EP1460201A1 - Verfahren zur Herstellung eines Bodenbelags und damit hergestellter Bodenbelag - Google Patents

Verfahren zur Herstellung eines Bodenbelags und damit hergestellter Bodenbelag Download PDF

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Publication number
EP1460201A1
EP1460201A1 EP04075677A EP04075677A EP1460201A1 EP 1460201 A1 EP1460201 A1 EP 1460201A1 EP 04075677 A EP04075677 A EP 04075677A EP 04075677 A EP04075677 A EP 04075677A EP 1460201 A1 EP1460201 A1 EP 1460201A1
Authority
EP
European Patent Office
Prior art keywords
layer
binder
aggregate material
flooring
particles
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP04075677A
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English (en)
French (fr)
Inventor
Christer Lindgren
Lars Askfelt
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
RA Golv AB
Original Assignee
RA Industrigolv AB
RA Golv AB
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by RA Industrigolv AB, RA Golv AB filed Critical RA Industrigolv AB
Publication of EP1460201A1 publication Critical patent/EP1460201A1/de
Withdrawn legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/12—Flooring or floor layers made of masses in situ, e.g. seamless magnesite floors, terrazzo gypsum floors

Definitions

  • the present invention relates to a method of producing a flooring resting on a sub-floor and comprising the steps of: providing the sub-floor with a first layer of liquid or paste binder, spreading a layer of aggregate over the layer of binder, allowing the binder to dry or set so that the individual pieces or particles of the aggregate are bonded therein, spreading a second layer of liquid or paste binder over the first and the aggregate material bonded therein, spreading a second layer of aggregate over the second layer of liquid or paste binder, allowing the second layer of binder to dry or set, and grinding the flooring to an even and planar finish.
  • the present invention also relates to a flooring resting on a sub-floor and comprising a lower layer of binder with pieces or particles of an aggregate bonded therein, an upper layer of binder with pieces or particles of an aggregate bonded therein, and a protective and sealing layer on the top side of the flooring.
  • Patent Specification CH 361 114 discloses a flooring which is applied on a porous concrete floor which is sealed and insulated with a number of insulating layers. On these, there is disposed a covering layer which is substantially based on a plastic binder. In the covering layer, there are further placed particles of aggregate, whereafter, after complete setting, the top surface of the flooring is ground smooth.
  • a floor of this type may, in certain cases, function satisfactorily, but is not particularly durable and does not withstand point loadings more than that permitted by the plastic material in the covering layer.
  • the costs for production of such a floor are extremely high, since a large proportion of the aggregate material and the plastic binder must be ground off before flatness in the floor can be guaranteed.
  • Patent Specification DE 1 509 879 discloses a similar prior art floor.
  • Patent Specification SE-C2-512 627 discloses a floor which is built up on a sub-floor by means of a binder layer and a layer of particulate aggregate.
  • the binder is intended to fix the aggregate material in the sub-floor but may also form bridges between adjacent particles of the aggregate so that this forms a three-dimensional, stable lattice.
  • an inorganic filler which is intended, as far as is possible, to fill out the cavities. Once the filler has dried or set, the top surface of the flooring is ground flat and possibly provided with an upper sealing layer of a paint.
  • the flooring according to this Swedish Patent Specification possesses superior load-carrying capacity and durability, but is expensive to produce int. al. because an extremely thick layer of filler and aggregate must be ground off before the floor may have a guaranteed planar and smooth top surface. Finally, the flooring according to the Swedish Patent Specification builds up to a relatively large level of height and, as a result, cannot be employed in such situations where a flooring in a thin layer is required.
  • the present invention has for its object to obviate the drawbacks inherent in the prior art constructions.
  • the present invention has for its object to realise a method which is simple and economical to reduce into practice, which makes for the construction of floorings of thin layers, and, above all, reduces the requirement for the removal of material in the final grinding operation.
  • the objects forming the basis of the present invention will be attained in respect of the method if this is characterised in that, prior to the drying or setting of the second layer of binder, the aggregate material in the second layer is mechanically processed for removing air and for orienting the individual pieces or particles of aggregate so that these are at least partly caused to turn with sharp edges and projecting tips and portions facing away from the future top side of the flooring.
  • the individual pieces or particles of aggregate are, after the mechanical processing, substantially turned with their most planar sides upwards, and where their most planar sides substantially lie flush with one another, the amount of material which must be removed by grinding before the floor is perfectly flat is reduced to a minimum.
  • the objects forming the basis of the present invention will be attained in respect of the flooring if this is characterised in that the pieces or particles of aggregate bonded by the upper layer of binder are at least partly oriented with projecting edges, tips and jaggedness turned to face away from the top surface of the flooring.
  • Fig. 1 shows a cross section through a flooring according to the present invention in the process of being built up and reference numeral 1 relates to a sub-floor or generally to a floor substrate.
  • Reference numeral 2 relates to a layer of binder, for example epoxy based.
  • the binder layer 2 is spread on the substrate 1, whereafter a first layer of particulate aggregate material, for example marble chips, are spread in the binder layer.
  • the individual pieces or particles of aggregate material have been given reference numeral 3.
  • one object of the present invention is to realise a thin flooring which saves material and which does not accumulate excessively in the vertical direction, it is vitally important that the sub-floor or substrate 1 is completely flat. Should this not be the case, the sub-floor 1 is adjusted in this respect using a cement-based screed possibly followed by grinding before the first layer 2 of binder is spread out.
  • the binder in the first binder layer is applied in a quantity of approximately 0.2 kg per m 2 and the aggregate in a quantity of approximately 2 kg per m 2 . This implies that the binder layer will have a thickness of the order of magnitude of 2 mm.
  • the aggregate material need not be graded, but, in the relevant embodiment, has a maximum particle size of 3-5 mm.
  • the aggregate material may consist, for example, of crushed marble, cullet, crushed stone of types other than marble, wood chips, seashells etc.
  • the individual pieces or particles 3 are of an irregular shape and the individual particles themselves may differ considerably in both shape and also size.
  • the aggregate material is spread out over the binder layer 2 applied on the substrate 1, the individual particles or pieces 3 of aggregate material will be wholly randomly oriented.
  • a certain orientation of the individual particles or pieces 3 may possibly be over-represented, where the pieces have their largest and flattest side turned to face downwards, since an upstanding piece or particle will probably show a tendency to "topple over”. This is illustrated in Fig.
  • the binder layer 2 applied on the substrate 1 it is possible to apply the binder on the individual pieces 3 of aggregate by running them in a suitable mixer with an addition of binder prior to the spreading operation.
  • Fig. 2 shows the same cross section as Fig. 1, but after the next step in the production process where the flooring in the process of being built up has been given an additional layer of binder 9, a second layer of binder with the top surface 10.
  • the binder in the second layer of binder is preferably of the same type, or at least same nature as the binder in the first layer 2.
  • the second layer 9 of binder is only applied once the first layer 2 has dried or set at least so far that the individual pieces or particles 3 of aggregate are properly bonded and can also most preferably be trodden on.
  • the binder in the second layer 9 is relatively fugitive, liqueform or paste, it may be assumed that, at least after the application in Fig. 2, it is largely free of air pockets.
  • the second layer of binder 9 is spread with a greater thickness than the first, and in such instance this thickness may lie in the order of magnitude of 3 to 4 mm, in which event the binder in the second layer 9 may also include filler in the form of aggregate material of finer grading than that which was otherwise employed, as well as colour pigment, suitably a colour pigment which harmonises with the colour of the aggregate material employed.
  • the spreading of the binder in the second layer may be put into effect using a rubber scraper or similar implement, since the binder is liqueform or in paste form.
  • the proportion of filler may be as much as two thirds of the total and the quantity may amount to 6 kg per m 2 .
  • a second layer of particulate aggregate 11 is applied or spread out, which, for example, may consist to two thirds of a fraction having a particle size of 1-3 mm and to one third of a fraction having a particle size of 3-5 mm.
  • the type of aggregate material is the same as in Figs. 1 and 2 and the applied quantity may amount to the order of magnitude of 4 kg per m 2 .
  • the individual pieces or particles 11 in the aggregate material will initially be randomly oriented in the same manner as the individual pieces or particles 3 in the first layer of aggregate material were randomly oriented.
  • the next step of the production process entails that the individual particles 11 in at least the upper region of the second layer of aggregate are oriented by a mechanical processing so that, on the one hand, air is driven out, and, on the other hand, the individual pieces 11 or particles of aggregate material are at least partly caused to turn with their sharp and jagged edges 13 away from the top side of the impending flooring.
  • the cross section through the flooring in the process of being built up will have the appearance as is apparent from Fig. 3.
  • the pieces 11 of the aggregate material have, at least to some degree, been oriented in such a manner that their more or less planar surfaces 12 are turned to face upwards, while sharp edges and jagged portions 13 are turned to face away from the top side of the floor. It will also be apparent from the Figure that the pieces 11 are thoroughly surrounded by the binder 9 and that also a thinner layer 14 of the binder may be present on the upper side of the pieces 11. It is also largely apparent that there are no air pockets 15 in the second layer of binder 9, nor in the second layer of aggregate 11, possibly with exception of the lower regions thereof.
  • the mechanical processing and orientation of the individual particles or pieces 11 proceeds such that these are subjected to forces which are substantially parallel with the upper defining surface of the flooring. This will cause the individual particles to turn to the positions illustrated in Fig. 3.
  • the mechanical processing also entails that the individual particles are acted on by forces that are directed downwards towards the substrate 1 so that the particles will thereby be "kneaded down" into the binder 9, which, as a result, may float up to the top side of the individual pieces 11 and form the upper, thin layer 14.
  • the lower layer of aggregate material functions as an arrest surface which prevents individual particles 11 or pieces in the upper layer of aggregate material from being depressed too far down so that the layer thickness in the flooring in the process of being formed locally may become too slight or that, in a later stage, a grinding down to an excessive grinding depth is required.
  • the peaks 6 of the lower layer of aggregate material may fulfil the same function as an arrest surface when the second layer of binder 9 is spread out using a suitable scraper.
  • the mechanical processing of the second layer of aggregate material 11 may be put into effect employing spring-biased plates which move approximately parallel with the top surface of the layer and in contact therewith.
  • the individual sheets or plates make an acute angle with the substrate so that their front edges in the direction of movement lie somewhat higher than the rear edges.
  • Fig. 5 shows the quantity of material which must be'removed for this to be put into effect.
  • the upper, broken line 16 shows the level that corresponds to the upper point 18 in the flooring, in this case, the upper surface of the thin binder layer 14 which may exist on the top side of any individual particle or piece 11 in the upper layer of aggregate material.
  • the lower broken line 17 shows the level of the lower point 19 where an individual piece or particle 11 of aggregate material has an upwardly facing, continuous grinding surface.
  • the grinding process between the steps of the production process illustrated in Figs. 5 and 6 takes place in several stages using gradually finer grinding material. IN the last stages, use is made of an extremely fine particulate grinding material, possibly a pure polishing agent so that, as a result, the upper surface 20 and 21 will be smooth.
  • the ground surface is sealed with a protective paint, a wax or the like, whereafter a possible further polishing takes place.
EP04075677A 2003-03-18 2004-03-03 Verfahren zur Herstellung eines Bodenbelags und damit hergestellter Bodenbelag Withdrawn EP1460201A1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE0300744 2003-03-18
SE0300744A SE526178C2 (sv) 2003-03-18 2003-03-18 Förfarande för framställning av golvbeläggning samt golvbeläggning framställd enligt förfarandet

Publications (1)

Publication Number Publication Date
EP1460201A1 true EP1460201A1 (de) 2004-09-22

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Family Applications (1)

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EP04075677A Withdrawn EP1460201A1 (de) 2003-03-18 2004-03-03 Verfahren zur Herstellung eines Bodenbelags und damit hergestellter Bodenbelag

Country Status (3)

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EP (1) EP1460201A1 (de)
DK (1) DK200500282U1 (de)
SE (1) SE526178C2 (de)

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1361763A (en) * 1920-06-08 1920-12-07 Hamil John Method of surfacing
US1646667A (en) * 1922-03-01 1927-10-25 William M Bailey Company Method of making floors
US2296453A (en) * 1941-04-16 1942-09-22 George J Saffert Method of molding concrete products
CH361114A (de) 1960-02-11 1962-03-31 Diethelm & Co Verfahren zur Herstellung von Fussbodenbelägen
DE1509879A1 (de) 1964-11-24 1969-05-22 Herbert Schaefer Verfahren zur Herstellung verschleiss-korrosionsfester Kunststoff-Bodenbelaege
DE4225613A1 (de) * 1992-08-03 1994-02-10 Wilfried Grund Estrich und Verfahren zu dessen Herstellung
US5339589A (en) * 1993-02-12 1994-08-23 Thrower John H Aggregate floor and method for forming same
EP0992639A1 (de) * 1998-10-09 2000-04-12 RA Industrigolv AB Bodenbelag
FR2820446A1 (fr) * 2001-02-07 2002-08-09 Interdesco Procede de realisation d'un revetement sur un support, notamment en beton, et revetement ainsi realise

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1361763A (en) * 1920-06-08 1920-12-07 Hamil John Method of surfacing
US1646667A (en) * 1922-03-01 1927-10-25 William M Bailey Company Method of making floors
US2296453A (en) * 1941-04-16 1942-09-22 George J Saffert Method of molding concrete products
CH361114A (de) 1960-02-11 1962-03-31 Diethelm & Co Verfahren zur Herstellung von Fussbodenbelägen
DE1509879A1 (de) 1964-11-24 1969-05-22 Herbert Schaefer Verfahren zur Herstellung verschleiss-korrosionsfester Kunststoff-Bodenbelaege
DE4225613A1 (de) * 1992-08-03 1994-02-10 Wilfried Grund Estrich und Verfahren zu dessen Herstellung
US5339589A (en) * 1993-02-12 1994-08-23 Thrower John H Aggregate floor and method for forming same
EP0992639A1 (de) * 1998-10-09 2000-04-12 RA Industrigolv AB Bodenbelag
FR2820446A1 (fr) * 2001-02-07 2002-08-09 Interdesco Procede de realisation d'un revetement sur un support, notamment en beton, et revetement ainsi realise

Also Published As

Publication number Publication date
SE526178C2 (sv) 2005-07-19
SE0300744D0 (sv) 2003-03-18
SE0300744L (sv) 2004-09-19
DK200500282U1 (da) 2006-04-18

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