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.

What is claimed is: 
     
         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.