Classifications

• • 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
  • E04F15/06—Flooring or floor layers composed of a number of similar elements of metal, whether or not in combination with other material
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F13/00—Coverings or linings, e.g. for walls or ceilings
  • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
  • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
  • E04F13/12—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of metal or with an outer layer of metal or enameled metal
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
  • E04F15/20—Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
  • E04F15/206—Layered panels for sound insulation

Definitions

• the present invention concerns the sector of building and carpentry, and in particular the field of coverings. More specifically, the present invention concerns a finishing product, for covering surfaces in the building field and a corresponding method for the production of said finishing product.
• finishing products are commonly used for covering a rough surface (such as a floor or a wall).
• a finishing product which offers an excellent aesthetic result is ceramic tiles.
• tiles are very expensive and difficult to apply; in practice, this limits their use to private homes. The same inconveniences are presented by parquet and carpeting; these products are also very delicate.
• Steel finishing products are also available at handicraft level. These finishing products are realised by covering a rough tile with a box-type structure (obtained from a corresponding steel plate).
• the finishing product described above has an exorbitant cost, which limits its use to very few niche applications.
• this solution has the same inconveniences as tiles (that is, the difficulty of application) and the final result does not present optimum functional characteristics.
• SUMMARY OF THE INVENTION The present invention proposes a solution motivated by the aim of supplying a finishing product of the type mentioned above, with improved characteristics and low cost, which may be industrially produced. These aims are achieved by a finishing product and by a method for realising it, as defined in the enclosed claims.
• the product according to the invention presents a substratum which is optimum from the point of view of the application of the finishing product, as it guarantees high adhesion and good elasticity; at the same time, its metal laminar component offers excellent functional characteristics, since it makes the finishing product resistant to wear, easy to clean, and hygienic.
• the finishing product of the invention is also relatively light and may be obtained by mass production at very low costs. DESCRIPTION OF THE DRAWINGS Further characteristics and advantages of the solution according to the present invention will be apparent from the description given below of its preferred embodiments, given purely as an indicative example without limitation, with reference to the enclosed figures, in which Figures I a-I c are section views of different embodiments of the finishing product;
• Figures 2a-2d show various versions of the finishing product
• Figures 3a-3b illustrate possible ways of supplying the finishing product
• Figures 4a-4d show different embodiments of the finishing product for specific applications
• Figures 5a-5c illustrate an example of application of the finishing product
• Figures ⁇ a- ⁇ c show the various phases of a searn folding process. DESCRIPTION OF THE PREFERRED EMBODIMENTS
• a finishing product 100 for building surfaces is shown, in a section view along a transverse plane.
• This product is essentially composed of a substratum 105 and of a metal laminar component 1 10 bonded to the substratum 105 on adjoining surfaces, in a way that will be seen below, the external surface of the metal laminar component being suited to form the finishing surface, while the external surface of the substratum is intended for application on a building surface, for example a wall; a floor or other.
• the bottom external surface of the substratum may be covered with a second laminar component, preferably metal.
• the metal laminar component 110 may be made of stainless steel containing alloy elements, in particular with a concentration not lower than 1 1%, so as to present an intrinsic resistance to the corrosive attack of atmospheric agents.
• This component 110 may also be composed of a sandwich of two or more laminates of which the external finishing one and the internal stiffening one or ones, made of stainless steel or galvanised carbon steel.
• the metal laminar component 1 10 is made of a ferritic steel (in which the Chrome content is generally between 12% and 28%, while the carbon content is normally lower than 0.12%) or of an austenitic steel (in which the Chrome content is generally higher than 16% and there is also Nickel as an alloy element with a content higher than 6%).
• Different examples of stainless steels that may be used for making the metal component 1 10 are defined by the following chemical compositions (per casting):
• the metal laminar component 1 10 has a thickness between 0.2mm and 3mm; preferably the thickness is between 0.3mm and 2.5mm, and even more preferably between 0.4mm and 2mm (for example, 0.8mm).
• the material described above has a bending modulus with typical values that are higher than 100N/mm2, preferably higher than 150N/mm2 and even more preferably higher than 200N/mm2 (for example, 250N/mm2).
• the metal component 1 10 may be easily deformed plastically and in particular it may present a bending resistance of a few tens of N/mm2
• the substratum 1 10 may be of two different types, that is a substratum of bituminous material, in which case a plastically deformable finishing product is obtained, or a substratum of thermosetting plastic material, in which case an essentially rigid and workable finishing product is obtained.
• the substratum 105 is of the bituminous type, it is preferably composed of a sound-proofing or sound-deadening material (for example that commonly used for soundproofing structures subject to vibrations).
• This bituminous substratum is obtained from a mixture with a bitumen base, that is it contains mainly hydrocarbons with a high molecular weight with small quantities of compounds with a base of sulphur and nitrogen.
• an elastomer and a filler may be added.
• the mixture is composed of bitumen (CAS 8052-42-4), butadiene-styrene copolymer (CAS 8003-55-8) and calcium carbonate (CAS 471-34-1 ).
• Bitumen may be present in a weight percentage between 10% and 35% of the total composition; preferably, the percentage is between 15% and 30%, and even more preferably between 20% and 25% (for example, 23%).
• the elastomer quantity may vary between 1% and 7%; preferably the percentage is between 1% and 5%, and even more preferably between 2% and 4% (for example, 3%).
• the filler may be present in a percentage between 65 and 80%, and even more preferably between 70% and 15% (for example, 11%).
• the bituminous substratum has a density (with relation to water) between 1 gr/cc and 3 gr/cc; preferably the density is between 1 .2 gr/cc and 2.5 g/cc, and even more preferably between 1.5 gr/cc and 2 gr/cc (for example, 1.8 gr/cc).
• the bituminous substratum has a flow point higher than 100 0 C; preferably the flow point is higher than 120° and even more preferably it is higher than 150 0 C (for example, equal to 180 0 C).
• This substratum presents a high viscosity (for example, higher than 50.10 3 cPs, and preferably higher than 100.10 3 cPs at 200 0 C). Moreover, it is relatively light (for example, it has a weight of 2-12Kg/m2) and the material of which it is composed is substantially fire-resistant. For example, said material has a flash point higher than 220 0 C, and preferably higher than 270 0 C (according to ASTM D 92-85), a combustion point higher than 250 0 C, and preferably higher than 300 0 C (according to ASTM D 92-85), and a combustion speed lower than 15mm/min, and preferably lower than 20mm/min (according to FMVSS 302).
• the bituminous substratum described above has a thickness between l mm and 15mm; preferably the thickness is between 1.2mm and 12mm, and even more preferably between 1.8mm and 8mm (for example, 3mm).
• bituminous substratum has a very low bending modulus (not higher than a few units of N/mm2); so, in the typical dimensions of use it is flexible.
• bituminous substratum has a relatively high compression strength (for example, of about a few tens of N/mm2) and therefore it is substantially elastic in normal conditions of use.
• bituminous substratum is subjected to greater pressures (for example, during a moulding process of the finishing product 100), it has a plastic behaviour and therefore maintains its bottom surface substantially flat, irrespective of the conformation of the metal lamina.
• the substratum 110 may be obtained from a thermosetting plastic material which is applied by moulding, preferably by hot injection and under pressure directly on the laminar component, which constitutes an element of the mould or anyway is inserted in the mould. With this type of substratum an essentially rigid finishing product is obtained, in which the thickness of the metal laminar component may be reduced with respect to the previous case, for example to 0.5 mm.
• the thermosetting material may also be reinforced, for example with glass fibre, and it may involve fillers and any additional ingredients to enhance particular characteristics of the product.
• a preferred composition of said thermosetting material comprises a base of resins with a thermosetting matrix, to which are added suitable quantities of thermoplastic resins to control shrinkage, mineral charges, fibrous reinforcements and technological additives.
• the embodiments of the product may be the simplest one illustrated' in fig. I a, possibly with the addition of conductive material to the substratum, such as copper or metal fragments 1 15 (fig. I b), thus to realise an electric connection with a low resistance between the metal laminar component 1 10 and a surface on which rests the finishing product 100. Supposing that the resting surface is equipped with earth connections, this makes it possible to avoid the build-up of electrostatic charges on the metal lamina 1 10. This characteristic is particularly useful in specific applications, such as in operating theatres, data processing centres, environments for the production of integrated circuits, and similar; in fact, the antistatic function of the finishing product 1 10 allows to avoid any risk of electric discharges.
• the bottom surface of the substratum 105 may be provided with a layer of adhesive material 120, preferably of the type having instantaneous stickiness less than 15cm, and better less than 10cm (according to DIN 75200) .
• the adhesive layer 120 has a base of acrylic copolymer, and is protected by a film of paper or of silicone-co ⁇ ted polythene.
• This structure makes the application of the finishing product 100 extremely simple. In fact, it is sufficient to remove the protective film from the adhesive layer 120, and then place the finishing product 100. In general, the adhesive layer 120 presents cohesion after a few hours, for example 4 hours (according to FINAT 8).
• FIGS 2a and 2b illustrate a particularly preferred embodiment, in which the metal laminar component 1 10 has an essentially box-type shape, with flanks that come down preferably on the four sides of the substratum 105.
• This substratum 105 may be of the bituminous type and be applied on the inside of the box-type component 1 10, binding it to the same by means of an adhesive or bi-adhesive, or by thermal action on the material of the substratum.
• the bottom surface of the substratum may be provided with shapings or projections to facilitate application on the rough surface to be covered with the finishing product.
• a wire mesh 227 is sunk into the substratum 105, so as to protrude from its bottom surface.
• the metal laminar component 1 10 also includes an edge 230 which extends beyond the substratum 105; the edge 230 is folded in a U shape downwards (on the wire mesh 227), so as to be substantially coplanar with the bottom surface of the substratum 105.
• This structure performs an antistatic function, similar to the case in which the substratum 105 is conductive.
• the edge 230 (together with the wire mesh 227) may be used to discharge to earth any electrostatic charges that may have accumulated on the metal lamina 1 10.
• a substratum 105 of a bituminous type this may have its top surface provided with a layer of heat-activated adhesive material, for example with a base of ethylene vinyl acetate copolymers, polyamide, terpene phenolic polymers, calcium carbonate and mineral wax.
• the metal laminar component 1 10 and the bituminous substratum 105 are hot-glued by means of a special oven having a working temperature of around 90- 160 0 C, and at any rate lower than the softening temperature of the bituminous substratum 105 (for example, 18O 0 C).
• the structure thus obtained may be subjected to a moulding process, so as to define any desired projections. It must be noted that the plasticity of the bituminous substratum 105 allows its bottom surface to be kept relatively flat so as not to create problems of adhesion during application of the finishing product 100.
• the finishing product described above may be sold as an article 300a, which consists of a plate with a substantially rectangular shape, for example like a tile; in this case, the article 300a has preferably a square shape and fairly small dimensions (for example, from lOcmxlOcm to I mxl m), preferably with its edges slightly tilted (about 10°) towards the outside.
• the article 300a may also be supplied as a long thin strip (for example, with a length of l-4m and a width of 50-100cm).
• the finishing product is sold as a roll 300b.
• the roll 300b is composed of a strip with large dimensions (for example, with a length of 10-5Om and a width of 50- 100cm), which is rolled along its length.
• the finishing product may be cut to the desired dimensions; this also facilitates the realisation of mats.
• the finishing 100 product is equipped with a series of quick fastening elements 410 (for example, near its corners).
• Each fastening element 410 consists of a rod 420, which ends at the top with a widened head 430 sunk in the substratum 105.
• the bottom end of the rod 420 is provided with an elastic button 440, which protrudes from the substratum 105.
• the fastening elements 410 are used to clip the finishing product 100 to a support frame (not shown in the figure).
• the elastic buttons 440 rest against corresponding through holes (with a diameter conjugate with that of the rods 420).
• the finishing product 100 is therefore pushed by force towards the frame.
• This causes the elastic yielding of the buttons 440, which resume their original shape as soon as they come out of the through holes in the frame.
• the elastic buttons 440 keep the finishing product 100 fixed to the frame; in any case, the finishing product 100 may be easily removed by pulling it hard.
• a series of spacers 450 extend outwardly from a profile of the article 300a (plate shaped).
• the spacers 450 consist of inserts sunk in the substratum near two adjacent edges.
• This structure allows other finishing products alongside to be kept at a distance and thus facilitate installation; for example, this is particularly useful for making floors with coursing joints.
• the spacers 450 may be easily knocked down onto the substratum 105 when not necessary.
• moulded material lips may also be provided, made especially of thermosetting material (figures 4c and 4d), which facilitate the laying of the tiles by keeping them at the desired distance from one another.
• the finishing product proposed with reference to the various figures listed above may be applied as a covering on any type of surface.
• the finishing product is generally glued, using an adhesive layer provided on the bottom surface of the substratum; likewise, separate bi-adhesive strips may be used (when the finishing product is not provided with an adhesive layer), or specific glues (for example, such as those used for laying ceramic tiles).
• the finishing product may be applied by clipping on (when provided with the quick fastening elements described above).
• a series of through holes is made in the finishing product (for example, near its corners).
• the finishing product is fixed onto the desired surface with lag screws which are inserted in the through holes and then screwed into corresponding threaded holes in the surface.
• the finishing product may be used as a floor for the ground in any premises, or to cover walls and/or ceilings (in offices, shopping centres, stations, fair stands, and similar); moreover, its elasticity makes it preferable, especially in the version with thermosetting substratum, in the known solutions for making floating floors subject to movements/vibrations.
• the finishing product is applied in the flooring of any means of locomotion by land, air or sea (as in railway convoys, for both passengers and goods, or underground railways); moreover, the finishing product may be used for the internal covering of vehicles, for the luggage compartments, or for making protective mats.
• the finishing product may also be applied to cover swimming pools (both indoors and outdoors), terraces, or roofs.
• the finishing product is also applied on building facades, on the faults of road tunnels, and similar. These applications make the best use of the characteristics of the finishing product (that is: resistance to wear, ease of cleaning, hygiene, low cost, speed of application, lightness, excellent aesthetic result).
• the clip-on or screw-on version is also particularly advantageous in temporary installations (such as fair stands).
• the characteristics of sound insulation and waterproofing are particularly useful in applications on terraces and on roofs.
• the metal lamina acts as a reflecting mirror
• the same characteristic is also advantageous when the finishing product is used for the flooring around a swimming pool (as it keeps cool the surface on which people walk barefoot).
• the satin-finished version (reflecting and diffusing) is instead advantageous in road tunnels, as it considerably increases their luminosity (without creating visibility problems).
• the plastic deformability of the finishing product with a bituminous substratum is particularly useful when it has to be applied on comer connected surfaces.
• the finishing product 100 may be used for covering a column 500 with a square plan; in particular, the column 500 has a front surface 505f and a right side surface 505r, which are connected by a sharp edge 510 (at 90°).
• special tiles may be produced, already folded at 90°, to be used for covering the edges.
• the finishing product 100 is folded in half (along its height) so as to define an angle conjugate with the edge 510 (90° in the example considered).
• the finishing product 100 thus folded can now be applied directly on the column 500 (so as to cover the surfaces 505f and 505r perfectly).
• the quick fastening elements are different in number and position, or they are of another type (even suitable for the connection to a support structure other than the frame described above); moreover, the spacers are realised in another way (for example, with metal coursing strips).
• the finishing product of the invention is suitable for application on other surfaces or architectural elements (such as the steps on a staircase), which also have two or more connecting edges.
• a particular embodiment of the invention which allows the seam folding of adjoining finishing products is shown in Figures 6a-6c.
• the finishing product 100 includes a pair of conjugate edges 6051 and 605r which protrude from opposite edges of the substratum 105.
• the edge 605r is folded upwards in a V shape (so as to form an angle smaller than 90°, for example 60°); likewise an outer end of the edge 6051 is folded downwards in a V shape.
• two finishing products are placed next to each other on the surface to be covered (these finishing products are indicated adding, respectively, the suffix "a” and "b” to the relative reference numbers).
• the edge 60510b of the finishing product 100b is stuck into the conjugate edge 605ra of the finishing product 100a.
• the joint thus obtained is pressed (for example, with a roller); this process may be carried out when cold or hot. Consequently, the edges 605Ib and 605ra are folded so as to seam fold the two finishing products 100a and 100b. At the same time, these seam folded edges 605Ib and 605ra penetrate the material resulting from the approach of the two bituminous substrata 105a and 105b. In this way, the resulting structure is substantially planar; in particular, this avoids all risks of accident (which could be caused by contact with a free edge of the metal laminas) and ensures a considerably fine aesthetic effect.
• this structure is perfectly watertight, so as to guarantee the waterproofing of the covered surface in a quick and easy way (for example, on terraces or in swimming pools). Similar considerations apply if there are two or more edges of each type, or if the edges are folded in a different way. Alternatively, equivalent seam folding methods are possible (for example, not concealed in the bituminous layers for connecting together parts of different rolls).

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Floor Finish (AREA)

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• 2004
  • 2004-06-22 IT IT001254A patent/ITMI20041254A1/it unknown
  • 2004-12-16 WO PCT/IB2004/004157 patent/WO2006008581A1/en not_active Application Discontinuation
  • 2004-12-16 EP EP04806363A patent/EP1759072A1/en not_active Withdrawn

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