembly 20, sliding post air seal assembly 30, sliding post guide assembly 40, air cylinder assembly 50, and quick disconnect coupling and air hose assembly 60. Associated with modular floor element 200 are portable compressed air supply with gun 70 and removable furnishings 100 mounted to floor panel assembly 10. A plurality of modular floor elements 200 make up a modular floor system.

According to the present invention, floor panel assembly 10 includes steel X-shaped frame 11 having associated therewith threaded studs 17 welded to its underside, for rigidly and removably connecting floor panel assembly 10 to sliding post top plate 22. Flooring 12 and associated side stiffening members 13 and toe guard 14 form a rigid panel, which panel is fastened on top of frame 11. Bumper strip 15 is fastened on all sides of the floor panel assembly at its top edge. Removable side element or plug 16 is placed into an opening at the side of the floor panel assembly. The opening is used for connecting portable air gun 70 into quick disconnect coupling 61 for raising or lowering sliding post assembly 20 and associated panel assembly 10, when floor panel assembly 10 and sliding post assembly 20 are at their lowest position. Flush anchoring devices with slotted key holes 117 are located at the end of each side of floor panel assembly 10. Anchoring sleeves 18, which are perpendicular to the top surface of floor panel assembly 10 and located at each corner thereof, are mounted within floor panel assembly 10. Anchoring sleeves 18 are furnished with cover plugs 19 for closing the sleeve openings when sleeves 18 are not used for anchoring furnishings 100 to floor panel assembly 10.

Sliding post assembly 20 is used for raising and lowering floor panel assembly 10 and for supporting floor panel assembly 10 through positioning pin 27 on sliding post guide assembly 40 when floor panel assembly 10 is placed at any of its raised positions. Sliding post assembly 20 includes tubular member 21 having a circular cross section when viewed perpendicular to its longitudinal axis. Top plate 22 is rigidly welded or otherwise rigidly connected onto the extreme top end of tubular member 21 perpendicular to the longitudinal axis of such tubular member. Top plate 22 is used for mounting floor panel assembly 10 to the top end of sliding post assembly 20. Circular cap 26 is welded or otherwise rigidly mounted onto the extreme bottom end of tubular member 21, perpendicular to the longitudinal axis of such member. Circular cap 26 is used for providing support and connection for sliding post air seal assembly 30. Pin 23 is inserted through the tubular member near its top end and welded to the tubular member with both its ends protruding through to the outside of tubular member 21. This pin is located at the longitudinal center-line of the tubular member and perpendicular to that center-line, in line with positioning pin holes 24. The purpose of pin 23 is to support sliding post assembly 20 vertically on top of sliding post guide assembly 40, thereby bearing against groove 43, and to prevent its rotation relative to sliding post guide assembly 40, when floor panel assembly 10 and sliding post assembly 20 are at their extreme lowermost positions. Sliding post assembly 20 is vertically supported on top of sliding post guide 40 at any pre-set use position by removable positioning pin 27, which pin is inserted through positioning hole 24 which corresponds to the desired elevation of floor panel assembly 10. Positioning pin 27 also prevents rotation of the sliding post assembly relative to sliding post guide assembly 40, when such pin is bearing on top of sliding post guide assembly 40 within groove 43.

Positioning holes 24 on sliding post tubular member 21 are drilled through both sides of tubular member 21 through the center-line thereof and at right angles to the longitudinal axis thereof. Positioning holes 24 are spaced parallel to the longitudinal axis of tubular member 21 so as to correspond to desired pre-set elevations of floor panel assembly 10 use positions. The outside edges of positioning holes 24 are beveled so as to prevent distortion of the outside face of tubular member 21 from possible impact forces resulting from positioning pin 27 hitting the top of the sliding post guide assembly during the lowering operation. Continuous keyway 25 is cut into one side of tubular member 21, keyway 25 being parallel to the longitudinal axis of member 21. In this embodiment, keyway 25 is located at right angles to positioning pin holes 24; however, any other relative positioning of keyway 25 and positioning pin holes 24 can be used. Keyway 25 is used to prevent the rotation of sliding post assembly 20 relative to sliding post guide 40 while sliding post assembly 20 is being raised or lowered and otherwise when it is not being supported by pin 23 or positioning pin 27. Keyway 25 engages a key 42 which is part of sliding post guide assembly 40.

The functions of sliding post guide assembly 40 are as follows:

a. to rotationally and laterally guide and support sliding post and floor panel assemblies 20 and 10, respectively;

b. to vertically support, via pin 23, positioning pin 27, or via compressed air in cylinder space 56, sliding post and floor panel assemblies 20 and 10, respectively;

c. to support air cylinder assembly 50;

d. to support the entire modular floor element on permanent structure 80; and

e. to provide simple means for positioning and leveling the entire modular floor element relative to permanent structure 80 before rigidly fastening it to the structure.

Sliding post guide assembly 40 includes cast or welded metal cylindrical housing 41, further including finished cylindrical guiding surfaces 46 inside thereof, near its top and bottom ends; means for mounting key 42 near its top end; and means for mounting air cylinder assembly 50 to its bottom end. Cylindrical housing 41 further includes support flange or flanges 47 on the outside portion thereof and groove 43 for engaging and supporting fixed pin 23 or removable positioning pin 27. The purpose of cylindrical guiding surfaces 46 is to provide lateral support to sliding post assembly 20 at any position, while in motion or while stationary. The purpose of groove 43 is to provide vertical support to sliding post assembly 20, through fixed pin 23 or through removable positioning pin 27 when either of these pins bears against the surfaces of groove 43. Groove 43 also prevents rotation of sliding post assembly 20 and floor panel assembly 10, when either pin 23 or 27 engages such groove.

Key 42 engages keyway 25 and rotationally guides sliding post assembly 20 and floor panel assembly 10 while they are in motion. Key 42 is fastened to cylindrical housing 41 so as to permit its initial alignment with relation to groove 43 during assembly. Key 42 is accurately positioned when pin 27 bears against groove 43 so that the sides of keyway 25 are free to slide in relation to key 42. After this alignment is accomplished, key 42 connection is tightened to prevent movement thereof relative to cylindrical housing 41. This alignment prevents possible binding, which can otherwise be caused by the jamming of keyway 25 against key 42 whenever the alignment of either pin 23 or pin 27 to groove 43 is not precise. Sliding post guide assembly 40 is supported during installation by leveling bolts 45 and nuts 44. After it is properly leveled and positioned, sliding post assembly 40 is rigidly grouted in place with non-shrink grout 82. It is apparent that means other than concrete slab 80 could be used for fastening sliding post guide assembly 40 to the permanent support structure.

Air cylinder assembly 50 includes tubular cylinder 51, bottom cap 53, pressure relief valve 54, and air pipe 55. The top end of air cylinder assembly 50 is fastened to the bottom end of sliding post guide assembly 40, their longitudinal axes being concentric. Air cylinder assembly 50 also includes pressure in cylinder space 56 whenever sliding post assembly 20 overtravels in the upward direction. A compressed air source, not shown, and air gun 70 are connected to air cylinder assembly 50 via quick disconnect coupling 61, by piping, and by flexible hose 60. Air gun 70 includes raising and lowering valves, not shown. Quick disconnect coupling 61, or its housing 63, includes a positioning device, not shown, which permits connecting air gun 70 to quick disconnect coupling 61 only in one position. This is done so that the operator's hand 71 would be out of the way of floor panel assembly 10 as it travels upward. Quick disconnect coupling 61 further includes an orifice, not shown, which relieves the pressure in cylinder space 56 whenever air gun 70 is removed from quick disconnect coupling 61. The controlled escape rate of air from cylinder space 56 through this orifice slowly lowers sliding post assembly 20 until either pin 27 or pin 23 engages groove 43 on top of sliding post guide assembly 40 thereby setting the height of floor panel assembly 10. The orifice in quick disconnect coupling 61 guarantees that floor panel assembly 10 is always positively supported by either positioning pin 27 or pin 23.

FIG. 3 shows air seal assembly 30 according to the present invention. Neoprene cup 31 is supported by retainer plate 32 and connected to circular cap 26 through shoulder bolt 33, which bolt is rigidly connected or welded to circular cap 26. Retainer plate 32 and cup 31 are free to move laterally within the limits of hole 36, which hole is larger than the diameter of bolt 33. This movement permits neoprene cup 31 to align with air cylinder assembly 50 and eliminates binding in case of minor misalignment between air cylinder assembly 50 and sliding post assembly 20. Circular bumper plate 34 is placed in between cap 26 and retainer plate 32 and held in place by shoulder bolt 33. Bumper plate 34 prevents the bottom end of sliding post assembly 20 from leaving sliding post guide assembly 40 in case of overtravel in the upward direction. Circular neoprene ring 35 is placed on top of the bumper plate to absorb the impact between bumper plate 34 and sliding post guide assembly 40 during their contact.

Sliding post assembly 20 can be moved from sliding post guide assembly 40 when bumper plate 34 is removed from the bottom of the sliding post assembly 20.

From FIG. 1 it is apparent that each floor panel assembly can be raised and set to any pre-set position, higher than its initial position, by going through the following steps:

a. remove plug 16;

b. insert air gun 70 into quick disconnect coupling 61;

c. release pressured air by opening the valve, not shown, in air gun 70, into cylinder space 56, thereby lifting pin 27 off groove 43;

d. remove positioning pin 27;

e. raise sliding post assembly 20, together with floor panel assembly 10, with compressed air, slightly above the desired elevation so that the corresponding positioning hole 24 is slightly above groove 43;

f. insert positioning pin 27 into the appropriate positioning hole;

g. release the compressed air from cylinder space 56 by using the valve, not shown, which is part of the air gun 70, or remove air gun 70 from quick disconnect coupling 61. The escape of air from the cylinder space 56 lowers sliding post assembly 20 until positioning pin 27 engages groove 43 and supports floor panel assembly 10 through sliding post assembly 20; and

h. replace the plug 16.

From FIG. 1 it is apparent that each floor panel assembly can be lowered to any pre-set position lower than the initial position by going through the following steps:

a. remove plug 16;

b. insert air gun 70 into quick disconnect coupling 61;

c. release pressurized air, by opening the valve, not shown, in air gun 70, into the cylinder space 56, thereby lifting pin 27 off groove 43;

d. remove positioning pin 27 and insert it into the appropriate positioning holes above, corresponding to the desired new lower position of floor panel assembly 10; and

e. release the compressed air from cylinder space 56 by the use of the valve, not shown, which is part of air gun 70, or remove air gun 70 from quick disconnect coupling 61. The escape of air from cylinder space 56 lowers sliding post assembly 20 until positioning pin 27 engages groove 43 and supports floor panel assembly 10 through sliding post assembly 20.

It is further apparent from FIG. 1 that each floor panel assembly 10 is positively supported by positioning pin 27 or pin 23 at any of its positions which are preset by positioning pin holes 24. Therefore, these modular floor elements do not rely on air pressure to maintain their positions while in use. Also, no slow or accidental drift can occur, which is a common problem with pneumatic or hydraulic systems when not properly maintained. Also individual floor elements can be placed and positively supported at one or at various elevations, thereby providing the means for changing the configuration of the floor to suit particular program requirements. In addition, each floor element can be used as a theatrical or display elevator for creating the desired visual or functional effects for a performance.

As an alternate, the portable air source, not shown, air gun 70, quick disconnect coupling 61, housing 63, and piping 62 can be eliminated and replaced by permanent compressed air, a supply, piping, and appropriate control valves which would effect functions similar to those described above.

As a further alternate, the entire compressed air operating system can be eliminated. This would include the deletion of sliding post air seal assembly 30; air cylinder assembly 50; quick disconnect coupling; air hose assembly 60; and portable compressed air supply with air gun 70. The compressed air lifting system can be replaced with a portable jack or lift engaging the bottom end of sliding post assembly 20, or by an overhead hoist system connected to the top end of sliding post assembly 20. The functions and details of all other components of the modular floor element described above would remain unchanged.

FIG. 2, in addition to the basic floor element components described above, shows some of furnishings 100, which can be used in conjunction with the modular floor elements. Seats 105 are supported by legs 104 and held in position on top of floor panel assembly 10 by pins 103 inserted into anchoring sleeves 18. Light 101, can be inserted into anchoring sleeves 18. Guardrail units 102, or fascias, not shown, can be connected to the floor panel assembly through anchoring devices 117. Many other furnishings, different floor panel shapes, turntables, or combined structures supported by one or more sliding post assemblies 20 can be used in conjunction with the modular floor system.

While the arrangement according to the present invention has been described in terms of a specific embodiment, it will be apparent to those skilled in the art that many modifications are possible within the spirit and scope of the disclosed principle.

Claims

What is claimed is:

1. In a modular floor system, a plurality of modular floor elements each of which can be lifted to and retained at a predetermined height and each comprising:

a vertically directed hollow cylindrical guide member including first vertical guide means, and seating means on the upper portion thereof;

a hollow cylindrical post adapted to be vertically slidable along the interior portion of said guide member, said post including second vertical guide means adapted to interact with said first vertical guide means, a plurality of uniformly spaced radially directed holes located along the post's length and 90.degree. away from said first and second vertical guide means, first pin means fixedly attached to the post's upper external portion, and an air seal assembly located on the post's bottom portion, said first pin means being adapted to rest upon said seating means when said post is at its lowermost position;

a vertically directed hollow cylinder attached to the bottom portion of said guide member and having one closed end and one open end, said post's air seal assembly being slidable along the interior portion of said cylinder; and

means for supplying air to said cylinder, said cylinder including orifice means for allowing air to controllably escape from said cylinder;

activation of said supplying means causing said post to be vertically raised relative to said guide member slightly above said predetermined height and said orifice means allowing said post to vertically drop to said predetermined height, second pin means being insertable into the hole corresponding to said predetermined height for resting on said seating means thereby retaining said post at said predetermined height.

2. In a modular floor system, a plurality of modular floor elements each of which can be lifted to and retained at a predetermined height and each comprising:

a vertically directed hollow cylindrical guide member including seating means on the upper portion thereof;

a hollow cylindrical post adapted to be vertically slidable along the interior portion of said guide member, said post including a plurality of uniformly spaced radially directed holes located along the post's length, first pin means fixedly attached to the post's upper external portion, and an air seal assembly located on the post's bottom portion, said first pin means being adapted to rest upon said seating means when said post is at its lowermost position;

a vertically directed hollow cylinder attached to the bottom portion of said guide member and having one closed end and one open end, said post's air seal assembly being slidable along the interior portion of said cylinder; and

means for supplying air to said cylinder;

activation of said supplying means causing said post to be vertically raised relative to said guide member slightly above said predetermined height and deactivation of said supplying means causing said post to vertically drop to said predetermined height, second pin means being insertable into the hole corresponding to said predetermined height for resting on said seating means thereby retaining said post at said predetermined height and means for allowing air to controllably escape from said cylinder.