Transportable flooring kit and method for assembling the same

• US 9,181,717 B1
• Filed: 10/07/2010
• Issued: 11/10/2015
• Est. Priority Date: 10/07/2010
• Status: Expired due to Fees

• Current Assignee: Stagestep, Inc.
• Original Assignee: Stagestep, Inc.
• Inventors: Jamison, Samuel H.
• Primary Examiner(s): Canfield, Robert
• Application Number:
  US12/924,874
• Time in Patent Office: 1,860 Days
• Field of Search: 525/861, 525/862, 525/821, 525/822, 525/915, 525/914, 521/77, 524/031, 52D/IG.4
• US Class Current: 1/1
• CPC Class Codes: E04F 15/02038 characterised by tongue and groove connections between neighbouring flooring elements
• CPC Class Codes: E04F 15/02144 by magnets
• CPC Class Codes: E04F 15/045 Layered panels only of wood
• CPC Class Codes: E04F 15/206 Layered panels for sound insulation
• CPC Class Codes: E04F 2201/06 Magnets
• CPC Class Codes: E04F 2203/065 in offset relationship longitudinally as well as transversely
• CPC Class Codes: E04F 2290/043 with a bottom layer for sound insulation
• CPC Class Codes: Y10S 52/04 Magnetic connecting means for building components

Abstract

A kit for making a floor on the permanent floor of a venue from modules. Adjacent modules are releasably interconnected by magnetic coupling means.

A flooring module base layer having an upper surface with upwardly facing grooves that include magnetic coupling means for connecting it to a complementary magnetic coupling means on an adjacent activity layer.

A flooring module activity layer having a lower surface with downwardly facing grooves that include magnetic coupling means for connecting it to a complementary magnetic coupling means on an adjacent base layer.

A method for making a floor from a plurality of modules that are placed in contact with each other so that a portion of each module overlies an upwardly facing or downwardly facing portion of each adjacent module. The adjacent modules are coupled to each other by the magnetic coupling means to create a floor of desired area.

Claims

1. An activity layer for a flooring module of the type that comprises an activity layer and a base layer,

said activity layer having a rectangular shape and including an upper surface and a lower surface and four sides;

said sides extending between said upper and lower surfaces;

said upper surface being adapted to be used for activities;

said lower surface including first and second downwardly facing grooves, said grooves extending across the lower surface of said activity layer and being closer to two adjacent ones of said sides than the opposite ones of said sides,

magnetic coupling means disposed in each of said downwardly facing grooves for being connected to a complementary magnetic coupling means on an adjacent base layer, said magnetic coupling means comprises a ferrous material,

each of said magnetic coupling means comprises

first and second members that are connected to each other by a pivot so that said first and second members can pivot between a first position where they can lie in substantial touching relation and a second position where they are angularly disposed relative to each other,

means for connecting one of said members to the bottom of said downwardly facing groove,

said other member having a distal edge which is remote from said pivot, and

at least said distal edge of said second member is comprised of said ferrous material so that it can pivot around said pivot to engage a complementary magnetic coupling means on an adjacent base layer.

2. In a flooring system of the type comprising a plurality of modules wherein each of said modules includes a base layer and an activity layer overlying said base layer and said base layers are connected to said activity layers in staggered relation so that a portion of each base and activity layer extends past the edges of the activity and base layers on an adjacent module,

each of said activity layers including first magnetic coupling means for releasably connecting it to complimentary magnetic coupling means on said the base layer of an adjacent module,

each of said base layers including second magnetic coupling means for releasably connecting it to said magnetic coupling means on said activity layer of an adjacent module and

wherein said first magnetic coupling means includes a first elongated member for being connected to one of said layers,

a second elongated member,

a pivot, said pivot connecting said first and second elongated members so that said second elongated member can pivot movement relative to said first elongated member.

3. A flooring system of the type defined in claim 2 wherein said first elongated member is adapted to be connected to said activity layer, and

said second elongated member can pivot into engagement with magnetic coupling means on said base layer.

4. A flooring system as defined in claim 3 wherein

said magnetic coupling means on of one of said layers is a ceramic magnet.

5. A flooring kit for creating a sport, dance, or exercising activity floor from modules comprising

a plurality of modules, each said module including

a base layer for being placed on a permanent floor, said base layer including a plurality of sides,

an activity layer for being placed on said base layer, said activity layer including a plurality of side edges,

said base layer and said activity layer comprising said module and being in staggered relation to each other so that a portion of each of said base or activity layers extends past the sides of the other base or activity layer,

each of said activity layers including first magnetic coupling means for releasably connecting it to complimentary magnetic coupling means on said base layer of another module,

each of said base layers including second magnetic coupling means for releasably connecting it to said first magnetic coupling means on said activity layer of an adjacent module,

one of said first or second magnetic coupling means comprises a ceramic magnet,

the other of said first or second magnetic coupling means comprises an elongated ferrous member, said elongated ferrous member comprises first and second elongated elements which are connected to each other along their longest edges by a joint, said joint being operative to permit said first and second elements of said elongated ferrous member to pivot relative to each other around their longest edges, and

means for connecting said elongated ferrous member to one of said base or activity layers, and means for connecting said ceramic magnet to an other of said base or activity layers.

6. An activity layer for flooring module of the type that comprises an activity layer and a base layer,

said activity layer having a rectangular shape and including an upper surface and a lower surface and four sides;

said sides extending between said upper and lower surfaces;

said upper surface being adapted to be used for activities;

said lower surface including first and second downwardly facing grooves, said grooves extending across the lower surface of said activity layer and being closer to two adjacent ones of said sides than the opposite ones of said sides, and

magnetic coupling means disposed in each of said downwardly facing grooves for being connected to a complementary magnetic coupling means on an adjacent base layer,

each of said magnetic coupling means comprises

first and second members that are connected to each other by a pivot so that said first and second members can pivot between a first position where they can lie in substantial touching relation and a second position where they are angularly disposed relative to each other,

connection means for connecting one of said members to the bottom of said downwardly facing groove,

said other member having a distal edge which is remote from said pivot, and

at least said distal edge of said second member is comprised of said ferrous material so that it can pivot around said pivot to engage a complementary magnetic coupling means on an adjacent base layer.

7. In a flooring system of the type comprising a plurality of modules for being adjacent each other and wherein each of said modules includes a base layer and an activity layer overlying said base layer and said base layers are connected to said activity layers in staggered relation so that a portion of each base and activity layer extends past the sides of the activity and base layers on an adjacent module,

each of said activity layers including first magnetic coupling means for releasably connecting it to complimentary magnetic coupling means on said base layer of an adjacent module,

each of said base layers including second magnetic coupling means for releasably connecting it to said first magnetic coupling means on said activity layer of an adjacent module

one of said first magnetic coupling means and said second magnetic coupling means includes a first elongated member for being connected to one of said layers,

a second elongated member,

a pivot, said pivot connecting said first and second elongated members so that said second elongated member can pivot movement relative to said first elongated member, and

said second elongated member is comprised of a ferrous material so that it can engage complementary magnetic coupling means on the other one of said of said layers.

8. In a flooring system of the type comprising a plurality of modules wherein each of said modules includes a base layer and an activity layer overlying said base layer,

said base layers are connected to said activity layers of adjacent modules in staggered relation so that a portion of each base and activity layer extends past the edges of the activity and base layers on an adjacent module,

each of said activity layers including a first elongated magnetic member,

each of said base layers including second elongated magnetic member;

said first and second elongated magnetic members being engagable with each other for releasably connecting said activity layer to a base layer of an adjacent module, and

said first elongated member includes a pivot so that it can pivot into magnetic engagement with said second elongated member on said adjacent module.

9. A flooring kit for creating a sport, dance, or exercising activity floor from modules comprising

a plurality of modules, each said module including

a base layer for being placed on a permanent floor, said base layer including a plurality of edges,

an activity layer for being placed on said base layer, said activity layer including a plurality of sides edges,

means on said base layer and on said activity layer for connecting said base layer to said the activity layer of another module in staggered relation so that a portion of each layer extends past the edges of the other layer on the other,

said means for connecting on each of said activity layers including first magnetic coupling means for releasably connecting it to complimentary magnetic coupling means on said the base layer of another module,

said means for connecting on each of said base layers including second magnetic coupling means for releasably connecting it to said first magnetic coupling means on said activity layer of an adjacent module,

said one of said first or second magnetic coupling means comprises a ceramic magnet,

the other of said first or second magnetic coupling means (34) comprises an elongated ferrous member, and

means for connecting said elongated ferrous member to one of said base or activity layers, and means for connecting said ceramic magnet to the other of said base or activity layers,

one of said first and second magnetic coupling means comprises first and second elongated elements which are connected to each other along their longest edges by a joint, said joint being operative to permit said first and second elements to pivot relative to each other around their longest edges.

10. A flooring kit as defined in claim 9 wherein

said flooring kit comprises a plurality of modules,

said plurality of modules are for being arranged in side by side and touching relation with the portion of each activity and base layer that extends past the sides of the other layer overlying each other,

said modules being releasably connected to each other by said ceramic magnets and said ferrous members to comprise an activity floor.

11. A flooring kit as defined in claim 9 wherein

said base layers and said activity layers are the same width.

12. A flooring kit as defined in claim 11 wherein

said base layers and said activity layers are rectangular.

13. A flooring kit as defined in claim 11 wherein

said base layers and said activity layers are square.

14. A flooring kit as defined in claim 11 wherein

said some of said modules are comprised of square activity layers and square base layers,

others of said modules are comprised of rectangular activity layers and rectangular base layers, and

said modules comprising square activity layers and square base layers, and said modules comprising rectangular activity layers and rectangular base layers are of the same width.

15. A flooring kit as defined in claim 14 wherein

the length of said rectangular modules is twice the length of said square modules so that when said modules are assembled to make a floor according to the kit the seams between adjacent modules are staggered in at least one direction across the floor.

16. A flooring kit as defined in claim 9 wherein

some of said modules comprise rectangular activity layers and rectangular base layers and others of said modules comprise square activity layers and square base layers,

the length of said modules comprising rectangular activity layers and rectangular base layers is twice the length of said modules comprising square activity layers and square base layers so that when said modules are assembled to make a floor according to the kit the seams between adjacent modules are staggered in at least one direction across the floor.

17. A flooring kit as defined it claim 9

wherein said lower surface is water resistant.

18. A flooring kit as defined in claim 9

including a layer of water resistant material on said lower surface.

19. A flooring kit as defined in claim 9

including a layer of cushioning material on said lower surface.

20. A flooring kit as defined in claim 9

including a layer of vinyl on said upper surface.

21. A flooring kit as defined in claim 9 including a layer of hardwood on said upper layer.

22. An activity layer as defined in claim 9

including a layer of slip resistant material (68) on said activity layer.

23. A method for making a floor for sport, dance, or exercising activity comprising the steps of

providing a plurality of modules, each of said modules including a base layer and an activity layer, said base and activity layers of each modules overlapping each other so that a portion of each layer extends past two adjacent edges of the other layer,

moving each of said modules into contact with another module so that said portion of each activity layer and each base layer overlies said portion of said base layer and said activity layer of the adjacent module, and

magnetically coupling said adjacent modules to each other to create said floor,

the step of magnetically coupling said adjacent modules to each other includes the step of providing a first magnetically coupling means on said portions of each of said base layers, and

providing a second magnetically coupling means on said portions of each of said activity layers, and said first and second magnetically coupling means magnetically engage each other,

providing said base layers with a lower surface, and

providing a layer of water resistant material on the lower surface of said base layer.