FLOATING SUB-FLOORING SYSTEM

Abstract

A floating sub-floor system includes panel assemblies in which each panel assembly includes a surface panel and a base panel. A bottom side of the base panel includes a vent channel system which provides passageways for moisture to evaporate and/or flow under the sub-floor. The surface panel and the base panel are coupled together so that complementary ship lap and overlap joints are formed along the sides of each panel assembly. Methods of fabrication and installation are disclosed.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of:

U.S. Provisional Patent Application Ser. No. 61/839,010, Attorney's Docket No. 4440.2.1p, entitled FLOATING SUB-FLOORING SYSTEM, which was filed on Jun. 25, 2013.

The foregoing is incorporated by reference as though set forth herein in its entirety.

TECHNICAL FIELD

The present disclosure relates to sub-flooring apparatus, systems, and methods of fabrication and use. More specifically, the present disclosure relates to a sub-flooring system that can be installed directly over concrete, wood, or other substrates used in the building construction industry for newly constructed or renovated facilities. The present embodiments may be installed as a floating floor system that can meet the rigorous requirements of heavy commercial applications for foot traffic and sound abatement, as well as providing the warmth, comfort and dryness aspects for use in residential applications.

BACKGROUND

This present embodiments relate to the use of sub-floor systems installed over substrates in today's building construction industry. Whether the building is a single family home, multi-residential high rise, office building, commercial enterprise, hotel, restaurant or institutional facility, issues of moisture, mold and mildew, sound transmission, and fire resistance are all of concern. In many circumstances, developers and architects are being forced to address and/or mitigate these issue in their building designs.

A substrate is the underlying support surface upon which a sub-floor is installed. In building construction, the substrate is commonly poured concrete or wood based materials adhered to a wood frame structure. Concrete substrates are often not smooth enough to provide a good surface upon which to install finished flooring, and generally cannot meet moisture, sound or mold mitigation requirements set by the architects, designers, or building codes. Also, many wood substrates may not be thick enough, smooth enough, or strong enough to support the finished floor and cannot meet moisture, sound or mold mitigation requirements.

A sub-floor is the underlying surface upon which a finished floor is installed. There are many different types of sub-floors used in the construction industry today; the specific type of sub-floor used may depend on the type of building construction, the geographical location, the finished flooring surface(s) to be installed, and the building code requirements.

In many applications, installing the sub-floor can be a difficult, labor intensive and costly operation. Most sub-floor manufacturers recommend their products be adhered to the substrate. In commercial applications, manufacturers may not warrant the floor system if the sub-floor has not been adhered to the substrate. Current sub-floors may be adhered to the substrate with bolts, or embedded in a layer of mortar, or glued down to ensure the sub-floor has conformed to the rough surface substrate.

Adhering a sub-floor to the underlying substrate may create a number of short and long term failure points in the life cycle of the finished floor installed over the sub-floor. For example, using anchoring bolts to adhere the sub-floor to a concrete substrate creates an ingress point for moisture to flow up through the substrate to the sub-floor. Adhering the sub-floor to a wood substrate with mortar introduces moisture to the wood and over time may cause the wood to distort. Adhering the subfloor to a wood or concrete substrate with adhesives or mortars dramatically increases the cost of floor removal and replacement installation in renovation or insurance claim projects. Removing glues or mortars from the substrate requires special equipment to chip or grind away the material, as well using solvents to clean the material from the rough surface substrate. Removal of the sub-floor in many cases causes significant damage to the substrate, which then has to be repaired or replaced. Finished floor failure is a significant problem within the building construction industry. These failures range from tile and/or grout failures to floors heaving, to buckling of carpets or laminated woods. All of these failures, over time, may create safety issues or trip hazards.

Floor system failures can also create health issues in the building as a direct result of moisture being trapped between the substrate and the sub-floor or between the sub-floor and the finished floor. These failures may actually create an environment for moisture to sponge up the interior walls of the building and allow mold to grow. Exposure to mold can cause cold-like symptoms, respiratory problems, nasal and sinus congestion, watery eyes, sore throat, coughing and skin irritations, and can trigger asthma attacks. Because some mold spores are very small and can easily be breathed deeply into the lungs, it may not be safe to live or work where there are high mold spore levels. Exposure to high mold spore levels can cause development of an allergy to mold. People can react to mold whether it is living or dead.

Rarely are the requirements of a sub-floor met with just one product. In many instances, specifications require the installation of multiple layers of different materials to meet the ever increasing demands of home owners, tenants, building codes, as well as developers, architects and designers. Typical sub-floor requirements include the following:

• 1. Moisture Barrier Used to prevent moisture being absorbed into finished floors, particularly wood products and carpets.
• 2. Anti-Microbial Protection Protection from growth of harmful mold, mildew, and other bacteria as a result of moisture issues.
• 3. Insulation Provide warmth to the finished surface.
• 4. Acoustical Prevent sound transmission between floors.
• 5. Anti-Fracture Protects against cracks in the structural floor from transferring to the finished floor's surface.
• 6. Ergonomics Provides a comfortable surface to walk upon, reducing fatigue, foot pain, and even back pain.
• 7. De-Coupling Easily removable for future renovation or remodelling plans.
• 8. Thickness Material must be low profile such that the overall thickness of the completed sub-floor and finished floor does not create issues with wall trims, door heights, appliances, and the like.
• 9. Environmental Provide green/environmentally friendly products.

It would be an advancement in the art to provide flooring that satisfies the requirements listed above. Further, it would be an advancement in the art to provide such flooring that is usable in various applications, such as in residential, commercial, and/or industrial settings. Further, it would be an advancement in the art to provide such flooring that is inexpensive and easy to produce. Yet further, it would be an advancement in the art to provide such flooring that is low-maintenance and relatively easy to reconfigure or replace.

SUMMARY

The present technology has been designed as a floating sub-floor system that is not adhered to the substrate and can be easily removed for renovation or replacement projects. When the sub-floor system is installed as described below, it creates a monolithic surface that is dimensionally stable and is decoupled from the substrate so that any changes or failures in the substrate will not transfer onto the finished floor material. The technology disclosed herein addresses all of the above sub-floor requirements in a single, low-profile, easy-to-install floating sub-floor system. The technology disclosed herein also provides insect resistance, combustion resistance, and low- to no-VOCs (volatile organic compounds).

Various embodiments of the technology include a sub-floor surface material that is impervious to mold, mildew, moisture, and insects but has sufficient porosity to allow adhesives, tile mortars and other fastening devices to bond with the surface material regardless of the finished flooring being installed over the surface material. Additional requirements of the technology may include insulating value, ergonomic comfort, fire resistance and dimensional stability properties that meet both residential and heavy commercial buildings sub-floor applications and codes.

A sub-floor base material may be added to the surface material. The base material may be impervious to mold, mildew, moisture, and insects yet have sufficient flexibility to conform to minor variations in the substrate it covers. The base material may have air flow channels, otherwise referred to as a duct system, on the underside of the base material that allows for any moisture that ingresses through the substrate or has accumulated on the surface of the substrate to evaporate or flow to a drainage system.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the technology will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only exemplary embodiments and are, therefore, not to be considered limiting of the scope of the technology, the exemplary embodiments will be described with additional specificity and detail through use of the accompanying drawings in which:

FIG. 1A is an isometric top view of a surface panel of a sub-floor system.

FIG. 1B is a top view of the surface panel of FIG. 1A.

FIG. 1C is an end view of the surface panel of FIG. 1A.

FIG. 2A is an isometric top view of a base panel of a sub-floor system.

FIG. 2B is an isometric bottom view of the base panel of FIG. 2A.

FIG. 2C is a bottom view of the base panel of FIG. 2A.

FIG. 2D is an end view of the base panel of FIG. 2A.

FIG. 3A is a bottom view of the base panel of FIG. 2A.

FIG. 3B is a detail view of a portion of the bottom of the base panel of FIG. 3A, taken at detail circle 3B of FIG. 3A.

FIG. 3C is a partial cross-sectional view of the base panel of FIG. 3A, taken along section line 3C-3C of FIG. 3A.

FIG. 4A is an exploded isometric top view of a panel assembly of a sub-floor system.

FIG. 4B is an isometric top view of the panel assembly of FIG. 4A.

FIG. 4C is an isometric bottom view of the panel assembly of FIG. 4A.

FIG. 4D is a detail view of a portion of the top of the panel assembly of FIG. 4B, taken at detail circle 4D of FIG. 4B.

FIG. 4E is a detail view of a portion of the bottom of the panel assembly of FIG. 4C, taken at detail circle 4E of FIG. 4C.

FIG. 4F is a bottom view of the panel assembly of FIG. 4A.

FIG. 4G is a side view of the panel assembly of FIG. 4A.

FIG. 4H is a top view of the panel assembly of FIG. 4A.

FIG. 5A is an exploded isometric top view of two of the panel assemblies of FIG. 4A in an end-to-end orientation.

FIG. 5B is a detail view of adjacent ends of the panel assemblies of FIG. 5A.

FIG. 5C is an isometric view of the panel assembly of FIG. 4A installed in an interior corner bounded by two wall portions and a substrate portion.

FIG. 5D is an isometric view of the panel assembly, wall portions, and substrate portion of FIG. 5C with additional panel assemblies in an installation pattern.

FIG. 6A is a bottom view of a portion of the base panel of FIG. 2A, illustrating a first vent channel configuration.

FIG. 6B is a bottom view of a portion of another base panel illustrating a second vent channel configuration.

FIG. 6C is a bottom view of a portion of yet another base panel illustrating a third vent channel configuration.

FIG. 6D is a bottom view of a portion of yet another base panel illustrating a fourth vent channel configuration.

FIG. 7A is a top view of a fixture for assembling the panel assembly of FIG. 4A.

FIG. 7B is a partial side view of the fixture of FIG. 7A taken along view line 7B-7B of FIG. 7A.

FIG. 8 is a top view of the surface panel of FIG. 1A and the base panel of FIG. 2A positioned in the fixture of FIG. 7A.

FIG. 9 is a top view of the base panel and fixture of FIG. 8, indicating an adhesive application area on the top of the base panel.

DETAILED DESCRIPTION

Exemplary embodiments of the technology will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood that the components of the technology, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the apparatus, system, and method, as represented in FIGS. 1A through 9, is not intended to limit the scope of the invention, as claimed, but is merely representative exemplary of exemplary embodiments of the technology.

The phrases “connected to,” “coupled to” and “in communication with” refer to any form of interaction between two or more entities, including mechanical, electrical, magnetic, electromagnetic, fluid, and thermal interaction. Two components may be functionally coupled to each other even though they are not in direct contact with each other. The term “abutting” refers to items that are in direct physical contact with each other, although the items may not necessarily be attached together. The phrase “fluid communication” refers to two features that are connected such that a fluid within one feature is able to pass into the other feature.

The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated.

The word “floating” is used herein to mean a floor or a sub-floor that is not coupled to an underlying layer, such as a substrate, for example by nailing or gluing the floor or sub-floor to the underlying layer. A “floating” floor or sub-floor may include individual elements that are coupled to each other, and may be said to “float” on the underlying layer.

The present embodiments have been specified to create a two layered floating sub-floor system that is a thermal barrier, vapour barrier, moisture barrier, sound barrier, and an overall sub-floor system that is decoupled from the underlying substrate preventing failures or changes in the substrate from transferring to the finished floor installed on the subfloor.

Furthermore, the present embodiments have been designed such that any finished flooring surface can be installed directly on the subfloor without additional layers of materials having to be used to meet the specifications or building code requirements.

One of the features of the present embodiments is that these embodiments may meet the specifications or building code requirements for use over concrete, wood based, or other types of substrates in commercial buildings, institutional facilities, hotels, restaurants, high or mid-rise multi-residential buildings, or single family homes.

Referring to FIGS. 1A-1C, a sub-floor surface panel 10 is shown. The surface panel 10 may be made of wood, plastic, rubber, magnesium oxide, magnesium phosphate or any other material or combination of materials that is waterproof, mold, mildew and fire resistant, and has sufficient porosity to allow adhesives, tile mortars and other fastening devices to bond with the surface panel material regardless of the finished flooring being installed over the surface panel. The example surface panel 10 has a rectangular shape with a top side 11, a length 12, a bottom side 13, a width 14, a height or thickness 16, and four edges 140, 141, 142, 143. The length 12 may be greater than or equal to the width 14. The width 14 may be greater than the height or thickness 16. The length 12, width 14, and/or thickness 16 may be any value. In one example, the length 12 is 47.19 in., the width 14 is 15.75 in., and the thickness is 0.25 in. A manufacturing tolerance may be assigned to the length 12, width 14, and/or thickness 16. The tolerances may all be the same or different, and may be any value. In one example, the length 12 and width 14 may be assigned a tolerance of ±0.13 in., and the thickness 16 may be assigned a tolerance of ±0.01 in. The surface panel 10 may be another shape. For example, the surface panel 10 may be triangular, hexagonal, polygonal, or curvaceous. Preferably, the surface panel 10 is a shape which can be used to cover a planar surface with no gaps or overlaps, in a tiling pattern or tessellation. Surface panels of more than one shape may be used together in a tiling pattern or tessellation.

Referring to FIG. 2, a sub-floor base panel 20 is shown. The base panel 20 may be a molded, extruded or machined component. The preferred material for the base panel 20 may be new or recycled high density polyethylene plastic or virgin or recycled rubber or a combination of high density polyethylene plastic and rubber (provided such material is waterproof, mold, mildew, etc. resistant). The base panel 20 has a smooth top side 21 such that it can be adhered to the bottom side 13 of the surface panel 10 of FIGS. 1A-1C. The example base panel 20 has a rectangular shape with a length 22, a width 24, a height or thickness 26, and four edges 240, 241, 242, 243. The length 22 may be greater than or equal to the width 24. The width 24 may be greater than the height or thickness 26. The length 22, width 24, and/or thickness 26 may be any value. In one example, the length 22 is 47.25 in., the width 24 is 15.75 in., and the thickness is 0.25 in. A manufacturing tolerance may be assigned to the length 22, width 24, and/or thickness 26. The tolerances may all be the same or different, and may be any value. In one example, the length 22 and width 24 may be assigned a tolerance of ±0.13 in., and the thickness 26 may be assigned a tolerance of ±0.01 in. The base panel 20 may be another shape. For example, the base panel 20 may be triangular, hexagonal, polygonal, or curvaceous. Preferably, the base panel 20 is a shape which can be used to cover a planar surface with no gaps or overlaps, in a tiling pattern or tessellation. Preferably, the base panel 20 is the same shape as the surface panel 10. Base panels of more than one shape may be used together in a tiling pattern or tessellation. The base panel has a vent channel system 200 on its bottom side 23.

Referring to FIGS. 3A-3C, the vent channel system 200 is illustrated in more detail. The specific design of the vent channel system 200 may allow for sufficient air to flow through the vent channel system 200 allowing moisture that may ingress from the substrate to evaporate, or allowing accumulating moisture to flow to a drainage system (not shown) installed in the substrate (e.g., cement or wood substrate). FIGS. 3A-3C illustrate one example of a vent channel system; FIGS. 6A-6D illustrate other examples of vent channel systems. Any of the vent channel systems disclosed herein may be used interchangeably.

The vent channel system 200 includes an arrangement of support pads 202 separated by vent channels 204. FIGS. 3A-3B show an example with a rectangular arrangement of square support pads 202 separated by straight vent channels 204. The support pads 202 are shown with rounded corners. The support pads 202 may be rectangular, round, polygonal, curvaceous, or any other shape. The area between one support pad 202 and an adjacent support pad 202 on the bottom side 23 of the base panel 20 is referred to as a vent channel 204. The vent channels 204 are straight, so that straight line travel along any vent channel is unobstructed by, for example, a support pad or any other structure. In other words, there is at least one straight line path along each vent channel 204. Each vent channel 204 has a depth 206 and a width 208. The depth 206 of a vent channel 204 may be less than the full thickness 26 of the base panel 20. The area between the top side 21 of the base panel 20 and the depth 206 of the vent channel 204 that has been molded, extruded or machined out is referred as the web thickness 210. The vent channel depth 206, vent channel width 208, and web thickness 210 may be any value. The web thickness 210 as illustrated in FIG. 3C may be of sufficient strength to meet the requirements of the ASTM C627 “Standard Test Method for Evaluating Ceramic Floor Tile Installation Systems” specifically for Heavy Commercial Applications such as shopping malls and auto showrooms. In one example, the thickness 26 of the base panel 20 may be 0.25 in., the vent channel depth 206 may be 0.125 in., the vent channel width 208 may be 0.75 in, and the web thickness 210 may be 0.125 in. The support pads 202 may have sufficient size, area, thickness and durometer hardness such that the amount of material coming into contact with the surface of the substrate has sufficient compression strength to support heavy commercial footfall traffic or support the use of light industrial machinery such as lift trucks or pump jacks.

In some embodiments, care should be taken to ensure that the overall size, thickness and design pattern of the support pads and the vent channel system is correct to optimize ventilation, strength, and stiffness of the sub-floor system.

FIGS. 6A-6D illustrate various design styles of vent channel systems 400, 500, 600, 700 that may be incorporated into the base panel 20 of FIGS. 2A-2D. The vent channel systems disclosed herein may be used interchangeably.

FIG. 6A shows a vent channel system 400 with a rectangular arrangement of square support pads 402 separated by straight vent channels 404. The support pads 402 have a length 412 and a width 414. The support pads 402 also have a vertical repeat dimension 416 and a horizontal repeat dimension 418. The vertical repeat dimension 416 is the sum of the length 412 and the vertical vent channel width 408. The horizontal repeat dimension 418 is the sum of the width 414 and the horizontal vent channel width 408. In one example, the length 412 and width 414 may be 2.25 in., and the vertical repeat dimension 416 and the horizontal repeat dimension 418 may be 3 in. In this arrangement, the combined area of the 16 support pads shown in FIG. 6A is 81 square inches per square foot. In other words, the combined area of the support pads is 56% of the total area of the bottom side of the base panel. The vent channels 404 have a width 408, and a depth like the depth 206 shown in FIG. 3C. The vent channels 404 are straight, so that straight line travel along any vent channel is unobstructed by, for example, a support pad or any other structure. In other words, there is at least one straight line path along each vent channel 404.

FIG. 6B shows a vent channel system 500 with an arrangement of rectangular support pads 502 separated by vent channels 504. In this example, the support pads 502 alternate between a vertical orientation and a horizontal orientation to form a herringbone pattern. The support pads 502 have a length 512 and a width 514. This arrangement provides vent channels 504 which are tortuous, convoluted, labyrinthine, serpentine, and/or meandering, in contrast to the straight uninterrupted vent channels 204, 404. Thus, straight line travel along any vent channel 504 is blocked by at least one support pad. Every path along each vent channel 504 includes at least one bend or turn. Each vent channel 504 encounters at least one three-way intersection 530, or T-intersection, with other vent channels in the pattern. The vent channels 504 have a width 508, and a depth like the depth 206 shown in FIG. 3C. The vent channel system 500 also has a vertical channel length 516 and a horizontal channel length 518. The vertical channel length 516 is the vertical length of straight line vent channel 504 between support pads 502. The horizontal channel length 518 is the horizontal length of straight line vent channel 504 between support pads 502. The vertical and horizontal channel lengths 516, 518 may be described as the maximum distance increment along a vent channel 504 before a bend or turn. In one example, the length 512 may be 2 in., the width 514 may be 0.75 in., the vent channel width 508 may be 0.5 in. (vertical and horizontal), and the vertical and horizontal channel lengths 516, 518 may be 4.25 in. In this arrangement, the combined area of the support pads 502 is 73 square inches per square foot. In other words, the combined area of the support pads is 51% of the total area of the bottom side of the base panel.

FIG. 6C shows a vent channel system 600 with an arrangement of V- or L-shaped support pads 602 separated by vent channels 604. This pattern may also be described as a herringbone pattern, or a chevron pattern. The support pads 602 have an overall length 612 and an overall width 614. This arrangement provides vent channels 604 which are tortuous, convoluted, labyrinthine, serpentine, and/or meandering, in contrast to the straight uninterrupted vent channels 204, 404. Thus, straight line travel along any vent channel 604 is blocked by at least one support pad. Every path along each vent channel 604 includes at least one bend or turn. Each vent channel 604 encounters at least one three-way intersection 630, or T-intersection, with other vent channels in the pattern. The vent channels 604 have a width 608, and a depth like the depth 206 shown in FIG. 3C. The vent channel system 600 also has a vertical channel length 616, a horizontal channel length 618, a minor length 620, and a minor width 622. The vertical channel length 616 is the vertical length of straight line vent channel 604 between support pads 602. The horizontal channel length 618 is the horizontal length of straight line vent channel 604 between support pads 602. The vertical and horizontal channel lengths 616, 618 may be described as the maximum distance increment along a vent channel 604 before a bend or turn. The minor length 620 is taken in the same direction as the overall length 612, and refers to a first side of the V- or L-shape. The minor width 622 is taken in the same direction as the overall width 614, and refers to a second side of the V- or L-shape. In one example, the overall length 612 and overall width 614 may be 2.35 in., the vent channel width 608 may be 0.63 in. (vertical and horizontal), the vertical and horizontal channel lengths 616, 618 may be 3.63 in., and the minor length and width 620, 622 may be 0.88 in. In this arrangement, the combined area of the support pads 602 is 73 square inches per square foot. In other words, the combined area of the support pads is 51% of the total area of the bottom side of the base panel.

FIG. 6D shows a vent channel system 700 with an arrangement of V- or L-shaped support pads 702 separated by vent channels 704. This pattern may also be described as a herringbone pattern, or a chevron pattern. Vent channel system 700 has vent channel width 708, overall length 712, overall width 714, vertical channel length 716, horizontal channel length 718, minor length 720, and minor width 722. This arrangement provides vent channels 704 which are tortuous, convoluted, labyrinthine, serpentine, and/or meandering, in contrast to the straight uninterrupted vent channels 204, 404. Thus, straight line travel along any vent channel 704 is blocked by at least one support pad. Every path along each vent channel 704 includes at least one bend or turn. Each vent channel 704 encounters at least one three-way intersection 730, or T-intersection, with other vent channels in the pattern. Vent channel system 700 is visually similar to vent channel system 600, but the support pads 702 have a larger area per square foot than the support pads 602, the vent channels 704 are narrower than the vent channels 604, and the vertical and horizontal channel lengths 716, 718 are shorter than the vertical and horizontal channel lengths 616, 618. In one example, the overall length 712 and overall width 714 may be 2.5 in., the vent channel width 708 may be 0.5 in. (vertical and horizontal), the vertical and horizontal channel lengths 716, 718 may be 3.5 in., and the minor length and width 720, 722 may be 1 in. In this arrangement, the combined area of the support pads 702 is 86 square inches per square foot. In other words, the combined area of the support pads is 60% of the total area of the bottom side of the base panel.

Any of the vent channel systems 200, 400, 500, 600, 700 may be varied by rounding corners of the support pads and/or vent channels (both in the plane shown and perpendicular to the page), using other polygonal, curved, or irregular shapes for the support pads, using multiple support pad shapes in a pattern, altering dimensions of the support pads and/or vent channels, rotating or mirroring the patterns, and the like. These variations may change the ratio of the combined area of the support pads to the total area to be less than 50%, between 50% and 60%, or greater than 60% of the total area of the bottom side of the base panel. For example, variations are contemplated in which the combined area of the support pads is 60% to 70% of the total area of the bottom side of the base panel. These variations may also change the vertical and/or horizontal vent channel length(s). For example, the embodiment of FIG. 6A may be modified by positioning the support pads 402 in a brick pattern instead of the grid pattern shown, or the embodiment of FIG. 6C may be modified by rotating every other support pad 180 degrees. Vent channel systems with relatively shorter vertical and/or horizontal vent channel lengths may improve sub-floor performance in high demand commercial applications. The vent channel systems disclosed herein may also be altered by providing a texture, coating, and/or surface finish to enhance moisture wicking and/or capillary action through the vent channel system.

Referring to FIG. 4, a sub-floor panel assembly 30 is shown. Panel assembly 30 includes surface panel 10 and base panel 20. The bottom side 13 of surface panel 10 faces the top side 21 of the base panel 20 with the lengths 12, 22 and widths 14, 24 aligned. The surface panel 10 and the base panel 20 may be adhered together with adhesives; melt bond, sonic or thermal welding, or otherwise coupled or fastened together such that the two panels remain permanently attached to each other through the assembly, packaging, storing, transporting and final installation processes. In one example, the surface panel 10 and base panel 20 may be assembled together using a pressure sensitive hot melt adhesive that has a cure time of less than 10 minutes. The process of adhering or coupling the two panels together preferably does not create any raised pattern or lumps anywhere on the panel assembly 30.

The widths 14, 24 of the surface panel 10 and base panel 20 are assembled together in an offset manner such that the top side 21 of the base panel 20 overhangs, or protrudes out from, the surface panel 10 along the full length 12 of the surface panel 10 along the edge 142. This type of offset is referred to as a ship lap joint 27 as shown in FIGS. 4B and 4D. Preferably, a minimum of 0.75 in. of the top side 21 of the base panel 20 overhangs, or protrudes past, the surface panel 10 to form the ship lap joint 27, although any amount of protrusion is contemplated. Conversely, when the base panel 20 is offset from the surface panel 10 as described above, this will result in the bottom side 13 of the surface panel 10 overhanging, or protruding past, the base panel 20 along the full length 12 of the surface panel 10 along the edge 140 opposite to the ship lap joint 27. This type of offset is referred to as an overlap joint 17 as shown in FIGS. 4C and 4E. Preferably, a minimum of 0.75 in. of the bottom side 13 of the surface panel 10 overhangs, or protrudes past, the base panel 20 to form the overlap joint 17, although any amount of protrusion is contemplated.

The lengths 12, 22 of the surface panel 10 and base panel 20 are also assembled together in an offset manner such that a ship lap joint 29 is created across the width 14 along the edge 141 of the surface panel 10 as shown in FIGS. 4B and 4D, and conversely an overlap joint 19 is created across the width 14 along the edge 143 at the opposite end of the surface panel 10 as shown in FIGS. 4C and 4E. Preferably, the ship lap joint 29 and the overlap joint 19 include a minimum of 0.75 in. of protrusion, although any amount of protrusion is contemplated. When a 47.19 in. long by 15.75 in. wide by 0.25 in. thick surface panel 10 and a 47.25 in. long by 15.75 in. wide by 0.25 in. thick base panel 20 are offset from each other as described above, with 0.75 in. of protrusion in each joint 17, 19, 27, 29, the finished sub-floor panel assembly 30 will have a finished dimension of 48 in. in length 32, 16.5 in. in width 34, and 0.5 in. in thickness 36.

A method of assembling the sub-floor panel assembly 30 may include the steps of coupling the surface panel 10 to the base panel 20 so that the bottom side 13 of the surface panel 10 faces the top side 21 of the base panel 20, the length 12 of the surface panel 10 is parallel to the length 22 of the base panel 20, and the width 14 of the surface panel 10 is parallel to the width 24 of the base panel 20. Coupling the surface panel 10 to the base panel 20 may include adhering the bottom side 13 of the surface panel 10 to the top side 21 of the base panel 20. Adhering the bottom side 13 to the top side 21 may include applying an adhesive to one or both of the bottom side 13 and the top side 21. The surface panel 10 may be offset relative to the base panel 20 along their mutual length, width, or both, to form ship lap and/or overlap joints.

Referring to FIG. 7, the sub-floor panel assembly 30 may be assembled using a fixture 80. The fixture 80 may be constructed of wood, plastic, metal, or a combination of materials. Preferably, the material(s) used to construct the fixture 80 may be easily cleaned of any adhesive over spray onto the fixture 80 during an assembly operation or step. The fixture 80 may include clearance 81 relative to the nominal finished panel assembly 30 length 32 and width 34 to allow for dimensional variation due to manufacturing tolerances, as seen best in FIG. 9. For example, the fixture 80 may be 0.125 in. larger than the nominal length 32 and width 34. The clearance 81 may be equal to the portion of the manufacturing tolerance range above nominal. Any oversized surface panel 10, base panel 20, or panel assembly 30 (in length or width dimension) may be trimmed and used.

The fixture 80 includes a base panel length stop 82, a base panel width stop 84, a surface panel length stop 86, and a surface panel width stop 88. The example shown in FIG. 7 includes a base panel length stop 82 which is a rectangular block, three base panel width stops 84 which are rectangular blocks, and a combination surface panel length stop 86 and surface panel width stop 88 formed together as an L-shaped plate or board 89. The length stops 82, 86 and width stops 84, 88 serve as datums against which the corresponding panel 10, 20 is urged to establish the offset relationships mentioned earlier. The fixture 80 may also include a base panel length limit 90, a base panel width limit 92, and/or a foundation plate or board 94. The example shown in FIG. 7 includes a combination base panel length limit 90 and base panel width limit 92 formed together as a C-shaped plate or board 96 which also carries the base panel length stop 82. The base panel length and width limits 90, 92 serve to indicate base panels 20 which exceed the corresponding upper tolerance limit for length 22 and/or width 24, thereby preventing the fabrication of panel assemblies 30 with undersize joints 17, 19, 27, 29. A first fixture length 104 exists between the base panel length stop 82 and the base panel length limit 90. A second fixture length 106 exists between the surface panel length stop 86 and the end of the L-shaped plate or board 89. A third fixture length 108 exists between the base panel length stop 82 and the surface panel length stop 86. A first fixture width 110 exists between the base panel width stop 84 and the base panel width limit 92. In one example, the first fixture length 104 may be 47.375 in., the second fixture length 106 may be 47.25 in., the third fixture length 108 may be 48.125 in., and the first fixture width 110 may be 16.625 in.

The base panel length stop 82 and base panel width stop 84 may be any height; preferably, the base panel length stop 82 and base panel width stop 84 are between 0.1 in. and 1 in. in height. The base panel length limit 90 and base panel width limit 92 may be any height less than or equal to 0.25 in; preferably, the base panel length limit 90 and base panel width limit 92 are between 0.1 in. and 0.25 in. in height. In the example of FIG. 7, the heights of the base panel length limit 90 and base panel width limit 92 may be determined by the thickness 98 of the C-shaped plate or board 96, which may be 0.25 in. thick. The surface panel length stop 86 and surface panel width stop 88 may be any height greater than or equal to 0.25 in.; preferably, the surface panel length stop 86 and surface panel width stop 88 are between 0.3 in. and 1 in. in height. In the example of FIG. 7, the heights of the surface panel length stop 86 and surface panel width stop 88 may be determined by the thickness 100 of the L-shaped plate or board 89, which may be 0.25 in. thick. The heights mentioned in this paragraph are measured from a reference surface, such as a tabletop, countertop, or granite block, if the fixture 80 lacks a foundation plate or board 94; otherwise, the heights mentioned in this paragraph are measured from a top side 102 of the foundation plate or board 94.

Referring to FIGS. 7-9, a method of assembling panel assemblies 30 will be described. The base panel 20 is placed with the bottom side 23 facing down in the fixture 80. The base panel 20 is shifted or urged along a first direction 112 against the base panel length stop 82 and along a second direction 114 against the base panel width stops 84 as shown in FIG. 8. The base panel 20 may be shifted or urged as described to ensure any oversized base panel 20 used will not reduce the overlap joint 17, 19 dimension as shown in FIG. 4E. Reducing the overlap joint 17, 19 dimension may cause panel seams not to fit evenly together when installed on the substrate. Using a hot melt spray applicator, spray the top side 21 of the base panel 20 with a spray setting that ensures the amount of glue sprayed on the top side 21 does not exceed 1 millimeter in thickness. The top side 21 of the base panel 20 is sprayed in a pattern such that the area of the top side 21 of the base panel 20 that will form the ship lap joints 27, 29, does not receive any glue, as illustrated in FIG. 9, which shows an adhesive application area 116 on the top side 21 of the base panel 20.

The surface panel 10 is then placed over the base panel 20 shifted or urged opposite to the first direction 112 against the surface panel length stop 86, and opposite to the second direction 114 against the surface panel width stop 88 ensuring the panel is squarely against the edges of the fixture. Hand pressure is used to temporarily adhere the two panels 10, 20 so the panel assembly 30 can be moved to a pressure roll machine. The assembled sub-floor panel assembly 30 is run through a pressure roller which has sufficient pressure to activate the adhesive as recommended by the adhesive manufacturer so as to permanently bond the two panels 10, 20 together.

FIGS. 5A-5D illustrate one example of a method for adhering sub-floor panel assemblies 30 to a substrate 120, and a pattern of installation that may be used for each finished sub-floor panel assembly 30 installed over the substrate 120. Each finished sub-floor panel assembly 30 is installed with the support pads 202 of the bottom side 23 of the base panel 20 facing the substrate they are going down onto. Finished panels 30 should be installed in a brick pattern as shown in FIG. 5D. The sub-floor should only be installed over concrete substrates that have had sufficient time to fully cure as recommended by the concrete manufacture, over wood substrates that have been properly installed and fastened to the floor joist system as required by the local building code, or over other properly-installed substrates.

Referring to FIGS. 5A-5B, two sub-floor panel assemblies 30 are shown in an end-to-end relationship. Referring to FIGS. 5C-5D, the substrate 120 forms an interior corner 122 with a first wall portion 124 and a second wall portion 126. Part of a stud 128 is visible. A method for installing a sub-floor may include the following steps:

• a) The surface of the substrate 120 should be clean of any debris or accumulated dust.
• b) The substrate 120 should be level. Where there is any apparent unevenness in the substrate of more than 0.25 in., a floor levelling compound (not shown) may be used to fill in these areas. Allow sufficient time for the compound to cure.
• c) Run chalk lines. Measure 16.75 in. out from the opposite end of the existing wall where the first row of the sub-floor system will be installed length wise and snap a chalk line. Measure 16.75 in. out from one end of the existing wall where the first row of the sub-floor system will be installed width wise. Measure 16.75 in. out from the opposite end of the wall where the sub-floor system will be installed width wise and snap a chalk line.
• d) Starting where the first row of the sub-floor system will be installed length wise, place the first full length panel 30 lengthwise with the ship lap joint 27 along the chalk line as shown in FIG. 5A.
• e) Place a 0.1875 in. diameter bead of urethane based adhesive 130 across the end (width) of the first panels' ship lap joint 29 as shown in FIG. 5B, place the second finished sub-floor panels' overlap joint 19 (width) over the adhesive 130 on the end of the first panel 30 as shown in FIG. 5B and press down firmly ensuring that the seams of the surface panels are butted against each other and that the length of the second panels' ship lap joint 27 is squarely along the chalk line. Note: Any gaps between the end seams of the sub-floor panels 30 is usually caused by the existing walls 122, 124 being out of square or where the ship lap joint 27 of the sub-floor panel 30 has not been place squarely along the chalk line. If the ship lap joint 27 of the sub-floor panel 30 has been placed squarely along the chalk line and a gap between the seams is still present, then these gaps can be filled in with a standard bonding material.
• f) Repeat step e) until all the finished sub-floor panels 30 are installed in the first row. Cut the last panel 30 in the first row approximately ¼″ short of the end wall (not shown) for ease of fitting in the remaining space.
• g) To achieve the recommended brick pattern, FIG. 5D, start the second row of finished sub-floor panels 30 with a panel cut to a length between 12″ and less than a full size panel. In most cases the last panel 30 from the previous row will be the starting panel for the next row provided it is a minimum of 12″ in length.
• h) Starting with the second row of sub-floor system panels to be installed, place a 0.1875 in. bead of adhesive 132 along the ship lap joint 27 of the first panel 30 in the first row of sub-floor system panels installed and place the overlap joint 17 of the cut panel of the second row over the adhesive 132 and place the overlap joint width 19 of the cut panel along the second chalk line measured in step c.
• i) Run a 0.1875 in. diameter bead of adhesive 134 along the exposed ship lap joint 27 lengths of each of the first row of panels installed. Run a 0.1875 in. bead of adhesive along the width of the cut panel in the second row, place the corresponding overlap joints 19 of the next full size panel over the adhesive and press down firmly.
• j) Repeat step i) until all sub-floor system panels 30 are installed in the second row. It may be necessary to cut the last sub-floor system panel 30 in the second row to fit the remaining space. Cut the last panel in the second row approximately ¼″ short of the end wall for ease of fitting in the remaining space. The remaining piece of sub-floor system panel can be used in subsequent rows provided it is more than 12″ in length.
• k) Alternate each subsequent row between using a full size sub-floor system panel 30 and a cut sub-floor system panel ensuring that cut panels are a minimum of 12 in. in length to start the row and the seams of the row being installed do not align with the width seams of the previous row. This will achieve the desired brick pattern as illustrated in FIG. 5D.
• l) Installing tile over the sub-floor system requires the use of poly-modified mortars and grouts. The sub-floor system should be clear of any debris or accumulated dust. Use a damp cloth or mop to remove any dust from the sub-floor system.
• m) Carpet tack strips should be adhered to the sub-floor system using both the urethane adhesive used to install the sub-floor system and the nails recommended by the tack strip manufacturer. Apply the adhesive to the back of the tack strip and set in the recommended position by the tack strip or carpet manufacturer. Use the recommended nails to secure the tack strip permanently in place.
• n) Engineered woods and laminated click flooring can easily be installed over the sub-floor system. It is recommended to use the suggested foam pad recommended by the engineered wood or laminated click flooring manufacturers to ensure the installation meets their warranty requirements.
• o) Glued down natural hardwood floors can be installed over the sub-floor system. Use only adhesives recommended by the hardwood floor manufacturers. If nailed down hardwood is desired it may be necessary to add an additional layer of plywood or oriented strand board over the sub-floor system depending on the substrate over which the sub-floor system has been installed.
• p) Vinyl plank floors and vinyl tile floors can be installed over the sub-floor system. Install as per manufacturers suggested installation method. It is not recommended to install thin sheet vinyl over the sub-floor system, unless all seams have been filled in with a filling compound and sanded smooth. Failure to fill the seams and sand smooth will cause the seams to appear in the thin sheet vinyl over time.

Any methods disclosed herein comprise one or more steps or actions for performing the described method. The method steps and/or actions may be interchanged with one another. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order and/or use of specific steps and/or actions may be modified.

Reference throughout this specification to “an embodiment” or “the embodiment” means that a particular feature, structure or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the quoted phrases, or variations thereof, as recited throughout this specification are not necessarily all referring to the same embodiment.

Similarly, it should be appreciated that in the above description of embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure. This method of disclosure, however, is not to be interpreted as reflecting an intention that any claim require more features than those expressly recited in that claim. Rather, as the following claims reflect, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment. Thus, the claims following this Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment. This disclosure includes all permutations of the independent claims with their dependent claims.

Recitation in the claims of the term “first” with respect to a feature or element does not necessarily imply the existence of a second or additional such feature or element. Elements recited in means-plus-function format are intended to be construed in accordance with 35 U.S.C. §112 Para. 6. It will be apparent to those having skill in the art that changes may be made to the details of the above-described embodiments without departing from the underlying principles of the technology.

While specific embodiments and applications of the present technology have been illustrated and described, it is to be understood that the technology is not limited to the precise configuration and components disclosed herein. Various modifications, changes, and variations which will be apparent to those skilled in the art may be made in the arrangement, operation, and details of the methods and systems of the present technology disclosed herein without departing from the spirit and scope of the technology.

Claims

1. A sub-floor system, comprising:

a surface panel having a top side and a bottom side opposite the top side; and

a base panel having a top side and a bottom side opposite the top side;

wherein the top side of the base panel is coupled to the bottom side of the surface panel, wherein the bottom side of the base panel comprises an arrangement of support pads separated by vent channels, wherein each vent channel encounters at least one three-way intersection with other vent channels.

2. The sub-floor system of claim 1, wherein the surface panel comprises a material selected from the group consisting of wood, plastic, rubber, magnesium oxide, magnesium phosphate, and combinations thereof.

3. The sub-floor system of claim 1, wherein the base panel comprises a material selected from the group consisting of new high density polyethylene plastic, recycled high density polyethylene plastic, virgin rubber, recycled rubber, and combinations thereof.

4. The sub-floor system of claim 1, wherein the surface panel and the base panel are the same polygonal shape.

5. The sub-floor system of claim 1, wherein the support pads are arranged in a herringbone pattern.

6. The sub-floor system of claim 1, wherein the combined area of the support pads is greater than or equal to 50% of the total area of the bottom side of the base panel.

7. The sub-floor system of claim 1, wherein every path along the vent channels includes at least one bend per a distance increment, wherein the distance increment is less than or equal to 4.25 in.

8. A sub-floor system, comprising:

a surface panel having a top side and a bottom side opposite the top side; and

a base panel having a top side and a bottom side opposite the top side;

wherein the top side of the base panel is coupled to the bottom side of the surface panel, wherein the bottom side of the base panel comprises an arrangement of support pads separated by vent channels, wherein straight line travel along each vent channel is blocked by at least one support pad.

9. The sub-floor system of claim 8, wherein the surface panel comprises a material selected from the group consisting of wood, plastic, rubber, magnesium oxide, magnesium phosphate, and combinations thereof.

10. The sub-floor system of claim 8, wherein the base panel comprises a material selected from the group consisting of new high density polyethylene plastic, recycled high density polyethylene plastic, virgin rubber, recycled rubber, and combinations thereof.

11. The sub-floor system of claim 8, wherein the surface panel and the base panel are the same polygonal shape.

12. The sub-floor system of claim 8, wherein the support pads are arranged in a herringbone pattern.

13. The sub-floor system of claim 8, wherein the combined area of the support pads is greater than or equal to 50% of the total area of the bottom side of the base panel.

14. The sub-floor system of claim 8, wherein straight line travel along each vent channel is blocked by at least one support pad per a distance increment, wherein the distance increment is less than or equal to 4.25 in.

15. A method of manufacturing a panel assembly of a sub-floor system, comprising:

positioning a surface panel relative to a base panel so that: the surface panel overhangs the base panel along a first edge of the surface panel to form a first overlap joint, the surface panel overhangs the base panel along a second edge of the surface panel to form a second overlap joint, and the base panel overhangs the surface panel along a third edge of the surface panel to form a first shiplap joint, wherein the first edge of the surface panel is adjacent to the second edge of the surface panel, wherein the third edge of the surface panel is adjacent to an edge of the surface panel selected from the group consisting of the first edge of the surface panel and the second edge of the surface panel; and

coupling the surface panel to the base panel to permanently maintain the first overlap joint, the second overlap joint, and the first shiplap joint;

wherein the bottom side of the base panel comprises an arrangement of support pads separated by vent channels, wherein straight line travel along each vent channel is blocked by at least one support pad.

16. The method of claim 15, wherein the base panel overhangs the surface panel along a fourth edge of the surface panel to form a second shiplap joint, wherein the fourth edge of the surface panel is adjacent to the third edge of the surface panel.

17. The method of claim 15, wherein the surface panel overhangs the base panel along the first edge of the surface panel, the surface panel overhangs the base panel along a second edge of the surface panel, and the base panel overhangs the surface panel along a third edge of the surface panel by a distance which is greater than or equal to 0.75 in.

18. The method of claim 15, comprising fabricating the surface panel from a material selected from the group consisting of wood, plastic, rubber, magnesium oxide, magnesium phosphate, and combinations thereof.

19. The method of claim 15, comprising fabricating the base panel from a material selected from the group consisting of new high density polyethylene plastic, recycled high density polyethylene plastic, virgin rubber, recycled rubber, and combinations thereof.

20. The method of claim 15, comprising fabricating the base panel by a process selected from the group consisting of molding, extruding, and machining.