Panel-type subfloor for athletic floor
View Patent ↗An athletic floor uses a panel-type subfloor to secure directly to a concrete base. The panel-type sections include upper and lower rigid layers which sandwich a resilient layer. The rigidity of the lower layer spans most uneven spots in the floor, while the resilient layer provides some degree of a compressibility and/or conformability, as needed, to provide a flat horizontal surface for supporting a layer of floorboards thereabove. The panel sections can be secured directly to the base, via anchors which secure the lower rigid layers to the base, the anchors residing in access openings formed along the perimeter of the upper rigid layer and in the resilient layer. This anchoring arrangement enables each anchor to hold at least two adjacently located panel sections, and it also eliminates precompression of the resilient layer. The subfloor panel sections are prefabricated, at the factory, and then shipped to the installation site. Overall, a subfloor of panel-type sections of this type provides a high degree of stability, resiliency, and uniformity in these parameters, with simpler and lower cost installation.
1. A floor comprising:
an upper wear layer residing over a base;
a subfloor residing on and in surface contact with the base and supporting the wear layer, the subfloor including a plurality of panel sections of predetermined dimension, each of the panel sections including upper and lower rigid layers sandwiching an intermediate resilient layer, the panel sections arranged end to end in parallel rows and the plurality of lower rigid layers of the panel sections substantially covering the base;
a plurality of anchors holding the lower rigid layers to the base, the anchors residing entirely below the upper wear layer; and
access openings formed in the upper rigid layers, thereby to enable the anchors to be secured to the base so as to hold the lower rigid layers wherein the access openings are defined by aligned cut out portions of adjacently located panel sections, so that a single anchor holds at least two adjacently located panels.
2. The floor of claim 1 further comprising:
a top subfloor between the wear layer and the panel sections, the wear layer secured to the top subfloor.
3. The floor of claim 1 wherein the wear layer comprises a plurality of parallel rows of tongue and groove floorboards laid end-to-end.
4. The system of claim 1 wherein the rigid upper and lower layers of the panel sections comprise plywood.
5. The floor of claim 1 wherein the panel sections are prefabricated such that the upper and lower rigid layers are pre-secured to the resilient layer, such that the upper, lower, and resilient layers of the panel sections are simultaneously installable.
6. The floor of claim 1 where for each panel section, the upper and lower rigid layers are generally uniform in width and length.
7. The floor of claim 1 wherein the upper rigid layer has a lower thickness than the lower rigid layer.
8. The floor of claim 1 , wherein, for at least some of the panel sections, the rigid lower layer comprises a single piece and the rigid upper layer comprises multiple pieces.
9. A method of forming a floor comprising:
arranging a plurality of panel sections over a base to form a subfloor, the panel sections arranged end-to-end in parallel rows oriented in a first direction, each of the panel sections including upper and lower rigid layers sandwiching an intermediate resilient layer, the arranged rows of panel sections defining a plurality of aligned access openings along adjacently located edges of corresponding, adjacently located panel sections, the access openings formed in the upper rigid layer of the adjacently located panel sections, wherein the subfloor panel sections of any given row of panel sections is staggered with respect to an adjacently located row of panel sections;
anchoring the panel sections to the base at the access openings via anchors driven downwardly alongside the lower rigid layers of at least two adjacently located panel sections, and into the base, such that each anchor holds the at least two adjacently located panel sections; and
securing an upper wear layer of elongated floorboards to the subfloor, the elongated floorboards secured end-to-end in parallel rows to cover the subfloor.
10. The method of claim 9 further comprising:
installing a top subfloor of panels above the subfloor of panel sections, the top subfloor of panels oriented in rows that are angled with respect to the rows of the panel sections, with the upper wear layer of elongated floorboards secured to the top subfloor.
11. A floor made by the process of claim 9 .
12. The method of claim 9 wherein the longitudinal dimension of the elongated floorboards intersects the first direction of the rows of panel sections.