EP0451619A1 - Method of manufacturing a composite polygonal panel for floors, panel made according to this method and a floor made from such panels - Google Patents

Abstract

In the manufacture of a composite polygonal panel (1) for floors, first of all a flat blank is produced from a laminated sheet, which comprises a tension-resistant rigid component (9) and a flexible component (10). The flexible component forms a foldable outer layer. This blank is provided within the rigid component at the points of the intended edges (11, 12) of the composite panel with in each case straight V-shaped notches, which have an included angle of about 90 DEG , delimit a base area (3) and several wall areas (4, 5) from one another and extend from the side facing away from the foldable outer layer. The vortex of the notches lies in the direct proximity of the uninterrupted foldable outer layer. Thereafter, the wall elements (4, 5) are folded up around the vortex lines to form a tray (2), which is filled with a curable casting compound (14). <IMAGE>

Description

The invention relates to a method for producing a polygonal composite panel for floors, in particular for floors arranged on supports, by filling a tub which is made of a tensile strength and which is arranged in the tension area of the panel and is made of rigid material and has a curable casting compound.

Composite panels of this type are used in large quantities for floors, under which there is a cavity in which lines of all types are laid. The individual slabs, which are also referred to as "raised slabs", are laid in a regular grid dimension, the slabs being to be laid close to one another and the slabs also having to be secured against transverse displacement.

A main area of application for such panels is flooring in offices, in particular those in which data processing devices are located. The various office facilities require a large number of lines which are "hidden" under the raised floor panels and can be led out through the floor directly under the connection point. However, other supply lines can also be laid in the cavities, likewise so-called underfloor heating.

Such panels have to meet a whole range of requirements: they have to be insensitive to impact and shock, punctiform and rolling heavy loads and to a high degree also resistant to high temperatures, with fire protection being the primary consideration here. The panels must also be covered with a floor covering, be it with an appropriate plastic panel or with panels that form a so-called carpet.

DE-AS 23 07 815 discloses a method of the type specified at the outset and a floor slab produced by the method: in a profiled trough referred to as formwork, which can consist of metal as well as plastic or a mineral or fiber material, a curable, originally mushy or viscous, preferably mineral mass is poured in and smoothed out.

As far as the tub or bowl is made of metal, it has the disadvantage of undesirable good heat conduction and a different coefficient of expansion compared to the filled and hardened mineral mass. Furthermore, the complicated shape of the shell base with a concave curvature and cross-shaped depressions makes it necessary for the shell to be deep-drawn. This requires expensive deep-drawing tools, as does the manufacture and storage of different deep-drawing tools for different plate sizes.

Insofar as the shell is made of plastic, mineral or fiber material, this also makes a mold, at least one casting mold or compression mold necessary, because the specified bonding of individual parts would be an extraordinarily labor-intensive process with the complicated shape, which is already eliminated from practical considerations .

The mentioned "bending of the edges" is only possible under certain conditions, namely, if the floor area has already been profiled by a molding process and the shell is either made of a flexible metal or is still in a plastically deformable state, which is possible for plastics by choosing appropriate processing temperatures, but only as long as this is possible for mineral substances Shell material is still in a malleable condition.

The invention is therefore based on the object of specifying a method of the type described at the outset, which can be used in mass production, is based on simple to manufacture preliminary products and, even in the case of the production of such plates in different dimensions, does not require the storage of different molding tools for the shell or Tub required. In addition, the composite panel is said to be considerably heat-resistant.

• a) zur Herstellung der Wanne eine ebene Platte aus einer zugfesten biegesteifen nichtmetallischen Komponente und aus einer eine faltbare Außenschicht bildenden flexiblen Komponente verwendet,
• b) aus dieser Platte einen Zuschnitt nach Maßgabe der Abwicklung der Wanne herstellt,
• c) diesen Zuschnitt innerhalb der biegesteifen Komponente an den Stellen der vorgesehenen Kanten der Platte mit jeweils geradlinigen V-förmigen Einkerbungen mit einem Öffnungswinkel von etwa 90 Grad versieht, die einen Bodenbereich und mehrere Wandbereiche voneinander abgrenzen, von der der faltbaren Außenschicht abgekehrten Seite ausgehen und deren Scheitel in unmittelbarer Nähe der ununterbrochenen faltbaren Außenschicht liegt,
• d) die durch die Einkerbungen begrenzten Wandelemente um die Scheitellinien herum zu einer Wanne auffaltet und die Wanne in aufgefaltetem Zustand festlegt und
• e) die Wanne mit der Gußmasse ausfüllt und die Gußmasse aushärten läßt.

The object is achieved in the method described above according to the invention in that

• a) a flat plate made of a tensile, rigid, non-metallic component and of a flexible component forming a foldable outer layer is used to manufacture the tub,
• b) produces a cut from this plate in accordance with the processing of the tub,
• c) this blank within the rigid component at the locations of the intended edges of the Provides a plate with straight V-shaped notches with an opening angle of approximately 90 degrees, which delimit a floor area and several wall areas from each other, from which the foldable outer layer faces and whose apex is in the immediate vicinity of the continuous foldable outer layer,
• d) unfolds the wall elements delimited by the notches around the apex lines into a tub and fixes the tub in the unfolded state and
• e) fills the tub with the casting compound and allows the casting compound to harden.

The flat plate according to feature a) is a preliminary product which, apart from the thickness and at least two layers, is not subject to any dimensioning regulations. The tensile rigid component can consist of one of the numerous known curable mineral materials, such as gypsum, concrete, anhydrite and the like. The tensile strength of such mineral materials can be achieved by fibrous or textile fillers, for example by glass or other mineral fibers, metal fibers etc. With concessions to heat resistance, organic fibers or fabric inserts can also be used. Laminates made of non-woven fabrics and fabric webs with mineral binders and chipboards with organic and inorganic binders such as cement and gypsum bindings can also be used. The thickness should be at least 4 mm.

As a flexible, foldable component, thin, soft metal foils are preferably used, for example aluminum foils, which not only have high corrosion resistance, but can also be folded with sharp edges without the risk of breakage. For example, it is possible to combine the plate-shaped mineral component with a self-adhesive sheet made of aluminum foil. However, the foldable component can also consist of a plastic film with and without glass fleece reinforcement, and of coated glass and textile fabric.

Both the production of the blank according to feature b) and the notching of this blank according to feature c) is possible on computer-controlled sawing and milling machines, the spatial position of the notches or folding lines and thus the machining path of the tool provided for this purpose being programmable.

In this way it is possible to produce a practically unlimited number of blank sizes and thus also of composite panels without the need to stock special tools. The blanks can be stacked in an extremely space-saving manner until they are called up for further processing.

The statement that the opening angle of the V-shaped notches is "approximately 90 degrees" is intended to express that, for example, the side walls of the tub need not be at an angle of 90 degrees to the floor area. In the case of composite panels of this type, it is common for the outer surfaces of the side walls to be under to arrange an angle between about 2 and 5 degrees to the normal direction on the composite plate delimited by plane-parallel surfaces. It goes without saying that the angle of the notches takes this special feature into account.

The unfolding of the individual wall elements according to feature d) is also an extremely simple measure to take, because the foldable, flexible outer layer forms the hinges for the unfolding process. In particular, it is not necessary to hold the individual wall elements, which are connected to the floor area via the foldable outer layer, in a certain spatial position until any adhesive or the like that has set has set.

The composite panel produced according to the invention is at least flame retardant and has an advantageous poor thermal conductivity. In particular, the heat conduction observed when using metal troughs does not take place from the underside of the plate to the top of the plate, on which there may be a less heat-resistant material.

The "rigid, non-metallic component" for the manufacture of the tub need not be a purely mineral component. It has already been stated above that organic fillers and binders can also be used. However, gypsum fiberboard, cement-bound or gypsum-bonded particle board or similar material are preferred.

When using a metal foil for the foldable and flexible outer layer there is the further advantage that in this way electrostatic charges can be dissipated from the top of the plate to the underside of the plate.

With regard to the filling material for filling the cavity of the tub, there is also the possibility of embedding reinforcing inserts, for example rods, grids, expanded metal, honeycomb structures, non-woven fabrics, fabrics or the like. As a result, the load-bearing capacity of such panels can be influenced in a targeted manner.

• a) die Platte auf jeder Seite ihres Umfangs mit zwei auffaltbaren Wandelementen versieht, von denen die zwischen dem Bodenbereich und den äußersten Wandelementen liegenden inneren Wandelemente an ihren Langseiten jeweils von parallelen Einkerbungen begrenzt sind, die für alle inneren Wandelemente gleichen Abstand voneinander haben, und daß man
• b) die inneren und die äußeren Wandelemente, bezogen auf den vertikalen Querschnitt der fertigen Wanne, auf jeder Seite des Umfangs zweimal um etwa 90 Grad auffaltet, so daß der Bodenbereich und die äußeren Wandelemente parallel zueinander verlaufen, wobei die nach innen gerichteten Endkanten der äußeren Wandelemente eine polygonale Öffnung begrenzen.

It is particularly advantageous to proceed in such a way that

• a) provides the plate on each side of its circumference with two foldable wall elements, of which the inner wall elements lying between the floor area and the outermost wall elements are each delimited on their long sides by parallel notches which have the same distance from one another for all inner wall elements, and that one
• b) the inner and outer wall elements, based on the vertical cross section of the finished tub, unfolded twice on each side of the circumference by about 90 degrees, so that the bottom region and the outer wall elements run parallel to one another, the inward end edges of the outer Wall elements limit a polygonal opening.

Such a method is the subject of the exemplary embodiment explained in more detail below.

It is furthermore advantageous if the rigid non-metallic component of the plate is provided with openings before it is combined with the flexible component, which openings are closed again on the outside by the combination with the flexible component. In this way, a toothing or claw, which is extremely resistant to shear forces, is created between the trough and the cast material filled into it. The casting mass penetrates into the said openings, it being possible for ventilation of the cavities to be ensured by means of an optionally provided perforation. By subsequently re-closing the openings with the flexible component, e.g. with the aluminum foil, it is prevented that the casting compound emerges through said openings and, if necessary, must be smoothed out again.

The production of the composite panel according to the invention can be carried out in a manufacturing plant, whereupon the finished composite panels are then transported to a construction site and laid there.

However, it is particularly advantageously possible to transport the preform of the tub to the construction site in a flat but foldable state, to form the tub there by unfolding and to lay out a large number of still unfilled tubs on a floor, preferably with the interposition of height-adjustable support elements, if necessary, to bring the tubs to an even height and then the cavities of all Fill the tubs in situ with the casting compound and allow the casting compound to harden.

In such a case, the composite panels can also be taken up again individually. It is particularly expedient to provide the trays with the necessary support elements before the installation, which are preferably height-adjustable. In the latter case, the height adjustment is expediently carried out through the tub cavity.

It goes without saying that when the tubs are filled at the construction site or when these tubs are laid over a cavity, the underside and the side walls of the tubs are not provided with openings in order to prevent the casting compound from flowing out. Instead, the outer wall elements are expediently provided with particularly large openings in order to achieve as complete a filling of the tubs as possible.

You can also create a continuous floor from either prefabricated or in-situ manufactured composite panels, namely if you apply a screed that is continuous across all composite panels to the composite panels filled with the casting compound.

Filling the tubs "in situ" has the additional advantage that the preliminary products of the tubs have a relatively low weight, so that they are easier to transport and to lay.

The invention also relates to a polygonal composite panel for floors, in particular for floors arranged on supports, consisting of a tension-proof trough arranged in the tension area of the panel with a filling of a hardened cast material, the trough consisting of a floor area and wall elements forming a frame.

• a) die Wanne aus einem Verbundwerkstoff besteht, der durch ein Laminat aus mindestens einer zugfesten biegesteifen, nichtmetallischen Komponente und mindestens einer außenliegenden faltbaren Komponente gebildet ist,
• b) die Wandelemente um in der faltbaren Komponente liegende lineare Biegekanten mindestens einmal um etwa 90 Grad (± 10 Grad) zur Zarge aufgestellt sind, und
• c) die Wandelemente mit dem Gußwerkstoff verbunden sind.

To solve essentially the same problem, such a polygonal composite panel is characterized according to the invention in that

• a) the tub consists of a composite material which is formed by a laminate of at least one tensile, rigid, non-metallic component and at least one external foldable component,
• b) the wall elements are set up at least once around linear bending edges in the foldable component to the frame, and
• c) the wall elements are connected to the cast material.

Further advantageous embodiments of the subject matter of the invention emerge from the remaining subclaims.

An embodiment of the subject matter of the invention is explained in more detail below with reference to FIGS. 1 to 5.

Figur 1

eine perspektivische Ansicht einer etwa in der Mitte durchgeschnittenen fertigen Verbundplatte nach der Erfindung,

Figur 2

eine Innenansicht des bereits mit sämtlichen V-förmigen Einkerbungen versehenen Zuschnitts vor dem Auffalten,

Figur 3

einen Teilschnitt durch den Gegenstand von Figur 2 entlang der Linie III-III in vergrößertem Maßstab,

Figur 4

eine perspektivische Ansicht analog Figur 1, jedoch mit einem eingebetteten Gitterrahmen, und

Figur 5

den Gitterrahmen nach Figur 4 vor dem Einbetten.

Show it:

Figure 1

2 shows a perspective view of a finished composite panel according to the invention, cut approximately in the middle,

Figure 2

an interior view of the blank already provided with all the V-shaped notches before unfolding,

Figure 3

3 shows a partial section through the object of FIG. 2 along the line III-III on an enlarged scale,

Figure 4

a perspective view analogous to Figure 1, but with an embedded grid frame, and

Figure 5

the grid frame of Figure 4 before embedding.

In Figure 1, a composite panel 1 is shown, which has a square plan. However, this layout is not the only possible form; rather, the plates can also be rectangular, hexagonal or octagonal. The plate consists of a trough 2 arranged in the tensile stress area and made of a tensile material, which has a bottom area 3, inner wall elements 4 and outer wall elements 5. The information “inner” and “outer wall elements” relates to their relative position within the blank shown in FIG. 2. To be more precise, it is essentially the Floor area 3 in the so-called tension area of the composite panel.

Bottom area 3 and wall elements 4 and 5 are delimited from one another by rectilinear, V-shaped notches 6 and 7, the notches 6 and 7 lying on the same side of the bottom area running parallel to one another and each enclosing an inner wall element 4 between them. The blank 8 according to FIG. 2 was produced from a plate-shaped primary material, which consists of a tensile, rigid, non-metallic component 9 and a foldable, flexible component 10. In this case, component 9 consists of plasterboard with glass fiber inlays.

According to FIG. 3, the opening angle of the notches 6 and 7 is approximately 90 degrees, deviations being caused by the later inclined position of the inner wall elements 4. The apex lines 6a and 7a of the notches 6 and 7 lie in the immediate vicinity of the surface of the uninterrupted flexible component 10, so that the apex lines 6a and 7a form the fold lines when the tray 2 shown in FIG. 1 is unfolded. In the final state, the fold lines form the lower and upper edges 11 and 12 of the composite panel 1.

As can be seen from FIGS. 1, 2 and 3, the tub 2 has two fold-out wall elements 4 and 5 on each side of the circumference of its bottom region 3, the notches 6 and 7 being made in such a way that two are formed when the tub is formed Folding operations made can be. First, the inner wall elements 4 are folded up by a little less than 90 degrees, and subsequently the outer wall elements 5 are folded around by a second folding process until they run parallel to the base region 3. This state is shown in Figure 1.

In the final state, the inwardly directed end edges 13 of the outer wall elements form a polygonal opening, which is used to introduce a hardenable casting compound 14.

It is the other way round and, with particular advantage, it is also possible to place the trough with the polygonal opening on a flat, smooth surface and to fill in the casting compound through a central opening in the floor area. Anhydrite-based liquid screed is particularly suitable for this. The diameter of the opening is preferably about 10 to 15 cm.

The mineral component of the plate-shaped primary material is provided at least in the bottom area 3 with openings 15, which are also filled when poured through the casting compound 14, so that the casting compound 14 forms an intimate connection with the tub 2. Preferably, at least the outer wall elements 5 are also provided with openings 16, which, however, are not visible in the final state according to FIG. 1 because they are covered by the flexible component 10 in this position (dashed line).

So that the composite panel 1 has the same height over its entire circumference, the notches 6 and 7 respectively provided in pairs or their apex lines 6a and 7a each have the same distance from one another. So that the corners of the outer wall elements 5 do not interfere with each other, they are bevelled accordingly at their corners so that they abut on miter joints 17.

In order to be able to fix the trough 2 spatially for the filling process, it is either possible to fix the unfolded trough by means of an adjustable holding device (not shown), or else the surfaces of the notches 6 and 7 that come into contact with one another and the miter joints 17 with an adhesive to brush that sets at short notice.

FIG. 1 also shows that a circumferential gap 18 is formed between the base region 3 and the outer wall elements 5 running parallel thereto, which is also filled by the cast material.

A composite panel produced in this way has a high strength against an impact or impact applied from above and against rolling movements of heavy objects. The composite panel has a very low thermal conductivity, so that in the event of a fire, high temperatures occurring on one side of the composite panel cannot be transferred briefly to the opposite side of the composite panel. If the flexible component made of a metal foil or a thin sheet there is a simple way to discharge electrostatic charges by appropriately trained supports.

Such composite panels are usually placed in the region of their corners on supports which are preferably adjustable in height. With the exception of corners of the room and near walls, four corners meet in the area of a column if the panels are square or rectangular. Each corner then covers a quadrant of the column. However, it is also possible to provide a single support in the area of each corner of the composite panel. It follows from this that the composite panel is subjected to bending stress when the load is applied, the tensile forces being absorbed essentially by the base region 3 of the trough 2.

It is also possible to subsequently process the composite panel according to the invention, for example to cut it to smaller dimensions or to provide it with cutouts, in order, for example, to be able to provide line bushings, plug-in connections and / or air connections for ventilating the cavity. Machining tools with which the notches 6 and 7 can be produced or the above-mentioned machining operations can be carried out are state of the art.

The use of a laminate for the cutting also results in a high impact resistance in the area of the edges 11 and 12 with regard to the finished composite panel generated. This advantage should not be underestimated - compared to purely mineral slabs - since the slabs in question are exposed to hard loads during transport, installation and, if necessary, use.

In the illustrated embodiment, the originally outer wall elements 5 lie with their top in the upper surface of the finished composite panel and thus in the compressive stress range. This is also advantageous because it creates a high compressive strength. Finally, the part of the flexible component lying in the upper surface is particularly well suited for adhesive bonding with a surface covering, so that the risk of this surface covering becoming detached is considerably reduced.

FIG. 4 shows a variant of the object according to FIG. 1: In this exemplary embodiment, a grid frame 19 is embedded in the casting compound 14, the details of which are explained in more detail with reference to FIG. 5:
The lattice frame 19 consists of two rectangular or square congruent frame parts 20 and 21, the individual profile parts of which are L-shaped in cross section. The one leg of each frame part lies in one plane, and the other legs run perpendicular to it. A circumferential gap 23 is present between the legs 20a and 21a of both frame parts lying in one plane, in FIG to which a mesh 22 made of steel wire is fixed, for example by spot welding.

The two respective other legs 20b and 21b are directed away from one another, and their outer sides lie in four common planes which run perpendicular to the plane in which the mesh 22 lies. The legs 20b pointing upwards in the position of use have a greater leg length than the legs 21b below. It is thereby achieved that the mesh in the position of use has a greater distance from the top of the casting compound 14 than from the bottom thereof, which has a common interface with the bottom region 13 of the trough 2. It is important that the mesh 22 is in the tension area of the composite panel. As a result, and in particular through the frame parts 20 and 21, the strength of the composite panel is increased significantly.

The mesh 22 can, as shown in Figure 5, consist of a steel wire fabric. However, perforated sheets, expanded metal or simply crossing bars can replace it. It is only important that those volumes of the casting compound 14 which lie above and below the mesh are inseparably connected to one another through the mesh. In addition, it is of course necessary that the casting compound can pass through the mesh as freely as possible during manufacture, regardless of whether the casting compound is filled through the polygonal opening of the top of the tub or through an opening in the bottom region 3 of the tub 2. It can may be appropriate to fix the lattice frame 19 against the tub 2 before pouring the casting compound.

Figure 4 also shows that the special manufacturing process of the tub by folding leads to the additional advantage that a lattice frame of relatively large horizontal dimensions can be accommodated in a tub which has a relatively small filling opening for the casting compound. Nevertheless, it is possible - if necessary using special spacers - to embed the reinforcement in the casting compound in such a way that it is surrounded on all sides by the casting material.

Claims (12)

A process for producing a polygonal composite panel for floors, in particular for floors arranged on supports, by filling a tub made of a tensile strength, arranged in the tensile region of the panel, made of rigid material with a curable casting compound, characterized in that a) a flat plate made of a tensile, rigid, non-metallic component and a flexible component forming a foldable outer layer is used to manufacture the tub, b) produces a cut from this plate in accordance with the processing of the tub, c) provides this blank within the rigid component at the locations of the intended edges of the plate with straight V-shaped notches with an opening angle of approximately 90 degrees, which delimit a floor area and a plurality of wall areas from each other, from which the foldable outer layer faces away and the apex of which is in the immediate vicinity of the continuous, foldable outer layer, d) unfolds the wall elements delimited by the notches around the apex lines into a tub and fixes the tub in the unfolded state and e) fills the tub with the casting compound and allows the casting compound to harden. A method according to claim 1, characterized in that a) provides the plate on each side of its circumference with two foldable wall elements, of which the inner wall elements lying between the floor area and the outermost wall elements are each delimited on their long sides by parallel notches which have the same distance from one another for all inner wall elements, and that one b) the inner and outer wall elements, based on the vertical cross section of the finished tub, unfolded twice on each side of the circumference by about 90 degrees, so that the bottom region and the outer wall elements run parallel to one another, the inward end edges of the outer Wall elements limit a polygonal opening. A method according to claim 1, characterized in that by providing the bending-resistant non-metallic component of the plate prior to their association with the flexible component provided with openings which are closed again by the union with the flexible component. A method according to claim 1, characterized in that it sweeps over the walls of the notches prior to the folding of the wall elements with an adhesive. Process for producing a floor using trays according to claim 1, characterized in that a large number of still unfilled trays (2) are laid out on a floor in grid dimensions, preferably with the interposition of height-adjustable support elements, optionally bringing the trays (2) to a uniform height and then fills the cavities of all trays in situ with the casting compound and allows the casting compound to harden. A method according to claim 5, characterized in that it still applies a continuous over all composite panels screed on the container filled with the molding compound composite panels. Polygonal composite panel (1) for floors, in particular for floors arranged on supports, consisting of a tension-proof trough (2) arranged in the tension area of the panel with a filling (14) made of a hardened cast material, the trough consisting of a floor area (3) and out a frame forming wall elements (4, 5), characterized in that a) the tub (2) consists of a composite material which is made of a laminate of at least one tensile, rigid, non-metallic Component (9) and at least one external foldable component (10) is formed, b) the wall elements (5, 6) are arranged around linear bending edges (11, 12) lying in the foldable component (10) at least once about 90 degrees (± 10 degrees) to the frame, and c) the wall elements (4, 5) are connected to the cast material (14). Composite panel according to claim 7, characterized in that in two times of folding the first and second wall elements (4 or 5), the bending edges (11, 12) of two immediately contiguous first and second wall elements (4, 5) parallel to each other and that the bottom portion (3) and the respective second wall elements (5) are parallel to each other and enclose between them a gap (18) filled with hardened cast material (14). Composite panel according to claim 7, characterized in that the bending-resistant non-metallic component (9) of the trough (2) has a fiber reinforcement. Composite panel according to claim 7, characterized in that the bending-resistant non-metallic component (9) of the trough (2) with openings (15, 16) is provided, on the outside covered by the foldable component (10) and with the hardened cast material (14 ) are filled out. Composite panel according to claim 7, characterized in that the foldable component (10) consists of a metal foil. Composite panel according to claim 7, characterized in that a reinforcement consisting of metallic frame parts (20, 21) and an in-frame opening mesh (22) is embedded in the casting material (14), wherein the reinforcement on all sides by the cast material (14) is surrounded.

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