CA2465213A1 - Methods for finishing top surfaces of concrete filled access floor panels - Google Patents
Methods for finishing top surfaces of concrete filled access floor panels Download PDFInfo
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- CA2465213A1 CA2465213A1 CA002465213A CA2465213A CA2465213A1 CA 2465213 A1 CA2465213 A1 CA 2465213A1 CA 002465213 A CA002465213 A CA 002465213A CA 2465213 A CA2465213 A CA 2465213A CA 2465213 A1 CA2465213 A1 CA 2465213A1
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- top surface
- floor panel
- access floor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C5/00—Processes for producing special ornamental bodies
- B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
- B44C5/0438—Ornamental plaques, e.g. decorative panels, decorative veneers containing stone elements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/08—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C3/00—Processes, not specifically provided for elsewhere, for producing ornamental structures
- B44C3/02—Superimposing layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C3/00—Processes, not specifically provided for elsewhere, for producing ornamental structures
- B44C3/12—Uniting ornamental elements to structures, e.g. mosaic plates
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C5/00—Processes for producing special ornamental bodies
- B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/46—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with organic materials
- C04B41/48—Macromolecular compounds
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/60—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
- C04B41/61—Coating or impregnation
- C04B41/62—Coating or impregnation with organic materials
- C04B41/63—Macromolecular compounds
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/024—Sectional false floors, e.g. computer floors
- E04F15/02405—Floor panels
- E04F15/02417—Floor panels made of box-like elements
- E04F15/02423—Floor panels made of box-like elements filled with core material
- E04F15/02429—Floor panels made of box-like elements filled with core material the core material hardening after application
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/08—Flooring or floor layers composed of a number of similar elements only of stone or stone-like material, e.g. ceramics, concrete; of glass or with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass
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- G—PHYSICS
- G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
- G09F—DISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
- G09F19/00—Advertising or display means not otherwise provided for
- G09F19/22—Advertising or display means on roads, walls or similar surfaces, e.g. illuminated
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/60—Flooring materials
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Structural Engineering (AREA)
- Architecture (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Mechanical Engineering (AREA)
- Civil Engineering (AREA)
- Marketing (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Theoretical Computer Science (AREA)
- Accounting & Taxation (AREA)
- Business, Economics & Management (AREA)
- General Engineering & Computer Science (AREA)
- Floor Finish (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
Abstract
Systems and methods for finishing top surfaces of concrete filled access flo or panels include the application of at least one material to a top surface of an access floor panel. The top surface may be prepared by grinding and cleaning prior to application of material. Stains, primers, concretes, epoxies, polyurethanes, clear coats, or other finishing materials may be applied to create a plurality of layers on the surface of the floor panel, producing different aesthetically pleasing, or well performing finished surfaces. Afte r application, the materials may be subjected to infrared light, ultraviolet light, or forced air to accelerate drying or curing. The materials may be applied, dried, and cured in an automated production line while the floor panel moves along a conveyor.
Description
SYSTEMS AND METHODS FOR FINISHING TOP SURFACES OF CONCRETE
FILLED ACCESS FLOOR PANELS
RELATED APPLICATIONS
This patent application claims priority to provisional patent application Serial No.
GO/381,250, filed on May 16, 2002, entitled "Surface Finishings For Concrete Filled Access Floor Panels," and provisional patent application Serial No. 60/341,014 filed October 29, 2001, entitled "Surface Treatment For Access Floor Panels," each of which is incorporated herein by reference.
This invention relates to finished top surfaces of access floor panels and methods for producing such surfaces.
BACKGROUND OF THE INVENTION
Access floors are typically used in data centers, rooms housing computer servers, and in other areas having devices requiring connection to external wires. Access floor panels are used to construct raised floors over sub-floors so that wires can be laid down and easily accessed between the sub-floor and the raised access flooring. Thus, access flooring provides a convenient location for cables. In some cases, HVAC air is also handled beneath the access floor panels.
Access floors are constructed of panels that are usually about 24 inches square and on the order of one to two inches thick. In one structure, the panels can be formed with an exterior sheet metal shell forming a cavity that can be filled with concrete.
The top surface of the concrete is prepared so that it is flush with the edges of the metal form. Typically, access floor panels are covered, either during manufacture or after installation, with carpet, carpet tiles, vinyl, high-pressure plastic laminate, ceramics, or stone.
Depending on the type of covering used, the covering may be changed or destroyed if the access flooring must be removed to perform maintenance on installed floor systems.
Access floor panel finishes applied prior to installation are disclosed in U.S. Patent No. 5,205,091 to Brown. However, Brown does not teach a method of applying finishing materials to top surfaces of floor panels to create durable finishes in a cost effective manner.
Consequently, a need exists for alternative methods of creating panel finishes, particularly including inexpensive and durable finishes capable of being quickly installed on panels during the manufacturing process in an assembly line environment.
SUMMARY OF THE INVENTION
This invention includes systems and methods for finishing a top surface o.f an access floor panel by applying at least one layer of material to the top surface. The top surface of the floor panel can be metal, concrete or other materials, but this invention is particularly well adapted for use on floor panels having a concrete top surface. The concrete top surface may be prepared before applying materials to the top surface. For instance, the top surface may be prepared by grinding the top surface to make it smooth and flat. After grinding, the top surface may be cleaned of loose materials by scrubbing or applying water at high pressure. Preparing the top surface facilitates binding of the material to the top surface and even application of the material to the top surface.
In one embodiment, a stain is applied to a prepared or a unprepared top surface of an access floor panel to give the top surface a colored appearance. The stain may be applied in various colors, may be applied separately to an entire surface or a portion of a floor panel, and may be used to form a pattern. Alternatively, the floor panel may be given a colored appearance by using colored concrete in the floor panel. Concrete is colored by adding a concrete colorant to uncured concrete prior to pouring the uncured concrete into a metal pan to form the colored concrete filled access floor panel.
The stain may dry or cure under ambient conditions in about 24 hours.
Alternatively, the stain may be subjected to infrared light to reduce the time required to cure the stain to about 15 seconds. Conventional drying processes other than infrared light may also be used, such as, but not limited to, chemical accelerators, ultraviolet light, or forced air with or without added heat. Once the stain has cured, a clear coat is applied to the surface of the stain. The clear coat seals and protects the stain. Alternatively, a grit anti-slip additive may be mixed with the clear coat to increase the slip resistance of the top surface of the floor panel. The clear coat may dry or cure under ambient conditions or through use of infrared light. In another embodiment, a clear coat, with or without grit anti-slip additive, is applied to the surface of an access floor panel without applying a stain.
In yet another embodiment, a finished surface is produced by applying a baselayer to a prepared or unprepared top surface of an access floor panel. Alternatively, a primer can be applied to the surface of the floor panel prior to applying the baselayer. The primer may be pigmented, but typically is not pigmented. The primer can dry under ambient conditions or through use of infrared light in the same manner described above. The baselayer can be composed of concrete, polymer concrete, epoxies, acrylics, or other polymeric material, such as a solvent based urethane or a water based urethane. Further, the baselayer can be composed of different colors and applied to form various designs. The baselayer can also be used to form a company's insignia or logo, an advertisement, other message, or any kind of patterned design. Alternatively, while the baselayer is still wet or uncured, a decorative material can be broadcast over the baselayer. The decorative material may be colored chips, or flakes, composed of ethylene vinyl acetate (EVA). Alternatively, a wide variety of other decorative materials can be used, including, for instance, fragments of glass, hardware, or seashells. The decorative materials may be applied in layers of different thickness to produce random patterns or calculated designs of one or more colors. The decorative materials may also be applied to form a pattern using stencils, masking sheets, masking tapes, screen printing, or other similar techniques. The baselayer, with or without applied decorative materials, may cure under ambient conditions, or with the assistance of infrared light, ultraviolet light, forced air with or without heat added, or other curing processes. After the baselayer has cured, decorative materials that did not attach to the baselayer are removed from the surface of the floor panel using a vacuum or other method. A clear coat, with or without grit anti-slip additive, may then be applied to the floor panel to protect the top surface. The clear coat may also be cured under ambient conditions or with infrared light.
In yet another embodiment, an access floor panel may be prepared and finished while the floor panel is on an assembly line. The surface of an access floor panel may be prepared by grinding, cleaning, sanding, sandblasting, water jet blasting, laser engraving, or any combination thereof. Surface treatments, such as stains, primers, baselayers, and clear coats (with or without grit anti-slip additives), may be applied to a prepared or unprepared surface of the floor panel by mechanically operated sprayers in spraying cabinets proximate to the floor panel on the assembly line. The mechanically operated sprayers may be movable in planes proximate to the top surface of the floor panel. Drying or curing processes, such as application of infrared light, ultraviolet light, chemical catalysts, heated forced air, and unheated forced air, may be performed on the surface treatments to decrease production time.
This invention permits production of access floor panels that can be supplied efficiently for use in a finished, ready-to-install condition, thereby eliminating the need to install a floor surface on the top surface of the panel after the panel has been installed.
Elimination of this step makes the installation process more efficient by decreasing the amount of time needed to install the panel and by reducing labor costs. The finishes that can be produced in accordance with this invention are also inexpensive, durable, attractive and easier to produce than other conventional finishes.
This invention is also advantageous because the coatings can be dried or cured using infrared light, or other drying processes, in a fraction of the time required to dry the same coatings under ambient conditions. Thus, production time for creating a finished floor surface for a single floor panel can be reduced from four days per floor panel in some situations to about one minute or less.
The finishing treatments of this invention can be easily applied on floor panels in an automated production line, thereby reducing the amount of labor required.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a cross-sectional schematic view of a portion of a concrete filled access floor panel having a prepared surface, a stain treatment, and a clear coat treatment.
Figure 2 is a cross-sectional schematic view of a portion of a concrete filled access floor panel having a prepared surface, a primer treatment, a baselayer treatment, a decorative material treatment, a stain treatment, and a clear coat treatment.
Figure 3 is a cross-sectional schematic view of a portion of a concrete filled access floor panel having a prepared surface and a clear coat treatment.
Figure 4 is a perspective view from above a plurality of concrete filled access floor panels that include a variety of designs formed by baselayers on their top surfaces in accordance with this invention.
Figure 5 is a perspective view from above a plurality of installed concrete filled access floor panels that include a variety of designs formed by baselayers on their top surfaces in accordance with this invention.
Figure 6 is a perspective view from above a concrete filled access floor panel having an uneven textured surface with two regions of different color sections that are formed by a baselayer.
Figure 7 is a perspective view from above a concrete filled access floor panel having a plurality of wavy shapes, a conch shell design, and a sand dollar design.
Figure 8 is a perspective view from above a plurality of concrete filled access floor panels having various colored baselayers forming part of an insignia of a company.
G
DETAILED DESCRIPTION OF THE DRAWINGS
The concrete filled access floor panel finishes of this invention include application of a colored material to a top surface of an access floor panel and application of a clear coat on top of the colored material for protection and increased durability.
Generally, the materials will be composed of polymeric compounds.
Some of these materials are intended for application to floors in place in buildings.
However, the circumstances of practice of this invention are typically significantly different from the circumstances present in application to floors in place in buildings.
For instance, among other differences, there are the following considerations:
First, adjacent portions of a floor in place in a building get similar finish applications as a result of their location, and a portion of an in situ floor on one side of a room is never relocated to be adjacent to another, remote portion of floor separately finished. By contrast, an access flooring panel manufactured at a particular time may be installed adjacent to other panels manufactured and finished in accordance with this invention at another widely separated time.
Second, floors finished in situ typically can be left undisturbed for at least several hours before there is any contact with the newly finished surface. By contrast, access flooring panels are typically manufactured on a production line requiring each manufacturing operation to be accomplished quickly. It is not practical or economically acceptable in a production line for panels to remain in a condition preventing their handling or contact with their top surfaces for an extended period of time.
In light of these manufacturing considerations, it is important for finishing techniques and materials to cure or dry quickly so that further manufacturing processes and panel handling can occur quickly after finish application. Accordingly, it is important for solvent-based finish systems and components to dry quickly, or for catalyzed or other systems to cure quickly. Some such rapidly curing systems employ mixing techniques that occur in or near a spray head, causing mixing to occur very close in time to application of the finish.
Another alternative is the use of finish materials for which curing time can be accelerated by exposure of the material to ultraviolet light. Yet another alternative is the use of infrared emitters that can dramatically reduce the drying or curing time of finishes, with associated reductions in production time and costs.
In one embodiment, as shown in Figure l, a stain 12 is applied directly to a top surface of an access floor panel 14. Stain 12 can be applied to a prepared surface or an unprepared surface. The surface can be prepared by grinding, cleaning, sanding, sandblasting, water jet blasting, laser engraving, or any combination thereof to provide a more aesthetically appealing surface or a surface having other desired characteristics such as flatness or texture. The surface can be composed of materials including, but not limited to, concrete, wood, or metal. However, access floor panel 14 preferably has a concrete surface.
Preferably, access floor panel 14 is ground flat prior to application of stain 12. Grinding exposes a concrete top surface 52 of the access floor panel 14 with a higher moisture content that an unground concrete top surface of the access floor panel 14. The increased moisture content of the top surface of the floor panel 52 assists stain 12, and other applied materials, to spread and adhere to the concrete surface. Stain 12, as well as other applied materials, is preferably selected from a group of aqueous based stains to take advantage of the increased moisture content of the top surface of access floor panel 52.
Stain 12 may be applied to access floor panel 14 using a brush, roller or sprayer. In addition, mechanically operated sprayers positioned in a spraying cabinet located proximate to an assembly line may apply stain 12 while the floor panel 14 is on the assembly line.
Stain 12 can be various colors or shades of color, and can include waterproofing and water resistant properties. Stain 12 can also be fowled using a single stain or mixture of stains having similar or different colors. At least one suitable stain is sold by Duckback Products, Inc., of Chico, California.
After application of stain 12 to the top surface of access floor panel 14, stain 12 is allowed to dry. Stain 12 can dry under ambient conditions, which typically takes about 24 hours. However, infrared light emitters may be used to accelerate the drying process. While applying infrared light to stain 12 for any amount of time reduces the total amount of time needed for stain 12 to dry, stain 12 is preferably subjected to temperatures of about 71 degrees Celsius by applying infrared light to stain 12 for about 15 seconds for optimal results. However, depending on the type and thickness of coating, and the intensity of the light source, the dry time could be within the range between about 1 second to about 15 minutes. Application of infrared light for about 15 seconds to stain 12 dries stain 12 sufficiently to receive a layer of material. Infrared light may be applied to stain 12 with any device. In one embodiment, infrared light is applied to stain 12 while access floor panel 14 is in an assembly line. An infrared light emitter is positioned proximate to a conveyor, and the rate by which the conveyor travels is such that any point on the top surface of access floor panel 14 is exposed to infrared light for about 15 seconds. This can be accomplished using numerous configurations because the position of the infrared light emitter may be dependent upon the speed of the conveyor belt and vice versa. Alternatively, ultraviolet light emitters, or heated or unheated air blowers, can be used to accelerate the drying or curing process.
Once stain 12 is dried, a clear coat 16 is applied to the surface of stain 12.
Clear coat 16 may be a water based urethane or epoxy, a solvent based urethane or epoxy, a water based acrylic sealant, or other materials. Clear coat 16 may be applied in gloss or matte finishes.
At least one suitable clear coat is sold by Duckback Products, Inc., of Chico, California.
Multiple coats of clear coat 16 may be applied to enhance the gloss and smoothness of the finish of clear coat 16. A grit anti-slip additive may be mixed with clear coat 16 to increase the f nish's slip resistance. At least one suitable grit anti-slip additive is sold by Behr Process, Corp., Santa Ana, California. Clear coat 16 can be applied by sprayers positioned in an assembly line in the same manner as described for stain 12. Clear coat 16 can cure in ambient conditions or clear coat 16 may be exposed to infrared light, or subjected to other drying processes, in the same manner as described for drying stain 12, to accelerate the curing process. Preferably, clear coat 16 is subjected to temperatures of about 71 degrees Celsius using infrared light for 30 to 90 seconds.
In another embodiment, as shown in Figure 3, a clear coat 18 is applied to a prepared or an unprepared surface of a concrete filled access floor panel 20 without applying a stain.
Alternatively, access floor panel 20 may be filled with a colored concrete.
Concrete is colored by including a concrete colorant, such as one sold by L.M. Scofield, Co., Los Angeles, California, in a concrete mixture, prior to forming the concrete filled access floor panel. The surface can be prepared in the same manner as described for access floor panel 14 in Figure 1. Clear coat 18 may have the same properties and characteristics and be applied in the same manner as clear coat 16 used on top of stain 12 in Figure 1. If concrete filled access floor panel 20 is filled with colored concrete, application of clear coat 18 enhances the colored appearance of the colored concrete. Clear coat 18 can dry in ambient conditions or clear coat 18 may be exposed to infrared light, or subjected to other drying processes, in the same manner as described for stain 12 in Figure 1, to accelerate the drying process.
In yet another embodiment of this invention, a plurality of materials are applied, as shown in Figure 2, to a top surface of an access floor panel 24. The top surface can be prepared in the same manner as described for access floor panel 14 in Figure 1.
A primer 22 may be applied to the top surface of the access floor panel 24 before application of a baselayer 26. The primer 22 is applied to ensure that baselayer 2G remains bonded to the top surface during use. The primer 22 can be a water or a solvent-based urethane, a water or solvent based acrylic, an epoxy, or other materials.
Preferably, primer 22 is composed of a water-based two-part epoxy. At least one suitable primer is sold by National Polymer, Pittsburgh, Pennsylvania. Primer 22 preferably does not contain 1 S pigments, but optimally may contain pigments in some embodiments. Primer 22 may be applied with a brush, roller, sprayer, spraying device, or any combination thereof, as described above. Primer 22 can be applied in an assembly line environment in the same manner as stain 12 in Figure 1. Primer 22 can be dried or cured at ambient conditions, with infrared emitters, or other drying processes, as previously described. Primer 22 is preferably exposed to temperatures of about 71 degrees Celsius using infrared light for at least 50 minutes.
Baselayer 2G is applied to the surface of access floor panel 24. Baselayer 26 can be composed of, but is not limited to, a concrete, a polymer-concrete, an epoxy, solvent based urethane, latex based urethane, or other polymeric material. At least one suitable baselayer is sold by National Polymer, Pittsburgh, Pennsylvania. Baselayer 26 can be formed in many colors. Baselayer 26 can be applied to the top surface by spraying, rolling, brushing or by squeezing the baselayer 26 through a stencil in a process somewhat similar to a silk screen process. The baselayer 26 can be applied in an assembly line environment in the same manner as stain 12 in Figure I .
Baselayer 26 may be covered with a variety of decorative materials 28 of any color.
In one embodiment, decorative materials 28 are composed of pigmented chips, or flakes.
The chips or flakes may be composed of numerous materials such as, but not limited to, plastics, resins such as ethylene vinyl acetate (EVA) resin, and other materials. One suitable chip is sold by Torginol, lnc. of Sheboygan Falls, Wisconsin. The chips can all be the same color or a mixture of two or more colors. In one embodiment, the chips are applied as a mixture of two or three different colored chips to a white baselayer. The chips are applied during the manufacturing process and are preferably applied while baselayer 26 is in an 1 S uncured condition. The chips may be applied while the floor panel is on an assembly line.
Insolvable chips are held in place by baselayer 26 and do not change shape or appearance during the drying process. In contrast, solvable chips may be partially dissolved by baselayer 26, which may cause the chips to appear as if they have been melted.
In yet another embodiment, baselayer 26 can be covered with decorative materials such as pebbles 44, hardware 4G, or glass 40, as shown in Figure 4. The glass 40 can include, but is not limited to, stained glass, recycled glass, or newly formed glass. The hardware 46 can include nails, fasteners, clamps, rings, and the like. These materials may be applied while the floor panel is on an assembly line. These materials can be ground during post-application processing to leave a uniform, flat surface.
Baselayer 2G, with or without decorative materials 28, is dried or cured under ambient conditions, with infrared light, or with other drying processes. Baselayer 2G
is preferably exposed to temperatures of about 71 degrees Celsius using infrared light for 50 minutes. The exposed surface of the raised access floor is then cleaned of any decorative materials 28 not attached to baselayer 2G. The exposed surface can be cleaned using a brush, vacuum, compressed air source, or other device. Baselayer 2G may be dried, cured, or cleaned while the floor panel is in an assembly line environment.
After cleaning the surface of the access floor panel, a clear coat 32 is applied. One suitable clear coat is sold by National Polymer, Pittsburgh, Pennsylvania.
Clear coat 32 may include a grit anti-slip additive as discussed above. The clear coat 32 can be applied and cured in the same manner as described above for clear coat 16 used on top of stain 12 in Figure 1. Preferably, clear coat 32 is subjected to temperatures of about 71 degrees Celsius by infrared light for 30 minutes.
Alternatively, the surface of the baselayer 2G can be coated with a stain 30 prior to application of clear coat 32. Stain 30 can be composed of the same materials as stain 12 in Figure 1. Stain 30 can be applied and cured in the same manner as described above for stain 12 in figure 1.
In yet another embodiment, as shown in Figure 2, an access floor panel 24 is finished by applying colored chips to a baselayer 2G while the floor panel 24 is conveyed along an assembly line. First, a metal pan is formed. Next, the metal pan is filled with concrete and allowed to cure. After the concrete is at least partially cured, the access floor panel 24 is placed on an assembly line where the floor panel 24 is conveyed to a surface preparation station. At the surface preparation station, the top surface of the concrete floor panel 24 is ground flat and scrubbed clean by machinery. Subsequently, the floor panel 24 is conveyed to a spraying cabinet, where mechanical sprayers apply a primer 22 to the top surface. Next, the floor panel 24 is conveyed proximate to infrared light emitters such that floor panel 24 is exposed to temperatures of about 71 degrees Celsius for 50 minutes.
Subsequently, the floor panel 24 is conveyed to another spraying cabinet where baselayer 26 is applied by mechanically operated sprayers positioned proximate to the top surface of the floor panel 24 on the assembly line. Subsequently, the floor panel 24 is conveyed to another cabinet where machinery broadcasts decorative materials 28 onto the baselayer 26. Next, the floor panel 24, with uncured baselayer 26 and embedded decorative materials 28, is conveyed under infrared light emitters so that each portion of the top surface is exposed to temperatures of about 71 degrees Celsius for SO minutes. Next, the floor panel 24 is conveyed to another cabinet where mechanically operated sprayers apply a clear coat 32, mixed with a grit anti-slip additive. Subsequently, the floor panel 24 is conveyed under infrared light emitters so that each portion of the top surface is exposed to temperatures of about 71 degrees Celsius for 30 minutes. Finally, the floor panel 24 is removed from the assembly line and packaged for shipping.
In yet another embodiment, as shown in Figure 1, an access floor panel 14 is finished by applying a stain 12 and a clear coat 16 while the access floor panel 14 is moved along an assembly line. First, a metal pan is formed. Next, the metal pan is filled with concrete and allowed to cure. After the concrete is at least partially cured, the access floor panel 14 is placed on an assembly line where access floor panel 14 is conveyed to a surface preparation station. At the surface preparation station, a top surface of the access floor panel 14 is ground flat and cleaned. Subsequently, the access floor panel 14 is conveyed to a spraying cabinet, where mechanical sprayers proximate to the top surface of access floor panel 52 apply a stain 12 to the top surface 52. Next, access floor panel 14 is conveyed proximate to infrared light emitters such that access floor panel 14 is subjected to temperatures of about 71 degrees Celsius for 12 to 15 seconds. Subsequently, access floor panel 14 is conveyed to another spraying cabinet where clear coat 16 along with a grit anti-slip additive is applied by mechanically operated sprayers positioned proximate the assembly line.
Subsequently, access floor panel 14 is conveyed under infrared light emitters so that each portion of the top surface is subjected to temperatures of about 71 degrees Celsius by infrared light for 30 to 90 seconds. Finally, access floor panel 14 is removed from the assembly line and packaged for shipping.
An access floor panel can also include a stained embossed surface, as shown in Figure 6. The baselayer 26 can be composed of various colors and designs, such as those shown in Figure 5 and 7, where a panel is shown as having a plurality of wavy shapes 48, a conch shell and a sand dollar. The color can be included within the baselayer 26 by using concrete colorants or colloidal dyes, such as those manufactured by the Richard James Specialty Chemical Corporation, Hastings-on-Hudson, New York. Finally, a plurality of panels can be made and assembled to form a collective design, as shown for example in Figure 8. The collective design can form a company's insignia, an advertisement, any other type of logo or symbol, or any other patterned design. Further, the collective design may form an aesthetically pleasing composite flooring system.
In some instances, it is desirable to leave an edge strip 50, as shown in Figures 4-8, of the metal forming an access floor panel free of finish materials, such as baselayer 26, primer 22, stains 12 and 30, or clear coats 16, 18, and 32. This may be desired for aesthetic reasons or for practical reasons such as the avoidance of damage during shipping.
Also, it is sometimes desirable to form holes 42, as shown in Figures 4-8, within the access floor panels to receive fasteners for securing the floor panels.
The present invention is further illustrated by the following examples, which are not to be construed in any way as imposing limitations upon the scope thereof. On the contrary, it is to be clearly understood that equivalents thereof which, after reading the description herein, may suggest themselves to those skilled in the art without departing from the spirit of the present invention and/or the scope of the appended claims.
EXAMPLES
Example 1 A finished floor panel with stain and clear coat treatments is created by first forming a metal pan. The metal pan is filled with concrete and is allowed to cure. A
drum grinder with industrial abrasives grinds a top surface of the concrete filled floor panel to make it flat, Lllllf01111, and smooth. The ground concrete top surface is scrubbed aggressively with a stiff bristled brush and is vacuumed clean. The concrete filled floor panel is conveyed to a spraying cabinet. Mechanically operated sprayers apply Mason's Select Flagstone Stain, sold by Duckback Products Inc., Chico, California, to the top surface. The concrete filled floor panel with wet stain is conveyed under banks of infrared lights so that each portion of the top surface is subjected temperatures of 71 degrees Celsius by infrared light for 15 seconds. The concrete filled floor panel is conveyed to another spraying cabinet where mechanically operated sprayers apply Mason's Select 6510 Clear Finish clear coat, sold by Duckback Products Iiic., Chico, California, to the top surface. The concrete filled floor panel with uncured clear coat is conveyed under banks of infrared lights so that each portion of the top surface is subjected to temperatures of 71 degrees Celsius by infrared light for 90 seconds.
Example 2 A finished floor panel with a clear coat treatment is created by first forming a metal pan. The metal pan is filled with concrete and is allowed to cure. A drum grinder with industrial abrasives grinds a top surface of the concrete filled floor panel to make it flat, uniform, and 511100th. The ground concrete top surface is scrubbed aggressively with a stiff bristled brush and is vacuumed clean. The concrete filled floor panel is conveyed to a spraying cabinet. Mechanically operated sprayers apply Mason's Select 6510 Clear Finish clear coat, sold by Duckback Products Inc., Chico, California, to the top surface. The concrete filled floor panel with uncured clear coat is conveyed under banks of infrared lights so that each portion of the top surface is subjected to temperatures of 71 degrees Celsius by infrared light for 90 seconds.
Example 3 A finished floor panel is created by first forming a metal pan. The metal pan is filled with concrete and is allowed to cure. A drum grinder with industrial abrasives grinds a top surface of the concrete filled floor panel to make it flat, uniform, and smooth. The ground concrete top surface is scrubbed aggressively with a stiff bristled brush and is vacuumed clean. The concrete filled floor panel is conveyed to a spraying cabinet.
Mechanically operated sprayers apply NP 015 primer, sold by National Polymer, Pittsburgh, Pennsylvania, to the top surface. The concrete filled floor panel with wet primer is conveyed under banks of infrared lights so that each portion of the top surface is subjected to temperatures of 71 degrees Celsius for 50 minutes. The concrete filled floor panel is conveyed to another spraying cabinet where mechanically operated sprayers apply NP 135 baselayer, sold by National Polymer, Pittsburgh, Pennsylvania, to the top surface. The concrete f lled floor panel is conveyed to an application cabinet where machinery broadcasts Torginol Vinyl Chips, sold by, Torginol, Inc., Sheboygan Falls, Wisconsin, over the uncured baselayer. The concrete filled floor panel with uncured baselayer and chips is conveyed under banks of infrared lights so that each portion of the top surface is subjected to temperatures of 71 degrees Celsius for 50 minutes. The concrete filled floor panel is conveyed to another spraying cabinet where mechanically operated sprayers apply NP 321 Clear Finish clear coat, sold by National Polymer, Pittsburgh, Pennsylvania, to the top surface. The concrete filled floor panel with uncured clear coat is conveyed under banks of infrared lights so that each portion of the top surface is subjected to temperatures of 71 degrees Celsius for 30 minutes.
Example 4 A finished floor panel with a clear coat treatment is created by first founing a metal pan. Uncured colored concrete is created by mixing Hydrotint, sold by Davis Colors, Los Angeles, California, concrete colorant with uncured concrete. The metal pan is filled with the colored concrete and is allowed to cure. A drum grinder with industrial abrasives grinds a top surface of the colored concrete filled floor panel to make it flat, uniform, and smooth.
The ground colored concrete top surface is scrubbed aggressively with a stiff bristled brush and is vacuumed clean. The colored concrete filled floor panel is conveyed to a spraying cabinet where mechanically operated sprayers apply NP 321 Clear Finish clear coat, sold by National Polymer, Pittsburgh, Pennsylvania, to the top surface. The concrete filled floor panel with uncured clear coat is conveyed under banks of infrared lights so that each portion of the top surface is subjected to temperatures of 71 degrees Celsius for 30 minutes.
While various embodiments of this invention have been described above, these descriptions are given for purposes of illustration and explanation.
Variations, changes, modifications and departures from the systems and methods disclosed above may be adopted without departure from the spirit and scope of this invention or the following claims.
FILLED ACCESS FLOOR PANELS
RELATED APPLICATIONS
This patent application claims priority to provisional patent application Serial No.
GO/381,250, filed on May 16, 2002, entitled "Surface Finishings For Concrete Filled Access Floor Panels," and provisional patent application Serial No. 60/341,014 filed October 29, 2001, entitled "Surface Treatment For Access Floor Panels," each of which is incorporated herein by reference.
This invention relates to finished top surfaces of access floor panels and methods for producing such surfaces.
BACKGROUND OF THE INVENTION
Access floors are typically used in data centers, rooms housing computer servers, and in other areas having devices requiring connection to external wires. Access floor panels are used to construct raised floors over sub-floors so that wires can be laid down and easily accessed between the sub-floor and the raised access flooring. Thus, access flooring provides a convenient location for cables. In some cases, HVAC air is also handled beneath the access floor panels.
Access floors are constructed of panels that are usually about 24 inches square and on the order of one to two inches thick. In one structure, the panels can be formed with an exterior sheet metal shell forming a cavity that can be filled with concrete.
The top surface of the concrete is prepared so that it is flush with the edges of the metal form. Typically, access floor panels are covered, either during manufacture or after installation, with carpet, carpet tiles, vinyl, high-pressure plastic laminate, ceramics, or stone.
Depending on the type of covering used, the covering may be changed or destroyed if the access flooring must be removed to perform maintenance on installed floor systems.
Access floor panel finishes applied prior to installation are disclosed in U.S. Patent No. 5,205,091 to Brown. However, Brown does not teach a method of applying finishing materials to top surfaces of floor panels to create durable finishes in a cost effective manner.
Consequently, a need exists for alternative methods of creating panel finishes, particularly including inexpensive and durable finishes capable of being quickly installed on panels during the manufacturing process in an assembly line environment.
SUMMARY OF THE INVENTION
This invention includes systems and methods for finishing a top surface o.f an access floor panel by applying at least one layer of material to the top surface. The top surface of the floor panel can be metal, concrete or other materials, but this invention is particularly well adapted for use on floor panels having a concrete top surface. The concrete top surface may be prepared before applying materials to the top surface. For instance, the top surface may be prepared by grinding the top surface to make it smooth and flat. After grinding, the top surface may be cleaned of loose materials by scrubbing or applying water at high pressure. Preparing the top surface facilitates binding of the material to the top surface and even application of the material to the top surface.
In one embodiment, a stain is applied to a prepared or a unprepared top surface of an access floor panel to give the top surface a colored appearance. The stain may be applied in various colors, may be applied separately to an entire surface or a portion of a floor panel, and may be used to form a pattern. Alternatively, the floor panel may be given a colored appearance by using colored concrete in the floor panel. Concrete is colored by adding a concrete colorant to uncured concrete prior to pouring the uncured concrete into a metal pan to form the colored concrete filled access floor panel.
The stain may dry or cure under ambient conditions in about 24 hours.
Alternatively, the stain may be subjected to infrared light to reduce the time required to cure the stain to about 15 seconds. Conventional drying processes other than infrared light may also be used, such as, but not limited to, chemical accelerators, ultraviolet light, or forced air with or without added heat. Once the stain has cured, a clear coat is applied to the surface of the stain. The clear coat seals and protects the stain. Alternatively, a grit anti-slip additive may be mixed with the clear coat to increase the slip resistance of the top surface of the floor panel. The clear coat may dry or cure under ambient conditions or through use of infrared light. In another embodiment, a clear coat, with or without grit anti-slip additive, is applied to the surface of an access floor panel without applying a stain.
In yet another embodiment, a finished surface is produced by applying a baselayer to a prepared or unprepared top surface of an access floor panel. Alternatively, a primer can be applied to the surface of the floor panel prior to applying the baselayer. The primer may be pigmented, but typically is not pigmented. The primer can dry under ambient conditions or through use of infrared light in the same manner described above. The baselayer can be composed of concrete, polymer concrete, epoxies, acrylics, or other polymeric material, such as a solvent based urethane or a water based urethane. Further, the baselayer can be composed of different colors and applied to form various designs. The baselayer can also be used to form a company's insignia or logo, an advertisement, other message, or any kind of patterned design. Alternatively, while the baselayer is still wet or uncured, a decorative material can be broadcast over the baselayer. The decorative material may be colored chips, or flakes, composed of ethylene vinyl acetate (EVA). Alternatively, a wide variety of other decorative materials can be used, including, for instance, fragments of glass, hardware, or seashells. The decorative materials may be applied in layers of different thickness to produce random patterns or calculated designs of one or more colors. The decorative materials may also be applied to form a pattern using stencils, masking sheets, masking tapes, screen printing, or other similar techniques. The baselayer, with or without applied decorative materials, may cure under ambient conditions, or with the assistance of infrared light, ultraviolet light, forced air with or without heat added, or other curing processes. After the baselayer has cured, decorative materials that did not attach to the baselayer are removed from the surface of the floor panel using a vacuum or other method. A clear coat, with or without grit anti-slip additive, may then be applied to the floor panel to protect the top surface. The clear coat may also be cured under ambient conditions or with infrared light.
In yet another embodiment, an access floor panel may be prepared and finished while the floor panel is on an assembly line. The surface of an access floor panel may be prepared by grinding, cleaning, sanding, sandblasting, water jet blasting, laser engraving, or any combination thereof. Surface treatments, such as stains, primers, baselayers, and clear coats (with or without grit anti-slip additives), may be applied to a prepared or unprepared surface of the floor panel by mechanically operated sprayers in spraying cabinets proximate to the floor panel on the assembly line. The mechanically operated sprayers may be movable in planes proximate to the top surface of the floor panel. Drying or curing processes, such as application of infrared light, ultraviolet light, chemical catalysts, heated forced air, and unheated forced air, may be performed on the surface treatments to decrease production time.
This invention permits production of access floor panels that can be supplied efficiently for use in a finished, ready-to-install condition, thereby eliminating the need to install a floor surface on the top surface of the panel after the panel has been installed.
Elimination of this step makes the installation process more efficient by decreasing the amount of time needed to install the panel and by reducing labor costs. The finishes that can be produced in accordance with this invention are also inexpensive, durable, attractive and easier to produce than other conventional finishes.
This invention is also advantageous because the coatings can be dried or cured using infrared light, or other drying processes, in a fraction of the time required to dry the same coatings under ambient conditions. Thus, production time for creating a finished floor surface for a single floor panel can be reduced from four days per floor panel in some situations to about one minute or less.
The finishing treatments of this invention can be easily applied on floor panels in an automated production line, thereby reducing the amount of labor required.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a cross-sectional schematic view of a portion of a concrete filled access floor panel having a prepared surface, a stain treatment, and a clear coat treatment.
Figure 2 is a cross-sectional schematic view of a portion of a concrete filled access floor panel having a prepared surface, a primer treatment, a baselayer treatment, a decorative material treatment, a stain treatment, and a clear coat treatment.
Figure 3 is a cross-sectional schematic view of a portion of a concrete filled access floor panel having a prepared surface and a clear coat treatment.
Figure 4 is a perspective view from above a plurality of concrete filled access floor panels that include a variety of designs formed by baselayers on their top surfaces in accordance with this invention.
Figure 5 is a perspective view from above a plurality of installed concrete filled access floor panels that include a variety of designs formed by baselayers on their top surfaces in accordance with this invention.
Figure 6 is a perspective view from above a concrete filled access floor panel having an uneven textured surface with two regions of different color sections that are formed by a baselayer.
Figure 7 is a perspective view from above a concrete filled access floor panel having a plurality of wavy shapes, a conch shell design, and a sand dollar design.
Figure 8 is a perspective view from above a plurality of concrete filled access floor panels having various colored baselayers forming part of an insignia of a company.
G
DETAILED DESCRIPTION OF THE DRAWINGS
The concrete filled access floor panel finishes of this invention include application of a colored material to a top surface of an access floor panel and application of a clear coat on top of the colored material for protection and increased durability.
Generally, the materials will be composed of polymeric compounds.
Some of these materials are intended for application to floors in place in buildings.
However, the circumstances of practice of this invention are typically significantly different from the circumstances present in application to floors in place in buildings.
For instance, among other differences, there are the following considerations:
First, adjacent portions of a floor in place in a building get similar finish applications as a result of their location, and a portion of an in situ floor on one side of a room is never relocated to be adjacent to another, remote portion of floor separately finished. By contrast, an access flooring panel manufactured at a particular time may be installed adjacent to other panels manufactured and finished in accordance with this invention at another widely separated time.
Second, floors finished in situ typically can be left undisturbed for at least several hours before there is any contact with the newly finished surface. By contrast, access flooring panels are typically manufactured on a production line requiring each manufacturing operation to be accomplished quickly. It is not practical or economically acceptable in a production line for panels to remain in a condition preventing their handling or contact with their top surfaces for an extended period of time.
In light of these manufacturing considerations, it is important for finishing techniques and materials to cure or dry quickly so that further manufacturing processes and panel handling can occur quickly after finish application. Accordingly, it is important for solvent-based finish systems and components to dry quickly, or for catalyzed or other systems to cure quickly. Some such rapidly curing systems employ mixing techniques that occur in or near a spray head, causing mixing to occur very close in time to application of the finish.
Another alternative is the use of finish materials for which curing time can be accelerated by exposure of the material to ultraviolet light. Yet another alternative is the use of infrared emitters that can dramatically reduce the drying or curing time of finishes, with associated reductions in production time and costs.
In one embodiment, as shown in Figure l, a stain 12 is applied directly to a top surface of an access floor panel 14. Stain 12 can be applied to a prepared surface or an unprepared surface. The surface can be prepared by grinding, cleaning, sanding, sandblasting, water jet blasting, laser engraving, or any combination thereof to provide a more aesthetically appealing surface or a surface having other desired characteristics such as flatness or texture. The surface can be composed of materials including, but not limited to, concrete, wood, or metal. However, access floor panel 14 preferably has a concrete surface.
Preferably, access floor panel 14 is ground flat prior to application of stain 12. Grinding exposes a concrete top surface 52 of the access floor panel 14 with a higher moisture content that an unground concrete top surface of the access floor panel 14. The increased moisture content of the top surface of the floor panel 52 assists stain 12, and other applied materials, to spread and adhere to the concrete surface. Stain 12, as well as other applied materials, is preferably selected from a group of aqueous based stains to take advantage of the increased moisture content of the top surface of access floor panel 52.
Stain 12 may be applied to access floor panel 14 using a brush, roller or sprayer. In addition, mechanically operated sprayers positioned in a spraying cabinet located proximate to an assembly line may apply stain 12 while the floor panel 14 is on the assembly line.
Stain 12 can be various colors or shades of color, and can include waterproofing and water resistant properties. Stain 12 can also be fowled using a single stain or mixture of stains having similar or different colors. At least one suitable stain is sold by Duckback Products, Inc., of Chico, California.
After application of stain 12 to the top surface of access floor panel 14, stain 12 is allowed to dry. Stain 12 can dry under ambient conditions, which typically takes about 24 hours. However, infrared light emitters may be used to accelerate the drying process. While applying infrared light to stain 12 for any amount of time reduces the total amount of time needed for stain 12 to dry, stain 12 is preferably subjected to temperatures of about 71 degrees Celsius by applying infrared light to stain 12 for about 15 seconds for optimal results. However, depending on the type and thickness of coating, and the intensity of the light source, the dry time could be within the range between about 1 second to about 15 minutes. Application of infrared light for about 15 seconds to stain 12 dries stain 12 sufficiently to receive a layer of material. Infrared light may be applied to stain 12 with any device. In one embodiment, infrared light is applied to stain 12 while access floor panel 14 is in an assembly line. An infrared light emitter is positioned proximate to a conveyor, and the rate by which the conveyor travels is such that any point on the top surface of access floor panel 14 is exposed to infrared light for about 15 seconds. This can be accomplished using numerous configurations because the position of the infrared light emitter may be dependent upon the speed of the conveyor belt and vice versa. Alternatively, ultraviolet light emitters, or heated or unheated air blowers, can be used to accelerate the drying or curing process.
Once stain 12 is dried, a clear coat 16 is applied to the surface of stain 12.
Clear coat 16 may be a water based urethane or epoxy, a solvent based urethane or epoxy, a water based acrylic sealant, or other materials. Clear coat 16 may be applied in gloss or matte finishes.
At least one suitable clear coat is sold by Duckback Products, Inc., of Chico, California.
Multiple coats of clear coat 16 may be applied to enhance the gloss and smoothness of the finish of clear coat 16. A grit anti-slip additive may be mixed with clear coat 16 to increase the f nish's slip resistance. At least one suitable grit anti-slip additive is sold by Behr Process, Corp., Santa Ana, California. Clear coat 16 can be applied by sprayers positioned in an assembly line in the same manner as described for stain 12. Clear coat 16 can cure in ambient conditions or clear coat 16 may be exposed to infrared light, or subjected to other drying processes, in the same manner as described for drying stain 12, to accelerate the curing process. Preferably, clear coat 16 is subjected to temperatures of about 71 degrees Celsius using infrared light for 30 to 90 seconds.
In another embodiment, as shown in Figure 3, a clear coat 18 is applied to a prepared or an unprepared surface of a concrete filled access floor panel 20 without applying a stain.
Alternatively, access floor panel 20 may be filled with a colored concrete.
Concrete is colored by including a concrete colorant, such as one sold by L.M. Scofield, Co., Los Angeles, California, in a concrete mixture, prior to forming the concrete filled access floor panel. The surface can be prepared in the same manner as described for access floor panel 14 in Figure 1. Clear coat 18 may have the same properties and characteristics and be applied in the same manner as clear coat 16 used on top of stain 12 in Figure 1. If concrete filled access floor panel 20 is filled with colored concrete, application of clear coat 18 enhances the colored appearance of the colored concrete. Clear coat 18 can dry in ambient conditions or clear coat 18 may be exposed to infrared light, or subjected to other drying processes, in the same manner as described for stain 12 in Figure 1, to accelerate the drying process.
In yet another embodiment of this invention, a plurality of materials are applied, as shown in Figure 2, to a top surface of an access floor panel 24. The top surface can be prepared in the same manner as described for access floor panel 14 in Figure 1.
A primer 22 may be applied to the top surface of the access floor panel 24 before application of a baselayer 26. The primer 22 is applied to ensure that baselayer 2G remains bonded to the top surface during use. The primer 22 can be a water or a solvent-based urethane, a water or solvent based acrylic, an epoxy, or other materials.
Preferably, primer 22 is composed of a water-based two-part epoxy. At least one suitable primer is sold by National Polymer, Pittsburgh, Pennsylvania. Primer 22 preferably does not contain 1 S pigments, but optimally may contain pigments in some embodiments. Primer 22 may be applied with a brush, roller, sprayer, spraying device, or any combination thereof, as described above. Primer 22 can be applied in an assembly line environment in the same manner as stain 12 in Figure 1. Primer 22 can be dried or cured at ambient conditions, with infrared emitters, or other drying processes, as previously described. Primer 22 is preferably exposed to temperatures of about 71 degrees Celsius using infrared light for at least 50 minutes.
Baselayer 2G is applied to the surface of access floor panel 24. Baselayer 26 can be composed of, but is not limited to, a concrete, a polymer-concrete, an epoxy, solvent based urethane, latex based urethane, or other polymeric material. At least one suitable baselayer is sold by National Polymer, Pittsburgh, Pennsylvania. Baselayer 26 can be formed in many colors. Baselayer 26 can be applied to the top surface by spraying, rolling, brushing or by squeezing the baselayer 26 through a stencil in a process somewhat similar to a silk screen process. The baselayer 26 can be applied in an assembly line environment in the same manner as stain 12 in Figure I .
Baselayer 26 may be covered with a variety of decorative materials 28 of any color.
In one embodiment, decorative materials 28 are composed of pigmented chips, or flakes.
The chips or flakes may be composed of numerous materials such as, but not limited to, plastics, resins such as ethylene vinyl acetate (EVA) resin, and other materials. One suitable chip is sold by Torginol, lnc. of Sheboygan Falls, Wisconsin. The chips can all be the same color or a mixture of two or more colors. In one embodiment, the chips are applied as a mixture of two or three different colored chips to a white baselayer. The chips are applied during the manufacturing process and are preferably applied while baselayer 26 is in an 1 S uncured condition. The chips may be applied while the floor panel is on an assembly line.
Insolvable chips are held in place by baselayer 26 and do not change shape or appearance during the drying process. In contrast, solvable chips may be partially dissolved by baselayer 26, which may cause the chips to appear as if they have been melted.
In yet another embodiment, baselayer 26 can be covered with decorative materials such as pebbles 44, hardware 4G, or glass 40, as shown in Figure 4. The glass 40 can include, but is not limited to, stained glass, recycled glass, or newly formed glass. The hardware 46 can include nails, fasteners, clamps, rings, and the like. These materials may be applied while the floor panel is on an assembly line. These materials can be ground during post-application processing to leave a uniform, flat surface.
Baselayer 2G, with or without decorative materials 28, is dried or cured under ambient conditions, with infrared light, or with other drying processes. Baselayer 2G
is preferably exposed to temperatures of about 71 degrees Celsius using infrared light for 50 minutes. The exposed surface of the raised access floor is then cleaned of any decorative materials 28 not attached to baselayer 2G. The exposed surface can be cleaned using a brush, vacuum, compressed air source, or other device. Baselayer 2G may be dried, cured, or cleaned while the floor panel is in an assembly line environment.
After cleaning the surface of the access floor panel, a clear coat 32 is applied. One suitable clear coat is sold by National Polymer, Pittsburgh, Pennsylvania.
Clear coat 32 may include a grit anti-slip additive as discussed above. The clear coat 32 can be applied and cured in the same manner as described above for clear coat 16 used on top of stain 12 in Figure 1. Preferably, clear coat 32 is subjected to temperatures of about 71 degrees Celsius by infrared light for 30 minutes.
Alternatively, the surface of the baselayer 2G can be coated with a stain 30 prior to application of clear coat 32. Stain 30 can be composed of the same materials as stain 12 in Figure 1. Stain 30 can be applied and cured in the same manner as described above for stain 12 in figure 1.
In yet another embodiment, as shown in Figure 2, an access floor panel 24 is finished by applying colored chips to a baselayer 2G while the floor panel 24 is conveyed along an assembly line. First, a metal pan is formed. Next, the metal pan is filled with concrete and allowed to cure. After the concrete is at least partially cured, the access floor panel 24 is placed on an assembly line where the floor panel 24 is conveyed to a surface preparation station. At the surface preparation station, the top surface of the concrete floor panel 24 is ground flat and scrubbed clean by machinery. Subsequently, the floor panel 24 is conveyed to a spraying cabinet, where mechanical sprayers apply a primer 22 to the top surface. Next, the floor panel 24 is conveyed proximate to infrared light emitters such that floor panel 24 is exposed to temperatures of about 71 degrees Celsius for 50 minutes.
Subsequently, the floor panel 24 is conveyed to another spraying cabinet where baselayer 26 is applied by mechanically operated sprayers positioned proximate to the top surface of the floor panel 24 on the assembly line. Subsequently, the floor panel 24 is conveyed to another cabinet where machinery broadcasts decorative materials 28 onto the baselayer 26. Next, the floor panel 24, with uncured baselayer 26 and embedded decorative materials 28, is conveyed under infrared light emitters so that each portion of the top surface is exposed to temperatures of about 71 degrees Celsius for SO minutes. Next, the floor panel 24 is conveyed to another cabinet where mechanically operated sprayers apply a clear coat 32, mixed with a grit anti-slip additive. Subsequently, the floor panel 24 is conveyed under infrared light emitters so that each portion of the top surface is exposed to temperatures of about 71 degrees Celsius for 30 minutes. Finally, the floor panel 24 is removed from the assembly line and packaged for shipping.
In yet another embodiment, as shown in Figure 1, an access floor panel 14 is finished by applying a stain 12 and a clear coat 16 while the access floor panel 14 is moved along an assembly line. First, a metal pan is formed. Next, the metal pan is filled with concrete and allowed to cure. After the concrete is at least partially cured, the access floor panel 14 is placed on an assembly line where access floor panel 14 is conveyed to a surface preparation station. At the surface preparation station, a top surface of the access floor panel 14 is ground flat and cleaned. Subsequently, the access floor panel 14 is conveyed to a spraying cabinet, where mechanical sprayers proximate to the top surface of access floor panel 52 apply a stain 12 to the top surface 52. Next, access floor panel 14 is conveyed proximate to infrared light emitters such that access floor panel 14 is subjected to temperatures of about 71 degrees Celsius for 12 to 15 seconds. Subsequently, access floor panel 14 is conveyed to another spraying cabinet where clear coat 16 along with a grit anti-slip additive is applied by mechanically operated sprayers positioned proximate the assembly line.
Subsequently, access floor panel 14 is conveyed under infrared light emitters so that each portion of the top surface is subjected to temperatures of about 71 degrees Celsius by infrared light for 30 to 90 seconds. Finally, access floor panel 14 is removed from the assembly line and packaged for shipping.
An access floor panel can also include a stained embossed surface, as shown in Figure 6. The baselayer 26 can be composed of various colors and designs, such as those shown in Figure 5 and 7, where a panel is shown as having a plurality of wavy shapes 48, a conch shell and a sand dollar. The color can be included within the baselayer 26 by using concrete colorants or colloidal dyes, such as those manufactured by the Richard James Specialty Chemical Corporation, Hastings-on-Hudson, New York. Finally, a plurality of panels can be made and assembled to form a collective design, as shown for example in Figure 8. The collective design can form a company's insignia, an advertisement, any other type of logo or symbol, or any other patterned design. Further, the collective design may form an aesthetically pleasing composite flooring system.
In some instances, it is desirable to leave an edge strip 50, as shown in Figures 4-8, of the metal forming an access floor panel free of finish materials, such as baselayer 26, primer 22, stains 12 and 30, or clear coats 16, 18, and 32. This may be desired for aesthetic reasons or for practical reasons such as the avoidance of damage during shipping.
Also, it is sometimes desirable to form holes 42, as shown in Figures 4-8, within the access floor panels to receive fasteners for securing the floor panels.
The present invention is further illustrated by the following examples, which are not to be construed in any way as imposing limitations upon the scope thereof. On the contrary, it is to be clearly understood that equivalents thereof which, after reading the description herein, may suggest themselves to those skilled in the art without departing from the spirit of the present invention and/or the scope of the appended claims.
EXAMPLES
Example 1 A finished floor panel with stain and clear coat treatments is created by first forming a metal pan. The metal pan is filled with concrete and is allowed to cure. A
drum grinder with industrial abrasives grinds a top surface of the concrete filled floor panel to make it flat, Lllllf01111, and smooth. The ground concrete top surface is scrubbed aggressively with a stiff bristled brush and is vacuumed clean. The concrete filled floor panel is conveyed to a spraying cabinet. Mechanically operated sprayers apply Mason's Select Flagstone Stain, sold by Duckback Products Inc., Chico, California, to the top surface. The concrete filled floor panel with wet stain is conveyed under banks of infrared lights so that each portion of the top surface is subjected temperatures of 71 degrees Celsius by infrared light for 15 seconds. The concrete filled floor panel is conveyed to another spraying cabinet where mechanically operated sprayers apply Mason's Select 6510 Clear Finish clear coat, sold by Duckback Products Iiic., Chico, California, to the top surface. The concrete filled floor panel with uncured clear coat is conveyed under banks of infrared lights so that each portion of the top surface is subjected to temperatures of 71 degrees Celsius by infrared light for 90 seconds.
Example 2 A finished floor panel with a clear coat treatment is created by first forming a metal pan. The metal pan is filled with concrete and is allowed to cure. A drum grinder with industrial abrasives grinds a top surface of the concrete filled floor panel to make it flat, uniform, and 511100th. The ground concrete top surface is scrubbed aggressively with a stiff bristled brush and is vacuumed clean. The concrete filled floor panel is conveyed to a spraying cabinet. Mechanically operated sprayers apply Mason's Select 6510 Clear Finish clear coat, sold by Duckback Products Inc., Chico, California, to the top surface. The concrete filled floor panel with uncured clear coat is conveyed under banks of infrared lights so that each portion of the top surface is subjected to temperatures of 71 degrees Celsius by infrared light for 90 seconds.
Example 3 A finished floor panel is created by first forming a metal pan. The metal pan is filled with concrete and is allowed to cure. A drum grinder with industrial abrasives grinds a top surface of the concrete filled floor panel to make it flat, uniform, and smooth. The ground concrete top surface is scrubbed aggressively with a stiff bristled brush and is vacuumed clean. The concrete filled floor panel is conveyed to a spraying cabinet.
Mechanically operated sprayers apply NP 015 primer, sold by National Polymer, Pittsburgh, Pennsylvania, to the top surface. The concrete filled floor panel with wet primer is conveyed under banks of infrared lights so that each portion of the top surface is subjected to temperatures of 71 degrees Celsius for 50 minutes. The concrete filled floor panel is conveyed to another spraying cabinet where mechanically operated sprayers apply NP 135 baselayer, sold by National Polymer, Pittsburgh, Pennsylvania, to the top surface. The concrete f lled floor panel is conveyed to an application cabinet where machinery broadcasts Torginol Vinyl Chips, sold by, Torginol, Inc., Sheboygan Falls, Wisconsin, over the uncured baselayer. The concrete filled floor panel with uncured baselayer and chips is conveyed under banks of infrared lights so that each portion of the top surface is subjected to temperatures of 71 degrees Celsius for 50 minutes. The concrete filled floor panel is conveyed to another spraying cabinet where mechanically operated sprayers apply NP 321 Clear Finish clear coat, sold by National Polymer, Pittsburgh, Pennsylvania, to the top surface. The concrete filled floor panel with uncured clear coat is conveyed under banks of infrared lights so that each portion of the top surface is subjected to temperatures of 71 degrees Celsius for 30 minutes.
Example 4 A finished floor panel with a clear coat treatment is created by first founing a metal pan. Uncured colored concrete is created by mixing Hydrotint, sold by Davis Colors, Los Angeles, California, concrete colorant with uncured concrete. The metal pan is filled with the colored concrete and is allowed to cure. A drum grinder with industrial abrasives grinds a top surface of the colored concrete filled floor panel to make it flat, uniform, and smooth.
The ground colored concrete top surface is scrubbed aggressively with a stiff bristled brush and is vacuumed clean. The colored concrete filled floor panel is conveyed to a spraying cabinet where mechanically operated sprayers apply NP 321 Clear Finish clear coat, sold by National Polymer, Pittsburgh, Pennsylvania, to the top surface. The concrete filled floor panel with uncured clear coat is conveyed under banks of infrared lights so that each portion of the top surface is subjected to temperatures of 71 degrees Celsius for 30 minutes.
While various embodiments of this invention have been described above, these descriptions are given for purposes of illustration and explanation.
Variations, changes, modifications and departures from the systems and methods disclosed above may be adopted without departure from the spirit and scope of this invention or the following claims.
Claims (31)
1. A method for creating a finished surface on a concrete filled access floor panel having a top surface, comprising: (a) applying at least one layer of material to the top surface; and (b) transferring energy to the at least one layer of material to accelerate curing or drying.
2. The method for creating a finished surface on a concrete filled access floor panel of claim 1, wherein transferring energy to the at least one layer of material comprises subjecting the at least one layer to infrared light.
3. The method for creating a finished surface on a concrete filled access floor panel of claim 2, wherein the at least one layer of material is subjected to infrared light for between 1 second and 50 minutes.
4. The method for creating a finished surface on a concrete filled access floor panel of claim 2, wherein subjecting the at least one layer to infrared light occurs while the panel is on a conveyor system.
5. The method for creating a finished surface on a concrete filled access floor panel of claim 1, wherein the energy transfer process comprises subjecting the at least one layer to ultraviolet light.
6. The method for creating a finished surface on a concrete filled access floor panel of claim 1, wherein the energy transfer process comprises subjecting the at least one layer to forced air.
7. The method for creating a finished surface on a concrete filled access floor panel of claim 1, wherein the at least one layer of material comprises at least one layer of a polymer material.
8. A method for creating a finished surface on a concrete filled access floor panel having a top surface, comprising: (a) applying at least one stain treatment to the top surface; and (b) subjecting the at least one stain treatment to infrared light.
9. The method for creating a finished surface on a concrete filled access floor panel of claim 8, further comprising applying at least one clear coat treatment to the top surface after subjecting the at least one stain treatment to infrared light.
10. The method for creating a finished surface on a concrete filled access floor panel of claim 9, wherein the at least one clear coat treatment comprises: (a) a clear coat; and (b) a grit anti-slip agent.
11. A method for finishing a concrete filled access floor panel having a top surface, comprising: (a) applying a primer to the top surface; (b) applying a baselayer treatment onto the primer; (c) subjecting the floor panel, primer, and baselayer to infrared light; and (d) applying a clear coat onto the baselayer.
12. The method for finishing a concrete filled access floor panel of claim 11, wherein steps (a), (b), (c), and (d) are performed while the floor panel is on a conveyor.
13. The method for finishing a concrete filled access floor panel of claim 11, wherein applying a baselayer treatment comprises: applying a baselayer; and (b) broadcasting decorative materials onto the baselayer.
14. A method for creating a finished top surface on a concrete filled access floor panel having a top surface, wherein at least one surface finishing technique is applied to the top surface in at least one finish-applying station to which and from which floor panels are conveyed by a conveyor system.
15. The method for creating a finished top surface on a concrete filled access floor panel of claim 14, wherein the at least one surface finishing technique comprises: (a) preparing the top surface; (b) applying a stain to the prepared top surface; (c) transferring energy to the stain to accelerate curing or drying; and (d) applying a clear coat to the top surface.
16. The method for creating a finished top surface of a concrete filled access floor panel of claim 14, wherein the at least one surface finishing technique comprises: (a) applying a primer to the top surface; (b) applying a baselayer onto the primer; (c) transferring energy to the baselayer to accelerate curing or drying; and (d) applying a clear coat onto the baselayer.
17. The method for creating a finished top surface of a concrete filled access floor panel of claim 14, wherein the at least one surface finishing technique comprises: (a) applying a plurality of materials to the top surface; and (b) transferring energy to at least one of the materials to accelerate curing or drying
18. The method for creating a finished top surface of a concrete filled access floor panel of claim 17, wherein the plurality of materials further comprise a plurality of polymer materials.
19. The method for creating a finished top surface of a concrete filled access floor panel of claim 17, wherein transferring energy to at least one of the materials comprises subjecting the at least one of the materials to infrared light.
20. A method for creating a finished top surface on an access floor panel in an assembly line environment, comprising: (a) positioning the floor panel on an assembly line;
(b) conveying the floor panel to an application station; (c) subjecting a top surface of the floor panel to a first finishing technique; (d) conveying the floor panel to an energy transfer station; and (d) subjecting the top surface to an energy transfer technique
(b) conveying the floor panel to an application station; (c) subjecting a top surface of the floor panel to a first finishing technique; (d) conveying the floor panel to an energy transfer station; and (d) subjecting the top surface to an energy transfer technique
21. The method for creating a finished top surface on an access floor panel in an assembly line environment of claim 20, wherein the application station comprises at least one mechanical stain sprayer and the first finishing technique comprises applying stain to the top surface.
22. The method for creating a finished top surface on an access floor panel in an assembly line environment of claim 20, wherein the energy transfer station comprises at least one infrared light emitter and the energy transfer technique comprises subjecting the top surface to infrared light.
23. The method for creating a finished top surface on an access floor panel in an assembly line environment of claim 21, wherein the at least one mechanical stain sprayer comprises:
(a) a first mechanical sprayer movable along a first line; and (b) a second mechanical sprayer movable along a second line that is substantially perpendicular to the first line.
(a) a first mechanical sprayer movable along a first line; and (b) a second mechanical sprayer movable along a second line that is substantially perpendicular to the first line.
24. A method for creating a finished top surface on a concrete filled access floor panel, comprising: (a) preparing a top surface on the concrete filled floor panel;
and (b) applying at least one finishing material to the top surface.
and (b) applying at least one finishing material to the top surface.
25. The method for creating a finished top surface on a concrete filled access floor panel of claim 24, wherein preparing the top surface on the concrete filled floor panel comprises grinding and cleaning the top surface.
26. A method for creating an access floor panel having a finished top surface, comprising:
(a) forming a metal pan; (b) mixing concrete colorants with uncured concrete to create uncured colored concrete; (c) pouring the uncured colored concrete into the metal pan; (d) allowing the uncured colored concrete to cure; (e) applying a clear coat to a top surface of the floor panel; and (d) subjecting the top surface to an energy transfer technique.
(a) forming a metal pan; (b) mixing concrete colorants with uncured concrete to create uncured colored concrete; (c) pouring the uncured colored concrete into the metal pan; (d) allowing the uncured colored concrete to cure; (e) applying a clear coat to a top surface of the floor panel; and (d) subjecting the top surface to an energy transfer technique.
27. The method for creating an access floor panel having a finished top surface of claim 26, wherein the top surface is ground flat prior to applying the clear coat.
28. The method for creating an access floor panel having a finished top surface of claim 26, wherein the energy transfer technique comprises subjecting the top surface to infrared light
29. A method for creating a finished concrete access floor panel having a top surface, comprising: (a) grinding the top surface to create a smooth top surface; and (b) applying an aqueous based surface treatment to the smooth top surface.
30. The method for creating a finished concrete access floor panel having a top surface of claim 29, further comprising: (c) subjecting the aqueous based surface treatment to infrared light; (d) applying a clear coat treatment onto the aqueous based surface treatment; and (e) subjecting the clear coat treatment to infrared light.
31. A method for creating a finished top surface on an access floor panel filled with colored concrete, comprising: (a) grinding a top surface of the access floor panel flat; and (b) applying a sealant treatment to the top surface.
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US34101401P | 2001-10-29 | 2001-10-29 | |
| US60/341,014 | 2001-10-29 | ||
| US38125002P | 2002-05-16 | 2002-05-16 | |
| US60/381,250 | 2002-05-16 | ||
| PCT/US2002/036423 WO2003037584A2 (en) | 2001-10-29 | 2002-10-29 | Methods for finishing top surfaces of concrete filled access floor panels |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2465213A1 true CA2465213A1 (en) | 2003-05-08 |
Family
ID=26992340
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002465213A Abandoned CA2465213A1 (en) | 2001-10-29 | 2002-10-29 | Methods for finishing top surfaces of concrete filled access floor panels |
Country Status (4)
| Country | Link |
|---|---|
| EP (1) | EP1448346A2 (en) |
| AU (1) | AU2002356940A1 (en) |
| CA (1) | CA2465213A1 (en) |
| WO (1) | WO2003037584A2 (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2926742B1 (en) * | 2008-01-24 | 2012-12-28 | Milene Guermont | METHODS OF MAKING AND DECORATING CONCRETE STRUCTURES |
| ES2354316B1 (en) * | 2008-06-16 | 2012-01-31 | Eduardo Martinez Muñoz | PREPARATION PROCEDURE FOR A ESCAYOLA PLATE OR EQUIVALENT WITH INSULATING, IGNIFUGAL AND WATERPROOF PROPERTIES SUBSTANTIALLY IMPROVED. |
| IT1400183B1 (en) * | 2009-03-19 | 2013-05-17 | Cipriani | METHOD FOR THE REALIZATION OF A DECORATIVE ELEMENT WITH A STONE APPEARANCE |
| ES2367500B1 (en) * | 2009-09-08 | 2012-09-04 | Inés María Cansado Trigo | DECORATIVE PIECE AND PROCEDURE FOR OBTAINING THE SAME. |
| DE102012111049B4 (en) * | 2012-11-16 | 2017-10-19 | Erwin Niedermeier | Raised floor element and method for applying an edge protection |
| ITPN20130029A1 (en) * | 2013-06-06 | 2014-12-07 | Silvano Ros | PROCESS FOR REALIZATION OF FURNISHING ELEMENTS |
| US10844595B2 (en) * | 2017-06-30 | 2020-11-24 | United States Gypsum Company | Exterior cementitious panel with multi-layer air/water barrier membrane assembly and system and method for manufacturing same |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB792334A (en) * | 1956-01-13 | 1958-03-26 | Burns & Russell Co | Masonry block having integral molded facing layer and method of providing the same |
| DE3643074A1 (en) * | 1986-10-04 | 1988-04-14 | Peter Volk | Process for producing construction elements and construction element produced according to the process |
| US5059471A (en) * | 1989-02-13 | 1991-10-22 | Tarkett Ab | Inlaid tile |
-
2002
- 2002-10-29 AU AU2002356940A patent/AU2002356940A1/en not_active Abandoned
- 2002-10-29 EP EP02802530A patent/EP1448346A2/en not_active Withdrawn
- 2002-10-29 WO PCT/US2002/036423 patent/WO2003037584A2/en not_active Application Discontinuation
- 2002-10-29 CA CA002465213A patent/CA2465213A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| WO2003037584A2 (en) | 2003-05-08 |
| EP1448346A2 (en) | 2004-08-25 |
| WO2003037584A3 (en) | 2004-02-26 |
| AU2002356940A1 (en) | 2003-05-12 |
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