US20230287691A1

US20230287691A1 - Modular element system for the installation of concrete raised floors and related process

Info

Publication number: US20230287691A1
Application number: US18/000,552
Authority: US
Inventors: Mirco Pegoraro
Original assignee: Geoplast SpA
Current assignee: Geoplast SpA
Priority date: 2020-06-03
Filing date: 2020-06-04
Publication date: 2023-09-14
Also published as: WO2021245445A1; IT202000013099A1; EP4162125A1

Abstract

A system for constructing raised floors includes a plurality of bases to be laid on a laying surface, and a plurality of upper modular elements or modules to be laid on the bases. A service cavity is created between the modules and the bases for the passage of cables, cable ducts, raceways, and/or for ventilation purposes. Each module has an upper part and support feet, and each base has a raised part or cup-shaped element, the upper edge of which is configured to support a foot of one or more of the modules, the one or more modules and the cup-shaped element being mutually constrained. Each of the bases also includes one or more arms and/or connecting portions, removably or non-removably constrained to the cup-shaped element and configured to mutually constrain two or more bases.

Description

The present patent relates to components for the construction of raised floors and in particular it concerns a new system of modular elements for the construction of raised floors, their installation process, and the raised floor obtained.
At present, in order to construct or install raised floors, conveniently spaced supports are first positioned on a laying surface and the elements or panels making up the flooring are subsequently positioned on said supports.
Prior art includes supports consisting of a base element which can be placed on a laying surface and support the four corners of four panels side by side.
The base element has a generally cylindrical shape, and is equipped with an enlarged support base at the bottom, while the upper support part is substantially flat, orthogonal to the axis of the cylindrical part, and suited to support the raised floor elements.
In particular, the corners of the panels placed side by side that make up the flooring rest on each of said flat parts.
The following is the procedure for the case in which a raised floor must be constructed on a laying surface, and where cables, cable ducts, raceways, etc., must pass between said laying surface and said raised floor.
Currently, installers first place the supports at a modular distance, according to the characteristics of the flooring to be installed. Then the cable ducts and cables are laid following a path that goes from the starting point to an end point, according to the arrangement deemed ideal.
Once the cables are fixed, the installers lay the flooring elements on top of said supports.
The flooring thus obtained, while achieving the intended purpose with excellent results, is an unstable structure. In fact, particularly in the case in which the laying surface is not perfectly level and horizontal, the flooring panels are not perfectly coplanar and thus not perfectly and stably positioned.
To address these drawbacks, height-adjustable supports with an inclinable support head, which require skilled installers to obtain perfect results, are also known in the prior art.
The object of this patent is a new modular elements system for the installation of raised floors.
An important object of the present invention is to provide a first correctly and perfectly positioned base grid used as a reference for the laying of cables, cable ducts, raceways, inspection wells, etc.
Another object of the present invention is to speed up and simplify all installation procedures.
Yet another object is to provide a very resistant and stable structure.
These and other direct and complementary objects are achieved by the new modular elements system for the installation of raised floors.
The new system includes a plurality of modular base elements, hereinafter simply called bases, intended to be laid on the laying surface and constrained to each other to create a modular base grid, and a plurality of modular upper elements, hereinafter simply called modules, intended to be laid on said bases and constrained to each other to create a surface on which concrete is poured, and where a service cavity is left between said modules and said bases for the passage of cables, cable ducts, raceways, etc.
Each of said bases comprises:

- a raised part, hereinafter called cup-shaped element-shaped element, the upper edge of which is configured to support and constrain a support foot of said modules;
- one or more arms and/or connecting portions, connected to said cup-shaped element and suited to mutually constrain several bases to each other in the correct positions and at the correct distance, so as to create a modular grid where the correct distance between the cup-shaped elements installed is determined by said arms.

In its preferred embodiment, said base comprises said cup-shaped element and one or more of said connecting arms which are removably or non-removably connected to said cup-shaped element.
The upper edge of said cup-shaped element is configured to support one foot of a module or two or more neighboring modules.
Said cup-shaped element is also configured to be stackable with other cup-shaped elements of other identical bases.
In particular, said cup-shaped element preferably has a substantially frustoconical shape, for example converging upwards, where the upper circumference is smaller than the bottom circumference.
Said connecting arms are for example constrained to said cup-shaped element-shaped element and oriented radially with respect to the latter. In the preferred embodiment, said arms of the same base are arranged so as to be at right angles with respect to each other.
Said arms further comprise elements for their coupling to arms or cup-shaped elements of neighboring bases.
Said modules comprise a substantially flat or domed upper part, generally square or rectangular, and four support feet located at the corners of said upper part.
The height of the feet together with the height of the cup-shaped elements determines the height of the module and the service cavity that will be created using this system and is a function of the design needs.
In particular, said upper part has shaped edges, preferably curved, so as to fit together with the corresponding shaped edges of adjacent modules and to connect them together.
For example, said edges are channel shaped and sized so that a female channel along one edge of a module, can house a male channel along the corresponding edge of an adjacent module. Said coupling channels also extend over the edges of the support feet.
Said upper part is suitably ribbed. In particular, a rib configuration that proved to be particularly effective was specially developed. In this configuration, on the upward facing side of the upper part, that is, on the formwork surface, there are lowered areas housing reinforcement ribs. In particular, there is a central lowered area, with ribs arranged in a cobweb configuration around it and four straight lowered areas along the diagonals of said upper part. There are also additional lowered parts along the edges of said upper part.
The lower ends of said module support feet consist of a flat wall, for example curved to form a quarter circle, so as to make up a complete ring together with three other feet of corresponding adjacent modules properly placed on the same cup-shaped element.
Said lower ends of the module support feet are also configured to rest stably on the upper edge of the cup-shaped elements.
In the preferred embodiment described and claimed below, said upper edge of a cup-shaped element is formed with a channel in which one or more corresponding downward-facing protrusions made on said lower end of the feet are inserted.
To ensure the correct and stable positioning of a foot on the cup-shaped element, one or more protrusions or teeth are also present inside said channel for the connection of the corresponding teeth present on said protrusions.
Said lower ends may also comprise elements for coupling or connecting the lower ends themselves with corresponding lower ends of other adjacent feet resting on the same cup-shaped element.
As noted, said base preferably comprises a frustoconical central cup-shaped element or in any case stackable with other identical base cup-shaped elements, and connecting arms to neighboring bases, preferably four at most and arranged orthogonal to each other.
Said arms have a certain height such that once placed on the ground, they serve as a support for the cables or cable ducts laid on them.
A first end of each of said arms is constrained, in a removable or preferably non-removable way, to said cup-shaped element, while the second opposite end comprises means for being coupled to a cup-shaped element of a second base or more preferably to a corresponding second end of an arm of a second base.
Said coupling means are suited to prevent the arms from detaching from each other and furthermore, are configured so that once the two second ends are joined, there are no raised portions that could hinder the laying of the cables or cable ducts.
+++Considering a laying surface on which the ribbed floor is to be installed, the first step is to lay the bases so as to create a grid where the cells are determined by said base arms, and the nodes are said regularly spaced and distributed cup-shaped elements.
Once the grid is installed, the installers can easily lay the cables, cable ducts, raceways and the like on the grid, following the established design.
Once the installation of the systems or preferably of the ducts to contain said systems is completed, the modules can be installed by connecting them to the cup-shaped elements of the bases and to each other, creating a very stable and resistant structure.
The present patent also relates to the process for the construction of raised flooring and the raised flooring obtained.

The characteristics of the present invention will be better clarified by the following description with reference to the drawings, attached by way of a non-limiting example.

FIG. 1 shows a three-dimensional view of the base (100).

FIG. 2 shows a section of the base (100).

FIG. 3 shows a detailed portion of FIG. 2 and in particular a detailed portion of the cup-shaped element (10).

FIG. 4 shows another detailed portion of FIG. 2 and in particular the end (17) of an arm (15).

FIG. 5 shows a three-dimensional view of the module (200).

FIG. 6 shows a three-dimensional view from below of the module (10) of FIG. 5 , while

FIG. 7 shows a detailed portion of it and in particular a support foot (22).

FIG. 8 shows a three-dimensional view of a raised floor (300) made up by assembling a plurality of bases (100) and modules (200), for the passage of cables, cable ducts, or raceways in general (A).

The new system for the construction of raised floors (300) includes a plurality of bases (100) to be laid on a laying surface and to be constrained together to make up a base grid, and a plurality of modules (200), to be laid on said bases (100) and constrained together to create a surface (301) on which concrete can be cast.
As shown in FIG. 8 , a service cavity (400) is created between said modules (200) and said bases (100) for the passage of cables, cable ducts, raceways, etc., as well as for ventilation purposes.
Each of said bases (100) comprises:

- a cup-shaped element (10), having an upper edge (12) configured to support and constrain a foot (22) intended to support said modules (200);
- one or more arms (15) and/or connecting portions, removably or non-removably constrained to said cup-shaped element (10) and suited to mutually constrain the other bases (100) in the correct position and at the correct distance.

In the example in the drawings, said base (100) comprises a central cup-shaped element (10) with a substantially truncated cone shape converging upwards, and four arms (15) orthogonal to each other and radial with respect to said cup-shaped element (10) constrained to the lower edge (11) of said cup-shaped element (10).
A first end (16) of each of said arms (15) is removably or non-removably constrained to said cup-shaped element (10), while the second opposite end (17) comprises coupling means (171, 172) with a corresponding second end of an arm of a second base.
Said coupling means (171, 172) comprise for example horizontal tabs (171) with teeth (172) intended to interlock the edge (173) of the end (17) of the opposite arm (15).
Said modules (200) comprise an upper part (21), substantially flat or domed, generally square or rectangular, and four support feet (22) located at the corners of said upper part.
Said upper part (21) is equipped with shaped edges (24, 25, 26, 27) so as to interlock with the corresponding shaped edges of adjacent modules and connect them together.
For example, said edges (24, 25, 26, 27) are configured like a channel and sized so that a female channel, arranged on one edge of one module (24, 27), can house a male channel placed on the corresponding edge (25, 26) of an adjacent module. Said coupling channels also suitably extend along the edges of the support feet (22), as shown in FIG. 7 ).
The lower ends (23) of said support feet (22) of the modules (200) consist of a flat wall, curved to form a quarter circle, so as to form a complete ring together with three other feet of corresponding adjacent modules correctly positioned on the same cup-shaped element.
Said lower ends (23) of the support feet (22) of the modules (200) are also configured to rest stably on said upper edge (12) of the cup-shaped elements (100).
As shown in detail in FIG. 3 and FIG. 7 , said upper edge (12) of a cup-shaped element (10) is shaped like a channel (13) in which one or more downward-facing protrusions (231) made on said lower end (23) are inserted.
To ensure the correct and stable positioning of the foot (22) of a module (200) on the cup-shaped element (100), one or more protrusions or teeth (14) may be made inside said channel (13) for the coupling with corresponding teeth (232) made on said protrusions (23) of the support foot (22).
Once the raised flooring (300) has been correctly installed, the modules (200) are arranged so that the upper parts (21) are all connected together along the edges (24, 25, 26, 27) resulting in a continuous surface with cylindrical holes made up by said support feet (22) and by said cup-shaped elements (10). Concrete can then be cast on the flooring (300), with or without mesh or reinforcement elements, which will fill said cylindrical holes and create a slab over the laying surface. Once the concrete is cured, a stable raised floor is obtained. One or more of said modules (200) may include an opening made on its upper part (21), in order to install inspection wells or accesses to the underlying service cavity (400).
Consequently, the concrete casting will also be carried out so as to enable the presence of such an opening.
These specifications are sufficient for the expert person to make and use the invention even if during the implementation process variations may be applied which would not change the substance of the innovative concept in any case.
Therefore, with reference to the preceding description and the attached drawings the following claims are made.

Claims

1. A system for creating raised floors (300), comprising:

a plurality of bases (100) to be laid on a laying surface; and

a plurality of modules (200) to be laid on said plurality of bases (100),

wherein a service cavity (400) is created between said plurality of modules (200) and said bases (100) for a passage of cables, cable ducts, raceways, (A) and/or for ventilation purposes,

wherein each module (200) comprises an upper part (21) and support feet (22), and

wherein each base (100) comprises:

a raised part configured as a cup-shaped element (10), an upper edge (12) of the cup-shaped element (10) being configured to support a support foot (22) of one or more of said modules (200), wherein said one or more modules (200) and said cup-shaped element (10) are mutually constrained; and

one or more arms (15) and/or connecting portions, removably or non-removably constrained to said cup-shaped element (10) and configured to mutually constrain two or more of the bases (100).

2. The system according to claim 1, wherein the upper edge (12) of said cup-shaped element (10) is configured to support and constrain said support foot (22) of one or more of said modules (200).

3. The system according to claim 1, wherein said cup-shaped element (10) has a section configured so as to be stackable with other cup-shaped elements of other identical bases.

4. The system according to claim 3, wherein a shape of said cup-shaped element (10) is frustoconical.

5. The system according to claim 1, wherein said arms (15) of said base (10) are arranged so as to be at right angles with respect to each other.

6. The system according to claim 1, wherein said upper part (21) of said modules (200) is provided with shaped edges (24, 25, 26, 27) for a connection with corresponding edges of neighboring modules, so that multiple modules (200) connected together make up a continuous upper surface (301), with cylindrical holes (302) in correspondence with the support feet (22).

7. The system according to claim 6, wherein said shaped edges (24, 25, 26, 27) of said upper part (21) of said module (200) have a channel configuration and are sized so that a female channel, located on an edge of a module (24, 27), can house a male channel located on a corresponding edge (25, 26) of an adjacent module.

8. The system according to claim 1, wherein said upper part (21) of said module (200) is ribbed, and wherein on an upward facing surface of said upper part (21) that provides a formwork surface, there are lowered areas housing reinforcement ribs.

9. The system according to claim 8, wherein on said formwork surface of said upper part (21) there are:

a lowered central part, with the reinforcement ribs arranged in a cobweb configuration;

four straight lowered parts arranged along diagonals of said upper part; and

additional straight lowered parts along edges of said upper part.

10. The system according to claim 1, wherein a lower end (23) of said support foot (22) of the modules comprise a flat wall, curved to form a quarter circle, so as to form a complete ring together with three other feet (22) of corresponding adjacent modules (200) properly positioned on a same cup-shaped element (10).

11. The system according to claim 10, wherein said upper edge (12) of said cup-shaped element (10) is shaped as a channel (13) one or more corresponding downward-facing protrusions (231) made on said lower end (23) of said foot (22) are inserted in said channel.

12. The system according to claim 11, wherein, within said channel (13), there are coupling means (14) configured to couple with corresponding coupling means (232) defined on said protrusions (232) of said lower end (23) of said foot (22).

13. The system according to claim 1, wherein said one or more arms (15) have first ends (17) constrained to said cup-shaped element (10), second opposite ends (17) of said arms (15) comprising means (171, 172) to couple with a corresponding second end (17) of an arm (15) of a second base (100) or to the cup-shaped element (10) of the second base (100).

14. The system according to claim 1, wherein said module comprises at least one opening on said upper part (21).

15. A raised flooring obtained with the system according to claim 1, the raised flooring comprising:

a base grid made up of said plurality of said bases (100) coupled together by said arms (15), wherein cells of the base grid are formed by said one or more arms (15) and nodes of the base grid are formed by said cup-shaped elements (10); and

an upper surface (301) formed by a plurality of said modules (200) juxtaposed to each other so that said upper surface creates a continuous surface, with cylindrical holes (302) in correspondence with said support feet (22) resting on the cup-shaped elements (10) of said base grid.

16. The raised flooring according to claim 15, further comprising a slab cast on said upper surface (301) with columns obtained inside said cylindrical holes (302).

17. A method of creating a raised flooring on a laying surface, with the system according to claim 1, the method comprising the following steps:

laying said plurality of said bases (100) constrained to each other by said one or more arms (15), to form a grid on said laying surface;

preparing a surface for a installation of utility elements, or laying said utility elements;

laying said plurality of said modules (200) on said cup-shaped elements (10) of said bases (100), so that a maximum of four support feet (22) of four neighboring modules (200) rest on a same cup-shaped element (10), wherein said modules (200) are joined together to form a continuous upper surface (301) with cylindrical holes (301) in correspondence with the support feet (22) and the cup-shaped elements (10); and

pouring of a casting of concrete on said continuous upper surface (301) to make a slab having a suitable thickness and columns inside said cylindrical holes.