Abstract:
A modular substrate system for use in the support of a flooring surface including a plurality of elongate substrate members which can be rapidly assembled to provide a semi-rigid support surface for a floor. Various flooring elements can be adhered to the semi-rigid support surface using an adhesive to, in cooperation with the modular substrate system, provide an enhanced composite rigidity to the assembled floor. The substrate member itself includes an upper surface, side surfaces, and lateral flange portions, the lateral flange portions of the substrate members maintain adjacent substrate members in parallel spaced apart relationship to each other defining substrate channels therebetween. The substrate channels strengthen the assembled modular substrate system and provide routes of egress for water from below the flooring surface disposed thereon.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates in general to flooring and decking/patio systems, and more specifically, relates to a modular substrate system for use in the support, of a floor surface. Various flooring elements can be adhered to the semi-rigid support surface to, in cooperation with the modular substrate system, provide an enhanced composite rigidity to the assembled floor incorporating the modular substrate system. 
       DESCRIPTION OF RELATED ART 
       [0002]    In the construction of decking and floors a common approach is to build a wooden or metal frame upon which upon some form of decking material is then placed to provide a suitable surface upon for furnishings or the like to be placed, as well as which can be occupied by people. In some cases the decking surface can consist of wooden or composite planks attached to the underlying frame. In these cases, the planks are attached such that there is a small space between each plank to allow for expansion, and for water to be shed from the top surface of the deck. 
         [0003]    A common problem with this type of decking system is that the area under the deck is un-protected from moisture, and so the support structure is typically exposed to the elements an subject to degradation over time as a result. Where wooden joists are used, they can when contacted with water below any waterproof treatment or membrane decay. If a metal substrate surface is used, with screws placed therethrough etc., often times that will rust and the rusting of the substrate can again lead to a structural destabilization of the overall installation as well as potentially ruining the visible appearance of the product if the rust bleeds through. Wooden and even composite materials must be maintained over time in order to preserve both the structural integrity of the deck or patio, as well as to maintain aesthetic appearance. If it were possible to create a substrate for use underneath the deck or other flooring installation which was manufactured of materials that were resistant to most types of decay this would represent an enhancement over current available products. 
         [0004]    In addition to prior art problems with the ingress of water below an attached flooring surface into the substrate in a floor installation, it would also be desirable to provide a system for the rapid deployment of a semi-rigid flooring substrate in a minimal amount of material and steps, to speed the overall assembly of decks or other floors. For example where a wooden joist structure is created, significant time is often required to cut and assemble the joist work and substrata beneath such an installation. Different types of brackets and other systems have been created to ease the creation to a degree the assembly of a flooring substrate, but if it were possible to address the issue of structural integrity and water egress from the substructure of a deck or floor with a subassembly that was rapidly and simply assembled this would also be considered desireable. 
         [0005]    Prior art methods of substrates and support for flooring surfaces have included the use of flexible surfaces such as thin or metal, plywood or the like, which are either too flexible, resulting in cracking or the possibility of cracking of the overlying floor surface, or which require the addition of a concrete layer or the like to provide additional rigidity. Provision of a method and apparatus for the construction of a modular substrate which would allow for rapid deployment of a substrate of reasonable rigidity would be attractive from a commercial perspective. 
         [0006]    Metal is often seen as a desireable material for construction due to its fluid resistant characteristics (dependent upon choice of material and fastening system). One of the issues with a metal surface of significant size however is often that it is too flexible for a flooring or decking purpose. If the substrate of a deck is too flexible, it is more likely that the flooring overlay or surface will crack or otherwise be damaged when the substrate flexes under weight load. As such, it is desired to provide a substructure assembly that is at least semi-rigid and would not flex so much as to make it ineffective as a supporting substrate for a deck or floor. If it were possible to create a substrate for adhesive attachment of flooring elements which enhance the ability of water to exit from beneath the flooring surface and had maximized rigidity, to provide maximum support to the overlying flooring surface it is also believed that this would be well received. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    The present disclosure describes components and methods of manufacture and installation of said components to provide a modular substrate system. The decking system provides a number of advantages over prior methods and components in that the components are simple to manufacture and assemble into a finished decking system. The modular substrate system described herein provides for the use of rigid or semi-rigid decking surface materials arranged in such a way that the components cooperatively provide an effective degree of flexibility to the system while avoiding the over-flex of the substrate which would result in the cracking or disruption of the flooring surface or membrane. 
         [0008]    The modular substrate system of the present invention is made for use in the support of a flooring surface. The floor surface might comprise a single membrane, or a multi-component diaphragm. Both such approaches are contemplated within the scope hereof. The substructure is further designed to permit ingress of air and egress of water such that the growth of mold or mildew, or damage to supporting structures by water is effectively prevented. 
         [0009]    In some embodiments, the modular substrate system may comprise a group of elongate substrate members configured to cooperatively form a substrate mounting surface for the adhesive attachment of flooring elements thereto. 
         [0010]    The modular substrate system is manufactured of metal which minimizes the likelihood of water-based decay and provides sufficient strength and workability to be advantageous as a material of manufacture. Adhesive is the likely desireable means of attachment of the flooring surface, to maintain the integrity of the substrate mounting surface as well as to achieve the flexible rigidity desired in terms of the cooperative action of the flooring surface and the modular substrate system under weight load. 
         [0011]    The completed modular substrate system comprises a plurality of elongate substrate members which align themselves with each other by cooperation of aspects thereof. Once the plurality of elongate substrate members are properly aligned to complete the modular substrate system, they can be attached to each other, and the top of the assembled modular substrate system comprises the substrate mounting surface. 
         [0012]    It is contemplated that in many embodiments the substrate member will effectively comprise a U-shaped member which will be inverted in installation. The substrate member may include a substantially flat upper surface, side surfaces meeting the upper surface in upper edges, and lateral flange portions at the distal ends of the side surfaces. The lateral flange portions are the portions of the substrate member which will cooperate with like components of adjacent substrate members to maintain them in properly spaced relationship in the assembly of the modular substrate system. 
         [0013]    In some embodiments, each substrate member is substantially rigid along a longitudinal axis, but is torsionally flexible around the longitudinal axis; each lateral flange portion of each substrate member capable of holding the substrate member when placed in parallel alignment with an adjacent substrate member such that a substrate channel is defined therebetween; and/or whereby when the modular substrate system is assembled the upper surfaces of the substrate members. 
         [0014]    In some embodiments, when the modular substrate system is assembled the upper surfaces of the substrate members may comprise the substrate mounting surface and substrate channels run from one edge to the other of the substrate mounting surface along the upper edges of the substrate members. In addition to providing channels for water to exit from the substructure, the substrate channels also effectively act as strengthening joists or corrugations within the completed assembly of the modular substrate system, which provide added strength and minimize the flexibility of the modular substrate system. 
         [0015]    In some embodiments, the lateral flange portions of a substrate member are configured to engage lateral flange portions of adjacent substrate members. The lateral flange portions, at the distal ends of the side surfaces of the substrate member, might comprise a flange extending outwards in a plane substantially parallel to the plane of the upper surface of the substrate member, optionally with a retaining tab at the end thereof to provide a system which can most easily and completely be rapidly assembled, and which will best strengthen the overall modular substrate system while maintaining the parallel and spaced apart relationship of adjacent substrate members during assembly or completion of the modular substrate system. 
         [0016]    In some embodiments; the modular substrate system is installed on a pre-existing rigid surface. In other cases, a supporting frame might be used beneath the plurality of substrate members to further support, or raise the height, of the finished modular substrate system. In some embodiments, the supporting frame may include risers to raise the modular substrate system above the rigid surface. 
         [0017]    In addition to the modular substrate system of the present invention, there is also disclosed a substrate member for use in construction of a modular substrate system for use in support of a floor surface. The substrate member comprises an elongate structure that is substantially rigid along a longitudinal axis, but is torsionally flexible around the longitudinal axis; and has a substantially flat upper surface, opposing side surfaces meeting the upper surface in upper edges, and lateral flange portions at the distal ends of the side surfaces. The lateral flange portions will engage a surface onto which installation of the floor surface is desired; and are capable of holding said substrate member when placed and engaged in parallel alignment with an adjacent substrate member such that a substrate channel is defined therebetween. The lateral flange portions can further comprise engagement tabs at the ends thereof, to fixedly engage the lateral flange portions of adjacent substrate members. 
         [0018]    Many different cross-sectional profiles can be envisioned for the substrate member, including a substantially U-shaped crosssection. The substrate member disclosed can be used in the assembly of a modular substrate system such as that outlined herein. 
         [0019]    Also disclosed is a method of constructing a modular substrate system for use in support of a floor surface, said modular substrate system comprising a plurality of elongate substrate members configured to cooperatively form a substrate mounting surface for the adhesive attachment of flooring elements thereto, each of the substrate members comprising an elongate U-shaped member having a substantially flat upper surface, side surfaces meeting the upper surface in upper edges, and lateral flange portions at the distal ends of the side surfaces, and being substantially rigid along a longitudinal axis, but torsionally flexible around the longitudinal axis; and the lateral flange portions of substrate members maintaining adjacent substrate members in parallel spaced apart relationship to each other defining substrate channels therebetween, said method comprising aligning the desired plurality of elongate substrate members parallel to each other by alignment of the lateral flange portions thereof; and attaching the aligned substrate members to each other. When the modular substrate system is assembled the upper surfaces of the substrate members comprise the substrate mounting surface and the substrate channels run from one edge to the other of the substrate mounting surface along the upper edges of the substrate members. 
         [0020]    In the method, the lateral flange portions of a substrate member are configured to engage lateral flange portions of adjacent substrate members. 
         [0021]    In some cases the method might be used to construct a modular substrate system on a pre-existing rigid surface, versus in others where a supporting frame was the be used beneath the substrate members the method might also include the installation of said supporting frame in advance of placement of the substrate members thereon. 
         [0022]    In assembly of a modular substrate system in accordance with the present invention, the substrate members can be cut and shaped to accommodate the general shape of the installation area, as can any supporting frame be manufactured to the proper height and size as well as potentially allowing for accommodation of surface irregularities at the point of installation. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0023]    To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced. 
           [0024]      FIG. 1  is a perspective view of an embodiment of a substrate member of the present disclosure. 
           [0025]      FIG. 2  is a perspective view of an embodiment of a partially assembled substrate mounting surface, secured to a supporting frame. substrate mounting surface 
           [0026]      FIG. 3  is a view of an embodiment of adjacent substrate members and showing the nesting of lateral flange portions of the adjacent members, and a means of securing to a supporting frame. 
           [0027]      FIG. 4  is a perspective view of an embodiment of a partially assembled system according to the present disclosure, depicting a supporting frame, substrate members forming a substrate mounting surface, and surface elements installed on the substrate mounting surface. 
           [0028]      FIG. 5  is a end on view of substrate members onto which surface elements have been placed directly without providing for an intervening space between the substrate members and surface elements. 
           [0029]      FIG. 6  is an embodiment shown in edge on view, in which the surface elements and substrate members are separated by flexible cushions into which the surface elements are mounted. 
       
    
    
     DETAILED DESCRIPTION 
       [0030]    As discussed above, most decking systems have limitations due to their design. In simple decking systems, the decking material is typically planks or slats that are installed with spaces between each slat/plank member. This design allows for the shedding of water, and permits airflow under the decking such that water does not accumulate and cause damage over time either directly, or by stimulating the growth of mold and mildew. In order to overcome this limitation and provide a more uniform surface, a variety of approaches including multilayer decking systems have been developed. However, these systems suffer from the limitation that they are more complicated to install, have more components, and thus are more expensive to manufacture, install and maintain. The present modular substrate system overcomes the limitations presented by prior art systems. 
         [0031]    A modular substrate system in accordance with one embodiment of the present invention is shown in  FIG. 1 . In some embodiments, for example as depicted in  FIG. 1 , a component of the system comprises a substrate member  10 . In some embodiments, the substrate member  10  can be formed from a piece of sheet metal such that it forms a U-shape structure. The formed substrate member  10  preferably has an substantially flat upper surface  12 , side surfaces  14 , and lateral flange portions  16 . The lateral flange portions  16  can also be formed with a hole through which a fastener can be passed in order to secure each substrate member  10  to an underlying supporting frame  20 , and to an adjacent substrate member  10 . 
         [0032]    Preferably a substrate member  10  can be fashioned from metal stock, such as that used in the making of the metal version of 2×4 members used in building construction. The U-shape of the substrate member  10  provides several structural and functional advantages. First, the U-shape provides for significant rigidity along the longitudinal axis of the member, such that it will be relatively resistant to bending—as a result of the multiple corrugations in its structure. Thus, a substrate member  10  is capable of supporting a significant weight load without collapsing or failing. 
         [0033]    Further, as a result of the open U-shape, each substrate member  10  will be capable of some torsional rotation around the longitudinal axis. This provides two advantages. First, the ability to rotate one end of the substrate member  10  relative to the other means that the underlying supporting frame  20  does not have to be perfectly aligned in order to install a substrate member  10  spanning different parts of the supporting frame  20 . In addition, this torsional flexibility provides for the ability of the substrate member  10  to adapt to small changes in the shape of the finished deck or flooring system that may occur over time. Such changes can occur as a result of movement of the underlying surface upon which the system is mounted, such as may occur with ground movement, or as a result of regular changes due to thermal expansion and contraction of the materials of which the decking system is comprised. As will be seen from the description below, the nature of the surface elements that are used to cover the substrate members,  10  and the way in which they are mounted and sealed, also provides for a membrane or surface that behaves as a rigid decking system, but which is able to flex without disrupting the integrity of the overall system. 
         [0034]    In constructing the modular substrate system of the present invention, and as shown in  FIG. 2 , a plurality of elongate substrate members  10  are secured to an underlying supporting frame  20 . The supporting frame  20  can be fashioned from any suitable building material including wood, composite or metal beams. The supporting frame  20  will in some cases be mounted on risers  22 , that are in turn mounted on the ground, or some other type of supporting surface, such as concrete or a prepared aggregate. In some cases, it may be preferable to place the supporting frame  20  directly on the ground or other surface, without the need for risers  22 . The particular type of installation of the supporting frame  20  will depend on the particular characteristics of the location where the modular substrate system is to be installed. 
         [0035]    In still other embodiments, it is possible to place the modular substrate system comprising a plurality of elongate substrate members  10  secured to each other directly upon a surface. The surface on which the system is placed can be the ground, a prepared site such as concrete or gravel fill, or on other materials such as foam sheets or other semi-rigid material. The modular substrate system is in this regard quite adaptable and suitable for use in a variety of locations. Moreover, because of the ease of assembly, the system is potentially even usable as a temporary substrate system that can be assembled, then disassembled for use at a different location. 
         [0036]    As also shown in  FIG. 2  a plurality of elongate substrate members  10  can be placed adjacent to each other to span the distance between opposing portions of a supporting frame  20 , where such a supporting frame  20  is used. Conveniently, the U-shape of the substrate member  10  and lateral flange portions  16  cooperate to maintain adjacent substrate members  10  in a parallel, spaced-apart relationship, defining substrate channels  21  between adjacent substrate members  10 . These substrate channels  21  serve to let water run out from the system, and to admit air, circulation in order to avoid the development of condensation, and drying underneath the finished surface that is eventually supported by the substrate system. This provides the advantage of protecting the substrate system from damage due to mold, mildew and corrosion from standing water. The substrate channels also effectively act as strengthening joists within the structure of the modular substrate system. 
         [0037]      FIG. 3  provides a more detailed view of the relationship between the supporting frame  20  and adjacent substrate members  10 . As can be seen, each substrate member  10  comprises an upper surface  12 , side surfaces  14 , and lateral flange portions  16 . The lateral flange portions  16  are shaped such that the lateral flange portion  16  of one substrate member  10  conveniently nests into the lateral flange portion  16  of an adjacent substrate member  10 . Once nested in this fashion, the substrate members  10  can then be secured to the underlying supporting frame  20  with a fastener  18 . 
         [0038]    In some embodiments, the lateral flange portions  16  and distal ends of the side surfaces  14  of the substrate members  10  will engage a surface onto which installation of a horizontal floor surface is desired, for example, and as shown, an underlying supporting frame  20 . Fasteners can include any suitable fastener known to those of skill in the art, and the choice of fastener is not meant to be limiting to the scope of the invention. As can also be appreciated from  FIG. 3 , the side surfaces  14  are angled away from the perpendicular with respect to the upper surface  12  of each substrate member  10 , thus creating slightly trapezoidal shaped substrate channels  21  between adjacent substrate members in some embodiments. 
         [0039]      FIG. 4  depicts a partially completed modular substrate system, manufactured and assembled as described herein. As can be appreciated, the supporting frame  20  is completely covered by a plurality of elongate substrate members  10 , arranged substantially parallel to each other, and secured to the supporting frame  20  as shown in  FIG. 3  and  FIG. 4 . The plurality of elongate substrate members  10  thus act cooperatively to provide a substrate mounting surface onto which surface elements  40  can be mounted. In the depicted embodiment, each surface element is depicted as a square tile. Other type of elements are suitable for use in the system, and other shapes are contemplated as well. As an example, for aesthetic reasons, a triangular shaped surface element might be desired. Because of the ease of assembly and adaptability of the present system, a wide variety of shapes, and types of material can be used in the surface elements. Tiles, or surfacing elements of many different types of material, can be used—including wood, plastic, ceramic, cement, vinyl, composite lumber to name a few. 
         [0040]      FIG. 5  depicts an edge-on view of a portion of the modular substrate system. In this case, three adjacent substrate members  10  are depicted mounted on an underlying supporting frame  20 . A series of adjacent surface elements  40  are also shown, installed on top of the substrate structure formed by the substrate members  10 . The shape of the edges results in the formation of a void  44 , which in the finished decking product is filled with a flexible adhesive joint material  46 . This joint material  46  serves a number of functions. First, when complete, the combination of surface elements and joint material operate such that the finished upper surface of the modular system functions as a unitary diaphragm. Moreover, this diaphragm is substantially waterproof, preventing moisture from getting underneath the finished surface, and thus substantially avoiding the risk of water damage to the underlying substrate components of the system. 
         [0041]      FIG. 6  depicts another embodiment wherein the surface elements are separated from the substrate members  10  by flexible adhesive cushions  60 . The cushions  60  operate to support surface elements  40  above the substrate members  10 , thereby creating an air space  61  of defined with between the surface elements  40  and the substrate members  10 . The air space  61  functions to admit airflow between these layers in order to avoid accumulation of moisture that might otherwise lead to water damage directly, or as a result of the growth of mold and/or mildew. Preferably the cushions  60  are formed from an elastomeric material such that they are flexible and can deform under conditions of loading to permit the finished flooring system to flex resiliently while in use. Any type of a fastening approach for surface elements which allowed for attachment of a flooring surface while maintaining the integrity of the substrate mounting surface and the semi-rigid character of the modular substrate system are contemplated within the scope hereof. 
         [0042]    In some embodiments, the modular substrate system can be installed on a pre-existing rigid surface, for example, a supporting frame  20  as depicted in  FIG. 2 . Such a supporting frame  20  can be formed in a manner known to those of skill in the art. In some cases it will be preferable to use a metal supporting frame  20  for reasons of strength and durability. In other cases, it may be desirable to produce a supporting frame  20  from wood or other materials. In installing the present system the supporting frame  20  can be placed directly on a prepared surface such as the ground, or an aggregate base. In other cases it will be convenient to mount the supporting frame  20  on supporting structures to raise the deck above ground level. The particular types and design of supporting structure on which the supporting frame  20  is mounted will depend on the nature of the building site, whether the deck is at or near ground level or elevated, and the requirements of local building codes. 
         [0043]    Once the supporting frame  20  is in place, individual substrate members  10  are secured to the frame as shown above. Conveniently, each substrate member  10  can be secured to the supporting frame  20  with typical fasteners such as metal screws. As depicted above, each substrate member  10  is nested alongside an adjacent substrate member  10  by virtue of the lateral flange portions  16  present on each substrate member  10 . These lateral flange portions  16  will run substantially the entire length of the substrate member  10 , thus providing maximal integrity of the substrate mounting surface formed. Further, because of the U-shape of each substrate member  10 , collectively the substrate mounting surface formed by a plurality of elongate substrate members  10  will include regularly spaced substrate channels that admit air, and allow for the egress of any water that may accumulate under the finished surface of the decking. 
         [0044]    Once the substrate members  10  are in place and attached, the construction of the modular substrate system is complete. A flooring layer can then be attached—for example by placing adhesive on each substrate member  10  and attaching flooring elements thereto. As described, support pylons are preferably formed from an elastomeric material that also has adhesive properties. Alternatively, it is possible to manufacture the substrate members with support pylons already installed, in order to save the decking installer effort during the building of a modular substrate system. Once the surface elements are positioned, an installer then fills the void between each surface element with a flexible adhesive joint material. This material is preferably also an elastomeric material that is elastically deformable. Once all the voids have been filled with the joint material, the upper finished surface of the deck will function as an unitary, substantially waterproof, membrane, that covers the underlying substrate members and supporting frame. The resilient nature of the joint material also permits a small amount of movement of each surface element relative to its neighboring elements, thus allowing the decking surface to respond to variations in temperature, or position of the underlying supporting structure, while preventing disruption of the membrane. 
         [0045]    One advantage of the present system is that each of the elements cooperate to provide a resilient and flexible decking surface that avoids problems with cracking of surface elements as can occur when hard materials such as tile or stone are mounted directly on a rigid substrate. 
         [0046]    It will be recognized that the specific materials used in constructing the various components of the system described herein, are not considered to be limiting to the scope of the invention. Those of skill in the art will readily recognize and be able to select materials and components that will accomplish the objectives of the invention without requiring any inventive skill. 
         [0047]    It should also be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the scope of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.