Abstract:
A tool for installing a floating floor includes a striking surface, a pair of opposed legs defining a cavity, and a body between the pair of opposed legs and the striking surface wherein forces created on the striking surface are transmitted to the legs via the body and wherein the cavity has a height that is set to limit a driving depth of a concrete anchor used to secure a subfloor panel to a substrate such that a pad disposed under the subfloor panel will not be compressed when the subfloor panel is secured to the substrate.

Description:
RELATED APPLICATION INFORMATION  
       [0001]     This application claims the benefit of and is a divisional of U.S. application Ser. No. 10/235,226 filed on Sep. 4, 2002 which application is incorporated herein by reference in its entirety. 
     
    
     FIELD OF THE INVENTION  
       [0002]     This invention generally relates to a tool for use in installing a subfloor assembly that is constructed to support a top sports floor surface.  
       BACKGROUND  
       [0003]     Sports floors provide a high level of resiliency and shock absorption, and also preferably provide uniform play and safety to all participants. It is also preferred that sports floor systems maintain stability especially under changing environmental conditions.  
         [0004]     A common sports floor system can be described as an upper playing surface attached to a subfloor structure, which is supported by resilient mounts. Often the upper playing surface is constructed of hardwood flooring. Sports floor systems such as these are disclosed in U.S. Pat. No. 5,365,710 to Randjelovic et al, entitled “Resilient subfloor pad”.  
         [0005]     The resilient mounts such as those described in the Randjelovic patent are widely used in support of subfloor construction. The resilient mounts provide deflection as athletic impacts occur on the surface of the system. Most typically the resilient mounts are attached to the underside of subfloor plates such as plywood sheeting. The subfloor structure supported by the resilient mounts is not limited to plywood plate components and may include other components such as softwood sleepers or other suitable support material.  
         [0006]     The sports floor systems previously described offer shock absorption to athletic participants. However, as these floor systems are free floating, there is no provision to assure proper contact of the resilient mounts to the supporting substrate. Free floating systems such as these, when installed over uneven substrates, may provide non-uniform deflection under athletic load, causing uneven shock absorption under impact. For example, the non-uniform reflection of the basketball off the floor creates a condition typically referred to as dead spots.  
         [0007]     It would be desirable to have a floating floor system that overcomes the limitations of the floors of the prior art as well as improving the load distribution and shock absorption characteristics.  
       SUMMARY  
       [0008]     In one aspect of the present invention, a resilient floor system is disclosed. The floor system includes a floor with an athletic surface supported by an upper subfloor. The upper subfloor is supported by a lower subfloor. The lower subfloor includes plates having at least one recess disposed along a long axis of each plate. The recess includes a center ridge. The lower subfloor is supported over a substrate by pads located in each of the recess. Each pad is coupled to the underside of the lower subfloor and extends between the substrate and lower subfloor to create a space. The lower subfloor floats on the pads over the substrate when the floor is in an unloaded state.  
         [0009]     In another aspect of the present invention, a floor support assembly includes first and second subfloors. The first subfloor is supported over a substrate by a plurality of pads. The second subfloor is located above the first subfloor and is supported by the first subfloor. Each pad is housed in a corresponding recess formed in the first subfloor. Each recess includes a ridge that is in contact with its respective pad when the floor is in an unloaded state. Light and initial athletic loads focus deflection of the pads below the center ridge providing shock absorption for individual players and small participants. Significant athletic loads such as a concentration of players or larger athletes create contact of the resilient pad across the full width of the subfloor recess, thus providing support and shock absorption for multiple players and larger participants. In the fully loaded state, such as below movable bleachers, portable basketball goals, or other significantly non-athletic loads, the first subfloor rests on the substrate. The subfloor resting fully on the substrate supports loads without stresses on the systems structural components, and prevents full compression of the resilient pads that are housed in the subfloor recess.  
         [0010]     In another aspect of the present invention, a method of installing a resilient sports floor is disclosed. A first subfloor section including a plurality of grooved recesses housing a pad along the long axis of the groove is placed on a substrate. One surface of the pad contacts the substrate and an opposed second surface contacts a ridge in the recess. A space is formed between substrate and the bottom of the first subfloor. A second subfloor is placed on the first subfloor. An athletic floor is placed on the second subfloor.  
         [0011]     A more complete appreciation of the present invention and its scope may be obtained from the accompanying drawings that are briefly described below, from the following detailed descriptions of presently preferred embodiments of the invention and from the appended claims. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]     The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:  
         [0013]      FIG. 1  is a top view of a portion of a floor system employing an exemplary embodiment of a subfloor according to the present disclosure.  
         [0014]      FIG. 2  is a perspective view of an example embodiment of a portion of a subfloor assembly usable with the floor system of  FIG. 1  according to the present disclosure.  
         [0015]      FIG. 3A  is a cross-sectional view of a floor system of the same type as shown in  FIG. 1 , with the subfloor in an unloaded position according to the present disclosure.  
         [0016]      FIG. 3B  is a cross-sectional view of the floor system of  FIG. 3A  with the subfloor in a partially loaded position according to the present disclosure.  
         [0017]      FIG. 3C  is a cross-sectional view of the floor system of  FIG. 3A  with the subfloor being more heavily loaded than in  FIG. 3B  according to the present disclosure.  
         [0018]      FIG. 3D  is a cross-sectional view of the floor system of  FIG. 3A  with the subfloor in a fully loaded position according to the present disclosure.  
         [0019]      FIG. 4A  is a perspective view of an example embodiment of an anchor clip useful in installing the subfloor of  FIG. 1  according to the present disclosure.  
         [0020]      FIG. 4B  is a cross-sectional view taken along a first axis of a floor system illustrating an example embodiment of an anchoring arrangement for a subfloor according to the present disclosure.  
         [0021]      FIG. 4C  is a cross-sectional view taken along a second axis of the floor system of  FIG. 4B  illustrating an example embodiment of an anchoring arrangement for a subfloor according to the present disclosure.  
         [0022]      FIG. 5  is a perspective view of a drive tool that can be used to install the subfloor according to the present disclosure.  
         [0023]      FIG. 6  is an elevation view of an alternative embodiment of an anchor arrangement according to the present disclosure.  
         [0024]      FIG. 7  is a close up view of the an anchoring arrangement illustrated in  FIG. 4B  according to the present disclosure. 
     
    
       [0025]     While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.  
       DETAILED DESCRIPTION  
       [0026]     In the following description of preferred embodiments of the present disclosure, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments in which the disclosure might be practiced. It is understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.  
         [0027]     In general, the present disclosure discusses a subfloor for use in a floor system. The subfloor is a resilient, multi-layer subfloor that has excellent shock absorption and load distribution characteristics and other desirable properties.  
         [0028]      FIG. 1  is a top view of a subfloor assembly  120  usable in a floor system  100 . The subfloor assembly  120  has many industrial applications, but is especially suited for sports floors that include a subfloor for supporting and distributing loads.  
         [0029]     In the example embodiment shown, the floor system  100  includes a floor  110  supported by a subfloor assembly  120 . The floor  110  is typically used for sporting events, for example, basketball or volleyball. The floor  110  includes a playing surface  112  that is subjected to various loads and forces, for example, forces exerted by players, bleachers, equipment, crowds, and other activities occurring on the floor  110 .  
         [0030]     The subfloor assembly  120  is supported by resilient pads  160 , which rest on a substrate  102 . The subfloor assembly  120  includes an upper subfloor  130  and a lower subfloor  140 . The upper subfloor  130  is coupled to the lower subfloor  140  by means of mechanical fasteners, for example, staples, screws, or nails. The flooring  112  is typically attached to the subfloor assembly  120  by means of nails, staples, or adhesive. One of skill in the art will recognize that methods and apparatus for floor  110  attachment to the subfloor assembly  120  are well known, including nailing, stapling, and gluing. The particular method or technique depends on many factors, including the primary use and purpose of the floor  110 , and such methods and apparatus are not the considered part of the focus of the present disclosure.  
         [0031]      FIG. 2  depicts an assembled subfloor section  161  consisting of an upper plate  132  that provides a section of the upper subfloor  130 , and a lower plate  142  that provides a section of the lower subfloor  140 . The lower plate  142  includes a plurality of recesses  144  on the underside. The upper plate  132  and lower plate  142  are preferably offset to form assembled subfloor sections  161  that provides a shoulder  162  along two edges. The upper plate  132  is preferably attached to the lower plate  142  by means of staples, nails, or adhesive. The assembled subfloor sections  160  are formed in what are referred to as a shiplap design. Elongated edge of upper plate  132  is preferably aligned over outer recess  144  where located on underside of lower plate  142 .  
         [0032]     Formation of the subfloor  120  includes integration of assembled subfloor sections  161  whereby protruding edges of upper plates  132  rest on and are attached to shoulder  162  areas of lower plates  142 . Subfloor  120  assembly preferably includes alignment of protruding elongated edges of upper plates  132  over first recess  144  in a manner that provides support from resilient pads  160 . Subfloor sections  161  are preferably staggered, as shown in  FIG. 1 . Attachment of upper plates  132  to lower plates  142  of adjacent subfloor sections  161  is preferably provided using staples, nails, or adhesive, or a combination of thereof. The staggering, or offset, allows for a more even distribution of forces from the floor  110  to the subfloor assembly  120  during use of the floor  110 , compared to when the subfloor sections  161  are not staggered. In addition, staggering subfloor sections provides added integrity of the full floor system  100 .  
         [0033]     The preferred material for the plates is plywood, but other suitable materials can also be used, for example, composite board and other engineered wood products, the material selection being known to one of skill in the art.  
         [0034]     The floor  110  and subfloors  130 ,  140  can be made from a variety of materials. One of skill in the art will recognize that the materials selected for the floor  110  and subfloor assembly  120  depend of the nature of the use of the floor system  100  and are not considered a focus of the present disclosure. Preferably, the floor  110  is made from wood species such as maple, oak, birch, or others commonly used for manufacturing wood flooring. The floor  110  surfaces may also consist of synthetic materials, for example, vinyl, rubber, urethanes, or other suitable materials. Non-wooden surfaces are most preferably attached to the subfloor  120  using an adhesive. Upper and lower subfloor plates  132 ,  142  are preferably made from plywood or engineered wood products.  
         [0035]     Referring to  FIGS. 2 and 3 A- 3 D, the lower subfloor  140  of the subfloor sections  161  includes one or more recesses  144  along a long axis of the lower plates  142 , though the recess orientation can vary depending on the particular conditions, and can be, for example, along a short axis of the plate  142 . A ridge  146  is located in each recess  144 . The ridge  146  contributes to the load distribution of the present disclosure. Preferably, each recess  144  includes a corresponding ridge  146  centered across the width of the recess. The ridge  146  preferably also runs the entire length of its corresponding recess  144 . Recesses  144  may include multiple ridges rather than a single center ridge  146 , and multiple ridges may be provided within the same recess  144 . Multiple ridges may be provided in different vertical dimensions within the same recess  144  to enhance floor system  100  performances. Ridges  146  may also be manufactured of assorted shapes, for example, arced, triangular, and other designs that impact the resilient pad in a manner to distribute forces.  
         [0036]     Each recess  144  houses a pad  160 , which also contributes to the load distribution and shock absorption characteristics of the floor assembly of the present disclosure. Preferably, the pad is made from a material having a high strength as well as a resilient elastic modulus, for example, rubber, foam, urethane, or other suitable materials. Preferably, the pad is made from combination rubber and foam mixture. More preferably, the combination foam and rubber mixture is 50 percent foam and 50 percent rubber.  
         [0037]     In the example embodiment shown, each pad  160  has a width Wp approximately equal to the width Wrr of the recess  144 . Referring to  FIGS. 1 and 2 , the pads  160  are arranged in rows perpendicular to the flooring  112  direction. The pads  160  rest on the substrate  102  as shown in  FIGS. 3A-3D . The resilient pads  160  align in the recesses  144  of the lower plate  142  and support subfloor assemblies  120 . Preferably, the pads  160  are affixed to the underside of the ridges  146  by adhesive. The resilient pads  160  can also be coupled to the surface of the substrate  102 . As used herein, the term “coupled” means any structure or method that may be used to provide connecting between two or more members or elements, which may or may not include a direct physical connection between the two elements.  
         [0038]     Referring to  FIGS. 3A-3D , the load carrying and distribution of the resilient floor system  100  of the present disclosure is illustrated. In an unloaded mode, the pad  160  (or pads) is uncompressed and supports the subfloor. An advantage of non- or slightly deflected resilient pads is that the floor  110  has excellent shock absorption qualities, available tending to reduce the chance of traumatic or cumulative stress related injuries during athletic impacts. In the mode illustrated in  FIG. 3A , the load is principally carried by the pad  160  contacting the ridge  146  in the recess  144  of the lower subfloor  140 .  
         [0039]     Referring to  FIG. 3B , as initial and/or light athletic loads occur on the floor  110 , the ridge  146  deflects the pad  144  in and near the contact region there between. The load deflects the pad  144  principally along the ridge  146 . In this load-bearing mode, the floor system  100  is still floating above the surface  104  of the substrate  102 , thus retaining much of its desirable load distribution and shock absorption qualities.  
         [0040]     Referring to  FIG. 3C , as the load on the floor  110  is further increased, the pad  160  continues its deflection or compression until the pad  160  is fully in contact with the ridge  146  and also in contact with faces  147  of the recess  144  on either side of the pad  160 . In this mode, the load is distributed over a larger area of the pad  160 . Even under the heavier loads, the floor system  100  still floats over the surface  104  of the substrate  102 , thus still retaining much of its desirable load distribution and shock absorption qualities, even under the heaviest of athletic loads.  
         [0041]     While it is desirable that the floor system be kept floating when athletic activities are taking place, if the pads  160  are sized such that the floor system  120  floats carrying any load, no matter how heavy, the result is that the floor  110  will not have the desired resilient characteristics for optimal use. For example, floating the floor system  100  when supporting very heavy loads, such as bleachers or maintenance equipment, would require very stiff pads. This would reduce the efficacy of load distribution and shock absorption of the floor  110  when absorbing lighter athletic loads. To accommodate all such loads, preferably the pads  160  are sized and manufactured of preferred material so that bottom  145  of the lower subfloor  140  rests on the surface  104  of the substrate  102  when very heavy loads are applied. Referring to  FIG. 3D , shown in the heavily loaded mode, when a pad  160  is fully loaded, the pad  160  deflects until the bottom surface  145  of the lower subfloor  140  is in contact with the surface  104  of the substrate  102 . The entire load is then carried by the substrate  102 . An advantage of this arrangement is that the pads  160  are not completely deformed, thereby not carrying the entire load when the floor  110  is bearing the heaviest loads. This reduces the chance that the pads  160  are deformed past their elastic limit and also reduces the permanent deformation of the pads  160 , which can decrease the floor system  100  efficacy over repeated use. Further, this feature protects subfloor  120  and floor  110  components from stresses that would otherwise occur without the support of the surface  104  of the substrate  102 .  
         [0042]     Referring to  FIGS. 3A-3D , for a given recess  144  width Wr and pad  160  width Wp, the load distribution and shock absorption characteristics are a function of the width Wr of the ridge  146  relative to the width of the recess Wrr. The wider the ridge  146  is relative to the recess  144 , the less the deformation is of the floor  110  for a given load. Stated another way, increasing the width Wr of the ridge  146  relative to the width Wrr of the recess  144 , also increase the stiffness of the floor  110 . Preferably, the widths Wp, Wrr of the pad  160  and the recess  144  are both 1.0 inch, with pad  160  thickness of 9/16″. A preferred arrangement provides three 96″ long resilient pad  160  sections for a 24″×96″ subfloor plate  142 . The width Wr of the ridge  146  for the above-described plate is between 0.25 inches and 0.75 inches, and more preferably is 0.025 inches. The height of the ridge  146  also affects the performance of the floor system  100 . Preferably, when the recess  144  is about 1.0 inch wide, and the width of the ridge  146  is between 0.25 and 0.75 inches, the height of the ridge  146  is between 0.0625 inches and 0.25 inches. More preferably, the height of the ridge  146  is about 3/32 inches.  
         [0043]     A method for installing a flooring system  100  according to the present invention is also disclosed. Subfloor sections  161  are pre-manufactured as shown in  FIG. 2 . The subfloor sections  161 , as previously described, include an upper plate  132  and lower plate  142  offset in a manner to create subfloor plate shoulders  162 . Subfloor plates  132  and  142  are preferably attached using staples, and can also be attached using nails, adhesive, or other suitable fastening methods. Subfloor sections  161  include machined recesses  144  for placement and attachment of resilient pads  160  prior to placement on substrate  102 . Subfloor sections include anchor pockets  150 , as well as anchor clips  155 , and rubber bushings  154  detailed in FIGS.  4 A- 4 B- 5 . The preferred assembly of subfloor sections  161  includes alignment of upper and lower plates  132  and  142  prior to machining anchor pockets  150  through both upper and lower plates  132  and  142 . Anchor clips  155  are positioned between plates  132  and  142  as shown in  FIG. 4B  prior to attachment of upper plate  132  to lower plate  142 . A center hole  159  is provided in the lower section  157  of the anchor clip  155 . The center hole  159  can accommodate a rubber bushing  154  or other insulating component to prevent friction of the concrete anchor  152  and anchor clip  155 . Manufactured subfloor sections  161  are preferably positioned in a staggered pattern as shown in  FIG. 1 . Protruding edges of upper plates  132  extend to rest on and attach to subfloor plate shoulders  162  and are most typically attach using adhesive and mechanical fasteners such as staples or nails.  
         [0044]     Referring to  FIGS. 4A-4C , an anchoring arrangement and tool for using the same with a subfloor of the present disclosure are described. Installation of subfloor sections  161  as described form a continuous integrated subfloor  120  that includes a preferred anchorage method to the substrate  102 . The subfloor  140  includes a plurality of anchor pockets  150 . Each anchor pocket includes a holding device, in this example embodiment an anchoring clip  155 , for securing the subfloor  120  to the substrate  102 . Referring to  FIGS. 4A and 4B , shown is an example embodiment of an anchor clip  155  that can be used for securing the subfloor  120  to the substrate  102 . The anchor clip  155  includes a lower portion  157  and an upper portion  158 . The lower portion is preferably seated slightly higher than the underside of the lower subfloor plate  142 . The flanged upper portions  158  are held in position as the upper and lower plates  132 ,  142  are secured together during the manufacturing process. Anchor pockets  150  provided in the subfloor  120  include pre-installed anchor clips  155  with inserted rubber bushings  154 . Preferably, the bushing also includes a shoulder  153  that centers the bushing in the hole  159 , with the bottom edge of the bushing shoulder  153  aligning rather evenly with the underside of the lower plate  142 . Alignment of the bushing shoulder  153  in this manner allows full deflection of the subfloor  120  without pressing the bushing shoulder  153  between the underside of the anchor clip section  157  and top of the substrate  104 .  
         [0045]     Placement of concrete anchors  152  is accomplished by drilling into what is most commonly a concrete substrate  102  with the appropriate drill size in relation to the concrete anchor  152  dimension. Each concrete anchor  152  is inserted through the rubber bushing  154  and driven to the correct depth into the substrate  102 .  
         [0046]     To assist in the installation of the floor system of the present disclosure, an anchor-driving tool  200  is also disclosed. The tool includes a strike surface  210 , legs  206 , and a body  204  extending between the strike surface  210  and legs  206 . In the example embodiment shown, the tool also includes a grip  202  and a hand guard  208 . The legs form a cavity  212  with a height Hc. The height Hc of the cavity  212  is set to limit the driving depth of the concrete anchor  152  into the substrate  102  so that the pads  160  will not be compressed when the subfloor  120  is secured over the substrate.  
         [0047]     The tool  200  of the present disclosure is used as described hereinafter when the subfloor  120  is placed and assembled over the substrate  104 . Concrete anchors  152  are initially hammer driven until the underside of the anchor head is in near contact with the top of the rubber bushing  154 . With the clip  155  properly positioned, the legs  206  of the tool  200  are positioned to straddle the bottom portion  156  of the clip  155  such that the head of the fastener  152  is in contact with the tool  200  at the top of the cavity  212 . The fastener  152  can then be driven into the surface  104  of substrate  102  using a hammer or other implement to create a driving force on the strike surface  210  of the tool  200 . The fastener  152  is driven into the substrate  102  until the legs  206  of the tool  200  contact surface  104  of the substrate  102 . In this manner, the subfloor  120  is installed while preventing or greatly limiting compression of the ridges  146  into the resilient pads  160 .  
         [0048]     In the preferred use of the invention the flooring surface  110  such as hardwood flooring  112  is attached to the subfloor assembly  120  by means of staples, nails, adhesive, or other suitable methods. The described anchor pockets  150  and anchor clips  155  are designed in a manner and dimension to prevent contact between the top of the concrete anchor and the underside of the flooring material  110  at any time especially when loads are significant to create contact between the underside of the subfloor plates  142  and surface  104  of the substrate.  
         [0049]     In an alternative embodiment of an anchor arrangement, as is illustrated in  FIG. 6 , the anchor clip  255  may be made from a planar member  256  without a stepped section. A planar member can be used when the thickness of the upper plate  232  is large compared to the thickness of the anchor head  252 , so that when the floor  210  is deflected it will not contact the anchor head  252 . For example, the alternative anchor arrangement can be used when the upper plate is ½ inch thick and the anchor head is 3/16 inches thick. An advantage of the anchor arrangement of the present disclosure is that it can be installed into the subfloor when the subfloor sections are prefabricated for installation.  
         [0050]     The present invention should not be considered limited to the particular examples described above, but rather should be understood to cover all aspects of the invention as fairly set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the present invention may be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the instant specification.