Patent Publication Number: US-10329777-B2

Title: Modular sprung floor

Description:
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 the beam cross-section, E*I. Bending stiffness or flexural rigidity may be measured in Newton millimeters squared (N*mm^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 along with an edge module that provides a finished edge to the frame modules. The frame and edge modules comprise a frame that 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 cost of materials and are dependent on specific aspects 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 members and Y-axis members. Joints are standardized components of an elastomeric material that join linear-structural members at right angles where X-axis members meet Y-axis members. These joints join structural members to form a frame while dampening vibration and impact. 
     Other elastomeric members engage with X-axis or Y-axis members and further join together lateral channels that support a performance surface. The performance surface is made up of flat panels that are keyed together. These lateral channels join together frame modules while aligning and connecting performance surface panels, and in some embodiments have a U-shaped cross section. In some embodiments, performance-surface panel joints do not align with frame-module joints. Lateral channels provide a way of joining together performance-surface panels across frame module seams. Elastomeric supports between frame modules and linear channels dampen vibrations between performance surface panels and frame modules. 
     An edge assembly provides a finished edge to the modular floor assembly. In one embodiment, an edge assembly is a long, linear structural member that resides along the Y axis of an assembled frame. Relatively short structural members along the X axis are joined perpendicularly to the long Y-axis members. Their distal ends are further joined to frame members coaxially (i.e., continuing along the X axis). A lateral support structure is affixed to the edge assembly by an array of elastomeric joint-members that join linear-structural members at right angles while also supporting the lateral channel and dampening vibrations between the lateral channel, and hence the performance surface, and the edge-assembly structure. 
     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 elastomeric components may be die-cut from stock material. 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 view of a complete modular floor assembly; 
         FIG. 2  is a perspective, partially exploded view of the embodiment of  FIG. 1 ; 
         FIG. 3  is a perspective view depicting the edge assembly of the embodiment of  FIG. 1 ; 
         FIG. 4  is an exploded view of the edge assembly of  FIG. 3 ; 
         FIG. 5  is a partially exploded, detail view of the frame portion of the embodiment of  FIG. 1 ; 
         FIG. 6  is a perspective view of a joint of the edge assembly of  FIG. 3  and  FIG. 4 ; 
         FIG. 7  is a perspective view of a channel support of the embodiment depicted in  FIG. 5 ; 
         FIG. 8  is a perspective view of a joint of the embodiment depicted in  FIG. 5 . 
         FIG. 9  is a perspective view of a second iteration of the embodiment. 
         FIG. 10  is a perspective, partially exploded view of the embodiment of  FIG. 9 . 
         FIG. 11  is a partially exploded, detail view of the frame portion of the embodiment of  FIG. 9 . 
         FIG. 12  is a detailed, perspective, exploded view of a frame joint of the embodiment depicted in  FIG. 11 . 
         FIG. 13  is a perspective view of a performance-surface support, also referred to as a pad. 
         FIG. 14  is a perspective view of a frame joint. 
     
    
    
     DESCRIPTION 
       FIG. 1  shows a perspective view of the present embodiment. A modular sprung floor assembly  100  has a performance surface  110  fixed on a frame assembly  112 . The frame assembly extends to meet the two edge assemblies  114 . Although one edge assembly is depicted, one skilled in the art understands that edge assemblies may be joined with any or all edges of a sprung-floor assembly. 
       FIG. 2  shows a perspective, partially exploded view of the embodiment of  FIG. 1, 100 . The performance surface  110  is made up of a plurality of surface panels  116  which are fastened together on their undersides by perpendicularly placed lateral channels  118 . A frame assembly  112  has X-axis members  126  and perpendicularly attached Y-axis members  128 . Frame joints  130  are elastomeric forms that join X-axis members  126  and Y-axis members  128  at right angles, while dampening vibration between members. Lateral channel supports  132  are elastomeric forms that join X-axis members  126  to the above lateral channels  118 . 
     An edge assembly  114  attaches to the frame assembly  112  on at least two sides. The edge assembly comprises relatively long Y-axis members  122  co-linear with Y-axis frame members  128 . Perpendicularly affixed to the edge assembly&#39;s Y-axis members  122  are relatively short X-axis members  120 , which are co-linear with X-axis frame members  126 . 
     The edge assembly&#39;s X- and Y-axis members  120 ,  122  are joined by edge-assembly joints  124 . Edge-assembly joints are elastomeric in form and serve to absorb shock and dampen vibrations between members. These edge-assembly joints further affix the X- and Y-axis members to an above lateral channel  118 . Lateral channels  118  fasten together the above performance-surface panels  116 . 
       FIGS. 3 and 4  illustrate an enlarged edge assembly and an exploded view of an edge assembly, respectively. The Y-axis member  122  is joined with relatively short X-axis members  120 . Edge-assembly joints  124  are elastomeric forms that affix the X-axis and Y-axis members and also fasten those members to an above lateral channel  118 , while dampening vibrations between members. In some embodiments, mounting pads  125  reside beneath Y-axis members  122  and provide vibration dampening between Y-axis members and a sub-floor. 
       FIG. 5, 112  is an exploded view and an exploded detail view of the frame assembly  112  with elastomeric joints  130  connecting X-axis members  126  to Y-axis members  128 . Through-holes in the elastomeric, lateral-channel supports  132  fixedly engage X-axis members  126  with Y-axis members  128 . 
       FIG. 6  is a perspective view of an edge-assembly joint  124  with a top surface  154 , a left-side surface  142  and a front surface  144 . In some embodiments left and right sides are substantially symmetrical as are front and back surfaces. The top surface  154  overlaps the front surface  144 . In other words the top surface  154  is larger than the cross-sectional area that is defined by left-side surface  142  and front surface  144 . The top surface is configured to engage with a lateral channel  118  ( FIG. 2 ). A through-hole  146  is configured to accept Y-axis members  122  ( FIG. 4 ) of the edge assemblies. Through-hole  148  is configured to accept X-axis members  120  of the edge assemblies. Fastener-holes  FIG. 6, 150  allow for fasteners to affix the edge-assembly joints  124  ( FIG. 4 ) with Y-axis members  122  ( FIG. 4 ). Fastener-holes  FIG. 6   153  allow for fasteners to affix the edge-assembly joints  124  ( FIG. 3 ) to lateral channels  118 . One skilled in the art understands how an elastomeric form similar to edge assembly joint  124  may join linear, structural members at right angles while also joining lateral structural members, while also dampening vibration between structural components. 
       FIG. 7  depicts an example lateral-channel support  132  with a top surface  160  and side surfaces  162 . A through-hole  164  is configured to accept Y-axis frame members ( FIGS. 2, 5 ). Fastener holes  166  allow fasteners to affix lateral channels with Y-axis members. 
       FIG. 8  shows a frame joint  130  which connects X-axis members and Y-axis members at right angles, one atop the other, through through-holes  182  and  180 . The frame joint  130  has a top surface  170  that is substantially symmetrical to a bottom surface  171 . The frame joint  130  also has a front surface  172  that is substantially symmetrical to a rear surface  173 . Similarly, a left-side surface  174  is substantially symmetrical to a right-side surface  175 . 
     Fastener-holes  176  are configured to affix the frame joint  130  with X-axis members  126  ( FIG. 2 ). Fastener-holes  178  are configured to allow fasteners to affix the frame joint  130  with Y-axis members  128  ( FIG. 2 ). 
     Frame joints  FIG. 8   130 , lateral channel supports  132  ( FIG. 5 ) and edge lateral channel supports  124  ( FIG. 4 ) are made of a flexible material capable of dampening vibration. One skilled in the art is familiar with injection-moldable, elastomeric material that may be consistently manufactured in appropriate forms and durometer to support the functional aspects of the aforementioned embodiments. One skilled in the art also understands that other manufacturing processes may be employed, including die-cutting, water-jet cutting or other subtractive processes and the like. 
     In  FIG. 9 , a perspective view shows a second iteration  200  with a performance surface  210  resting atop a frame assembly  212 . 
     In  FIG. 10, 200  frame joints  230  connect X-axis members  226  and Y-axis members  228  at right angles, one atop the other, in the frame assembly  212 . 
     In  FIG. 11, 212  a partially exploded detail view of the frame assembly is shown. Frame joints  230  are elastomeric forms that join X-axis  226  and Y-axis members  228  at right angles, while dampening vibration between members. Elastomeric pads  232  in their upright position support surface panels  116  ( FIG. 2 ). Inverted, the elastomeric pads  232 ′ support Y-axis cross members  228  and offset those members from a sub-floor. In the example of elastomeric pads  232  and elastomeric pads  232 ′ one skilled in the art understands that the same part may be used for both purposes. The same manufactured part is used in an upright orientation  232  and in an inverted orientation  232 ′ to perform different functions; one adheres the grid structure to the performance surface, and the other dampens vibrations against a sub-floor. 
     In  FIG. 12 , two modules  212  and  212 ′ are joined. The frame joint  230  is shown in an exploded view. The frame joint connects X-axis members  226  through through-holes  282  and Y-axis members  228  through through-holes  280 , at right angles, one atop the other, in the frame assembly  212  and  212 ′. One skilled in the art understands that this assembly can be repeated to add more modules over a given area and to join Y-axis members through the pad fittings  232 . 
     Fastener holes  276  are configured to affix the frame joint  230  to X-axis members  226  with the use of any generic fastener. Fastener holes  278  are configured to allow fasteners to affix the frame joint  230  with Y-axis members  228  or to butt-join two Y-axis members  228 ,  228 ′ with the use of a pin  234 . When a set of frame assemblies are joined, they are finished with a final X-member assembly  213  that has the same components as other X members in the assembly. One skilled in the art understands how the entire assembly can be completed with members  232  attached to open-ended members  226 . One skilled in the art understands that in a similar manner X-axis members may be joined with pads  232 . 
       FIG. 13  shows a performance surface support, also known as a pad,  232  with a top surface  260  and side surfaces  262 . The top surface  260  fixedly engages with a performance surface  210  ( FIG. 10 ). A through-hole  264  is configured to accept X-axis frame members  226  ( FIG. 11 ). Fastener-holes  266  allow fasteners to affix to X-axis members. One skilled in the art understands that  232  inverted ( 232 ′) can be configured to affix to Y-axis members, and also to be used as a pad between the Y-axis members and a sub-floor. 
       FIG. 14  shows a frame joint  230  which connects X-axis members and Y-axis members at right angles, one atop the other, in the frame assembly. The frame joint  230  has a top surface  270  that is substantially symmetrical to a bottom surface  271 . The frame joint  230  also has a front surface  272  that is substantially symmetrical to a rear surface  273 . Similarly, a left-side surface  274  is substantially symmetrical to a right-side surface  275 . 
     Fastener-holes  276  are configured to affix the frame joint  230  with X-axis members  226  ( FIG. 11 ). Fastener-holes  FIG. 14, 278  are configured to allow fasteners to affix the frame joint  230  with Y-axis members  228  ( FIG. 11 ). X-axis members go through through-holes  282  ( FIG. 14 ) and Y-axis members go through through-holes  280 . 
     Frame joints  230  are made of a flexible material capable of dampening vibration. One skilled in the art is familiar with injection-moldable elastomeric material that may be consistently manufactured in appropriate forms and durometer to support the functional aspects of the aforementioned embodiments. One skilled in the art also understands that other manufacturing processes may be employed, including die-cutting, water-jet cutting or other subtractive processes and the like.