WO2006059058A1

WO2006059058A1 - Levelling cradles for supporting a batten and method of supporting a batten

Info

Publication number: WO2006059058A1
Application number: PCT/GB2005/004201
Authority: WO
Inventors: William Charles Ansell; David John Garrard
Original assignee: William Charles Ansell; David John Garrard
Priority date: 2004-12-03
Filing date: 2005-10-31
Publication date: 2006-06-08
Also published as: GB2420796A; GB0426569D0

Abstract

In order to provide a level support for a batten (14) over an uneven surface, a cradle (1) is provided that is configured so that it can be stacked. Each cradle (10) is provided with four legs which between them define channels for guiding the batten (14) in a particular direction. The legs are arranged to fit into each other to allow the cradles to be stacked so that an appropriate number can be utilised to support the batten approximately at a desired height. Spacers (9) are provided to enable the height to be more accurately determined.

Description

LEVELLING CRADLES FORSUPPORTING Q BATTEN AND METHODOF SUPPORTINGABATTEN

The present invention relates to a support, in particular a cradle for supporting a batten, e.g. a beam or joist, used in the construction of raised floors or lowered ceilings.

Conventionally, raised flooring, such as a wooden floor, is constructed by supporting the flooring above; for example, a concrete surface by way of one or more flooring battens (also known as beams or joists). These battens are themselves supported by a series of ground supports, commonly known as cradles, which maintain the battens at the desired height above the surface.

Typically, known cradles comprise a base of generally planar configuration, having walls upstanding therefrom which define a channel in which the flooring batten to be supported can be received. The channel may also accommodate one or more spacers or packers which adjust the height at which the batten is supported. In addition, the cradles may incorporate a material which dampens acoustic vibrations, thereby acoustically insulating the flooring.

A problem associated with the mounting of flooring battens is that the supporting surface, e.g. concrete, on which the battens are to be mounted, is often not level. To compensate for this, the cradles used are often of a configuration which allows for the level positioning of the battens despite any unevenness present throughout the supporting surface. To a certain extent, the level of the battens can be adjusted by using the spacers as mentioned above. However the number and thickness of spacers required to maintain the batten at a level position, may vary dramatically depending on the particular location of each cradle along the surface. It has thus previously been common to provide a range of differently sized cradles, for example three, each size of cradle being adapted to accommodate up to a particular number of spacers of a certain size whilst having upstanding walls of a height sufficient to maintain a deep enough channel, notwithstanding the presence of the spacers, for effectively receiving and holding in place the batten. Often, a range of spacers of different thicknesses was also provided. Thus, large cradles might be provided to support a batten at positions along the floor where a large distance between the supporting surface and the batten is required to maintain the batten in a level position. Conversely, smaller cradles might be used at positions where a shorter distance between the supporting surface and the batten is required.

The requirement for several cradles and spacers of varying sizes adds to the complexity both in terms of manufacturing and using the cradles since a reasonable supply of all the different sizes and thicknesses would need to be provided at a building site in order to cope with differences in the level of the concrete (or other) base surface.

In contrast to the prior art, in one aspect, the present invention provides a levelling cradle for supporting a batten, the cradle comprising a base and a region for receiving the batten, the cradle being modular in configuration such that it is interlockably stackable with another cradle having the same configuration.

The cradle of the present invention avoids the need to employ a large range of differently sized cradles when constructing a raised floor. Instead, where a batten needs to be supported at a greater distance from the supporting surface than can be achieved using one cradle alone, two or more cradles may be employed in a stacked assembly (together with an appropriate number of spacers if needed) to maintain the batten in a level position.

The versatility of the cradle of the present invention means that the range of different support shapes and sizes to be manufactured and used in mounting the floors can be reduced, thereby reducing costs. Preferably the region of the cradle for receiving the batten defines a channel for receiving the batten.

In a particularly preferred embodiment, the cradle has a plurality of legs upstanding from the base and configured such that together the legs define the channel. Preferably, there are at least four legs arranged to define a pair of channels set at right angles to each other, each capable of receiving battens. The cradle may be provided with more than one channel extending parallel to each other to allow two battens to be effectively supported next to each other, for example with one end of one batten being supported next to one end of a second batten that extends substantially parallel to the first batten.

Preferably the legs comprise upper and lower portions, the upper portions being interlockable with the underside of another cradle of the same configuration, such that stacking can occur.

Preferably the cradle has recesses on the underside of the base, capable of receiving upper portions of the legs of another cradle of the same configuration. The recesses may be defined by the lower portions of the legs, the recesses being open from the underside of the base. The recess is preferably between about 4mm and about 6mm in depth.

In a preferred embodiment the base of the cradle is generally rectangular in shape, for example a square, having four upstanding legs positioned substantially at the corners of the base. Preferably, the base of the cradle measures about 100mm width by about

100mm length. The overall height of the cradle is preferably about 22mm.

Optionally, the base of the cradle may be configured to receive, on its underside, a layer of acoustic damping material in the form of, for example, a rubber pad or a layer of foam of the open or closed cell type. Preferably, the layer of acoustic damping material has a thickness of between about 10mm and about 20mm.

In a preferred embodiment, the cradle is moulded of a plastics material, e.g. of UPVC or polypropylene.

In a further aspect, the invention provides a levelling support kit comprising a plurality of cradles of the type described above, and a plurality of spacers positionable in use between the base of the cradle and a batten, to support the batten at a desired height above the base.

Preferably, the spacers have a thickness of about 2mm.

The kit may additionally comprise a layer of acoustic damping material, e.g. a rubber pad or layer of acoustic foam, receivable on the underside of the base of the cradle. In yet a further aspect, the invention provides a method of supporting a batten in a level manner in relation to an uneven surface, the method comprising the steps of determining the required spacing between the batten and the uneven surface, stacking an appropriate number of cradles of the type described above to provide a support distance closest to, but less than, the required spacing, choosing a number of spacers of the type described above that, in conjunction with the stacked cradles, provide the closest match to the required spacing, positioning the stacked cradles and the spacers in the desired location, and mounting the batten on the spacers and cradles so that the batten is supported at the required spacing from the uneven surface.

Preferably, the batten is supported in a level manner as described above at a plurality of locations across the uneven surface, the numbers of cradles and spacers being chosen independently for each of the locations.

Embodiments of the invention are now described, by way of example only and with reference to the accompanying drawings in which;

Figure 1 is a perspective view of a levelling cradle of one embodiment of the invention;

Figure 2 is a perspective view of the cradle of Figure 1 revealing the underside of the cradle; Figure 3 is a perspective view of three of the cradles of Figure 1 assembled in a stacked position and supporting a batten; and

Figure 4 is a perspective view showing an alternative assembly of two cradles supporting crossing battens running perpendicular to one another.

Referring to Figure 1 , a levelling cradle 1 , for supporting a batten, is illustrated. The cradle comprises a generally square base 2 of planar configuration having downwardly extending walls or feet 3 which run along the periphery of the base but which do not extend around the corners 4 of the base. The corners 4 of the base are curved.

Upstanding from each corner are legs 5 which define channels set at right angles to one another. The outwardly facing wall of each leg is curved such that it corresponds to the curve of the corner of the base at which it is positioned. The side facing walls of the legs 5 are generally perpendicular to the edge of the base from which they extend, whilst the inner facing wall is convexed such that it allows for the positioning of one or more disk like spacer elements 9 over the base and between the legs. Each of the four legs 5 of the cradle comprises relatively smaller, upper and relatively larger, lower portions 6 and 7 respectively. A peripheral flange or shelf 8 extends around the periphery of each leg at the point between the two portions. The outer facing walls of the upper portions are complementary to the configuration formed by the underside of the cradle, such that the upper portions of each leg fit into the lower portion of a corresponding leg having the same configuration from the underneath of a second cradle.

Figure 2 reveals the underside of the cradle. As can be seen, extending feet 3 form a wall around the periphery of the base thereby defining a recess. The upstanding legs 5 of the cradle are hollow, the internal space of the legs being accessible by openings 10 at the corners of the base. These openings are configured to receive the upper portions of legs of a cradle having the same configuration thereby facilitating stacking.

The base 2 of the cradle is reinforced by a webbed frame 11 integral with the underside of the base. Figure 3 illustrates how the cradle 1 may be employed in a support assembly. The recess formed on the underside of base 2 of cradle 1c receives a layer of acoustic damping material in the form of a pad 12. The pad is square in shape such that its corners extend beyond the curved periphery 4 of the base. The pad may be made of rubber crumb material, an acoustic foam material, or any other suitable material to provide acoustic damping between the surface and the cradle assemblies.

In use, the cradle-pad assembly may be placed on a supporting surface such as concrete and the batten 14 to be supported is aligned along one of the channels formed by the legs 5. The desired height of the batten above the supporting surface is achieved by incorporating spacer elements 9 between the batten 14 and the base 2. The spacer elements have hollow centres which reduce the overall weight of the element and which aid in allowing the user to grip the spacers for insertion into and removal from the cradle. The inner facing walls of the legs 5 contact the spacer element at points along its periphery thereby holding the spacer element in place and preventing lateral movement. Once the batten is placed in the supporting position along the channel, the legs 5 extend upwardly against the lengthwise edges 1of the batten, thereby guarding against any lateral movement of the batten.

Where a greater height is desired between the supporting surface and the batten, two or more cradles can be employed. As shown in Figure 3, a first cradle 1c is aligned to receive the acoustic damping pad 11 on its underside. A second cradle 1b is then aligned such that its underside is in a position to receive the upper portions 6 of the upstanding legs 5 of cradle 1a. This way cradle 1b can be stacked on top of cradle 1 a, with a portion of the underside edge of its feet 3 resting on flanges 8 of the lower cradle 1c. Similarly, if desired, a third cradle 1 c can be stacked on top of cradle 1 b. Positioning of the batten is further facilitated by the use of spacer elements 9 which support the batten 14 above the base of cradle 1c.

An alternative assembly which can be adopted by the cradles of the invention is shown in Figure 4. Here, two cradles 1a and 1b are joined using the acoustic rubber pad 12 as a bridge, the opposing faces of which are received by the undersides of the cradles. Such an assembly is particularly useful in supporting battens which cross one another at right angles. As shown, lower batten 14a is received in a lower channel defined by the leg portions 5a of cradle 1a whilst an upper batten 14b is received by an upper channel perpendicular to the lower channel and defined by the leg portions 5b of cradle 1b. If necessary, spacers (not shown) may be employed to obtain the desired distance between the upper and lower battens. Also, when required, additional cradles stacked above and below cradles 1a and 1b may be used where a greater distance between the crossing battens is desired (also not shown). In a particularly preferred configuration, the support assembly described above has any one or combination of the following dimensions: the planar base 2 of the cradle has a length and width of about 100mm; the downwardly extending feet measure about 4 to 6mm in height; the overall height of the cradle is approximately 22mm; the heights of the upper and lower portions, 6 and 7, of legs 5 are such as to provide a stacking height of about 20mm to 25mm, preferably about 22mm and are able to receive up to about 10 spacers, each having a thickness of about 2mm; the acoustic pad for use with the assembly has a thickness of approximately 10 to 20mm. Although the above embodiments, relate to a cradle of a specifically defined configuration, it will be appreciated that certain variations of this configuration are permissible and within the scope of the invention. Thus, the cradle can be of any support shape provided that the shape is such as to allow the batten to be received and supported and to allow stacking of the cradle. It will also be appreciated that the size and shape of the spacers together with the acoustic pads to be used, can vary provided that they are compatible with the particular configuration of cradle adopted.

Furthermore, the cradle, although so-called herein, need not provide a channel for receiving the batten. It will be appreciated that any number of legs, including one, could be used in a stackable configuration providing a support for receiving the batten. The cradle does not need to physically restrict movement of the batten laterally provided it provides the required height support. Thus, any number of legs could be provided, of any configuration, that provide support for one or more battens in one or more configurations relative to each other, for example, in parallel or perpendicular to each other, at the required height by employing a stackable configuration.

Thus, it will be appreciated that the foregoing description merely identifies preferred embodiments of the invention. Although features thought to be of particularly preferred embodiments are defined within the present claims, the applicant reserves the right to claim subsequently for any novel feature embodied or described herein, or as illustrated in the drawings.

Claims

1. A levelling cradle for supporting a batten, the cradle comprising a base and a region for receiving the batten, the cradle being modular in configuration such that it is interlockably stackable with another cradle having the same configuration.

2. A cradle according to claim 1 , wherein the region for receiving the batten defines a channel for receiving the batten.

3. A cradle according to claim 1 or claim 2, having a plurality of legs upstanding from the base and configured such that together the legs define the channel.

4. A cradle according to claim 3, having at least four legs arranged to define a pair of channels set at right angles to each other, each capable of receiving battens.

5. A cradle according to claim 3, having more than one channel extending parallel to each other to allow two battens to be effectively supported next to each other.

6. A cradle according to any one of claims 3 to 5, wherein the legs comprise upper and lower portions, the upper portions being interlockable with the underside of another cradle of the same configuration, such that stacking can occur.

7. A cradle according to claim 6, further comprising recesses on the underside of the base, the recess being capable of receiving upper portions of the legs of another cradle of the same configuration.

8. A cradle according to claim 7, wherein the recesses are defined by the lower portions of the legs, the recesses being open from the underside of the base.

9. A cradle according to claim 8, wherein the recess is between about 4mm and about 6mm in depth.

10. A cradle according to any of claims 3 to 9, wherein the base of the cradle is generally rectangular in shape, having four upstanding legs positioned substantially at the corners of the base.

11. A cradle as claimed in any preceding claim, wherein the base is configured to receive on its underside, an acoustic damping pad.

12. A cradle as claimed in claim 11, wherein the acoustic damping pad has a thickness of between about 10 and about 20mm.

13. A cradle according to claim 11 , wherein the acoustic damping pad comprises a layer of acoustic foam or a rubber pad.

14. A cradle as claimed in any preceding claim, having a height of about 22mm.

15. A cradle as claimed in any preceding claim being formed of either a polypropylene material or a UPVC material.

16. A levelling support kit comprising a plurality of cradles as claimed in any preceding claim, and a plurality of spacers positionable in use between the base of the cradle and a batten, to support the batten at a desired height above the base.

17. A kit as claimed in claim 16, wherein the spacers have a thickness of about 2mm.

18. A kit as claimed in any of claims 16 or 17, further comprising a layer of acoustic damping material or a rubber foam material receivable on the underside of the base of the cradle.

19. A method of supporting a batten in a level manner in relation to an uneven surface, the method comprising the steps of: determining the required spacing between the batten and the uneven surface, stacking an appropriate number of cradles from the kit according to any one of claims 16 to 18 to provide a support distance closest to, but less than, the required spacing, choosing a number of spacers from the kit according to any one of claims

16 to 18 that, in conjunction with the stacked cradles, provide the closest match to the required spacing, positioning the stacked cradles and the spacers in the desired location, and mounting the batten on the spacers and cradles so that the batten is supported at the required spacing from the uneven surface.

20. A method according to claim 19, wherein the batten is supported in a level manner at a plurality of locations across the uneven surface, the numbers of cradles and spacers being chosen independently for each of the locations.