U.S. patent number RE37,615 [Application Number 09/266,398] was granted by the patent office on 2002-04-02 for anchored/resilient hardwood floor system.
This patent grant is currently assigned to Robbins, Inc.. Invention is credited to Michael W. Niese.
United States Patent |
RE37,615 |
Niese |
April 2, 2002 |
Anchored/resilient hardwood floor system
Abstract
An anchored/resilient floor system includes at least one upper
flooring layer supported by parallel rows of attachment members
which are supported above a base by a plurality of compressible
pads, the attachment members being secured to the base at
predetermined positions therealong by a fastener construction which
permits downward deflection under loaded conditions but prevents
vertical raising of the members beyond their initial static
position. The attachment members are anchored in a manner which
does not hold the pads in a precompressed state when the floor is
unloaded. The fastener construction may include a one, two or three
piece construction. The single member fastener construction is
particularly suitable for reanchoring or retrofitting an already
installed floor at a significantly lower cost than that of
installing a new floor, and the one-piece fastener construction
also may be adapted for use with a portable floor.
Inventors: |
Niese; Michael W. (Cincinnati,
OH) |
Assignee: |
Robbins, Inc. (Cincinnati,
OH)
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Family
ID: |
46276349 |
Appl.
No.: |
09/266,398 |
Filed: |
March 10, 1999 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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912310 |
Jul 13, 1992 |
5388380 |
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Reissue of: |
388388 |
Feb 14, 1995 |
05609000 |
Mar 11, 1997 |
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Current U.S.
Class: |
52/480; 52/393;
52/403.1; 52/508 |
Current CPC
Class: |
E04F
15/22 (20130101) |
Current International
Class: |
E04F
15/22 (20060101); E04B 005/00 () |
Field of
Search: |
;52/480,508,403.1,481.1,479,393,346 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
Superior Floor Company Inc., Hard Maple Floors, A Superior
Performance Stats With a Superior Floor, 09550/SUP, BuyLine 3624
and 08200/GRA, BuyLine 3245, 1992, 6 pages. .
Kenai Peninsula Borough of Alaska Project. .
YMCA of Groesbeck, Ohio Project. .
Utah County Armory of Springvile, Utah Project. .
L. A. Fitness, Inc. of Diamond Bar, California Project..
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Primary Examiner: Stephan; Beth A.
Attorney, Agent or Firm: Wood, Herron & Evans, LLP
Parent Case Text
This application is a continuation-in-part application of
applicant's U.S. patent application Ser. No. 912,310, now U.S. Pat.
No. 5,388,380, entitled "Anchored/Resilient Sleeper For Hardwood
Floor System", which was filed on Jul. 13, 1992, which is expressly
incorporated herein by reference in its entirety.
Claims
I claim:
1. A floor system supporting a wear surface above a non-portable
base comprising:
an elongated attachment member with upper and lower surfaces;
at least two compressible pads contacting the lower surface and
supporting the attachment member in spaced relation above the base;
and
a fastener arrangement for anchoring the attachment member to the
base in a manner which does not hold the pads in a precompressed
state when the floor system is unloaded, said fastener arrangement
begin located at spaced positions along the attachment member and
enabling said member to be downwardly deflectable but not upwardly
raisable beyond a static position, wherein the attachment member
has at least one vertically oriented bore extending therethrough
from the upper surface to the lower surface, said bore having an
enlarged-diameter upper portion and a reduced-diameter lower
portion and said fastener arrangement extends through said
bore.
2. The floor system of claim 1 and further comprising:
means for reducing frictional engagement between the fastener
arrangement and the attachment member, said reducing means located
within the reduced diameter lower portion of said bore.
3. The floor system of claim 2 wherein the reducing means comprises
a cylindrical sleeve.
4. The floor system of claim 1 wherein the pads are secured to the
lower surface of the attachment member.
5. The floor system of claim 1 wherein the pads are spaced
horizontally away from said bore.
6. The floor system of claim 1 wherein the vertical distance
between the top of the fastener arrangement and the upper surface
is greater than the vertical compressibility of the pad.
7. The floor system of claim 1 wherein the fastener arrangement
further comprises:
an anchor pin having a first end with an upper head with a diameter
less than said bore upper portion and greater than said bore lower
portion, a second end adapted to be extended into the bore and a
depth stop located between the first and second ends, the depth
stop adapted to limit downward extension of the pin into the bore,
the vertical dimension of the pin from the depth stop to the upper
head being approximately equal to the combined vertical dimension
of the attachment member and the pads when the pads are not in a
compressed state.
8. The floor system of claim 7 wherein the anchor pin has an
expansion curve located adjacent the second end.
9. The floor system of claim 7 wherein the anchor pin includes an
externally threaded bottom end which is received within an
internally threaded anchor embedded in the base.
10. The floor system of claim 7 and further comprising:
means for reducing frictional engagement between the anchor pin and
the attachment member, said reducing means located within the
reduced diameter lower portion of said bore.
11. An anchored/resilient floor system supporting an upper flooring
layer above a base, comprising:
a plurality of attachment members arranged in parallel rows below
the upper layer to form a subfloor layer;
a plurality of compressible pads located below the attachment
members to support the attachment members and the upper flooring
layer in spaced relation above the base; and
a fastener arrangement for anchoring each of the attachment members
to the base in a manner which does not hold the pads in a
precompressed state when the floor system is unloaded, said
fastener arrangement enabling the members to be downwardly
deflectable but not upwardly raisable beyond an initial static
position, said fastener arrangement located at spaced positions
along the lengths of each of the attachment members, wherein each
of the attachment members has at least one bore extending
vertically therethrough, each of the bores having an
enlarged-diameter upper portion and a reduced-diameter lower
portion, and the fastener arrangement extends through the
bores.
12. The floor system of claim 11 and further comprising:
means for reducing frictional engagement between the fastener
arrangement and the attachment member, said reducing means located
within the reduced diameter lower portion of said bore.
13. The floor system of claim 12 wherein the reducing means
comprises a cylindrical sleeve.
14. The floor system of claim 11 wherein said upper flooring layer
comprises a plurality of floorboards having an upper wear
surface.
15. The floor system of claim 14 wherein said upper flooring layer
further comprises a layer of panels.
16. The floor system of claim 15 and further comprising:
a plurality of floorboards secured to the panels.
17. The floor system of claim 11 wherein the attachment members of
the subfloor are relatively narrow and spaced from each other in
parallel rows.
18. The floor system of claim 11 wherein the attachment members of
the subfloor comprise panels.
19. The floor system of claim 18 wherein the panels are laid end to
end in parallel rows with edges of adjacently situated rows spaced
apart a predetermined distance.
20. The floor system of claim 11 wherein the fastener arrangement
further comprises:
an anchor pin having a first end with an upper head with a diameter
less than said bore upper portion and greater than said bore lower
portion, a second end adapted to be driven into the bore and a
depth stop located between the first and second ends, the vertical
dimension of the pin between the depth stop and the upper head
being approximately equal to the combined vertical dimension of the
lower portion of the bore of the attachment member and the pads
when the pads are not in a compressed state.
21. The floor system of claim 20 wherein the anchor pin includes an
externally threaded bottom end which is received within an
internally threaded anchor embedded in the base.
22. The floor system of claim 20 and further comprising:
means for reducing frictional engagement between the anchor pin and
the attachment member, said reducing means located within the
reduced diameter lower portion of said bore.
23. An anchored/resilient hardwood floor system comprising:
a top layer of floorboards;
an upper subfloor located below the top layer;
a plurality of attachment members arranged in parallel rows to form
a lower subfloor located below the upper subfloor;
a plurality of compressible pads located below the attachment
members and supporting the attachment members, the upper subfloor
and the top layer in spaced relation above a base; and
means for mechanically fastening the attachment members to the base
in a manner which does not hold the pads in a precompressed state
when the floor system is unloaded, said anchoring means permitting
downward deflection but preventing vertical raising of the
floorboards, the upper subfloor and the attachment members beyond
an initial static position, the mechanically fastening means
located at spaced positions along the lengths of each of the
attachment members, wherein each of the attachment members has at
least one bore extending vertically therethrough, each of the bores
having an enlarged-diameter upper portion and a reduced-diameter
lower portion, and the mechanically fastening means extends through
the bores.
24. The floor system of claim 23 wherein the attachment members are
narrow and elongated and located in spaced rows and the rows of
attachment members are spaced at least about fifteen inches
apart.
25. The floor system of claim 24 wherein the attachment members are
at least eight feet long.
26. A floor system comprising:
an upper wear layer having top and bottom surfaces;
a subfloor located below the wear layer and secured thereto, the
subfloor supporting the wear layer above a non-portable base;
the subfloor having a plurality of substantially vertical bores
formed therethrough, each bore having an upper section and a lower
section, the diameter of the upper section being greater than the
diameter of the lower section;
a plurality of pads, the pads supporting the subfloor and wear
layer above the base;
.[.a plurality of anchor pins having top and bottom ends, each
anchor pin extended through one of the bores and having its
respective bottom end secured to the base, the top end being of
diameter greater than the bore lower section, the anchor pin
further including a depth stop located between the top and bottom
ends, the depth stop limiting downward movement of the anchor pin
into the base during installation, the vertical dimension between
the depth stop and the top end being approximately equal to the
combined vertical dimension of the lower section of the bore and
the pads when the pads are in an uncompressed state so that the
secured anchor pins permit downward deflection of the wear layer
and subfloor upon impact from above the prevent vertical raising
above a static position..].
.Iadd.a fastener arrangement for anchoring the subfloor to the base
in a manner which does not hold the pads in a precompressed state
when the floor system is unloaded, said fastener arrangement being
located at spaced positions along the subfloor and enabling the
subfloor to be downwardly deflectable but not upwardly raisable
beyond a static position, wherein the subfloor has at least one
vertical opening extending therethrough from the upper surface to
the lower surface, said bore having an upper portion and a lower
portion and said fastener arrangement extends through said
opening..Iaddend.
27. The floor system of claim 26 wherein the subfloor further
comprises:
a single layer of attachment members with the bores formed
therethrough.
28. The floor system of claim 26 wherein the subfloor further
comprises:
an upper layer .[.secured to.]. .Iadd.located above .Iaddend.a
lower layer, the upper portions of the bores defined by the upper
layer and the lower portions of the bores defined by the lower
layer.
29. The floor system of claim 28 wherein the upper layer comprises
panels and the lower layer comprises spaced rails.
30. The floor system of claim .[.29.]. .Iadd.28 .Iaddend.wherein
the upper portions of the bores are defined by spaces between
.[.adjacently located panels.]. .Iadd.parallel rows .Iaddend.of the
upper layer.
31. The floor system of claim .[.30.]. .Iadd.29 .Iaddend.wherein
the panels are angled with respect to the rails, adjacently located
panels are spaced from each other and not all rails include bore
lower portions, thereby allowing reduced area portions of the floor
to act in a free floating manner.
32. The floor system of claim .[.26.]. .Iadd.41 .Iaddend.and
further comprising:
means for reducing frictional engagement between the anchor pin and
the attachment member, said reducing means located within the
reduced diameter lower portion of said bore.
33. A method for installing an anchored/resilient floor system to a
non-portable base comprising the steps of:
forming a bore through an attachment member from a top surface
thereof to a bottom surface thereof, the bore having an
enlarged-diameter portion adjacent the top surface and a
reduced-diameter portion adjacent the bottom surface;
securing at least two compressible pads to the bottom surface of
the attachment member;
laying the attachment member on a base with the pads contacting the
base;
drilling a hole in the base in alignment with the bore; and
extending a fastener downwardly through the bore and driving the
fastener into the hole in the base, the fastener including an upper
end which cooperates with the bore lower portion to secure the
attachment member to the base in a manner which permits downward
deflection of the attachment member but prevents vertical raising
thereof and whereby said driving step does not vertically compress
the pads, thereby to retain optimum compression capability for the
pads.
34. The method of claim 33 wherein the forming step further
comprises:
aligning and securing two separate pieces to form the attachment
member.
35. A method of reanchoring an installed floor system of the type
having an upper wear layer secured to a subfloor which is supported
above a base by a layer of compressible pads, the method comprising
the steps of:
removing a plug of the wear layer;
forming a bore through the subfloor, the bore having an enlarged
diameter upper portion and a reduced diameter lower portion;
drilling a hole in the base in alignment with the bore;
extending an anchor pin through the plug and the bore and driving
the pin into the hole in the base to securely anchor a bottom end
of the pin thereto, the anchor pin including a top end with a
diameter greater than the bore lower portion but less than the bore
upper portion, thereby to hold the subfloor to the base, the anchor
pin further including a depth stop located between the top and
bottom ends, the depth stop adapted to limit downward movement of
the pin into the base to a predetermined vertical position during
driving, the vertical dimension between the top end and the depth
stop being approximately equal to the combined vertical dimension
of the lower portion of the bore and the pads when the pads are in
an uncompressed state, thereby to permit downward deflection of the
wear layer and the subfloor upon impact to the wear layer but to
prevent vertical raising thereof; and
replacing the plug back into the wear layer.
36. The method of claim 35 wherein the bore is formed by
drilling.
37. The method of claim 35 wherein the floor system includes at
lest two subfloor layers and the lower portion and the upper
portion of the bore are formed in separate layers of the
subfloor.
38. A portable floor system covering a rigid non-portable base,
comprising:
a plurality of portable and connectable floor sections adapted to
be connected in a predetermined manner to form a floor overlying
the base, each of the connectable sections further including:
an upper wear layer;
at least one subfloor layer below the upper wear layer;
a plurality of compressible pads supporting the subfloor layer and
wear layer in spaced relation above the base; and
a fastener arrangement for removably securing the section to the
base in a manner which allows a downward vertical deflection but no
upward vertical raising of the wear layer and subfloor layer.
39. The floor system of claim 38 wherein the fastener arrangement
further comprises:
an anchor pin with an upper end engaging the section and a threaded
lower end adapted to be received within an internally threaded
anchor embedded in the base. .Iadd.
40. The floor system of claim 26 wherein the opening is a bore
which is circular in cross-sectional shape and has an enlarged
diameter for the upper portion and a reduced diameter for the lower
portion..Iaddend..Iadd.
41. The floor system of claim 40 wherein the fastener arrangement
further comprises:.Iaddend.
.Iadd.a plurality of anchor pins having top and bottom ends, each
anchor pin extended through one of the bores and having its
respective bottom end secured to the base, the top end being of
diameter greater than the bore lower section, the anchor pin
further including a depth stop located between the top and bottom
ends, the depth stop limiting downward movement of the anchor pin
into the base during installation, the vertical dimension between
the depth stop and the top end being approximately equal to the
combined vertical dimension of the lower section of the bore and
the pads when the pads are in uncompressed state so that the
secured anchor pins permit downward deflection of the wear layer
and subfloor upon impact from above but prevent vertical raising
above a static position..Iaddend..Iadd.
42. The floor system of claim 28 wherein the fastener arrangement
further comprises:.Iaddend.
.Iadd.a clip having spaced upper and lower sections and a
midsection therebetween;.Iaddend.
.Iadd.the upper section engaging a top surface of the lower layer
of the subfloor and residing in the upper portion of the
opening;.Iaddend.
.Iadd.the midsection extending vertically through the lower portion
of the opening; and.Iaddend.
.Iadd.the lower section secured to the bore..Iaddend..Iadd.
43. The method of claim 34 wherein during said extending there is a
solid line or rigid material between the upper end of the fastener
and the bore, thereby to permit vertical compression of the
pads..Iaddend..Iadd.
44. The method of claim 42 wherein the fastener is single pin with
a depth stop..Iaddend..Iadd.45. The method of claim 43 wherein the
single pin has a depth stop, and the depth stop, the pin itself and
the upper end of the pin define the solid line of rigid
material..Iaddend.
Description
FIELD OF THE INVENTION
This invention relates to hardwood floor systems. More
particularly, this invention relates to an anchored and resilient
sleeper for a hardwood floor system.
BACKGROUND OF THE INVENTION
Floor systems, particularly hardwood floor systems, are commonly
supported by sleepers. Sleepers are elongated nailing members,
often of wood, laid end to end in parallel rows to form a subfloor
layer for supporting a layer of floorboards secured thereabove. The
sleepers may be relatively narrow and spaced from each other, or
the sleepers may be relatively broad with edges of adjacent rows in
abutting relationship. If desired, one or more subfloor layers may
be used between the wear layer and the sleepers. The sleepers
support the other floor components above a base.
One recognized advantage of supporting a floor system with sleepers
relates to moisture susceptibility. The components of most floor
systems are made of wood. Humidity changes from season to season
cause wooden components of floor systems, and particularly an upper
layer of floorboards, to expand with moisture intake and contract
with moisture expulsion. Because sleepers support these other
components above the base, the sleepers limit moisture transfer
between the base and these other components. Moreover, if the
sleepers are narrow and spaced away from each other, the free space
between the supported components and the base enables air to
circulate air therebetween to minimize moisture transfer.
Because moisture-caused expansion and contraction of floor system
components may result in buckling, it is desirable to securely
anchor the floor system, particularly the sleepers, to the base
below. Anchoring of the sleepers provides an acceptable level of
dimensional stability for the floor system, compared to a floor
system wherein the sleepers are unanchored.
It is also desirable for hardwood floor systems to provide a degree
of resilience. In the context of this application, resilience
generally means the ability of a floor system to absorb shock upon
impact and to deflect downwardly upon impact. Particularly for
hardwood floors used in athletic contests, the resilience of the
floor system may play a major role in reducing the incidence of
athletic injury. In short, if a floor provides some degree of give,
the stress placed upon the musculoskeletal structure of the athlete
is reduced.
It is common practice to provide resiliency for a floor system by
locating compressible pads below the sleepers. The compressibility
of the pad enables the sleepers and the floorboards thereabove to
deflect downwardly. The amount of downward deflection and the shock
absorption of the floor system will depend upon a number of
factors, including the shape and composition of the pads.
Recent studies indicate that, while resiliency is important to the
reduction of susceptibility to athletic injury, uniformity in
resiliency is also critical. Thus, it is desirable to provide a
floor system with a high degree of resiliency which is also uniform
throughout its surface area.
Unfortunately, it has proved difficult to achieve dimensional
stability, optimum resiliency and uniformity in resiliency for
hardwood floors supported by sleepers. The enhancing of one of
these two features commonly adversely affects the other. For
instance, when sleepers are supported above the base by a plurality
of compressible pads and the sleepers are fastened to the base,
direct fastening of the sleeper produces some initial compression,
or precompression of the pads which is greater than the normal
compression due to gravity from the components located thereabove.
The pads remain compressed to this state throughout the life of the
floor, even when the floor is unloaded.
Because of this already compressed state, the capability of the
pads for further deflection is inhibited, and the overall
resiliency of the floor system is greatly reduced. Another
disadvantage results from this excess precompression. Because an
excessive percentage of the compressibility is "used up", the floor
has a higher chance of "bottoming out" or deflecting to its
maximum, upon impact from above. This occurs when the pads compress
maximally to a state where the floorboards deflect into contact
with the rigid fasteners. On the other hand, if the floor system is
free-floating, i.e. the sleepers are not anchored securely to the
base, the entire floor system may be dimensionally unstable.
While some commercially available floor systems have achieved some
degree of success in addressing one or more of these concerns, such
floor systems tend to have a relatively high cost due to an
increase in the number or complexity of structural components
required for achieving these features and the increased costs
associated with shipping and installing these components. As a
result, the benefits of these floor systems have been limited
unnecessarily to a relatively low number of users.
It is an objective of this invention to achieve optimum dimensional
stability and optimum resiliency and uniformity of resiliency for a
hardwood floor system.
It is another objective of this invention to substantially improve
resiliency and dimensional stability for a relatively low cost
hardwood floor system.
It is still another objective of this invention to enhance the
dimensional stability of a hardwood floor system without producing
a corresponding loss of resiliency, or loss in uniformity of
resiliency.
The objectives of this invention are achieved by a sleeper
construction which utilizes an attachment or nailing member
supported by compressible pads above a base and a fastening
arrangement which secures the attachment members directly to the
base without interacting with the pads. This fastening arrangement
enables the attachment members to deflect downwardly upon impact to
upper floor layers but restricts upward raising of the attachment
members beyond the initial static position of the pads. More
importantly, this fastening arrangement enables the attachment
members to be anchored to the base in a manner which does not
precompress the pads when the floor system is unloaded. Thus, this
anchored/resilient sleeper provides optimum dimensional stability
and resiliency.
Because the manner of anchoring the attachment members does not
precompress the pads or hold them in a precompressed state, i.e.
beyond the normal weight bearing compression due to components
located thereabove, an even distribution of the compressible pads
along the attachment members will assure a uniformly resilient, yet
firmly anchored, floor system.
Additionally, because of its simplicity and relatively few number
of parts, the embodiments of this invention provide anchoring,
resiliency and uniformity in resiliency for a sleeper-type floor
system at a low cost. Fabrication and installation of the
attachment members is also simplified. Finally, because the
fastening arrangement provides secured anchoring, the lengths of
the attachment members may be increased if narrow, spaced
attachment members are used. As a result, less waste is produced
and shipping, handling and installation costs are reduced.
According to one preferred embodiment of the invention, a fastener
construction is utilized which may be of one, two or three piece
construction. With this embodiment, each attachment or nailing
member has at least one vertical bore extending from an upper
surface to a lower surface thereof. At least one compressible pad
is secured to the lower surface. The vertical bore includes an
enlarged-diameter upper portion and a reduced-diameter lower
portion.
The three piece construction includes a sleeve, a washer and the
fastener. The sleeve resides within the lower, reduced-diameter
portion, with the bottom edge of the sleeve contacting the base and
the top edge of the sleeve residing adjacent the upper portion of
the bore. The washer resides on top of the sleeve, in alignment
therewith, and the fastener extends therethrough.
According to a second variation of this first preferred embodiment
of the invention, the sleeve includes an upper flange, and no
washer is necessary. For both variations, a fastener extends
downwardly through the flange, through the sleeve and into the
base. An enlarged head at the top of the fastening pin engages and
holds the washer or the flange against the bottom surface of the
upper portion of the bore.
According to a third variation of the invention, the fastener
arrangement may comprise a single anchor pin with an enlarged top
end, or head, having a diameter greater than the bore lower portion
but less than the bore upper portion, a bottom end to be driven
into the base and a depth stop located between the top and bottom
ends. The depth stop feature may not be necessary for some
installations. The vertical distance between the depth stop and the
top end is approximately equal to the combined vertical dimension
of the attachment member and the pad.
For all three variations, because the outer diameter of the sleeve
or fastener is less than the diameter of the reduced-diameter lower
portion of the bore, upon impact from above the attachment member
may deflect downwardly in an unimpeded manner. The combined
vertical dimension of the: 1) sleeve and the washer (first
variation); 2) the sleeve with flange (second variation); or 3) the
non-embedded portion of the fastener (third variation), is equal to
the combined vertical dimension of the pad and the lower portion of
the bores. Thus, for all three variations, the structure provides a
solid line of rigid material between its top end and the base, so
that downward driving forces applied via the fastening pin do not
precompress the pads.
Preferably, the vertical dimension between the top of the fastening
pin and the upper surface of the nailing member is greater than the
maximum compression of the pads. This ensures that, upon downward
deflection of the nailing members, the fastening pin will not
project above the upper surface of the nailing member to contact an
above-subfloor or floorboard layer.
To produce this structure, the nailing members are cut to a desired
length and to a desired width, which may be relatively narrow or
relatively broad, depending upon the type of floor system. The
bores are then cut vertically through the nailing members from the
upper surface to the lower surface. Thereafter, the compressible
pads are secured to the lower surface of the nailing member. The
number of pads and bores will depend upon the lengths and widths of
the nailing members and the desired orientation. With the bores cut
and the pads secured, the sleepers are ready for shipping to the
job site. Alternately, if desired, these two latter steps may be
performed at the job site.
To install this structure, multiple nailing members are laid end to
end in parallel rows, with the spacing between the rows dependent
upon the widths of the nailing members, and also dependent on
whether any open space is necessary between adjacent rows. The pads
support the members above the base. If the nailing members are
panel-type, there will be some spacing between adjacent rows. If
desired, every other nailing member in each row may offset
laterally. If using the first or second variation, the sleeves and
washers, or sleeves with flanges, are then placed within the bores.
Subsequently, fastening pins are driven through the sleeves, or
through the sleeve and washer, and then into the base below. For
the third variation, the fasteners are driven into the base without
prior placement of the sleeves and/or washers.
Alternatively, holes may initially drilled into the base, as by
extending a drill bit through the bores, and then the fastening
pins may be driven into the drilled holes, This eliminates the
possibility of cracking of the base, which may occur upon impact
when pre-drilled holes are not used. When fully extended, the head
ends of the fastening pins engage either the top surfaces of the
washers, the top surface of the flanges or the nailing member
itself, depending upon which construction is used. In this manner,
the heads of the fastening pins hold the bottoms of the
counterbores in the nailing members.
Because the sleeve and washer, the sleeve with the flange, or the
fastener alone, does not compress vertically during installation,
the fastener structure bears all the vertical force during
installation. As a result, driving of the fasteners into the base
does not vertically compress the pads. Moreover, after
installation, when the floor system is unloaded, the pads are not
held in a compressed state, i.e. beyond the compression due to
normal weight bearing of components thereabove. Accordingly, after
installation, the compressible pads retain their maximum
compressive capability, thereby providing optimum resiliency
potential throughout the floor system.
With the single piece anchor pin construction, after drilling the
holes in the base, the anchor pins are extended through the bores
and driven directly into the holes in the base to achieve secured
engagement therein. The depth stops limit downward movement of the
anchor pins to position the top ends thereof at a predetermined
vertical distance above the base, this predetermined distance being
equal to the combined vertical dimension of the pads and the lower
portions of the bores of the attachment members.
The upper flooring layers are then secured to the tops of the
nailing members. According to one preferred construction, at least
one subfloor of panels is secured to the relatively narrow nailing
members, and then tongue-and-groove maple floorboards are secured
to the uppermost layer of panels. Because of the combination of
anchored and resilient nailing members, along with the one or more
layers of panels, this particular floor construction provides
resiliency with a high degree of uniformity through its entire
surface area. As indicated previously, recent studies suggest that,
in addition to resiliency, uniformity of resiliency also plays a
critical role in reducing athletic injury on athletic floor systems
and enhancing performance.
Alternatively, the floorboards may be secured directly to the
nailing members. This embodiment may be desirable if only one
subfloor layer of wide, panel-type nailing members is utilized, or
even if one layer of relatively narrow, spaced rows of attachment
members is used. As still another alternative, if desired, the
upper flooring layer may comprise one or more wood or non-wooden
layers, depending upon the primary commercial use of the floor
system.
Because of the relatively few number of parts and simple
construction, this inventive structure provides conventional
stability, resiliency and uniformity in resiliency for a hardwood
floor system at a relatively low cost, compared to prior anchored
and resilient sleeper-type floor systems.
Additionally, with the third variation of the invention, an already
installed free floating floor or an anchored floor supported on
resilient pads may be easily retrofitted or repaired to securely
anchor the attachment members to the base in a manner which
accomodates downward deflection but no vertical rising.
The invention contemplates several additional features applicable
to all of the embodiments, such as "slicing" the attachment members
horizontally to use a stacked or two-component attachment member.
This eliminates the need to mill a two diameter bore, and it also
provides an additional degree of versatility in constructing and
arranging the subfloor.
These and other features of the invention will be more readily
understood in view of the following detailed description and the
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view which illustrates a hardwood floor system
according to a first preferred embodiment of the invention, wherein
the attachment members are relatively narrow.
FIG. 2A is a disassembled perspective showing the fastener
arrangement for a hardwood floor system constructed in accordance
with a first preferred embodiment of the invention.
FIG. 2B is a cross-sectional view taken along lines 2B--2B of FIG.
1.
FIG. 2C is an elevational view which depicts a two-piece variation
of the fastener arrangement.
FIG. 2D is a cross-sectional view, similar to FIG. 2B, showing
another variation of the first preferred embodiment of the
invention, a one-piece fastener arrangement.
FIG. 3A is a perspective view which depicts an alternative
embodiment of the invention which is particularly suitable for a
floor with a relatively narrow attachment member.
FIG. 3B is a cross-sectional view taken along lines 3B--3B of FIG.
3A.
FIG. 4A is a perspective view which depicts another alternative
embodiment of the invention which is particularly suitable for use
with relatively narrow attachment members.
FIG. 4B is a cross-sectional view which depicts still another
alternative embodiment of the invention which is particularly
suitable for relatively narrow attachment members.
FIG. 5 is a plan view, similar to FIG. 1, which illustrates a
hardwood floor system according to a second preferred embodiment of
the invention, wherein the attachment members are relatively
broad.
FIG. 6 is a disassembled perspective, similar to FIG. 2A, showing
the anchoring means for a hardwood floor system constructed in
accordance with a second preferred embodiment of the invention.
FIG. 7 is a cross-sectional view, similar to FIG. 2B, of the
hardwood floor system shown in FIGS. 5 and 6.
FIG. 8 is a cross-sectional view, similar to FIGS. 2B and 7, which
depicts a single piece fastening arrangement for anchoring the
attachment members to a base, in accordance with a variation of the
invention applicable to the other embodiments.
FIG. 9 is a cross-sectional view, similar to FIG. 8, which shows
another feature of the invention which is applicable to all of the
embodiments.
FIG. 10 is a transverse cross-sectional view, similar to FIG. 8,
which shows a single piece fastener arrangement in combination with
an attachment member which comprises two separate, layered pieces,
another feature which is applicable to all of the embodiments.
FIG. 10A is transverse cross-sectional view which shows another
subfloor structure which may be used with the single piece
fastening arrangement, separate layered pieces of different
dimension.
FIG. 10B is a bottom view of the subfloor structure of FIG.
10A.
FIG. 11 is a plan view which shows yet another version of the
single piece fastening arrangement shown in FIG. 8.
FIG. 12 is a cross-section taken along lines 12--12 of FIG. 11.
FIG. 13 shows still another embodiment of this invention, a single
piece fastener arrangement for anchoring a resilient permanent
floor system in a manner which allows the floor system to be
removed, similar to a portable floor system.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view which depicts, in section, a hardwood floor
system 10 in accordance with a first preferred embodiment of the
invention. The floor system 10 includes a plurality of floorboards
12 (Section I), an upper subfloor comprising a layer 14 of panels
underlying and supporting the floorboards 12 (Section II), a
plurality of nailing or attachment members 16 laid end to end in
parallel rows to support the nailing or attachment members 16 above
a base 20 (Section III). The construction of this floor system 10
generally includes the pads 18, the nailing members 16 and the
structural components which anchor the nailing members 16 to the
base 20.
Typically, for athletic floors, the floorboards 12 are tongue and
groove maple floorboards, as is well known in the industry. If
desired, the floorboards 12 may have kerfs in their bottom
surfaces. Kerfing the floorboards 12 provides breaks or
discontinuities in the floor system 10 which will effect the impact
response frequency and impact deflection attenuation within a
reduced surface area. The floorboards 12 are secured by nails (as
in FIG. 3) to the subfloor layer 14. The subfloor layer 14 is
preferably formed from a plurality of 4'.times.8' plywood panels
having a uniform thickness of about 1/2 inch. The nailing members
16 depicted in FIG. 1 are wood, with cross sectional height and
width dimensions of about 11/2" and 21/2" respectively, and a
length of either 4 feet or 8 feet. In the past, the spacing for the
parallel rows of this type of nailing member 16 has been about 12",
although it is to be understood that the spacing may vary depending
upon the widths of the nailing members 16. If the nailing members
16 have a greater width, and/or are panel-type, there may be
relatively little spacing between adjacent rows.
According to one aspect of the invention, the lengths of the
nailing members 16 of the type shown in FIG. 1 may be increased to
about 8' and the spacing between the rows of nailing strips 16 may
be increased to about 15" to 17". The pads 18 shown in FIGS. 1 and
2 are described in applicant's co-pending application, U.S. Ser.
No. 857,232 filed on Mar. 25, 1992, and entitled "Prefabricated
Sleeper For Anchored and Resilient Hardwood Floor System". However,
it is also to be understood that the advantageous features of this
invention could be achieved with any one of a number of pad types,
as long as the pads 18 support the nailing members 16 in spaced
relation above base 20, and so long as the pads 18 are
compressible.
The primary feature of the invention relates to anchoring the
nailing members 16 to the base 20 in a manner which permits
downward deflection and prevents vertical raising but does not
substantially precompress the pads 18 during unloaded conditions.
Because the nailing members 16 are downwardly deflectable but not
vertically raisable, the floorboards 12 and the subfloor layer 14,
or any alternative upper flooring layer supported by the nailing
members 16, are also downwardly deflectable but not vertically
raisable.
To accomplish these features, each nailing member 16 has at least
one bore 22 extending vertically therethrough from an upper surface
24 to a lower surface 25, as shown in FIG. 2A and FIG. 2B. Each
bore 22 has an enlarged-diameter upper portion 27 and a
reduced-diameter lower portion 28. Upper portion 27 has a
preferable diameter of about 11/8", and lower portion 28 has a
preferable diameter of 5/8". Preferably, the vertical dimension of
the upper portion 28 is about 1/2"-3/4", and the vertical dimension
of the lower portion is about 3/4"-1". Preferably, the bores 22 are
spaced laterally away from the pads 18, though this is not critical
or necessary.
For a thin nailing member 16 which is 4' long, it is preferable to
use two bores 22, with the nailing member 16 supported by five pads
spaced equidistantly along the entire length of the nailing member
16. For a nailing member which is 8' in length, it is preferable to
utilize three bores 22, with nine pads spaced equidistantly along
the length of the nailing strip 16. However, it is also to be
understood that the number of bores 22 and/or pads 18 may be varied
and reoriented, depending upon the use of the floor system 10 and
the structural composition of the upper subfloor layer or layers.
More particularly, if the nailing members 16 are panel-type, with a
width of up to four feet, each nailing member 16 may include up to
four rows of bores 22 and pads 18.
To anchor the nailing members 16 to the base 20, according to a
first variation of the first preferred embodiment, as shown in FIG.
2B, a sleeve 30 is located within the reduced-diameter lower
portion 28 of each of the bores 22. The sleeve 30 has a bottom edge
32 which contacts the base 20 and a top edge 33 located adjacent
the enlarged-diameter upper portion 27. The outer diameter of the
sleeve 30 is preferably about 9/16", so that the nailing member 16
may deflect downwardly without frictionally engaging the sleeve 30.
A washer 35 rests upon the top edge 33 of the sleeve 30. The washer
35 is coaxial with the sleeve 30, and a peripheral portion of the
washer 35 rests upon a horizontal surface 36 of the nailing member
16 which defines the bottom of upper portion 27. The washer 35 has
an inner diameter which is less than the diameter of the sleeve 30
and greater than the diameter of the anchor pin 40.
According to a second variation of this embodiment, as shown in
FIG. 2C, the sleeve 30 includes an integrally-formed upper flange
37 at the top end thereof. The combined vertical dimension of the
sleeve 30 with the flange 37, or the sleeve 30 and the washer 35,
is substantially equal to the combined vertical dimension of the
pad 18 and the lower portion 28.
For either embodiment, a fastening pin 40 extends downwardly
through sleeve 30 and into the base 20, as shown in FIG. 2B. Pin 40
has an enlarged head 41 at a top end thereof which tightly engages
and holds the washer 35, or the sleeve 30 and the flange 37,
against surface 36, thereby tightly securing the bottom edge 32 of
the sleeve against the base 20. In this position, the head 41 of
the pin 40 prevents upward movement of the sleeve 30 and the washer
35, or the flange 37. The pin 40 also cooperates with the washer 35
or the sleeve 30 and the flange 37 to hold the nailing member 16 in
a secured, anchored position with respect to the base 20, so that
the nailing member 16 cannot raise upwardly therefrom.
Additionally, due to the relative diameter of the sleeve 30 with
respect to lower portion 28, and due to the sleeve 30 with respect
to lower portion 28, and due to the compressibility of the pads 18,
the nailing members 16 are downwardly deflectable upon impact to
the floorboards 12.
Anchoring of the nailing members 16 with the pin 40 and sleeve 30
combination provides dimensional stability for the nailing members
16 and the entire floor system 10. The downward deflectability of
the nailing members 16 also provides resiliency for the entire
floor system 10. In addition, this invention optimizes the
resiliency of the compressible pads that are utilized. The
interrelationship of the bore 22, the washer 35, the sleeve 30 and
the surface 36 anchors the nailing members 16 in a manner which
does not hold the pads 18 in a precompressed state when the floor
system 10 is unloaded. Finally, because of the uniform distribution
of the pads 18 and the pins 40, the floor system 10 is highly
uniform in resilient response characteristics.
To further enhance the ability of the floor system 10 to withstand
horizontal movement due to moisture intake or egress, the diameters
of the bores 22 may be oversized with respect to the sleeve 30.
During installation, the sleeve 30 and the washer 35, or the sleeve
30 and the flange 37, bear the downward compressive force applied
when the pin 40 is driven vertically downward. The pads 18 are
sufficiently isolated from the downward force so that they are not
precompressed. As a result, the floor system 10 provides optimum
resiliency characteristics for whatever type of compressible pad is
used.
FIG. 2D shows another variation, a more basic approach which
contemplates a one-piece fastener structure, as opposed to a
two-piece or three-piece construction. With this approach, the
fastener 40a alone extends through the attachment member 16.
Preferably, the fastener 40c does not bear against the attachment
member 16 within the lower portion of the bore 28.
To manufacture an anchored/resilient sleeper according to the
invention, the nailing members 16 are cut to the desired height,
width and length dimensions. As indicated previously, if narrow
sleepers are desired, the nailing members 16 may be cut in 4', 8'
or even 12' lengths. Several benefits are achieved with these
longer lengths. The amount of wasted material is reduced, and
shipping, handling and installation costs are decreased. The bores
22 are then cut vertically through the nailing members 16, from
upper surface 24 to lower surface 25, and the pads 18 are secured
to the lower surface 25. The pads 18 may be adhered by gluing or
mechanically fastened by stapling.
At the job site, the nailing members 16 are laid end-to-end in
parallel rows, preferably with staggered ends and with the pads 18
contacting the base 20. Due to the anchored, dimensional stability
provided by the pins 40 and the sleeves 30, the spacing between the
rows of attachment members 16 may be increased from the prior
commonly used dimension of 12" up to about 15", or even 18" or 24",
or possibly higher, if a subfloor layer of panels 14 is also used.
As a result of this increased spacing, the cost of the nailing
members 16 per unit surface area of the floor is reduced.
With the nailing members 16 in place, the sleeves 30 are placed
within the bores 22. The washers 35 may then be placed on the top
edges 33 of the sleeves 30. If sleeves 30 with flanges 37 are used,
no washers 35 are necessary. The pins 40 are then extended through
the sleeves 30 and driven into the base 20. This latter step may be
performed with a nail gun or manually. As mentioned previously,
holes in the base 20 may be predrilled, prior to driving the pins
40. When driven in, the heads 41 of the pins 40 engage the washers
35, or the flanges 37, thereby causing the washers 35 or flanges 37
to tightly engage the horizontal surfaces 36 and causing the bottom
edges 32 of the sleeves 36 to engage the base 20 firmly and anchor
the nailing member 16 to the base 20.
In this position, the washers 35 or flanges 37 prevent vertical
raising of the nailing members 16, and the relative diameters of
the sleeves 30 and the lower portions 28, along with the
compressibility of the pads 18, enable the nailing members 16 to
deflect downwardly upon impact from above. Moreover, the pads 18
are neither precompressed during installation nor held in a
precompressed state as a result of installation. Rather, the pads
18 are held between the nailing members 16 and the base 20 in a
substantially uncompressed state. Thus, the floor system 10 allows
optimum resilient performance for the pads 18, regardless of the
type of compressible pad that is used.
After installation of the nailing members 16, the upper layer 14 of
panels may be secured thereto. A layer of floorboards 12 is then
secured to the subfloor layer 14 of panels. Because the vertical
distance between the top of pin 40 and the top of the nailing
member 16 is greater than the maximum vertical compression of the
pads 18, the pin 40 cannot contact the bottom of the subfloor layer
14 when force is applied from above, even under very heavy loads.
This prevents "bottoming out" of the floor system 10 upon impact,
thereby avoiding interference by the anchor pins 40 with the action
of the floor system 10.
This invention also contemplates alternative structures and methods
for providing a resilient and anchored attachment strip supported
by compressible pads held in a substantially noncompressed state
when unloaded. One such alternative is shown in FIG. 4A and
involves the use of predetermined lengths of a semi-rigid, but
flexible, member 50, such as mesh, graphite tissue, film glass or
wire mesh wrapped around the relatively narrow nailing strips 16
and pads 18.
According to this embodiment, a central portion 52 of each of the
lengths 50 of mesh spring steel is adhered or mechanically fastened
to the base 20 in an orientation which is perpendicular to the
direction of the nailing strips 16. The nailing strip 16 is then
laid upon the base 20 with each of the compressible pads 18
supported on a centrally-adhered portion 52 of one of the lengths
50 of mesh spring steel. Opposite ends of the members 50 are then
wrapped snugly around the nailing strip 16 and secured in place by
one or more nails or staples 58 and/or adhesive driven into the
upper surface 24 of the nailing strip 16.
When wrapping the member 50 around the pad 18 and the nailing strip
16, care must be taken to assure that the pads 18 will not be held
therebetween in a compressed state. Although the pads 18 may become
compressed somewhat during driving of the staples or nails to
secure the wrapped ends of the member 50, the pads 18 will be able
to rebound immediately thereafter, before the upper floor system
components are secured to the nailing strips 16. In short, the pads
18 will allow downward deflectability, and the snugness of the
secured members 50 will prevent upward raising, but the pads 18
will not be held in precompressed state when the floor system 10 is
unloaded.
Although this alternative embodiment of the invention has been
described with respect to a member 50 of mesh spring steel, it is
also to be understood that other flexible, high strength material
would also prove suitable. Also, the mesh may be located away from
the pads 18.
According to another embodiment of the invention, as shown in FIGS.
3A and 3B, the attachment strips 16 are held to the base 20 by a
plurality of spaced clips 60. Each of the clips 60 has a first
section 61 spaced from a second section 62, with a rigid section 63
located therebetween. Preferably, first and second sections 61 and
62 are parallel with each other. First section 61 is fastened to
the base 20 by a pin 66, or by adhesive. The second section 62
contacts a top surface of the attachment strip 16, but is
positioned within a recess or notch 68 in the upper surface 24 of
the attachment strip 16. One clip 60 is used for each notch 68. The
vertical dimension of the rigid third section 62 is equal to the
vertical dimension of the pad 18 plus the vertical dimension of the
attachment strip 16 at the notch 68. Preferably, the depth of the
notch 68 is greater than the vertical compressibility of the pads
18 so that the floor system 10 will not bottom out under heavy
loads. Preferably, as shown in FIG. 3A, every other clip 60 is
located on an opposite side of the attachment strip 16.
According to still another alternative embodiment of the invention,
as shown in FIG. 4B, the attachment strips 16 are held to the base
20 by a plurality of overlying, transversely oriented bands 70.
Preferably, the bands 20 are metal, though other materials would
also work. On opposite sides of the attachment strip 16, the bands
70 are fastened to the base 20 by pins 72. The bands 70 are
fastened in such a manner that the attachment strips 16 may deflect
downwardly upon impact, but are not permitted to raise upwardly
beyond the initial static position of the floor system 10.
If desired, the bands may extend all the way across the surface
area to be covered by the floor system 10. According to this
variation, the bands 70 would extend across the tops of all of the
attachment strips 16 of the floor system 10.
For all of the above-described embodiments, the attachment strips
16 are held to the base 20 in a manner which permits downward
deflection, but prevents upward movement beyond the initial static
position of the pads 18 when the floor system 10 is unloaded.
Additionally, for all of the embodiments, the attachment strips 16
are held to the base 20 at spaced, predetermined locations along
the lengths thereof, and in a manner which does not result in a
holding of the pads 18 in a precompressed condition.
FIG. 5, 6, and 7 show a floor system constructed in accordance with
a second preferred embodiment of the invention. More specifically,
FIG. 5 shows floorboards 112 overlying and secured directly to
sleepers, or attachment strips 116, which are supported above the
base 120 by pads 18. FIGS. 6 and 7 show additional details of this
floor system. In this embodiment, the attachment members 116 are
laid end to end in parallel rows with edges of adjacent rows
closely spaced so that the attachment members 116 act as a subfloor
layer of panels. This embodiment provides a stable anchored and
resilient floor system at a relatively low cost and with a
relatively low profile.
FIG. 8 shows a variation of the invention applicable to the other
embodiments. In this variation, the fastener arrangement, or
anchoring means, comprises a single-piece anchor pin 140 with a
head 141 at a top end thereof, a bottom end 142 adapted to be
driven into the base 120 and a depth stop 143 located therebetween.
The depth stop 143 is oversized with respect to a predrilled hole
144 in the base 20, thereby to limit downward movement of the
anchor pin 140 and to secure the head 141 a predetermined vertical
distance 160 above the base 120. In effect, with this variation the
depth stop 143 serves the same purpose as the sleeve in the
two-piece and three-piece arrangements, by limiting downward
movement during installation. As with the other embodiments, for
this embodiment the predetermined distance 160 is approximately
equal to the combined vertical dimension of the lower portion 128
of the bore 122 and the pads 118 when in an uncompressed state.
Preferably, the anchor pin 140 has an expansion curve 148 located
adjacent the bottom end 142 to enhance securement to the base
120.
For all of the fastener arrangements of this invention, frictional
engagement between the lower subfloor and the fasteners or
anchoring pin 140 may be reduced by using a cylindrical lubricating
sleeve 180, therebetween, as shown in FIG. 9. This sleeve 180 may
be of teflon or any other low-friction material. The sleeve 180 may
also include an upper flange (not shown). Applicant has used a
teflon sleeve 180 with side walls having a thickness of 0.08".
Alternatively, a liquid lubricant may be applied between the anchor
pin 140 and the inside surface of the lower portion 128 of the
bore. This reduction in friction reduces squeaks in the floor
system 110 during downward deflection.
The one-piece fastener construction simplifies the structure and
installment needed to anchor a resilient floor system in the manner
desired, i.e., with the upper surface layer 112 and the subfloor
116 downwardly deflectable but prevented from raising upwardly.
This variation eliminates the step of placing a flanged sleeve or a
sleeve and washer in the bores 122 prior to driving the fastening
members 140.
Another advantage that results from this one-piece fastening
arrangement relates to reduced installation costs. If desired,
regardless of the length and width dimensions of the attachment
members 116, the upper portions 127 of the bores 122 may be
predrilled at the factory in an upper portion 116a of each
attachment member 116. This eliminates the need to perform this
labor step at the job site. The lower portions 128 of the bores 122
could then be drilled in a lower portion 116b of each of the
attachment members 116, simultaneously with drilling of the base
120. In FIG. 8, the upper portion 116a and the lower portion 116b
are defined by horizontal line 211.
Additionally, if desired, the attachment members can actually
include two separate layers or pieces which are stacked and then
fastened together at the job site. This is demonstrated in FIG. 10,
wherein the portion 116a residing above line 211 is separately
formed as a top piece and the portion 116b residing below line 211
is separately formed as a bottom piece. In this manner, each of
these two separate layers 116a and 116b may be predrilled at the
factory. At the job site, the layers 116a and 116b are stacked in
alignment and then fastened along line 211, as by adhesive staples,
mechanical fastener, etc., to form a composite attachment member
116 with a plurality of two portion bores 122 formed therethrough.
This feature of a dual component, "stacked" attachment member is
also applicable to the embodiments shown in FIGS. 3A, 3B, 4A and
4B.
FIGS. 10A and 10B depict another variation of this embodiment of
the invention. According to this variation, the subfloor 216
comprises an upper layer 216a of panels supported by a lower layer
216b of spaced rails. The upper portions 227 of the bores 222 are
formed in the panels, preferably at the factory, while the lower
portions 228 of the bores 222 may be either predrilled at the
factory or formed simultaneously with forming the holes 244 in the
base 220, prior to driving of the anchor pins 240 therein.
This structure also eliminates the labor costs associated with
drilling multiple two portion bores 222 through the subfloor 216 at
the job site. Additionally, the use of an upper layer 216a of
panels and a lower layer 216b of spaced rails provides some open
volume 205 between the upper layer 216a of panels and the base 220,
a feature which promotes drying out of the floor 210 if moisture
problems happen to arise.
FIGS. 11 and 12 show a further variation of the floor system shown
in FIGS. 10, 10A and 10B. More specifically, FIG. 11 shows a
subfloor 216 which comprises an upper layer 216a of panels and a
lower layer 216b of spaced rails. In each row of panels, adjacent
panels have the standard industry spacing required for panel-type
subfloors, i.e., 1/4-3/4 inch. Adjacently situated rows of panels
are spaced away from each other by a distance designated 206, a
predetermined distance which is preferably in the range of about
4-12 inches. This distance is slightly exaggerated in FIG. 11.
Also, the joints of the adjacently located rows of panels are
staggered, and the panels 216a are oriented at an acute angle with
respect to the rails 216b. No bores are formed or drilled through
the panels 216a. Rather, the spacing 206 between adjacently
situated rows forms or defines the "upper portion" 227 of the bores
222, with each of the lower portions 228 of the bores 222 formed
through the rails 216b and located in vertical alignment with an
open space 206 between two rows of panels. This structure reduces
costs associated with forming or drilling upper bore portions 227
through the upper subfloor layer of panels 216a.
Additionally, if it is desired to have the floor system 210 act as
a free floating floor, at least within reduced area regions, not
all of the rails of the lower layer 216b are secured to the base
220. These unsecured rails "float" above the base 220, in contact
therewith via pads 218 but not anchored thereto. This structure
isolates the unsecured rails located between secured rails and
causes the floor within each of these reduced area sections to act
in a free floating manner.
This one-piece fastener variation of the invention is particularly
suited for retrofitting, or reanchoring, an installed resilient
floor system which has been in use for an extended period of time.
To do this, at each location of securement, a circular plug may be
cut into the upper layer and all subfloor layers but the bottommost
layer, as outlined in phantom by reference numeral 170 in FIG. 8.
The plug 170 is then removed therefrom to access the bottommost
subfloor layer, (attachment number 116, in this case) which is
supported above the base 120 by pads. In FIG. 8, the pads are
designated by reference numeral 118, though it is to be understood
that the actual construction and vertical dimension of the
supporting pads will vary from job to job. A two portion bore is
then formed in the lowermost subfloor layer 116, preferably by
drilling. The bore 122 is similar in configuration to the bore 22
shown in FIGS. 2 and 6. A hole 144 is then drilled in the base 120,
and subsequently, an anchor pin 140 is extended through the bore
122 and driven into the base 120 to a depth determined by the depth
stop 143. The plug 170 is then replaced in the floorboards 112.
This reanchors the floor in a manner which allows downward
deflection but no vertical raising.
Alternatively, if more than one subfloor layer is used, and a plug
170 is removed from an upper subfloor layer 116a, only the reduced
diameter portion 128 of the bore is formed in the lowermost
subfloor layer 116b. After driving the anchor pin 140, the plug 171
for the subfloor layer 116a directly above the lowermost subfloor
layer 116a is not replaced. This creates, in effect, a two diameter
portion bore 122.
The correct vertical position of the depth stop 143 relative to the
head 141 may be determined by studying the specification for the
installed floor or by actual measurement. With this dimension
known, customized anchor pins 140 may be readily manufactured to
re-anchor the floor, simply by raising or lowering the position of
the depth stop with respect to the head and the bottom end of the
pin.
Because the vertical dimensions of the fastening means may be
varied as needed, the floor system of this invention more readily
accommodates an uneven base, i.e., a base which requires
substantial shimming.
According to still another embodiment of the invention, as shown in
FIG. 13, a single piece fastener 340 may be used to anchor a
permanent floor system 310 in a resilient manner, and in such a way
that the normally permanent floor system 310 may be removed, if
necessary. Thus, the single piece anchor pin 340 provides the floor
system 310 with the advantages of a permanently installed floor and
of a portable floor.
To accomplish this, the floor 310 comprises a plurality of
interconnected 4'.times.8' sections 305, as is typical in the
construction and use of portable floors. Applicant's presently
pending U.S. application Ser. No. 08/008,721, filed on Jan. 21,
1993 and entitled "Resilient Portable Floor System" and applicant's
already issued U.S. Pat. No. 3,967,428 issued on Jul. 6, 1976 and
entitled "Portable Floor Construction" are directed to portable
floors which comprise a plurality of connectable sections. This
presently pending patent application and this issued patent are
expressly incorporated by reference herein, in their entirety.
To form a portable floor, as disclosed in these references, the
sections 305 are secured row by row, and the next row of sections
305 includes a horizontally extending subfloor tongue 376a which is
horizontally received within a correspondingly shaped void or slot
376b in the previously installed row sections 305. This locks the
adjacent sections 305 in a common horizontal plane.
In accordance with this embodiment of the present invention, each
of the connectable sections 305 includes one or more horizontally
extending brackets 306 which extend a predetermined distance above
the base 320. Various versions of such brackets have been used in
the past to enhance interconnection of adjacently situated sections
305. A plurality of bored 309 are drilled in the base 320 below the
locations of the brackets 306, and thread-in anchors 380 are then
inserted or embedded within the bores 309. The thread-in anchors
380 preferably have a curved midsection or expansion curve 309a to
enhance holding force within the base 320, as shown in FIG. 13.
The single piece fastener 340 has a threaded bottom end 381 which
threadably connects within the embedded anchor 380. The fastener
340 also has a jam/lock nut 382 fixed thereon a predetermined
distance form a head end 341 at the top thereof. This predetermined
distance corresponds to the vertical dimension between the top of
the bracket 306 and the base 320. The fastener 340 is threaded into
the anchor 380 recessed in the base 320 until the jam/lock nut 382
contacts the base 320 and prevents further fastening. This amount
of downward threading also places the head end 341 of the fastener
340, or a washer 383 located adjacent thereto, in direct contact
with the top of the bracket 306. As shown in FIG. 13, the washer
383 also bears against the top surface of the bracket 306 of both
adjacently located sections 305.
Thus, the jam/lock nut 382 provides a depth stop feature for pin
340. If desired, the jam/lock nut 382 may be a washer, which is
secured at the predetermined vertical position on the anchor pin
340, as by welding. The exact location of the depth stop will
depend upon the vertical distance between the top of the bracket
306 and the base 320. Alternatively, the jam/lock nut 382 may be a
bolt fixed in vertical position relative to the fastener 340.
FIG. 13 also illustrates a resilient pad 318 which rests on a shim
302 which contacts the base 320, as is sometimes required in the
industry during installation of a permanent floor.
In this manner, as the sections 305 are interconnected to form the
floor system 310, each successively connected row of sections 305
is secured to the base 320. Once installed, the interconnected
sections 305 are restrained from upward vertical movement but
allowed to deflect downwardly, by the thread-in fasteners 340.
If for some reason the floor 310 needs to be removed, i.e., due to
construction, water damage, or even moving to a new location if the
facility is rented or leased by the user, etc., the fasteners 340
can be readily unthreaded from the base 320 and the floor sections
305 are removed therefrom, row by row. When needed thereafter, the
"permanent" floor 310 can be reinstalled just as easily as a
portable floor.
From the above disclosure of the general principles of the present
invention and the preceding detailed description of the preferred
embodiments, those skilled in the art will readily comprehend the
various modifications to which the present invention is
susceptible. Therefore, we desire to be limited only by the scope
of the following claims and equivalents thereof.
* * * * *