Patent Publication Number: US-11047138-B2

Title: Modular sprung floor

Description:
This application is a continuation-in-part application of U.S. patent application Ser. No. 16/407,348 filed 2019 May 9. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates to modular floor systems and impact and shock-absorbing floors. 
     BACKGROUND 
     A sprung floor is a floor that is designed to absorb impact or vibration. Such floors are used for dance and indoor sports, martial arts and physical education to enhance performance and reduce injury. Impact injuries and repetitive stress injuries are mitigated by sprung floors. 
     Sprung-floor requirements are similar for dance or sports. Aspects of sprung floors include: stability; balance; flatness; flexion to prevent injuries without being so soft as to cause fatigue; sufficient traction to avoid slipping without causing one&#39;s foot to twist due to excessive grip. 
     Common construction methods include woven slats of wood or wood with high-durometer rubber pads between the wood and sub-floor, or a combination of the woven slats with rubber pads. Some sprung floors are constructed as permanent structures while others are composed of modules that slot together and can be disassembled for transportation. When constructed, a gap is left between the sprung floor and walls to allow for expansion and contraction of the sprung-floor materials. 
     The surface of a sprung floor is referred to as the performance surface and may be constructed of either a natural material such as solid or engineered wood or may be synthetic such as vinyl, linoleum or other polymeric construction. The surface upon which a sprung floor is installed is referred to as the sub-floor. 
     Some pads or shock absorbers used in sprung-floor construction are made of rubber or elastic polymers. The term elastic polymer is commonly referred to as rubber. Elastomers are amorphous polymers having viscosity and elasticity with a high failure strain compared to other polymers. Rubber is a naturally occurring substance that is converted into a durable material through the process of vulcanization. Elastomers or elastomeric materials may be thermosets or thermoplastic. A thermoset material is formed and set with a heating process. Thermoset materials do not return to their liquid state upon re-heating. Thermoplastic materials return to a liquid state when subject to sufficient heat. Thermoplastic materials may be injection-molded while thermoset materials are commonly molded in low-pressure, foam-assisted molds or are formed in stock material that may be die-cut or machined. 
     Bending stiffness, also referred to as flexural rigidity, may be understood to be the result of a material&#39;s elastic modulus (E) multiplied by the area moment of inertia (I) of a beam cross-section, E*I. Bending stiffness or flexural rigidity may be measured in Newton millimeters squared (N*mm{circumflex over ( )}2) A beam is also referred to as an elongate member. 
     SUMMARY 
     In accordance with example embodiments of the present disclosure, a method, system and apparatus for a modular sprung-floor is disclosed. An example embodiment is a sprung floor module having interchangeable components. Interchangeable components make up standardized assemblies. An example embodiment has a frame module that may be installed in a series to cover a given area. The frame module supports a performance surface. Standardized components include linear structural members combined with elastomeric joints and support members. Linear structural members may be hollow rectangular tubes. 
     One skilled in the art is familiar with hollow rectangular structural members made of steel, aluminum, fiber-reinforced polymers and the like. Manufacturing methods include casting, extruding, pultrusion, laminate molding and the like. Material properties vary as to the type of material, direction of fibers of a composite and the shape of the cross section. Cost of materials and weight are dependent on specific requirements of applications. For example, fiber-reinforced structural members may be appropriate for a modular system that must be rapidly assembled, disassembled and moved, whereas a permanent installation may utilize wood, composite, polymer, aluminum or steel structural members for reasons of durability and cost. 
     Frame modules are made up of linear-structural members arranged in a grid pattern having X-axis frame members and Y-axis frame members. Vertical joints are standardized components of an elastomeric material that join linear-structural members at right angles where X-axis frame members meet Y-axis frame members. These joints join structural members to form a frame while damping vibration and impact. 
     Other elastomeric members engage with X-axis or Y-axis frame members and movably engage with linear, structural channels that are fastened to edges of adjacent performance-surface panels. Linear, structural channels join edges of performance-surface panels and support the performance surface atop elastomeric members. These linear, structural channels join together frame modules while aligning and connecting performance surface panels, and in some embodiments have a U-shaped cross section. The performance surface is made up of flat panels joined to linear, structural channels at adjacent edges, allowing for removal of a single panel in an array, by removing the fasteners that join the edges to the structural channels. In some embodiments, performance-surface panel joints do not align with frame-module joints. Linear, structural channels provide a way of joining together performance-surface panels across frame module seams. The linear, structural channels also allow the performance surface to float atop the elastomeric supports so that the performance surface may expand and contract in varying environmental conditions without stressing the materials. Elastomeric supports between frame modules and linear, structural channels damp vibrations between performance surface panels and frame modules. 
     To join grid modules together, elastomeric pads and brackets are installed to abutting elongate members, forming a lateral joint. The elastomeric pads transmit load from a performance surface perpendicularly to these joints. 
     Weight on the performance surface creates a perpendicular force that transmits a compressive force on the top of elongate members, and a tensile force on the bottom of the elongate members. Within a joint, the tops of the abutting elongate members push into each other, supporting the compressive load. 
     The bottoms of the elongate members in a joint have the tendency to spread apart when under load. The brackets hold the bottoms of the elongate members together. The perpendicular force from the performance surface imparts a tensile force to the brackets holding them together and preventing spreading. 
     One skilled in the art understands that there are various methods for manufacturing elastomeric forms. In some embodiments the joint and support components are injection-molded. In other embodiments, elastomeric components may be manufactured by a low-pressure molding process using foamed urethane. In still other embodiments sheet metal components may be cut from stock material and bent. One skilled in the art also understands that elastomeric components may be placed between frame members and a sub-floor. 
     Other objects and features will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration and not as a definition of the limits of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       To assist those of skill in the art in making and using the disclosed floor system and associated methods, reference is made to the accompanying figures, wherein: 
         FIG. 1  is a perspective, partially exploded view of the embodiment  100 . 
         FIG. 2  is a perspective view of a pad (performance-surface support). 
         FIG. 3  is a perspective view of a frame joint. 
         FIG. 4  is a perspective, detailed view of the pad of  FIG. 2  and the frame joint of  FIG. 3  shown assembled in the embodiment  100 . 
         FIG. 5  is a perspective, detailed and partially exploded view of a pad and a bracket shown installed. 
         FIG. 6  is a perspective, partially exploded view of the embodiment  100   
         FIG. 7  is a perspective, partially exploded, detail view of the embodiment  100 . 
     
    
    
     DESCRIPTION 
     The present disclosure relates to a modular sprung floor assembly  100 . A frame assembly  112  forms a grid, made up of X-axis frame members  126  and Y-axis frame members  128  that are joined at nodes by frame joints  130 . A performance surface, made up of performance-surface panels  110  is supported above the frame assembly by linear, structural channels  118  that reside atop performance-surface supports  132 , also referred to as pads. Pads are also used in an inverted orientation  132 ′ to support the frame assembly above a subfloor. Linear, structural channels  118  are fastened with fasteners, about the perimeter of performance-surface panels  110 , joining edges of performance-surface panels  110  firmly. By resting atop performance-surface supports  132  the performance-surface panels  110  float and shift freely over the supports  132  as the floor expands and contracts with environmental conditions, allowing seams between performance-surface panels  110  to remain tight and unstressed without the need for edge fastening such as tongue-and-groove edge treatment. Performance-surface panels  110  may be removed individually, anywhere in an array, by removing fasteners and lifting a panel  110 . At some joints, the short edges of square panels meet a long edge  107  of an adjacent panel. 
       FIG. 2  is a perspective view of a performance-surface support or pad  132  with a top surface  160  and side surfaces  162 . Top surface  160  is designed to slidably engage with linear, structural channels  118  ( FIG. 1 ). An aperture  164  accepts X-axis frame members  126 , ( FIG. 1 ). Fastener-holes  166  affix fasteners to X-axis frame members  126 . One skilled in the art understands that  132  inverted ( 132 ′,  FIG. 1 ) can serve as a pad between the Y-axis members and a sub-floor. 
       FIG. 3  shows a frame joint  130  which connects X-axis frame members  126  and Y-axis frame members  128  stacked at right angles in the frame assembly ( FIG. 1 ). Aperture  182  is parallel to the frame joint&#39;s front surface  172  and receives X-axis frame members  126  ( FIG. 1 ). Aperture  180  accepts Y-axis frame members  128  ( FIG. 1 ). Fastener-holes  176 ,  178  are for affixing fasteners to X-axis frame members  126  and Y-axis frame members  128  respectively. 
       FIG. 4, 100  shows the pad  132  of  FIG. 2  and the frame joint  130  of  FIG. 3  installed on a frame assembly  112 . Elastomeric pads  132  in their upright position support linear, structural channels  118  ( FIG. 1 ) and performance-surface panels  110  ( FIG. 1 ). One skilled in the art understands the various types of laminate material that may be used as a performance surface. Inverted, the elastomeric pads  132 ′ support Y-axis frame members  128  and offset those members from a sub-floor. One skilled in the art understands that the same part may be used for both purposes; in the example of elastomeric pads  132  and elastomeric pads  132 ′ the same manufactured part is used in an upright orientation of the pad  132  and in an inverted orientation of the pad  132 ,′ performing different functions: one adheres the channels  118  ( FIG. 2 ) and hence the frame assembly, another adheres to the performance surface while damping vibrations, and another damps vibrations against a sub-floor. The frame joint  130  accepts X-axis frame members  126  and Y-axis frame members  128  at right angles. 
     A bracket  135  has an inverted U-shaped cross-section. It serves to join the X-axis frame members  126  end to end. At least one pin  134  may be used to fasten the bracket  135  to an X-axis frame member  126 . 
     Fastener holes  176  are configured to affix the frame joint  130  to X-axis frame members  126  with the use of common fasteners. Fastener holes  178  are configured to affix the frame joint  130  to Y-axis frame members  128 . 
       FIG. 5  illustrates how the elastomeric pads  132  install on the frame assembly. In their upright position the pads support structural channels ( FIG. 6, 118 ) and performance-surface panels ( FIG. 6, 110 ) of a sprung floor. One skilled in the art understands that this grid structure may support a performance surface of a sprung-floor assembly similar to that of  FIG. 1 . 
     A bracket  135  has an inverted U-shaped cross-section. It serves to join the x-axis frame members  126  end to end. Fastener holes  137  through the bracket  135  match those  176  of the frame members  126 . At least one pin  134  may be used to fasten the bracket  135  to a frame member  126 . Fastener holes  137  in the pad  132  match those  176  of the frame members and may be used to fortify this joint. Perpendicular force transmits a tensile force to the brackets, which hold the elongate members together from the bottom. 
       FIG. 6  illustrates the assembly of an example linear, structural channel  118  and an example performance-surface panel  110 . An insert  119  having three fastener holes  113 ,  115  and  117  is placed on the underside of a linear, structural channel  118 . The insert is affixed to the structural channel with a fastener  129  that passes through a hole  123  in structural channel  118  and fastened into fastener hole  115 . Fastener  127  passes through a fastener hole in a first performance-surface panel  110 , through hole  121  in a structural channel  118  and then fastened into fastener hole  113 . One skilled in the art understands how a series of such fasteners arrayed along the edge of a first performance-surface panel  110  will affix the edge of the performance-surface panel  110  along the center of a structural channel  118 . 
     Fastener  131  passes through a fastener hole in a second performance-surface panel, through hole  125  in a structural channel  118  and is fastened into fastener hole  117 . One skilled in the art understands how a series of such fasteners arrayed along the edge of a second performance-surface panel will affix the edge of the second performance-surface panel along the center of a structural channel  118  and abut the edge of the first performance-surface panel  110 . Panels fastened in this manner are fixedly engaged at their edges with structural channels and may be removed by removing the fasteners, without the need to remove multiple panels as when tongue-and-groove joints are used. Structural channels  118  are thus allowed to move about the top of pads  132  ( FIG. 1 ) to allow for expansion and contraction of the performance surface during environmental changes. 
       FIG. 7  illustrates a detail of the channel layout. In some embodiments, a channel  118  having an end  109  may extend past a joint  108  and into a long edge of a surface panel  107  ( FIG. 1 ). By extending the channel end  109  into a surface panel long edge  107 , the structural connection is extended and so, loading is distributed into the performance surface away from the joint  108 .