US20240287797A1

US20240287797A1 - Floor assembly and method of forming thereof

Info

Publication number: US20240287797A1
Application number: US18/588,589
Authority: US
Inventors: Darrin Russell Griechen; Benjamin Michl Hall; Tulio Cesar Squarcio; Abigail Christine Willets; Daniel Geoffrey Bacon
Original assignee: Green Canopy Node Technologies Inc
Current assignee: Green Canopy Node Technologies Inc
Priority date: 2023-02-27
Filing date: 2024-02-27
Publication date: 2024-08-29
Also published as: CA3229730A1

Abstract

A floor assembly includes a base panel including a depression, a spacing block at least partially disposed in the depression, and a floor panel spaced apart from the base panel by the spacing block.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority under 35 U.S.C. § 119 to U.S. Provisional Application No. 63/487,113 filed on Feb. 27, 2023, in the United States Patent and Trademark Office, the disclosure of which is incorporated by reference herein in its entirety.

BACKGROUND

The following relates generally to a floor assembly and a method of forming thereof. A prefabricated structure can be built, or partially built, in a factory setting, rather than in an on-site setting. A prefabricated structure offers multiple advantages compared to a traditional stick-built structure that is built on-site of pre-cut wood elements, including quality control, reduced waste, and a reduced build time. A prefabricated structure can be built to a same code standard as a traditional structure.

SUMMARY

A floor assembly is described. One or more aspects of the floor assembly includes a base panel including a depression; a spacing block at least partially disposed in the depression; and a floor panel spaced apart from the base panel by the spacing block.
A floor assembly is described. One or more aspects of the floor assembly includes a base panel including a depression; a spacing block at least partially disposed in the depression, wherein a lower surface of the spacing block is in contact with an upper surface of the base panel within the depression; and a floor panel spaced apart from the base panel by the spacing block, wherein an upper surface of the spacing block overlaps and is in contact with a lower surface of the floor panel and wherein the spacing block is located within an interior region of the base panel in a plan view.
A method for forming a floor assembly is described. One or more aspects of the method include removing material from a base panel to form a depression; inserting a spacing block on the base panel at least partially within the depression; and placing a floor panel on the spacing block.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an example of an exploded isometric view of a floor assembly according to aspects of the present disclosure.

FIG. 2 shows an example of an isometric view of the floor assembly of FIG. 1 including a floor panel according to aspects of the present disclosure.

FIG. 3 shows an example of a cross-sectional view of the floor assembly of FIG. 2 according to aspects of the present disclosure.

FIG. 4 shows an example of an exploded isometric view of the floor assembly of FIG. 2 according to aspects of the present disclosure.

FIG. 5 shows an example of a cross-sectional view of a base panel according to aspects of the present disclosure.

FIG. 6 shows an example of an isometric view of a base panel according to aspects of the present disclosure.

FIG. 7 shows an example of a transparent isometric view of a spacing block according to aspects of the present disclosure.

FIG. 8 shows an example of a plan view of a base panel of FIG. 1 according to aspects of the present disclosure.

FIG. 9 shows an example of a plan view of the floor assembly of FIG. 2 according to aspects of the present disclosure.

FIG. 10 shows an example of an exploded isometric view of a floor assembly according to aspects of the present disclosure.

FIG. 11 shows an example of a plan view of a base panel of FIG. 10 according to aspects of the present disclosure.

FIG. 12 shows an example of a plan view of the floor assembly of FIG. 10 according to aspects of the present disclosure.

FIG. 13 shows an example of an isometric view of a floor assembly including a floor panel according to aspects of the present disclosure.

FIG. 14 shows an example of a method for forming a floor assembly according to aspects of the present disclosure.

DETAILED DESCRIPTION

Aspects of the present disclosure provide a floor assembly. In some cases, the floor assembly includes a base panel including a depression, a spacing block at least partially disposed in the depression, and a floor panel disposed on the spacing block. Conventional flooring systems use a grid of floor joists to separate a subfloor from a foundation. Locating floor joists at their proper positions is laborious and time intensive, and requires a large amount of lumber to fully span the foundation.
By contrast, aspects of the present disclosure provide a spacing block to separate a base panel from a floor panel, thereby saving on material costs compared to conventional floor joists. Furthermore, in some cases, the spacing block may include material recycled from a formation of another component of a prefabricated building structure, further saving material costs.
Additionally, by providing a depression in the base panel to accept the spacing block, aspects of the present disclosure save on labor and time costs by providing a predetermined and marked location for placement of the spacing block, thereby avoiding the on-site measurement of floor joist spacing required by conventional flooring systems.

Floor Assembly

A floor assembly is described with reference to FIGS. 1-13 . One or more aspects of the floor assembly include a base panel including a depression; a spacing block at least partially disposed in the depression; and a floor panel spaced apart from the base panel by the spacing block. In some aspects, the base panel further comprises a tab disposed in the depression, wherein the tab provides a fiction fit for the spacing block. Some examples of the floor assembly further include an additional floor panel disposed on the floor panel.
In some aspects, a lower surface of the spacing block is in contact with an upper surface of the base panel within the depression. In some aspects, an upper surface of the spacing block overlaps and is in contact with a lower surface of the floor panel. In some aspects, the spacing block is located within an interior region of the base panel in a plan view.
In some aspects, the depression extends in a first direction. In some aspects, the base panel comprises a first surface exposed by the depression and extending in the first direction, and a second surface exposed by the depression and extending in a second direction crossing the first direction. In some aspects, the spacing block overlaps the first surface.
In some aspects, the base panel comprises a third surface contacting the second surface, disposed above the first surface in the second direction, and extending in the first direction. In some aspects, at least a portion of the spacing block at least partially overlaps the third surface.
In some aspects, the depression extends in a first direction. In some aspects, the spacing block extends for a greater distance in the first direction. In some aspects, the spacing block extends for an equal or lesser distance in the first direction. In some aspects, the depression extends in a second direction. In some aspects, the spacing block extends for an equal or lesser distance in the second direction.
In some aspects, the spacing block is attached to the base panel. In some aspects, the spacing block is fastened to the base panel. In some aspects, the spacing block is attached to the floor panel.
In some aspects, the base panel, the spacing block, or a combination thereof comprises mid-density fiber (MDF), oriented strand board (OSB), mass timber, cross-laminated timber (CLT), glulam, or mass plywood. In some examples, a majority grain direction of the spacing block is perpendicular to a majority grain direction of the base panel.
In some aspects, the depression extends in a first direction, the depression further comprising a secondary depression extending into the base panel in a second direction crossing the first direction. In some aspects, at least a position of the spacing block is disposed in the secondary depression.
A floor assembly is described with reference to FIGS. 1-13 . One or more aspects of the floor assembly include a base panel including a depression; a spacing block at least partially disposed in the depression, wherein a lower surface of the spacing block is in contact with an upper surface of the base panel within the depression; and a floor panel spaced apart from the base panel by the spacing block, wherein an upper surface of the spacing block overlaps and is in contact with a lower surface of the floor panel and wherein the spacing block is located within an interior region of the base panel in a plan view.
FIG. 1 shows an example of an exploded isometric view of a floor assembly according to aspects of the present disclosure. Floor assembly 100 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2-13 . In one aspect, floor assembly 100 includes base panel 105 and spacing block 130. Base panel 105 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2-13 . In one aspect, base panel 105 includes depression 110 and panel surface 125.
Depression 110 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2-13 . In one aspect, depression 110 includes depression surface 115 and face 120. Depression surface 115 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2, 3, and 13 . Face 120 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2, 3 , and 13. Panel surface 125 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2, 3, 10, and 13 . Spacing block 130 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2-4, 7, 9, 10, 12, and 13 .
Referring to FIG. 1 , according to some aspects, base panel 105 includes depression 110 and panel surface 125. In some cases, depression 110 is an area of base panel 105 in which depression surface 115 is spaced apart from panel surface 125 in a vertical direction (e.g., a Y direction) by face 120. For example, in some cases, face 120 extends in the vertical direction from panel surface 125 to depression surface 115. In some cases, each of depression surface 115 and panel surface 125 are planes extending in a width direction (e.g., an X direction) crossing the vertical direction and a depth direction (e.g., a Z direction) crossing the width direction and the vertical direction. In some cases, depression surface 115 and panel surface 125 extend parallel to each other. In some cases, depression surface 115 and panel surface 125 extend approximately parallel to each other. As shown in FIG. 1 , depression surface 115 is at least partially surrounded by face 120.
In some cases, base panel 105, spacing block 130, or a combination thereof include mid-density fiber (MDF), oriented strand board (OSB), mass timber, cross-laminated timber (CLT), glulam, or mass plywood. MDF is an engineered wood product that is generally denser than plywood. OSB is an engineered wood similar to particle board.
In some cases, mass timber is an engineered wood product comprising solid wood billet or sheet stock. In some cases, mass timber is beneficial because it is made from a renewable resource and provides an opportunity to act as long-term carbon storage when used in a structure. In some cases, in addition to environmental benefits, the engineered nature of mass timber overcomes many of the issues related to “stick-built” systems (e.g., a structure that is built on-site of pre-cut wood elements). In some cases, each element of a mass timber panel is carefully selected, processed, and oriented to overcome natural variations of lumber products.
In some cases, a CLT panel includes an odd number of laminations of linear wood elements (e.g., layers). In some cases, a thickness of the linear wood elements is in a range from 10 mm (about 0.39 in) to 35 mm (about 1.38 in). In each layer of the CLT panel, a grain of the wood comprised in the CLT panel is oriented perpendicular to a prior layer (e.g., an adjacent layer). The layers are glued together, causing the CLT panel to be a strong and robust wood panel product that is strong in multiple directions. In some cases, a strength of the CLT panel in one direction is typically dominant due to a higher layer count of grain alignment in the odd-numbered layout. CLT offers excellent dimensional stability and the ability to be processed with digital fabrication tools to a high tolerance, thereby providing manufacturability flexibility and an increased prefabrication speed.
In some cases, glulam, or glue-laminated timber (GLT), is similar to CLT. However, while wood grains of adjacent layers of a CLT panel are orientated in an alternating fashion, wood grains in adjacent layers of a GLT panel are oriented in a same direction. In some cases, a GLT panel includes an even number of layers or an odd number of layers. In some cases, a GLT panel has a greater load capacity due to the alignment of the wood grain orientation among the layers of the GLT panel. In some cases, a GLT panel can be used to optimize load capacity in critical areas such as floor/ceiling spans and wall load capacity, particularly with regards to walls that must meet fire resistance ratings.
A mass plywood panel (MPP) is a mass timber panel that can be used in prefabricated housing. Similarly to a CLT panel, MPP is composed of layers having an alternating grain orientation. However, an MPP comprises thin layers of wood veneers. An MPP is similar in dimension to a CLT panel and a GLT panel, but is often heavier due to an increased adhesive content.
In some cases, a majority grain direction of spacing block 130 is perpendicular to a majority grain direction of base panel 105. For example, in some cases, a grain is a longitudinal arrangement of fibers in an item of wood (such as lumber) or engineered wood product (such as mass timber). Traditionally, the grain extends in a lengthwise direction of the lumber. In a mass-timber panel, there are certain beneficial properties in each grain section (i.e., layer) of the mass timber panel. For example, cross-laminated timber (CLT) comprises layered boards (usually three boards, five boards, or seven boards) alternatingly stacked crosswise at 90-degree angles and glued into place. As a result, in CLT, grain direction alternates at a 90-degree angle. In some cases, a grain direction of a majority of layers in spacing block 130 is perpendicular to a grain direction of a majority of layers in base panel 105, and spacing block 130 is therefore configured to withstand a large load. Alternatively, in some cases, the majority grain direction of spacing block 130 is parallel to the majority grain direction of base panel 105.
In some cases, spacing block 130 is at least partially disposed in depression 110, as described with reference to FIGS. 2 and 3 . As shown in FIG. 1 , depression 110 includes rounded corners. In some cases, the rounded corners are due to a formation of depression 110 using a router. In some cases, depression 110 has a rectangular shape in a plan view. In some alternative embodiments, depression 110 may have any shape in a plan view. In some cases, spacing block 130 has a rectangular shape in a plan view. In some alternative embodiments, spacing block 130 may have any shape in a plan view.
FIG. 2 shows an example of an isometric view of the floor assembly of FIG. 1 including a floor panel according to aspects of the present disclosure. Floor assembly 200 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1, and 3-13 . In one aspect, floor assembly 200 includes base panel 205, spacing block 230, floor panel 235, and additional floor panel 240. Base panel 205 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1, and 3-13 . In one aspect, base panel 205 includes depression 210 and panel surface 225.
Depression 210 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1, and 3-13 . In one aspect, depression 210 includes depression surface 215 and face 220. Depression surface 215 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1, 3, and 13 . Face 220 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1, 3, and 13 . Panel surface 225 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1, 3, 10, and 13 .
Spacing block 230 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1, 3, 4, 7, 9, 10, 12, and 13 . Floor panel 235 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 3, 4, and 13 . Additional floor panel 240 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 3, 4, and 13 .
Referring to FIG. 2 , spacing block 230 is at least partially disposed in depression 210. For example, in some cases, a lower surface in the vertical direction (e.g., the Y direction) of spacing block 230 is in contact with an upper surface in the vertical direction of base panel 205 within depression 210 (e.g., depression surface 215). In some cases, face 220 extends in the vertical direction along a portion of spacing block 230 extending in the vertical direction. In some cases, at least a portion of spacing block 230 overlaps panel surface 225 in the vertical direction. In some cases, at least a portion of spacing block 230 is in contact with panel surface 225. In some cases, by providing depression 210 such that depression surface 215 is smaller in area than the lower surface of spacing block 230, less material is removed from base panel 205, less money is spent on removing the material, and base panel 205 is provided in a more efficient manner.
In some cases, spacing block 230 is held in place in depression 210 by a friction fit. In some cases, spacing block 230 is attached to base panel 205. For example, in some cases, base panel 205 is attached to spacing block 230 via adhesive, a fastener (such as a nail, a screw, etc.), a magnet, or a combination thereof. In some cases, spacing block 230 is fastened to base panel 205 as described with reference to FIG. 5 .
In some cases, floor panel 235 is separated or spaced apart from base panel 205 in the vertical direction by spacing block 230. For example, in some cases, floor panel 235 is disposed on spacing block 230, and spacing block 230 thereby prevents floor panel 235 from contacting base panel 205. In some cases, therefore, floor assembly 200 is provided such that services such as wiring, piping, etc. may be efficiently and conveniently distributed between base panel 205 and floor panel 235, vibration may be reduced, and insulation may be increased.
In some cases, spacing block 230 is attached to floor panel 235. For example, in some cases, floor panel 235 is attached to spacing block 230 via adhesive, a fastener (such as a nail, a screw, etc.), a magnet, or a combination thereof. In some cases, floor panel 235 comprises a floor panel depression, similar to depression 210, configured to accept spacing block 230, such that at least a portion of spacing block 230 is disposed in floor panel 235. For example, in some cases, at least a portion of floor panel 235 contacts a side surface of spacing block 230 that faces the horizontal direction or the depth direction.
In some cases, additional floor panel 240 is disposed on floor panel 235. In some cases, floor panel 235 is a subfloor. In some cases, additional floor panel 240 includes a flooring material such as wood, tile, carpet, or the like.
In some cases, a plastic barrier is installed between floor panel 235 and base panel 205. In some cases, the plastic barrier is configured to prevent moisture from passing between base panel 205 and floor panel 235.
FIG. 3 shows an example of a cross-sectional view of the floor assembly of FIG. 2 according to aspects of the present disclosure. Floor assembly 300 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1, 2, and 4-13 . In one aspect, floor assembly 300 includes base panel 305, spacing block 330, floor panel 335, and additional floor panel 340. Base panel 305 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1, 2, and 4-13 . In one aspect, base panel 305 includes depression 310 and panel surface 325.
Depression 310 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1, 2, and 4-13 . In one aspect, depression 310 includes depression surface 315 and face 320. Depression surface 315 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1, 2, and 13 . Face 320 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1, 2, and 13 . Panel surface 325 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1, 2, 10, and 13 .
Spacing block 330 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1, 2, 4, 7, 9, 10, 12, and 13 . Floor panel 335 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2, 4, and 13 . Additional floor panel 340 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2, 4, and 13 .
Referring to FIG. 3 , in some cases, at least a portion of spacing block 330 overlaps depression surface 315 in the vertical direction (e.g., the Y direction), and at least a portion of spacing block 330 overlaps panel surface 325 in the vertical direction. In some cases, face 320 overlaps at least a portion of spacing block 330 in the horizontal direction (e.g., the X direction). In some cases, face 320 overlaps at least a portion of spacing block 320 in the depth direction (e.g., the Z direction).
As shown in FIG. 3 , in some cases, face 320 extends in the vertical direction. However, in some cases, at least a portion of face 320 extends in a direction angled between the vertical direction and the horizontal direction, or in a direction angled between the vertical direction and the depth direction. Therefore, in some cases, a means for indexing spacing block 330 into base panel 305 via depression 310 is provided.
As shown in FIG. 3 , in some cases, depression surface 315 extends in the horizontal direction. However, in some cases, depression surface 315 extends in a direction angled between the horizontal direction and the vertical direction. Therefore, in some cases, a means for indexing spacing block 330 into base panel 305 via depression 310 is provided.
As shown in FIG. 3 , depression 310 has a semi-rectangular cross-section. In some cases, a depression has a semi-triangular cross-section, such that the depression includes two depression surfaces which form an angle. As shown in FIG. 3 , spacing block 330 has a rectangular cross-section. In some cases, a spacing block has a cross-section shaped to matching a cross-section of a depression, such that the depression accepts the spacing block and one or more lower surfaces in the vertical direction of the spacing block contacts one or more upper surfaces in the vertical direction of the depression.
FIG. 4 shows an example of an exploded isometric view of the floor assembly of FIG. 2 according to aspects of the present disclosure. The example shown includes floor assembly 400 and wall assembly 440. Floor assembly 400 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-3, and 5-13 . In one aspect, floor assembly 400 includes base panel 405, spacing block 420, floor panel 425, additional floor panel 430, and additional spacing block 435. Base panel 405 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-3, and 5-13 .
In one aspect, base panel 405 includes depression 410 and additional depression 415. Depression 410 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-3, and 5-13 . Additional depression 415 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 8, 9, 11 , and 12. Spacing block 420 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-3, 7, 9, 10, 12, and 13 .
Floor panel 425 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2, 3, and 13 . Additional floor panel 430 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2, 3, and 13 . Additional spacing block 435 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 9 and 12 .
Referring to FIG. 4 , in some cases, floor assembly 400 is assembled with wall assembly 440 to form at least a portion of a building structure. In some cases, additional depression 415 extends further in the horizontal direction (e.g., the X direction) than depression 410, and additional spacing block 435 corresponding to the additional depression 415 extends further in the horizontal direction than spacing block 420.
FIG. 5 shows an example of a cross-sectional view of a base panel according to aspects of the present disclosure. Floor assembly 500 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-4, and 6-13 . In one aspect, floor assembly 500 includes base panel 505. Base panel 505 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-4, and 6-13 .
In one aspect, base panel 505 includes depression 510. Depression 510 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-4, and 6-13 . In one aspect, depression 510 includes secondary depression 515.
Referring to FIG. 5 , in some cases, secondary depression 515 protrudes in the vertical direction (e.g., the Y direction) into base panel 505. In some cases, secondary depression 515 is a slot for accepting a spacing block including a protrusion that matches secondary depression 515, such that the spacing block indexes into depression 510. In some cases, secondary depression 515 extends in the depth direction (e.g., the Z direction). In some cases, secondary depression 515 extends in the horizontal direction (e.g., the X direction). In some cases, secondary depression 515 increases a surface area of base panel 505, thereby providing an increased shear strength.
FIG. 6 shows an example of an isometric view of a base panel according to aspects of the present disclosure. Floor assembly 600 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-5, and 7-13 . In one aspect, floor assembly 600 includes base panel 605.
Base panel 605 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-5, and 7-13 . In one aspect, base panel 605 includes depression 610 and tab 615. Depression 610 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-5, and 7-13 .
Referring to FIG. 6 , in some cases, tab 615 is a portion of base panel 605 that protrudes into depression 610 in the horizontal direction (e.g., the X direction) or the depth direction (e.g., the Z direction). In some cases, tab 615 narrows a portion of depression 610, allowing base panel 605 to compensate for any inconsistency in a spacing block. For example, tab 615 may allow a warped spacing block to be snuggly placed in base panel 605 via depression 610. In some cases, tab 615 may be reduced (e.g., ground down) to accommodate a tolerancing of the spacing block. In some cases, tab 615 comprises a same material comprised in base panel 605. In some cases, tab 615 comprises a secondary material, such as a polymer, metal, aramid, or wood. As a result, tab 615 may wear more beneficially.
FIG. 7 shows an example of a transparent isometric view of a spacing block according to aspects of the present disclosure. Floor assembly 700 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-6, and 8-13 . In one aspect, floor assembly 700 includes base panel 705, spacing block 715, and fastener 720.
Base panel 705 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-6, and 8-13 . In one aspect, base panel 705 includes depression 710. Depression 710 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-6, and 8-13 . Spacing block 715 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-4, 9, 10, 12, and 13 .
Referring to FIG. 7 , in some cases, spacing block 715 (shown as transparent for ease of illustration) is fastened to base panel 720 via fastener 720 (such as a nail, a screw, etc.). In some cases, spacing block 715 includes a pilot hole for accepting fastener 720.
FIG. 8 shows an example of a plan view of a base panel of FIG. 1 according to aspects of the present disclosure. Floor assembly 800 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-7, and 9-13 . In one aspect, floor assembly 800 includes base panel 805. Base panel 805 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-7, and 9-13 . In one aspect, base panel 805 includes depression 810 and additional depression 815. Depression 810 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-7, and 9-13 . Additional depression 815 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 4, 9, 11, and 12 .
Referring to FIG. 8 , in some cases, base panel 805 includes a set of depressions (including depression 810 and additional depression 815) arranged in an array of rows and columns. In some cases, the depressions of the set of depressions are spaced equally apart from each other in the horizontal direction (e.g., the X direction). In some cases, the set of depressions are spaced equally apart from each other in the depth direction (e.g., the Z direction). In some cases, each depression in a particular row or a particular column extends for an equal distance in one direction (e.g., the horizontal direction or the depth direction) as each other. For example, referring to FIG. 6 , each depression in a depth-direction column including depression 810 extends for an equal distance in the horizontal direction, and each depression in a depth-direction column including additional depression 815 extends for an equal distance in the horizontal direction. In some cases, each depression in the set of depressions is equally sized. In some cases, each depression is spaced apart from an outside edge of base panel 805 in the horizontal direction and/or in the depth direction.
FIG. 9 shows an example of a plan view of the floor assembly of FIG. 2 according to aspects of the present disclosure. Floor assembly 900 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-8, and 10-13 . In one aspect, floor assembly 900 includes base panel 905, spacing block 920, and additional spacing block 925. Base panel 905 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-8, and 10-13 . In one aspect, base panel 905 includes depression 910 and additional depression 915.
Depression 910 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-8, and 10-13 . Additional depression 915 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 4, 8, 11 , and 12. Spacing block 920 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-4, 7, 10, 12, and 13 . Additional spacing block 925 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 4 and 12 .
FIG. 9 omits a floor panel for ease of illustration. As shown in FIG. 9 , spacing block 920 extends in the horizontal direction for a greater distance than depression 910, additional spacing block 925 extends in the horizontal direction for a greater distance than additional depression 915, and additional spacing block 925 extends in the horizontal direction for a greater distance than spacing block 920. In some cases, each spacing block is equally sized.
FIG. 10 shows an example of an exploded isometric view of a floor assembly 1000 according to aspects of the present disclosure. Floor assembly 1000 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-9, and 11-13 . In one aspect, floor assembly 1000 includes base panel 1005 and spacing block 1020. Base panel 1005 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-9, and 11-13 .
In one aspect, base panel 1005 includes depression 1010 and panel surface 1015. Depression 1010 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-9, and 11-13 . Panel surface 1015 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-3, and 13 . Spacing block 1020 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-4, 7, 9, 12, and 13 .
FIG. 10 shows an example of a spacing block 1020 and a depression 1010 having a different surface area ratio as compared to the spacing block and depression described with reference to FIG. 1 . For example, a smaller portion of spacing block 1020 is disposed in depression 1010 as compared to the spacing block and depression described with reference to FIG. 1 , and a greater portion of spacing block 1020 contacts panel surface 1015 as compared to the spacing block and depression described with reference to FIG. 1 .
FIG. 11 shows an example of a plan view of a base panel of FIG. 10 according to aspects of the present disclosure. Floor assembly 1100 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-10, 12, and 13 . In one aspect, floor assembly 1100 includes base panel 1105. Base panel 1105 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-10, 12, and 13 .
In one aspect, base panel 1105 includes depression 1110 and additional depression 1115. Depression 1110 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-10, 12, and 13 . Additional depression 1115 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 4, 8, 9 , and 12.
Comparing FIG. 11 to FIG. 8 , depression 1110 and additional depression 1115 extend for a greater distance in the horizontal direction (e.g., the X direction) than the corresponding depression and additional depression of FIG. 8 , respectively.
FIG. 12 shows an example of a plan view of the floor assembly of FIG. 10 according to aspects of the present disclosure. Floor assembly 1200 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-11, and 13 . In one aspect, floor assembly 1200 includes base panel 1205, spacing block 1220, and additional spacing block 1225. Base panel 1205 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-11, and 13 . In one aspect, base panel 1205 includes depression 1210 and additional depression 1215.
Depression 1210 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-11, and 13 . Additional depression 1215 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 4, 8, 9, and 11 . Spacing block 1220 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-4, 7, 9, 10, and 13 . Additional spacing block 1225 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 4 and 9 .
Referring to FIG. 12 , a floor panel is omitted for ease of illustration. Comparing FIG. 12 to FIG. 9 , spacing block 12120 and additional spacing block 1225 extend for a greater distance in the horizontal direction (e.g., the X direction) outside of depression 1210 and additional depression 1215, respectively, than the corresponding spacing block, depression, additional spacing block, and additional depression of FIG. 9 , respectively.
FIG. 13 shows an example of an isometric view of a floor assembly 1300 including a floor panel 1335 according to aspects of the present disclosure. Floor assembly 1300 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-12 . In one aspect, floor assembly 1300 includes base panel 1305, spacing block 1330, floor panel 1335, and additional floor panel 1340. Base panel 1305 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-12 . In one aspect, base panel 1305 includes depression 1310 and panel surface 1325.
Depression 1310 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-12 . In one aspect, depression 1310 includes depression surface 1315 and face 1320. Depression surface 1315 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-3 . Face 1320 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-3 . Panel surface 1325 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-3, and 10 .
Spacing block 1330 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1-4, 7, 9, 10, and 12 . Floor panel 1335 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2-4 . Additional floor panel 1340 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2-4 .
Referring to FIG. 13 , as compared to FIG. 2 , spacing block 1330 is located in an interior region of base panel 1305 in a plan view. For example, no portion of spacing block 1330 overlaps panel surface 1325 in the vertical direction (e.g., the Z direction). For example, a lower surface of spacing block 1330 in the vertical direction is in contact with depression surface 1315, a portion of spacing block 1330 is in contact with face 1320, and no portion of spacing block 1330 is in contact with panel surface 1325. For example, in some cases, depression 1310 extends for a distance in the horizontal direction (e.g., the X direction), and spacing block 1330 extends for an equal or lesser distance in the horizontal direction.
According to some aspects, any depression and corresponding spacing block described herein may be provided in a floor assembly in combination with any other depression and corresponding spacing block described herein.

Forming a Floor Assembly

A method for forming a floor assembly is described with reference to FIG. 14 . One or more aspects of the method include removing material from a base panel to form a depression; inserting a spacing block on the base panel at least partially within the depression; and placing a floor panel on the spacing block. Some examples of the method further include fastening the spacing block to the base panel. Some examples further include fastening the floor panel to the spacing block.
FIG. 14 shows an example of a method 1400 for forming a floor assembly (such as a floor assembly described with reference to FIGS. 1-13 ) according to aspects of the present disclosure. Generally, these operations are performed according to the methods and processes described in accordance with aspects of the present disclosure. In some cases, the operations described herein are composed of various substeps, or are performed in conjunction with other operations.
Referring to FIG. 14 , tectonic architecture refers to a methodology for the design and assembly of individual materials of a building into a singular building structure. Tectonic architecture is an additive process, meaning sub-components are used to create higher-level components. For example, a stick-frame building may be considered tectonic, as smaller pieces are used to create frames, frames are used to create walls, and so on.
By contrast, stereotomic architecture refers to a methodology for the design and assembly of a structure using stereotomy, which refers to the removal of material to form a structure. Stereotomic architecture is a subtractive process, meaning the final structure is derived by the removal of parts or material. For example, a tunnel may be considered stereotomic due to the process of removing material from a mountain to achieve an open space in the mountain.
Parametric architecture is a building design method that uses equations or algorithms to determine a shape, a size, or an orientation of building components. Parametric architecture may fall under two primary design intents: propagation-based design and constraint-based design. Propagation-based design determines an unknown final shape of a design based on an input, while constraint-based design determines a set of input parameters to achieve final known parameters. Mass timber manufacturing may be considered stereotomic, leading to innovative processes when compared to tectonic manufacturing, such as parametric architecture.
In some cases, a base panel for a floor assembly is designed according to parametric architecture principles and formed using stereotomy, to obtain a prefabricated base including a depression for the floor assembly. A machine or a technician can then easily place a spacing block in the depression, and a floor panel on the spacing block, to obtain a floor assembly in a more efficient and less costly manner than conventional, stick-built floor construction techniques.
At operation 1405, material is removed from a base panel to form a depression. For example, in some cases, a computer numerical controller (CNC) machine cuts the depression from the base panel using a router. In some cases, further material is removed from the base panel to form a secondary depression. In some cases, the CNC machine cuts the depression from the base panel such that a tab (e.g., a portion of the base panel) protrudes into the depression. In some cases, a tab including a different material from the base panel is inserted into the depression.
At operation 1410, a spacing block is inserted on the base panel at least partially within the depression. For example, in some cases, a machine or a technician places the spacing block into the depression. In some cases, the machine or the technician attaches the spacing block to the base panel. In some cases, the machine or the technician fastens the spacing block to the base panel. In some cases, the spacing block is inserted after the base panel is provided at a site of a building structure.
At operation 1415, a floor panel (e.g., a subfloor) is placed on the spacing block. In some cases, a machine or a technician places the floor panel on the spacing block. In some cases, the floor panel includes a depression such that the spacing block protrudes partially into the floor panel. In some cases, the machine or the technician attaches the floor panel to the spacing block. In some cases, a machine or a technician places an additional floor panel (e.g., a floor veneer) on the floor panel.
The description and drawings described herein represent example configurations and do not represent all the implementations within the scope of the claims. For example, the operations and steps may be rearranged, combined or otherwise modified. Also, structures and devices may be represented in the form of block diagrams to represent the relationship between components and avoid obscuring the described concepts. Similar components or features may have the same name but may have different reference numbers corresponding to different figures.
Some modifications to the disclosure may be readily apparent to those skilled in the art, and the principles defined herein may be applied to other variations without departing from the scope of the disclosure. Thus, the disclosure is not limited to the examples and designs described herein, but is to be accorded the broadest scope consistent with the principles and novel features disclosed herein.
In this disclosure and the following claims, the word “or” indicates an inclusive list such that, for example, the list of X, Y, or Z means X or Y or Z or XY or XZ or YZ or XYZ. Also the phrase “based on” is not used to represent a closed set of conditions. For example, a step that is described as “based on condition A” may be based on both condition A and condition B. In other words, the phrase “based on” shall be construed to mean “based at least in part on.” Also, the words “a” or “an” indicate “at least one.”

Claims

What is claimed is:

1. A floor assembly, comprising:

a base panel including a depression;

a spacing block at least partially disposed in the depression; and

a floor panel spaced apart from the base panel by the spacing block.

2. The floor assembly of claim 1, wherein:

a lower surface of the spacing block is in contact with an upper surface of the base panel within the depression.

3. The floor assembly of claim 1, wherein:

an upper surface of the spacing block overlaps and is in contact with a lower surface of the floor panel.

4. The floor assembly of claim 1, wherein:

the spacing block is located within an interior region of the base panel in a plan view.

5. The floor assembly of claim 1, wherein:

the depression extends in a first direction;

the base panel comprises a first surface exposed by the depression and extending in the first direction, a second surface exposed by the depression and extending in a second direction crossing the first direction; and

the spacing block overlaps the first surface.

6. The floor assembly of claim 5, wherein:

the base panel comprises a third surface contacting the second surface, disposed above the first surface in the second direction, and extending in the first direction; and

at least a portion of the spacing block at least partially overlaps the third surface.

7. The floor assembly of claim 1, wherein:

the depression extends in a first direction; and

the spacing block extends for a greater distance in the first direction.

8. The floor assembly of claim 1, wherein:

the depression extends in a first direction; and

the spacing block extends for an equal or lesser distance in the first direction.

9. The floor assembly of claim 8, wherein:

the depression extends in a second direction; and

the spacing block extends for an equal or lesser distance in the second direction.

10. The floor assembly of claim 1, wherein:

the spacing block is attached to the base panel.

11. The floor assembly of claim 10, wherein:

the spacing block is fastened to the base panel.

12. The floor assembly of claim 1, wherein:

the spacing block is attached to the floor panel.

13. The floor assembly of claim 1, wherein:

the base panel further comprises a tab disposed in the depression, wherein the tab provides a fiction fit for the spacing block.

14. The floor assembly of claim 1, wherein:

the base panel, the spacing block, or a combination thereof comprises mid-density fiber (MDF), oriented strand board (OSB), mass timber, cross-laminated timber (CLT), glulam, or mass plywood.

15. The floor assembly of claim 14, wherein:

a majority grain direction of the spacing block is perpendicular to a majority grain direction of the base panel.

16. The floor assembly of claim 1, wherein:

the depression extends in a first direction, the depression further comprising a secondary depression extending into the base panel in a second direction crossing the first direction; and

at least a position of the spacing block is disposed in the secondary depression.

17. The floor assembly of claim 1, further comprising:

an additional floor panel disposed on the floor panel.

18. A floor assembly, comprising:

a base panel including a depression;

a spacing block at least partially disposed in the depression, wherein a lower surface of the spacing block is in contact with an upper surface of the base panel within the depression; and

a floor panel spaced apart from the base panel by the spacing block, wherein an upper surface of the spacing block overlaps and is in contact with a lower surface of the floor panel and wherein the spacing block is located within an interior region of the base panel in a plan view.

19. A method for forming a floor assembly, comprising:

removing material from a base panel to form a depression;

inserting a spacing block on the base panel at least partially within the depression; and

placing a floor panel on the spacing block.

20. The method of claim 19, further comprising:

fastening the spacing block to the base panel; and

fastening the floor panel to the spacing block.