Patent Publication Number: US-7587865-B2

Title: Modular floor tile with multi level support system

Description:
RELATED APPLICATIONS 
   This is a continuation-in-part of U.S. patent application Ser. No. 11/291,002 filed Nov. 30, 2005 and entitled “Modular Floor Tile With Nonslip Insert System”, which is a continuation-in-part of U.S. patent application Ser. No. 11/143,337 filed Jun. 2, 2005 and entitled “Modular Floor Tile System with Sliding Lock.” 

   TECHNICAL FIELD 
   This relates generally to floor tiles, and more particularly to modular floor tiles with multiple level support systems. 
   BACKGROUND 
   Floor tiles have traditionally been used for many different purposes, including both aesthetic and utilitarian purposes. For example, floor tiles of a particular color may be used to accentuate an object displayed on top of the tiles. Alternatively, floor tiles may be used to simply protect the surface beneath the tiles from various forms of damage. Floor tiles typically comprise individual panels that are placed on the ground either permanently or temporarily depending on the application. A permanent application may involve adhering the tiles to the floor in some way, whereas a temporary application would simply involve setting the tiles on the floor. Some floor tiles can be interconnected to one another to cover large floor areas such as a garage, an office, or a show floor. Other interconnected tile systems are used as dance floors and sports court surfaces. 
   However, typical interconnected tile systems are rigid and unforgiving. Short and long term use of modular floors for sports activities and dance can result in discomfort to the users. Conventional interconnected tile systems absorb little, if any, of the impact associated with walking, running, jumping, and dancing. Consequently, some users may experience pain or discomfort of the joints when using the interconnected tile systems. Therefore, there is a need for modular interconnected tile systems that include features that provide a more comfortable, useful surface. 
   SUMMARY 
   Some embodiments address the above-described needs and others. In one of many possible embodiments, a modular floor tile is provided. The modular floor tile comprises a top surface, a plurality of edge surfaces, an interlocking mechanism for attachment to adjacent tiles, and a support system comprising multiple levels of support. In one embodiment, at least one of the multiple levels of support comprises a first resilient level, and another of the multiple levels of support comprises a first rigid level. In one embodiment, the first resilient level comprises a plurality of inserts disposed under the top surface. In one embodiment, the first resilient level comprises a plurality of interconnected elastomeric removable inserts nested under the top surface. In one embodiment, each of the plurality of inserts comprises a length equal to or greater than a height of the plurality of edge surfaces. In one embodiment, the plurality of inserts each comprise a generally cylindrical post. In one embodiment, the at least one insert comprises a base and a post extending from the base. According to one embodiment, the top surface comprises a solid surface. 
   In one embodiment of the modular floor tile, the first rigid level of the multiple levels of support comprises a first set of support legs having a first length extending from the top surface, and the multiple levels of support comprise a second rigid level comprising a second set of support legs having a second length, the second length being shorter than the first length. In one embodiment, the first and second sets of support legs are arranged in an alternating pattern comprising a first leg of the first length, a group of three to four legs of the second length, and the resilient level comprises a plurality of inserts nested in the group of three to four legs. The resilient level may extend in length beyond the first and second rigid levels. In one embodiment, the first resilient level comprises a plate of multiple inserts interconnected by a webbing, the plate shaped substantially the same as the top surface. 
   In one embodiment of the modular floor tile, the top surface comprises an open surface. The open surface comprising a pattern of gaps, and the first resilient level comprises a plurality of elastomeric inserts with a length greater than a height of the edge surfaces, each of the plurality of inserts comprising a base and a post extending from the base. The post is sized small enough to pass through one of the gaps, and the base is sized large enough to resist passage through one of the gaps. In one embodiment, each of the plurality of elastomeric inserts comprises a post straddling the open surface at the gaps. 
   In one embodiment of the modular floor tile, the interlocking mechanism comprises a plurality of lipped loops disposed in at least one of the plurality of edge surfaces, and a plurality of locking tab assemblies disposed in at least one of the plurality of edge surfaces. Each of the plurality of locking tab assemblies comprises a center post and flanking hooks. 
   One embodiment provides an apparatus comprising a modular floor. The modular floor comprises a plurality of interlocking tiles connected to one another. Each of the plurality of interlocking tiles comprises a top surface and a plurality of support levels under the top surface. The plurality of support levels comprises at least one rigid level and at least one flexible level extending beyond the at least one rigid level. In one embodiment, at least one flexible level comprises a plurality of elastomeric inserts, and each of the plurality of interlocking tiles comprises a bottom, the bottom including a plurality of receivers sized to hold one of the plurality of elastomeric inserts. 
   One aspect provides a method of making a modular floor. The method comprises providing an interlocking modular tile having a top surface and a bottom plane parallel to and spaced from the top surface, inserting a plurality of resilient inserts into associated nests opposite of the top surface, and protruding the plurality of resilient inserts beyond the bottom plane. In one aspect, the top surface comprises a solid top surface, and the inserting further comprises contacting an underside of the top surface with the plurality of resilient inserts. In one aspect, inserting comprises inserting the resilient inserts as a single, interconnected unit of inserts. In one aspect, inserting further comprises fitting the plurality of resilient inserts into a nest by an interference fit. In one aspect, the top surface comprises an open surface, and inserting comprises pressing the plurality of resilient inserts through associated gaps in the first open surface in a first direction. 
   In one aspect of the method, the plurality of resilient inserts comprise a first support level. In one aspect, the method further comprises providing a second, rigid support level flush with the bottom plane, and providing a third, rigid support level between the bottom plane and the top surface. 
   One aspect provides a method of making a modular tile comprising forming a tile body having a solid top surface, providing a plurality of elastomeric inserts having a length at least as great as a height of the tile body, and pressing the plurality of elastomeric inserts into nests under the solid top surface. In one aspect, providing a plurality of elastomeric inserts comprises providing an interconnected webbing of the elastomeric inserts. 
   The foregoing features and advantages, together with other features and advantages, will become more apparent when referring to the following specification, claims and accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings illustrate various embodiments and are a part of the specification. The illustrated embodiments are merely examples and do not limit the claims. 
       FIG. 1  is a perspective view of a modular floor tile with an open top surface and a plurality of non-slip inserts according to one embodiment. 
       FIG. 2  is a magnified inset of a portion of the modular floor tile of  FIG. 1 . 
       FIG. 3  is a partial bottom assembly view the modular floor tile of  FIG. 1 . 
       FIG. 4  is a magnified partial cross-sectional view of the modular floor tile of  FIG. 1 . 
       FIG. 5  is a magnified bottom perspective view of the modular floor tile of  FIG. 1 . 
       FIG. 6  is a perspective assembly view of multiple modular floor tiles according to one embodiment. 
       FIG. 7  is partial cross sectional view of the modular floor tiles of  FIG. 6  illustrating the connection between tiles according to one embodiment. 
       FIG. 8  is a perspective view a modular floor arranged as a sports court according to one embodiment. 
       FIG. 9  is a bottom perspective cut-away view of a partial tile and a plurality of interconnected inserts according to another embodiment. 
       FIG. 10  is a top perspective cut-away view of the tile and nonslip inserts of  FIG. 9 . 
       FIG. 11  is an assembly view of a full tile and multiple interconnected inserts according to one embodiment. 
       FIG. 12  is a side view of a tile with multiple levels of support according to one embodiment. 
       FIG. 13  is a side view of a tile with multiple levels of support under a load according to one embodiment. 
       FIG. 14  is an assembly view of a tile with multiple levels of support and a solid top surface according to one embodiment. 
       FIG. 15  is a bottom assembly view of a full tile with a solid top surface and multiple interconnected inserts according to one embodiment. 
   

   Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements. 
   DETAILED DESCRIPTION 
   As mentioned above, typical modular flooring comprises solid or open top surfaces that tend to be slippery. The slippery surfaces compromise the footing of users, especially sports court users that tend to start and stop abruptly. The typical modular floor offers less than ideal traction to dance, sport, pedestrian, and other traffic. The principles described herein present methods and apparatus that provide better traction and more flexibility than previous flooring systems. However, the application of the principles described herein is not limited to the specific embodiments shown. The principles described herein may be used with any flooring system. Moreover, although certain embodiments shown incorporate multiple novel features, the features may be independent and need not all be used together in a single embodiment. Tiles and flooring systems according to principles described herein may comprise any number of the features presented. Therefore, while the description below is directed primarily to interlocking plastic modular floors, the methods and apparatus are only limited by the appended claims. 
   As used throughout the claims and specification, the term “modular” refers to objects of regular or standardized units or dimensions, as to provide multiple components for assembly of flexible arrangements and uses. “Resilient” means capable of returning to an original shape or position, as after having been compressed; rebounds readily. “Rigid” means stiff or substantially lacking flexibility. However, a “rigid” support system may flex or compress somewhat under a load, although to a lesser degree than a “resilient” support system. A “post” is a support or structure that tends to be vertical. A “top” surface of a modular tile refers to the exposed surface when the tile is placed on a support, or the designated surface for stepping on, driving on, supporting objects, etc. An “insert” is an object at least partially inserted or intended for insertion relative to another object. A “post” may be cylindrical, but is not necessarily so. The words “including” and “having,” as used in the specification, including the claims, have the same meaning as the word “comprising.” 
   Referring now to the drawings,  FIGS. 1-3  illustrate in partial assembly view a modular floor tile  100  according to one embodiment. The modular floor tile  100  of  FIGS. 1-3  may comprise injection molded plastic. The modular tile  100  and other similar or identical tiles may be interlocked according to principles described herein to form a floor, such as a sports court floor discussed below with reference to  FIG. 7 . However, unlike conventional modular flooring systems, the modular tile  100  facilitates extra traction and more resiliency by the addition of nonslip inserts and/or. 
   The modular tile  100  of  FIGS. 1-3  comprises a first or top open surface  104 . The term “open” indicates that the top open surface  104  includes open holes, gaps, or spaces through which fluid may drain. For example, the modular tile  100  of  FIGS. 1-3  may include a plurality of diamond shaped holes  102  patterned relative to the rectangular or square shape of the modular tile  100  as shown. However, any other shape for the gaps  102  and the modular tile  100  may also be used. 
   Each of the holes  102  in the open surface  104  is receptive of an insert  105 . However, it is not necessary for every hole  102  to include an insert  105 . For example,  FIGS. 1-3  illustrate an insert  105  disposed in every other hole  102 . Nevertheless, some embodiments include inserts  105  in every hole  102 , and other embodiments may include other spacings between the inserts  105 . The insert  105  may be inserted or removed from the modular tile  100 . According to some embodiments, however, the insert  105  may be permanently attached to the modular tile  100 . The insert  105  is insertable at least partially into the holes  102  and protrudes from the plane of the open surface  104 . 
   The insert  105  may comprise a resilient material, which may be an elastomer such as rubber and may include many different shapes. For example, as shown in  FIGS. 1-3 , the insert  105  may include a base  107  with a post or compressible column  109  extending normally from the base. The post  109  may terminate at an end  113  with a pad  111  opposite of the base  107 . As shown in  FIGS. 1-3 , the base  107  may be generally circular, and the post  109  may be generally cylindrical. The base  107  and the pad  111  may comprise first and second radial lips, respectively, extending radially from the post  109 . 
   As shown in  FIGS. 1-3 , the post  109  is sized small enough to pass easily though the holes  102  and protrude from the open surface  104 . The base  107 , on the other hand, is sized large enough to resist passage though the holes  102 . Therefore, the insert  105  may be inserted from the bottom of the modular tile  100  until the base  107  contacts the periphery of the holes  102 . As shown in  FIGS. 4-5 , the base  107  of the insert  105  may nest in a receiver or holder  115  of the modular tile  100 . The receiver  115  is sized smaller than the base  107  to provide an interference fit between the insert  105  and the receiver  115  and generally hold the insert  105  tightly in place. However, the insert  105  is resilient and therefore may be removed from the interference fit with the receiver  115  by applying an adequate force to the insert  105 . The receiver  115  may comprise a number of legs  154  described in more detail below with reference to  FIGS. 3-5 . The base  107  deforms around the legs  154  as shown in  FIGS. 4-5  to partially hold the insert  105  in place. 
   Continuing to refer to  FIGS. 4-5 , the base  107  and the pad  111  may straddle or partially straddle the open surface  104  of the modular floor tile  100 . The pad  111  may be sized to slightly resist passage through the holes  102 . Therefore, the insert  105  may be inserted into one of the holes  102  by applying a sufficient force to the insert  105  to elastically deform the pad  111  as it passes through the hole  102 . The pad  111  may be tapered or rounded to facilitate insertion through the hole  102  in an insertion direction. When the pad  111  emerges through the hole  102 , it tends to resume its original shape and resist passing back out of the hole  102  in a direction opposite of the insertion direction. Nevertheless, the pad  111  tends to displace to a generally flush position relative to the open surface  104  upon the application of force. The post  109  is also resilient and compressible, and a sufficient force on the pad  111  (e.g. a person stepping on the pad) causes the post  109  to compress without displacing the base  107  within the receiver  115 . 
   The protruding inserts  105  advantageously provide traction and comfort to users of the modular tile  100 . As mentioned above, the inserts  105  may be elastomeric, and soft elastomeric materials such as rubber and santoprene provide excellent traction for users. The inserts  105  are compressible as well, providing a comfortable surface for users to walk across. The number of inserts  105  used with the modular tile  100  may be varied according to preference. Moreover, as described below, the modular tile  100  includes an interlocking mechanism for attachment to adjacent tiles. Therefore, multiple modular tiles  100  may be interlocked to create a floor of any size and shape. One embodiment of an interlocking mechanism is described in the following paragraphs. 
   The modular tile  100  includes a plurality of side edges, which, according to the embodiment of  FIGS. 1-3 , include four side edges  106 ,  108 ,  110 ,  112 . At least one of the side edges of the modular tile  100  includes a plurality of loops  114 . However, according to the embodiment of  FIGS. 1-3 , a plurality of loops  114  is disposed in each of the first and second adjacent side surfaces  106 ,  108 . The loops  114  may be spaced along the first and second side surfaces  106 ,  108  at substantially equal intervals. 
   Each of the plurality of loops  114  is receptive of a mating locking tab assembly  116  from an adjacent modular tile. According to the embodiment of  FIGS. 1-3 , each of the third and fourth adjacent side surfaces  110 ,  112  includes a plurality of locking tab assemblies  116 . The modular tile  100  may include an equal number of locking tab assemblies  116  and loops  114 . Moreover, the locking tab assemblies  116  may be spaced at the same intervals as the loops  114 . 
   Referring now to  FIG. 6 , the loops  114  of the modular tile  100  are receptive of the locking tab assemblies  116  of an adjacent modular tile such as a second tile  102 . Thus, the first and second modular tiles  100 ,  102  may be interlocked or connected together.  FIG. 6  illustrates three modular tiles already interconnected, and fourth modular tile  100  being attached to the other three. 
     FIG. 7  best illustrates the details of the interconnection between adjacent modular tiles  100 ,  102 . Each of the locking tab assemblies  116  may comprise a center post  118  of depth D and flanking hooks  120 . The flanking hooks  120  may be cantilevered. In addition, as best shown in  FIG. 2 , each of the loops  114  comprises a rim or lip, which may include first and second lips  122 ,  124  protruding from first and second sides  126 ,  128 , respectively, of the loops  114 . As the adjacent modular tiles  100  are locked together as shown in  FIG. 7 , the center post  118  is inserted into the associated loop  114 , and the flanking hooks  120  flex around and snap-fit over the associated lips  122 ,  124 . Once snapped over the lips  122 ,  124 , the flanking hooks  120  resist disconnection of the adjacent modular tiles  100 . However, the length of the flanking hooks  120  provides a vertical clearance  130  between the lips  122 ,  124  and prongs  132  of the flanking hooks  120 . The vertical clearance  130  allows adjacent, interlocked modular tiles  100  to displace vertically a predetermined distance with respect to one another, even while remaining interlocked. According to some embodiments, the vertical clearance  130  (and thus the vertical displacement) comprises at least about 0.0625 inches, and may be at least about 0.125 inches or more. Moreover, the flanking hooks  120  comprise double locks and operate independent of one another. Therefore, even if one of the flanking hooks  120  breaks or is otherwise incapacitated, the lock between the locking tab assembly  116  and the loop  114  remains intact. 
   In addition, although the prongs  132  of the flanking hooks  120  provide a double lock against disconnection of the adjacent modular tiles  100 , they permit sliding lateral displacement between the adjacent modular tiles  100 . A predetermined amount of sliding lateral displacement between the adjacent modular tiles  100  may be controlled, for example, by the depth D of the center post  118 , in combination with the depth D′ ( FIG. 2 ) of the loop  114 . A predetermined clearance between the depth D of the center post  118  and the depth D′ ( FIG. 2 ) of the loop  114  may fix the maximum lateral displacement between the adjacent modular tiles  100 . According to some embodiments, the predetermined lateral displacement may be at least 0.0625 inches, and may be at least about 0.100-0.125 inches. Thus, the interconnection between adjacent modular tiles  100  according to some embodiments, advantageously permits some relative displacement both vertically and laterally, and provides a more comfortable feel to users, especially at quick stops and starts. 
   However, although some embodiments facilitate lateral displacement between interlocked modular tiles, a complete floor may tend to look sloppy and misaligned in some configurations. Therefore, according to some embodiments, adjacent modular tiles may be biased or spring loaded to a specific, generally equal spacing therebetween. Referring to  FIGS. 1-3  one or more of the side walls  106 - 112  may include one or more biasing members such as spring fingers  134  disposed therein. The spring fingers  134  may comprise three cantilevered, angled spring fingers spaced between alternating loops  114  and disposed in both of the first and second side walls  106 ,  108 . Nevertheless, the spring fingers  134  may just as effectively be placed in the third and fourth side walls  110 ,  112 , or even in all four side walls. The spring fingers  134  thus tend to bear against adjacent side walls of adjacent tiles, aligning all of the modular floor tiles in a floor to a substantially equal spacing, while also permitting lateral displacement upon the application of a sufficient lateral force. 
   Each of the modular tiles  100  includes a support system under the top open surface  104 . According to some aspects, the support system comprises a multiple-tier suspension system. One embodiment of the multiple-tier suspension system is illustrated in  FIGS. 3-5 , and comprises a two-tier suspension system  150 . The two-tier suspension system  150  comprises a plurality of support legs extending down from the first open surface  104 . The plurality of support legs may comprise a first set of generally rigid primary support legs  152  having a first length, and a second set of generally rigid support legs  154  having a second length. The second length of the second set of support legs  154  is shorter than the first length of the first set of support legs  152 . Therefore, absent a load, only the first set of support legs  154  contacts the ground. The first and second sets of support legs  152 ,  154  may be arranged in an alternating pattern as shown in  FIG. 3 . The pattern may comprise alternating rows or columns of first and second sets of support legs  152 ,  154 . In addition, the first set of support legs  152  may each comprise a split or fork leg as shown, and the second set of support legs  154  may comprise clusters of three or four legs. The inserts  105  may be nested in one or more of the groups of three or four legs. Thus, the base  107  of the insert  105  may be deformed around the legs  154  by forcing the insert  105  into the cluster of three or four legs, causing the base  107  to bear against the legs, which tends to hold the insert  105  fast. The second set of support legs  154  may thus comprise the receiver  115 . 
   The spacing of the first set of support legs  152  facilitates vertical flexing or springing of each of the modular tiles  100 . That is to say, as a load is applied to one or more of the modular tiles  100 ,  102  on the first open surface  104 , the first open surface  104  “gives” or tends to flex somewhat, until the second set of support legs  154  contacts the ground. In addition, the inserts  105  tend to compress as they are stepped on. Accordingly, application of the principles described herein may result in a comfortable spring-like modular floor. 
   The modular tile  100  described above, along with a plurality of additional similar or identical modular tiles, may be arranged in any configuration to create a floor. For example, as shown in  FIG. 8 , a plurality of modular tiles  100  may be arranged to form a sports court floor  160 . The sports court floor  160  may include lines corresponding to regulation sports floor lines, such as the basketball court lines  162  shown in  FIG. 7 . The lines may be painted onto or otherwise formed in the modular tiles  100 . 
   For many uses of the modular tiles  100 , including the sports court floor  160 , traction can be important. Therefore, nonslip inserts  105  ( FIG. 2 ) provide a significant advantage over traditional modular floors. According to some embodiments, the modular tiles  100  include multiple traction layers. For example, as shown in  FIG. 2 , the modular tile  100  comprises four traction layers. A first of the three traction layers may comprise a first webbing  164  that runs in lines generally parallel and perpendicular to edges of the modular tile  100 . The first webbing  164  is at a first elevation that may be, for example, at about 0.6875 inches from a ground surface (the height of the side walls  106 - 112  ( FIG. 1 ) may be about 0.75 inches). A second of the traction layers may comprise the general diamond pattern surface  166  defining the holes  102 , and are disposed in between perpendicular lines of the first webbing  164 . The diamond pattern surface  166  may be substantially flush with the side wall height at about 0.75 inches. A third traction layer may comprise a plurality of ridges  168  protruding from the diamond pattern surface  166 . The plurality of ridges  168  may comprise three ridges in each side of the diamond pattern. The plurality of ridges  168  may be elevated slightly from the diamond pattern surface  166  a distance of about 0.05-0.125 inches. A fourth traction layer may comprise the pad  111  of the protruding insert  105 . The four traction layers  164 ,  166 ,  168 ,  111  provide exceptional traction and reduce the risk of slipping and other hazards. 
   Referring again to  FIG. 1 , according to some aspects, the modular floor tiles  100  may be made by providing a mold, injecting liquid polymer into the mold, shaping the liquid polymer with the mold to provide a top surface  104  and an interlocking system  114 ,  116 , and solidifying the liquid polymer. The inserts  105  may then be inserted into the holes  102  in the top surface  104  through the bottom of the tile  100  in a first direction indicated by arrows in  FIGS. 2-3 . The inserts  105  are pushed into the holes  102  until the pads  11  protrude from the top surface  104  and the inserts  105  deform to a snug or interference fit with the receiver  115  ( FIG. 4 ) or other component of the tile  100 . Thus the pads  111  and the bases  107  straddle the top surface  104 . The shaping of the modular tiles  100  may comprise creating the plurality of loops  114  disposed in at least one side edge  106  ( FIG. 1 ), the loops  114  having a protruding rim  122 , and creating a plurality of locking tab assemblies  116  ( FIG. 1 ) disposed in at least one other side edge  108 , each of the plurality of locking tabs assemblies  116  ( FIG. 1 ) comprising a center post  118  and flanking hooks  120  ( FIG. 1 ). The method may further comprise varying a depth D ( FIG. 7 ) of the center posts in the mold to adjust the predetermined amount of lateral sliding allowed between adjacent tiles. 
   Referring next to  FIGS. 9-11 , another embodiment of inserts is disclosed. According to one embodiment, the modular floor tile  100  is accompanied by one or more full-length nonslip inserts  205 . Each of the holes  102  in the open surface  104  of the modular floor tile  100  is receptive of a full-length insert  205 . However, as with the inserts  105  described above, it is not necessary for every hole  102  to include a full-length insert  205 . For example,  FIGS. 9-11  illustrate a full-length insert  205  disposed in every other hole  102 . Nevertheless, some embodiments include full-length inserts  205  in every hole  102 , and other embodiments may include other spacings between the full-length inserts  205 . The full-length inserts  205  may be inserted or removed from the modular tile  100 . According to some embodiments, however, the full length inserts  205  may be permanently attached to and comprise the modular tile  100 . The full-length inserts  205  are insertable at least partially into the holes  102  and protrude from the plane of the top open surface  104 . 
   Unlike the inserts  105  illustrated above, the full-length inserts  205  may be substantially equal in length to, or slightly longer than, the side walls  106 - 112 . Therefore, the full-length inserts  205 , when the assembled in the floor tile  100  and setting on a support surface, cannot fall out of the holes  102 . The full length inserts  205  contact the ground or other support surface and extend though the open surface  104  in the floor tile  100 . 
   The full-length inserts  205  may comprise a resilient material, which may be an elastomer such as rubber, or it may comprise plastic or other nonslip materials. The full-length insert  205  may include many different shapes. For example, as shown in  FIGS. 9-11 , the full-length insert  205  may include a base comprising a post or compressible column  209 . The post  209  may be generally cylindrical, and may include a taper. The post  209  may terminate at an end  213  with a pad  211 . The pad may be rectangular or square. According to one embodiment, the pad  211  is substantially the same shape as the holes  102  in the floor tile  100 . The pad  211  may be slightly oversized with respect to the holes  102 , creating a snug or interference fit between the pad  211  and the holes  102 . 
   The full-length inserts  205  may be inserted from the bottom of the modular tile  100 . As shown in  FIG. 9 , according to embodiment, the full-length inserts  205  may nest in the receivers or holders  115  of the modular tile  100 . According to one embodiment, the full-length inserts  205  may come in pairs and be interconnected by a pair of generally triangular webbings  280 . When assembled, one of the legs  154  of the floor tile  100  may extend through the triangular webbing  280  as shown in  FIG. 9 . 
   As shown in  FIG. 11 , according to one embodiment, a plurality of full-length inserts  205  may be injection molded together as a unit. The unit may comprise substantially the same shape as the floor tile  100 . Therefore, a set or plate  286  of full-length inserts  205  may be pressed into the holes  102  of the floor tile  100  at once. A webbing, for example a generally rectangular webbing  282 , may interconnect the full-length inserts  205  in the same general shape as the floor tile  100  or open surface  104 . The generally triangular webbing  280  may be offset at an angle with respect to the generally rectangular webbing  282 . For example, according to one embodiment, the generally triangular webbings  280  interconnecting pairs of full length inserts  205  may be arranged at forty-five degree angles from intersection points  284  of the generally rectangular webbing  280 . However, certain portions of the generally rectangular webbing  282  may break or be cut as the plate  286  of full length inserts  205  is installed. Portions of the generally rectangular webbing  282  may be cut because the generally rectangular webbing  280  may interfere with other components of the floor tile  100 . For example, as best shown in  FIG. 9 , the generally rectangular webbing  280  may interfere with the center post  118 . Therefore, the generally rectangular webbing  280  may be cut or predisposed to break as the full length inserts  205  of the plate  286  are pressed into the holes  102 . The rectangular webbing  280  is flexible, however, so the webbing may also simply be re-routed around obstructions without being cut as well. It will be understood by those of ordinary skill in the art having the benefit of this disclosure, that the full length inserts  205  are not necessarily interconnected in the configuration shown in  FIGS. 9-11 . According to one embodiment, each full-length insert  205  is completely separate and individual. Other embodiments may include any number of full-length inserts  205  interconnected in any pattern. 
   Continuing to refer to  FIGS. 9-11 , the full-length inserts  205  may straddle or partially straddle the open surface  104  of the floor tile  100 . As mentioned above, the pad  211  may be sized to slightly resist passage through the holes  102 . Therefore, the full-length insert  205  may be inserted into one of the holes  102  by applying a sufficient force to the full-length insert  205  to elastically deform the pad  211  as it passes through the hole  102 . The pad  211  tends to displace to a generally flush position relative to the open top surface  104  upon the application of force. The post  209  is resilient and compressible, and a sufficient force on the pad  211  (e.g. a person stepping on the pad) causes the post  209  to compress. 
   In one embodiment, the protruding full-length inserts  205  provide traction to users of the modular tile  100 . As mentioned above, the full-length inserts  205  may be elastomeric, and soft elastomeric materials such as rubber and santoprene provide excellent fraction for users. The full-length inserts  205  may be compressible as well, providing an addition level of support and a comfortable surface for users to walk across. Some embodiments of the insert  105  and the full-length insert  205 , however, may be rigid. The number of full-length inserts  205  used with the modular tile  100  may be varied according to preference. Moreover, as described above, the modular tile  100  includes an interlocking mechanism for attachment to adjacent tiles. Therefore, multiple modular tiles  100  may interlocked to create a floor of any size and shape. 
   Another embodiment is disclosed in  FIGS. 12-15 .  FIGS. 12-15  illustrate a modular floor tile  300  comprising a top surface  304 . The top surface  304 , however, may be solid, instead of open. The top surface  304  may be smooth or include raised or recessed features in any shape and pattern. Similar or identical to the embodiment of  FIGS. 1-3 , one embodiment of the modular floor tile  300  includes the four side edges or surfaces  106 ,  108 ,  110 ,  112 . The side edges  106 ,  108 ,  110 ,  112  may include the same or similar features to those shown in  FIGS. 1-7  for interlocking to adjacent tiles. Accordingly, in the embodiment of  FIGS. 12-15 , the first and second side edges  106 ,  108  include the loops  114 , and the third and fourth adjacent side edges  110 ,  112  include a plurality of locking tab assemblies  116 . 
   The modular floor tile  300  of  FIGS. 12-15  includes a support system under the top surface  304  comprising multiple levels of support. According to one embodiment, at least one of the multiple levels of support comprises a first resilient level  370 . In one embodiment, the first resilient level  370  comprises a plurality of the elastomeric, full length inserts  205  disposed under the top surface  304 . Similar or identical to the embodiment shown in  FIG. 11 , the full length inserts  205  of  FIGS. 12-15  may be interconnected, removable inserts nested under the top surface  304 . As mentioned above, each of the full length inserts  205  may be substantially equal in length to, or slightly longer than, the side edges  106 - 112 . Therefore, the full-length inserts  205 , when the assembled in the modular floor tile  300 , extend beyond a bottom plane  372  parallel to and spaced from the top surface  304 . Accordingly, the full length inserts  205  contact the ground or other support surface. 
   As mentioned above, the full-length inserts  205  comprise a resilient material, which may be an elastomer such as rubber, or they may comprise plastic or other materials. The full-length inserts  205  may include any shape. For example, as shown in  FIGS. 12-15 , the full-length inserts  205  may comprise a post or compressible column  209 . In one embodiment, the full-length inserts  205  may be inserted from the bottom of the modular tile  300 . The bottom of the modular floor tile  300  is shown in  FIG. 15  and may be similar or identical to the bottom of the floor tile  100  shown in  FIGS. 4 ,  5  and  9 . Therefore, according to embodiment, the full-length inserts  205  may nest in the receivers or holders  115 . However, the full length inserts  205  of  FIGS. 12-15  abut an underside of the solid top surface  304 , rather than inserting into holes  102  ( FIG. 1 ). 
   The first resilient level  370  of support comprising the plurality of full length inserts  205  tends to comfortably compress under a load as illustrated in  FIG. 13 . For example, when multiple modular tiles  300  are used to form a sports or dance floor, each step by a user  374  puts a localized load on certain of the full length inserts  205  comprising the first resilient level  370 . The full length inserts  205  tend to compress under a load as shown in  FIG. 13 , providing a forgiving surface for the user  374 . The full length inserts  205  rebound to their original length when the load is removed. 
   In one embodiment, at least one other of the multiple levels of support comprises a first generally rigid level  376 . The first rigid level  376  may comprise the first set of generally rigid primary support legs  152  having the first length. The first rigid level  376  may coincide with the bottom plane  372 . The first set of support legs  152  may each comprise the split or fork leg as shown in  FIG. 15 . Absent a load, only the first resilient level  370  contacts the ground. However, under a sufficient load, the full length inserts  205  compress until one or more of the generally rigid primary support legs  152  of the first rigid level  376  reaches the ground. The first rigid level  376  may support the bulk of the load when the first resilient level  370  compresses. 
   In some embodiments, the modular floor tile  300  includes another support level. For example, the multiple levels of support may comprise a second generally rigid level  378 . The second generally rigid level  378  may comprise the second set of generally rigid support legs  154  having the second length. The second set of support legs  154  may comprise clusters of three or four legs. The second length of the second set of support legs  154  is shorter than the first length of the first set of support legs  152 . Therefore, absent a load sufficient to overcome the supporting capability of the first set of generally rigid support legs  152 , only the first or second levels  370 ,  376  contact the ground. In the embodiment of  FIGS. 12-15 , the full length inserts  205  are nested in one or more of the groups of three or four legs. Although generally rigid, the spacing of the first set of support legs  152  facilitates vertical flexing or springing of the modular tiles  300  under a sufficient load. As a load is applied to one or more of the modular tiles  300  via the top surface  304 , the full length inserts  205  collapse and the first set of generally rigid support legs  152  contact the ground. Additional loads cause the top surface  304  or the support legs  152  to “give” or flex until the second set of support legs  154  (comprising the second rigid level  378  of support) contacts the ground. The first set support legs  152  and/or the top surface  304  only flex elastically before the second set of support legs  154  contact the ground. Therefore, the support levels  370 ,  376 ,  378  and the modular tile  300  all tend to rebound to an original shape when loads are removed. 
   Accordingly, application of the principles described herein may result in another especially comfortable spring-like modular floor with multiple layers of support. In one embodiment, there are at least three separate layers of support, but there may be as few as two and as many as four or more. It will be understood that the top surface  304  need not be solid as shown in  FIG. 14  to enable the multiple levels of support. There may also be holes in the top surface  304  in some embodiments (e.g.,  FIGS. 7 and 11 ). 
   As discussed above, the full length inserts  205  may be removeably inserted into the modular tile  300 . In some embodiments, however, the full length inserts  205  or another resilient support level are part of a one-piece, unitary tile. 
   The preceding description has been presented only to illustrate and describe exemplary embodiments. It is not intended to be exhaustive or to limit the claims. Many modifications and variations are possible in light of the above teaching. The scope of the invention is defined by the following claims.